CN102619095A - Manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather - Google Patents
Manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather Download PDFInfo
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Abstract
The invention relates to a manufacturing method of artificial leather and especially relates to a manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather. The manufacturing method comprises that through a high-density needle-punching process on polyester sea-island fibers and high-shrinkage polyester fibers, a three-dimensional leather net structure is formed; through a special process of weaving a cloth by a needle-punching compound machine, a basic raw cloth having a stable size is obtained; through modified poly urethane (PU) impregnation, a leather structure is obtained; through a high-temperature high-pressure flash evaporation-based NaOH process, product ultrafining is realized; and through a process adopting a combined technology of an odorless flame-retardant technology, a polyvinyl acetate (PVA) ventilation technology, a high-shrinkage polyester density-increasing technology and a high-performance aging-resistant PU resin, a super leather performance reaching to or exceeding a leather performance of natural suede leather is obtained.
Description
Technical field
The present invention relates to a kind of manufacturing approach of dermatine, the manufacturing approach of a kind of specifically pencil island environmental protection flame retardant automobile chamois leather.
Background technology
Six great technological changes have been experienced in the evolution of dermatine.Be coated with Corvic from the woven cloth of the first generation, second generation tWarp Knitted Fabrics is coated with polyurethane and is coated with polyurethane to third generation regular staple non-weaving cloth, is referred to as synthetic leather.
The 4th generation was to adopt indefinite island short fiber non-woven base fabric, and the leather of production is removed from office indefinite island micro fiber leather.Indefinite island short fiber normally polyamide and polyethylene in the blend of 50:50 ratio reel off raw silk from cocoons process non-woven base fabric after; Take out polyethylene with toluene again and open fibre, reached at the 0.001dtex that filament number is thin is more than thick reached at the 0.1dtex; Be used to produce footwear mostly with leather, product applications is restricted.Because world's public's environmental consciousness grows to even greater heights; More and more strict to the control of Chemical Manufacture organic solvent contaminated environment in the world; ISO has released the international standard of producing to the contaminative chemical solvent; Some developed countries all transform original technology and equipment when formulation standard and market access principle, and this has caused China colleague's attention.
The nonwoven fabric that uses island fiber with figured sea-island production as the leather of base belong to the 5th generation artificial leather; The leather of producing is deciding island micro fiber leather leather, and its production technology is complicated, and difficulty of processing is bigger; So owing to adopted the final Color of island fiber with figured sea-island product far above indefinite island product; Owing to do not adopt toluene in the technology, product does not have toluene residual in addition, but because self process characteristic decision DIMENSIONAL STABILITY, physical index and pliability are relatively poor.
The island fiber with figured sea-island branch has two kinds of light face and anti-suedes; The anti-suede micro fiber leather leather in state island decided at the higher level but not officially announced is produced to some extent at present; But all be low-and-medium-grade products; Owing to can not solve technical problems such as fire-retardant, DIMENSIONAL STABILITY, gas permeability, the surface of product are ageing-resistant, smell, nuisance volatilization, so can't on automotive material, use.
Because automotive trim requires must be mandatory fire-retardant; And commonsense method is processed automotive leather and can't be reached fire-retardant requirement; Face fabric for automobile seat requires that good DIMENSIONAL STABILITY must be arranged, and the ultra fibre of present anti-suede can't reach this requirement, and face fabric for automobile seat requires to reach surperficial ageing-resistant requirement;, the ultra fibre of present anti-suede can't reach this requirement.
In fact, the present also useful anti-suede corium of automotive seat, reason is that anti-suede corium has the high ventilation water vapour permeability; But because anti-suede corium deals with not environmental protection and costs an arm and a leg and can't use in batches; Common leather can't reach such requirement, though fabric can reach ventilative, dimensionally stable requirement, because low, nonelastic, the toughness of performance; Generally be used for low-grade economical-type automobile, can't satisfy the high-grade requirement of auto vendor's high-performance.
Therefore before the present invention occurred, the anti-suede superfine fiber leather of automobile domestic production research and development were still blank.
Summary of the invention
The objective of the invention is to be devoted to develop a kind of island environmental protection flame retardant automobile chamois leather that can be used in automotive seat and inner decoration facing; Make it performance and meet and exceed anti-suede corium; And reduce the automotive seat production cost, to watch for animals and ecological environment is a purpose, realize low-carbon economy; Reduce the animal animal and kill, just reduced the carbon emission of animal in culturing.
The objective of the invention is to realize like this, this manufacturing approach may further comprise the steps:
1.,
Fiber opening mixes:3.5D with 95% * 51mm terylene island fiber with figured sea-island (this fiber can be bought from domestic or Korea S, Japan) carries out shredding with 5D * 51mm high-shrinkage polyester (this fiber can be bought from domestic or Korea S) of 5% through the nonwoven opener; Shredding tentatively mixes two kinds of fibre transportation to mixing bale opener after becoming fritter; Deliver to fiber again through Fan pipeline and to give opener and carry out further opener; Fiber block is further reduced; Detect through metal detector by blower fan then, get rid of the metal that the inside possibly be mingled with, do not have inspection the transmitting fiber tow of metal to deliver to many storehouses mixing compartment at last; Tiny fiber is fully mixed; Carry out further opener through passing to fine opener by the blower fan suction through pipeline again after the mixing bunker mixing, make fiber be split into the tiny alabastrine fiber that is, send the air pressure hopper through blower fan to by the air channel again and process fiber bat with certain volume density;
2.,
Compound ultra fine nonwoven fabric is made:The bat that 1. above-mentioned steps makes is weighed through electronic-weighing, makes the evenly mixed and disorderly carding machine of feeding of fiber; Fiber further mixes removal of impurities through carding machine again; Fiber is thoroughly divided comb into single fiber; Fibre web through mixed and disorderly combing changes to the brute force ratio in length and breadth to some extent; The fibre web of output is held the lapping machine through double fastener again and is carried out lapping, through being folded transversally into the fibre web of certain thickness and width, gives acupuncture with becoming lace curtaining to deliver into;
A, give acupuncture
The fibre web that adopts the elliptical orbit needing machine become lace curtaining to carry to come high fluffy not had brute force gives acupuncture, and delivering to main acupuncture then carries out main acupuncture, and wherein the pre-needling needling density is 88 thorn/cm
2, depth of needling is 8 millimeters;
B, main acupuncture
The crosspointer plate Double felting needle felting machine that is transported to the good fibre web that certain intensity is arranged of pre-needling the control of high frequency computer carries out acupuncture; Requiring set needing machine is just to sting and two of anti-thorns; Make the fiber obvolvent of fully tangling through acupuncture up and down, increase hyper-base cloth brute force and density, form the 3-D solid structure fibre web; It is compound to get into woven cloth, and wherein first needing machine needling density is 260 thorn/cm
2, depth of needling is 5 millimeters, second needing machine needling density is 400 thorn/cm
2, depth of needling is 8 millimeters;
C, woven cloth are compound
With ready 40 g/m
2The woven cloth of polyamide fibre is put into below the 3-D solid structure fibre web of the 3rd main needing machine; The high frequency needle punching machine that gets into acupuncture from top to bottom simultaneously carries out acupuncture; And then get into the 4th from bottom to top the high frequency needle punching machine of acupuncture carry out reverse side acupuncture, make the fiber obvolvent of fully tangling through acupuncture up and down, and woven cloth firmly be compound to the 3-D solid structure fibre web; Form ultra fine compound nonwoven cloth, wherein the needling density of the 3rd main needing machine is 550 thorn/cm
2, depth of needling is 6 millimeters, wherein the needling density of the 4th main needing machine is 480 thorn/cm
2, depth of needling is 10 millimeters;
D, thorn is had a shave
Ultra fine compound nonwoven cloth compound good in the C step delivered to the thorn machine is had a shave, the needing machine needling density of wherein having a shave is 800 thorn/cm
2, depth of needling is 3 millimeters, the every Gram Mass of ultra fine compound nonwoven cloth that stings is 400 g/m
2, thickness is 1.8mm;
3., compound ultra fibre
Nonwoven fabric plates: above-mentioned2. compound ultra fine nonwoven fabric need plate, eliminate stress to eliminate to shrink through the heating of 120 ℃ of hot-rollings, again with the pressure roller that can set the 1.2mm gap, be processed into the walking speed of 10m/min have certain thickness, density and powerful compound ultra fine nonwoven fabric;
4.,
The PVA impregnation is handled:
In the PVA of 90 ℃ of impregnator thorough impregnations (polyvinyl alcohol) solution, wherein the PVA solution concentration is 5% the compound ultra fine nonwoven fabric after plating, and the degree of crystallinity of PVA is 99%; Through the unnecessary PVA of roll pressed, the roll seam reaches pick-up 80%, carries out prebake through 110 ℃ of far infrared baking ovens more then; Make PVA one-step film forming just, avoid migration, and then dry through tensionless dryer; Oven temperature is set at 110-130 ℃; Because PVA oven dry heating effect shrinks high-shrinkage polyester fully, further improves compound ultra fine nonwoven fabric density, thickness is 1.8-1.9mm after the PVA drying and shaping;
5.,
Wet method PU impregnation is handled:
Warp
PVA handlesCompound ultra fine nonwoven fabric is delivered to wet production line and is carried out modification PU resin impregnation, and wet method impregnation operation is to force dipping to the compound ultra fine nonwoven fabric of last operation in this operation with the wet polyurethane slurry, and wherein PU resin modulus is 55; Speed of production is 4-6m/min, solidifies in the coagulating basin of DMF (dimethyl formamide) aqueous solution through finite concentration and concentration gradient are housed then, and setting temperature is 25-30 ℃; Moisturizing speed is 1000kg/h; And then wash through multiple roll pressure rolling rinsing bowl, remove the PVA and the clean DMF of the inside at last through 90-100 ℃ of high-temperature water washing trough flush away, be that 115-130 ℃ of drying room formula tentering baking oven carries out dryness finalization through bake out temperature again; Product P U content after the typing is 35-40%; Thickness is 1.7-1.8 mm, becomes the semi-finished product of automobile chamois leather, i.e. bass;
6.,
Bass carries out the alkali decrement treatment:This operation is to carry out the alkali decrement to the bass behind the wet method impregnation PU to extract out, contains bass to be immersed in 8% the NaoH solution and floods, and pick-up is 100%; Get into then in 100 ℃ the steam box and carry out chemical reaction, making the sea part in NaoH and the islands-in-sea type fibre is that COPET (alkali solubility terylene) carries out the complete hydrolysis reaction, and makes COPET thoroughly resolve into micromolecule; Make composite fibre be pencil super-refinement structure; Clean out with the alkaline terylene reaction residues that the ultrasonic wave washing effect makes decomposition through the COPET reaction residues of high pressure sucktion fan centrifugal extraction hydrolysis then, wash through rinsing bowl again, thoroughly wash reaction residues off; Regulate pH value at rinsing bowl at last; Make bass reach neutral requirement, send down pre-grinding skin operation to carry out the processing of pre-grinding skin again after sending down drying line oven dry then, wherein alkali decrement speed of production is 8m/min; Steam box storage cloth amount 150m, decrement oven dry back thickness requirement 1.4mm;
7.,
Pre-grinding skin after the decrement:
Adopting the belt decorticating mill to carry out the pre-grinding skin according to product requirement to the surface of the bass after the decrement oven dry handles; Reach the surperficial velvet and the specific thickness requirement of automobile lining; Product behind the mill skin is delivered to dyeing process dyeing; Wherein belt machine grinds shelling skin speed 5-6m/min; Belt sand paper order is counted the positive mill of 240-320-400 skin and is amounted to 3 times; Reverse side need not be handled, bass thickness 1.2mm behind the pre-grinding skin;
8.,
The pre-grinding skin is handled bass dyeing:
This operation is that the bass behind the pre-grinding skin dyes; Dyeing is based on product colour need dye various colors; This patent uses the disperse dyes of conventional ultra fine dyeing to use the overflow dyeing method to reach product colouring requirement, and the product after dying is delivered to the oven dry upper wick and oiled and flame treatment;
9.,
Dyeing product oils fire-retardant:
Oiling process is after the bass through dyeing is passed through the tentering drying machine drying; Again in the solution tank that contains the environmental protection fire retarding agent that is soaked with 10-15%; Carrying out two rolls two and soaks; Shut out redundant solution with roll at last; Pick-up 80%; Dry with the tentering dryness finalization then, bake out temperature is 110-130 ℃, offers the final sanding of next procedure after the oven dry and handles;
10.,
The product sanding:
Adopt 400-500 order roll-type decorticating mill that sanding is carried out on the surface according to product requirement and handle, rod formula mill skin speed 4-5 m/min reaches the surperficial chamois leather velvet requirement of automobile lining, and the product behind the mill skin is this patent product island environmental protection flame retardant automobile chamois leather.
Advantage of the present invention and good effect:
Technically how to substitute the key that natural skin is this product, because structurally, the present invention is imitation natural leather 3-D solid structure and chemical composition, develops pencil island environmental protection flame retardant automobile chamois leather.
The basic technique principle of " pencil island environmental protection flame retardant automobile chamois leather ": by with natural leather in pencil collagenous fibres structure (fineness 3-4um) the ultra fibre similar with performance process (skeleton material); Employing has the nonwoven process of three-dimensional net structure; The PU resin finishing that recharges excellent performance and have an open type microcellular structure high tenacity is handled and to be formed (imitative characteristic amino acid), reaches this three and requires to reach the characteristics above corium.
Air-moisture-permeable, toughness and DIMENSIONAL STABILITY requirement for automobile skin needs; The highly dense needling process technology that the composite fibre that my company adopts mixes is a domestic initiation; Also be that a unique family has this technological company; Guarantee the innovation performance of product island environmental protection flame retardant automobile chamois leather, thereby be that gas permeability, DIMENSIONAL STABILITY are able to solve.We adopt the fire-retardant method of impregnation to reach the requirement of automotive seat producer for flame-retarded technology.Because above factor island environmental protection flame retardant automobile chamois leather technology has characteristics such as environmental protection, ultra corium property be strong.
1, this project mainly is the fiber that mixes by a certain percentage through to terylene island fiber with figured sea-island and high-shrinkage polyester; Through the combing lapping; And then carry out the composite acupuncture PROCESS FOR TREATMENT with woven cloth, and form the network structure of three-dimensional structure, contain soaking technology through PVA more afterwards base material is carried out impregnation; Product density is further increased; The good base cloth of impregnation forms the cortex structure of porous through modification PU impregnation after coagulation, and flush away PVA makes material have stable ventilating porous structure in water-washing process again, and then handles through the NaOH friendly process and to make the product super-refinement; Handle through dyeing, special process such as mill skin etc. at last, thereby adopt tasteless technology such as fire-retardant to reach ultra corium performance above natural leather.
2, the invention solves technical problems such as gas permeability, DIMENSIONAL STABILITY, smell property and gas permeability on the automotive leather, adopt unique green technology, realize low-carbon economy; It is shown one's talent from low and middle-grade micro fiber leather leather; Make product lot quantity be applied to the automotive trim field, enhance product performance and reduce the automobile production cost simultaneously, realize automobile lightweight and environmental protection developing goal; Greatly solve current medium-to-high grade car interior trim leather in short supply with the quality problem that do not pass a test, market prospects are quite wide.
3, product environmental protection flame retardant automobile chamois leather of the present invention belongs to the high-tech material of a kind of new development in the artificial synthetic leather, is not natural skin.Because of it has advantages such as fire-retardant, wear-resisting, cold-resistant, ventilative, ageing-resistant, that quality is soft and outward appearance is beautiful, become the ideal that replaces anti-suede natural leather and selected.
4, natural corium is to be formed by the collagenous fibres " braiding " that many thicknesses do not wait, and divides grain layer and lamina reticularis two-layer, and grain layer is knitted by superfine collagenous fibres and formed, and netted the braiding by thicker collagenous fibres forms.Because the collagen bundle of ox-hide interts each other in corium and interweaves with closely becoming net; And the superfine fibre skin of this product is to adopt the woven cloth of three-dimensional structure PROCESS FOR TREATMENT and the technology of the non-woven fabric compounded production of needle point method with base cloth; Be mainly vertical up and down acupuncture; Making tangles between vertical and the horizontal direction fiber each other is woven into network; Environmental protection flame retardant automobile chamois leather of the present invention is to adopt the modified polyamine ester layer close with natural corium grain layer structure to form; Casing play is to be composited with woven acupuncture after adopting island, Dinghai fiber and high-shrinkage polyester mixing acupuncture again, and the lamina reticularis of its structure and natural corium is extremely similar, thereby ultra corium has extremely similar structure and performance with the natural corium of anti-suede.
Compare with natural corium, environmental protection flame retardant automobile chamois leather mainly contains following characteristics:
(1), stable, the employing of percentage elongation moderate size and the similar group molecule formation of natural leather (skin sense, toughness, elastic recovery are good).
(2), permeability is very good, can reach more than the corium twice.
(3), tearing strength and peel strength higher (ABRASION RESISTANCE, tear edge, tension intensity height).
(4), folding fastness can compare favourably with natural leather.
(5), the product weather resisteant can be superior, the normal temperature bending reaches flawless 250,000 times, crooked 80,000 flawlesses of low temperature (20 ℃) (temperature tolerance, mechanicalness good).
(6), do not have any pollution, adopt green process technology, do not contain harmful material, environmental-protecting performance is superior from producing to use.
5, product environmental protection flame retardant automobile chamois leather of the present invention can substitute all anti-suede corium products; Can effectively reduce animal kills; Keep ecosystem balance; The protection environment, the carbon emission of minimizing animal-breeding ight soil, exhaust, product can be widely used in fields such as automobile both domestic and external, steamer, aircraft interior trim and environmental purification.
This formula for a product is reasonable, the advanced feasible environmental protection of technology, steady quality, is applicable to substituting the natural leather product.
(1) because the textile fabric work in-process is restive, non-weaving cloth Cheng Buqian particularly, fiber is to be the unit free state with single, its uniformity is the difficult point of production control always.But adopt high-precision CV1 drawing-off control lapping device to make fibre web uniformity generation fundamental turn for the better, products C V value will be dropped to below 1.5% by 3%;
(2) produce ultra-fine highly dense non-weaving cloth, of crucial importance through the application of broadwise brute force comparison product, therefore must make the powerful ratio of product near 1, this project adopts high precision double doffer pair mixed and disorderly carding machines can guarantee that this index is stable;
(3) production island environmental protection flame retardant automobile chamois leather all has harsh requirement to indexs such as product fabric quality and inherent matter density; The domestic production line is difficult to solve at present; This project adopts needle plate form and the mixed and disorderly cloth pin of computer and the needing machine of having a shave of the Special Elliptic type track of German Di Luo company development, not only solves the problem of product thickness, matter density, flatness but also solve drawing-off and fault that needle tracking causes.
(4) adopt low-density composite acupuncture technology that woven cloth well is bonded together with eedle-punched non-wovens before compound, guarantee that product peels off index, compound back adopts highly dense technology to make the product density increasing, uses the preliminary draft device simultaneously, and product can smoothly be integrated.Through the special process parameter adjustment, reach optimum efficiency again, guarantee that final products surpass natural leather DIMENSIONAL STABILITY and pliability requirement.
The woven cloth of A, employing requires as follows:
A, specification are 40g/m
2,
B, Density are: 12 * 12/cm
2,
C, elongation: 30-80%,
D, chemical composition terylene.
E, intensity: 240N/5mm.
B, composite demand: peel strength is greater than 70N.
(5) needling process: when we adopt the terylene islands-in-sea type fibre, increase a small amount of high-shrinkage polyester fiber, because follow-up raising volume density needs are satisfied in the follow-up contraction that receives temperatures involved of high-shrinkage polyester; The three-dimensional structure of non-weaving cloth is more even, and company has adopted unique highly dense needling process simultaneously, and the volume density of product is greatly improved, and reaches the peculiar density requirements and the rebound performance that surmount corium, saves PU; The acupuncture combination process adopts woven nonwoven combination process, improves product size stability.
(6) preliminary treatment of PVA impregnation process using far infrared, free shrink setting process, and make between back PU and fiber and form diaphragm, water-wash away at last and make the flexible, porous moisture-penetrable ventilated purpose of product, be that product density further increases simultaneously; The above high temperature of 90 degree of PVA operation thoroughly shrinks the high-shrinkage polyester in the fiber, further raising product volume density.
(7) the PU wet processing adopts special impregnation product processing technique to make its product reach the specific (special) requirements of emulation skin.
(8) for to adopting multiple group technology in the post processing of product, make properties of product unique through product being carried out special technology such as fire-retardant, different style satisfies the requirement of automotive leather purposes.
(9) DMF all adopts recovery tower to carry out whole recyclings according to water and DMF boiling point different principle among the present invention.
Description of drawings
Fig. 1 is the island fiber with figured sea-island fibre section Electronic Speculum figure on raw materials used 37 islands in the fiber opening blend step of the present invention.
Fig. 2 is Electronic Speculum figure behind the bass behind the compound nonwoven cloth impregnation PU in the wet method PU impregnation treatment step of the present invention.
Fig. 3 is that bass of the present invention carries out in the alkali decrement treatment step bass and handles through NaOH and extract product cross section Electronic Speculum figure behind the sea component out.
Fig. 4 is to be this patent product pencil island environmental protection flame retardant automobile chamois leather Electronic Speculum figure in the product sanding step of the present invention.
Fig. 5 is natural leather Electronic Speculum figure.
The specific embodiment
Manufacturing approach of the present invention comprises following processing step:
This manufacturing approach may further comprise the steps:
1.,
Fiber opening mixes:3.5D with 95% * 51mm terylene island fiber with figured sea-island (all can by 37 islands or 51 islands; Sea component is COPET; The island component is PET)) with 5D * 51mm high-shrinkage polyester of 5% be main production raw material; Wherein terylene island fiber with figured sea-island Electronic Speculum figure sees accompanying drawing 1, and the Electronic Speculum figure that amplifies 4500 times by accompanying drawing 4 finds out that 37 island components are surrounded by sea component.Mixed fiber carries out shredding through the nonwoven opener, makes the monoblock fiber become fritter by mechanical shredding, tentatively mixes two kinds of fibre transportation to mixing bale opener through a convoying curtain then; Produce static for reducing fibre frictoin; Add gentle level and smooth and the requirement of good saturability is arranged to reach, need open the antistatic finish of terylene of mixed cotton opener after-applied 0.3%, deliver to fiber again through Fan pipeline and give opener and carry out further opener; Fiber block is further reduced; And then, get rid of the metal that the inside possibly be mingled with by the detection of blower fan process metal detector, there is not inspection the transmitting fiber tow of metal to deliver to many storehouses mixing compartment then; Tiny fiber is fully mixed; Carry out further opener through passing to fine opener by the blower fan suction by pipeline again after the mixing bunker mixing, make fiber be split into the tiny alabastrine fiber that is, send the air pressure hopper through blower fan to by the air channel again and process fiber bat with certain volume density.
2.,
Compound ultra fine nonwoven fabric is made:1. above-mentioned steps has certain volume density by the fiber that the air pressure hopper quantitatively feeds; Because pressure evenly makes fibre density uniform and stable " bat "; Such bat is weighed through the electronic belt of import and is weighed automatically; Make the evenly mixed and disorderly carding machine of feeding of fiber, guarantee the uniform and stable property of finished product grammes per square metre with this; Bat can make fiber further mix removal of impurities by carding machine through high property more in a jumble; And fiber is thoroughly divided comb into single fiber; The fibre web that makes through having the mixed and disorderly effect of mixed and disorderly roller carding machine changes to the brute force ratio in length and breadth to some extent; But the fibre web of carding machine output is held the lapping machine through the import Ao Tefa double fastener of stage Compensation Regulation again and is carried out lapping, through being folded transversally into the fibre web of certain thickness and width, gives acupuncture with becoming lace curtaining to deliver into.
A, give acupuncture
We adopt elliptical orbit needing machine that German Di Luo company produces that the lapping machine is carried come high fluffy and the fibre web that do not have a brute force gives acupuncture; Its first tool brute force and thickness are greatly reduced; And guarantee minimum drawing-off amount and do not have obvious needle tracking; Deliver to main acupuncture then and carry out acupuncture, wherein the pre-needling needling density is 88 thorn/cm
2, depth of needling is 8 millimeters.
The acupuncture principle is on the needle plate of needing machine, to be implanted with up to ten thousand pieces of triangle prickers, the hook thorn towards the needle point direction is all arranged, through the reciprocating motion of needle plate on the corner angle of each pricker; Pricker passes the stripping web plate and gets into fiber web, passes trawl board again, passes in the process of fibre web at pricker; Because oriented needle point direction hook thorn on the pricker; Bring fiber into fibre web inside from the surface, just as pin nail one by one on fiber web, web thickness is significantly reduced and intensity is strengthened.
B, main acupuncture
The crosspointer plate Double felting needle felting machine that is transported to the good fibre web that certain intensity is arranged of pre-needling the control of high frequency computer carries out acupuncture; Requiring set needing machine is just to sting and two of anti-thorns; Make the fiber obvolvent of fully tangling through acupuncture up and down, increase hyper-base cloth brute force and density, form the 3-D solid structure fibre web; It is compound to get into woven cloth, and wherein first needing machine needling density is 260 thorn/cm
2, depth of needling is 5 millimeters, second acupuncture
MachineNeedling density is 400 thorn/cm
2, depth of needling is 8 millimeters.
C, woven cloth are compound
With ready 40 g/m
2The woven cloth of polyamide fibre is put into below the 3-D solid structure fibre web of the 3rd main needing machine; The high frequency needle punching machine that gets into acupuncture from top to bottom simultaneously carries out acupuncture; And then get into the 4th from bottom to top the high frequency needle punching machine of acupuncture carry out reverse side acupuncture, make the fiber obvolvent of fully tangling through acupuncture up and down, and woven cloth firmly be compound to the 3-D solid structure fibre web; Form ultra fine compound nonwoven cloth, wherein the needling density of the 3rd main needing machine is 550 thorn/cm
2, depth of needling is 6 millimeters, wherein the needling density of the 4th main needing machine is 480 thorn/cm
2, depth of needling is 10 millimeters.Wherein the thorn density degree of depth reduces significantly down, avoids stabbing woven cloth, and can make woven cloth and nonwoven fabric strong bonded, when increasing micro fiber leather base cloth brute force density is increased, and size is able to stablize.
D, thorn is had a shave
Ultra fine compound nonwoven cloth compound good in the C step delivered to the thorn machine is had a shave, guarantee that compound base cloth density improves to make compound base cloth surfacing bright and clean simultaneously.The needing machine needling density of wherein having a shave is 800 thorn/cm
2, depth of needling is 3 millimeters, the every Gram Mass of ultra fine compound nonwoven cloth that stings is 400 g/m
2, thickness is 1.8mm.
3.,
Compound ultra fine nonwoven fabric plates: above-mentioned compound ultra fine nonwoven fabric 2. need plate; Eliminate internal stress through 120 ℃ of hot-rolling heating to eliminate to shrink; Again with can setting the pressure roller in 1.2mm gap, be processed into the walking speed of 10m/min have certain thickness, density and powerful compound ultra fine nonwoven fabric.
4.,
The PVA impregnation is handled:
In the PVA of 90 ℃ of impregnator thorough impregnations (polyvinyl alcohol) solution, wherein the PVA solution concentration is 5% the compound ultra fine nonwoven fabric after plating, and the degree of crystallinity of PVA is 99%; Through the unnecessary PVA of roll pressed, the roll seam reaches pick-up 80%, carries out prebake through 110 ℃ of far infrared baking ovens more then; Make PVA one-step film forming just, avoid migration, and then dry through tensionless dryer; Oven temperature is set at 110-130 ℃, makes PVA and wraps the fiber surface that is attached to compound nonwoven cloth fully, forms diaphragm; Go out in order to next procedure impregnation PU after washing, make between fiber and PU and form the space, be convenient to the breathable moisture permeability needs; Because PVA oven dry heating effect shrinks high-shrinkage polyester fully, further improves compound ultra fine nonwoven fabric density, thickness is 1.8-1.9mm after the PVA drying and shaping.
5.,
Wet method PU impregnation is handled:
Warp
PVA handlesCompound ultra fine nonwoven fabric is delivered to wet production line and is carried out modification PU resin impregnation; Wet method impregnation operation is to force dipping to the compound ultra fine nonwoven fabric of last operation in this operation with the wet polyurethane slurry, and the immersion trough that contains that DMF solution is housed has three, and the DMF concentration of first groove is 28%; The DMF concentration of second groove is 15%; The DMF concentration of second groove is 10%, owing in DMF solution solidifies groove, adopt different DMF Pressure, Concentration, Temperature condition control, makes and gets the distinctive porous ductile structure of leather that the PU generation has minute aperture on the impregnation compound nonwoven cloth; See accompanying drawing 2; The Electronic Speculum figure that amplifies 500 times by accompanying drawing 2 finds out that the PU after solidifying is coated on around the fiber of compound nonwoven cloth, and forms a lot of apertures.
Wherein PU resin modulus is 55; Speed of production is 4-6m/min, and through solidifying in the coagulating basin that certain density DMF solution is housed, setting temperature is 25-30 ℃ then; Moisturizing speed is 1000kg/h; And then wash through multiple roll pressure rolling rinsing bowl, remove the PVA and the clean DMF of the inside at last through 90-100 ℃ of high-temperature water washing trough flush away, be that 115-130 ℃ of drying room formula tentering baking oven carries out dryness finalization through bake out temperature again; Product P U content after the typing is 35-40%, and thickness is 1.7-1.8 mm.Become the semi-finished product of automobile chamois leather, i.e. bass.
The PU slurry of this operation needs need be used chemical reaction kettle in addition; Earlier be extracted into agitated reactor to the PU resin in proportion; Throw DMF then into and carry out stirring and dissolving, prescription adds other auxiliary agent by a certain percentage afterwards, and fully stirs about 2 hours; Be put into then and deliver to the wet method line in the carrying ladle, with air pump be extracted into contain in the immersion trough for use.
Wet polyurethane slurry PU raw material composition and formulation weight portion rate are following:
DMF:65-69 part
Modified polyurethane resin: 20-24 part
Foam stabilizer AR600:0.4-0.6 part
Accelerant A R120:1-2 part
Blowing agent AR100:3-4 part
Abscess mediator agent S-25:0.6-0.8 part
Mill base: 3-5 part
All there is production above resin, domestic each the big leather resin of auxiliary agent, auxiliary reagent factory.
Wet-process modified polyurethane slurry PU slurry collocation method is following, and 220 kilograms of the modified polyurethane resins that will weigh are earlier thrown 3 tons agitated reactor into air pump, and then throw 660 kilograms of DMF solution into air pump, and turn on agitator fully stirred 30 minutes; Weigh up 5 kilograms to AR600 again, AR120 weighs up 2 kilograms, and AR100 weighs up 4 kilograms, and S-25 weighs up 7 kilograms, pours into successively in the agitated reactor, and the limit bevelling stirs, and stirs 30 minutes again; Weigh up 4 kilograms to mill base as required at last and also drop into and fully stirred in the agitated reactor 60 minutes, the outlet valve of opening again below the agitated reactor is emitted the PU slurry for preparing, and it is for use to deliver to production line with all turning barrels.
6.,
Bass carries out the alkali decrement treatment:This operation is to carry out the alkali decrement to the bass behind the wet method impregnation PU to extract out, contains bass to be immersed in 8% the NaoH solution and floods, and pick-up is 100%; Get into then in 100 ℃ the steam box and carry out chemical reaction; Making the sea part in NaoH and the islands-in-sea type fibre is that COPET (alkaline terylene) carries out the complete hydrolysis reaction, and makes COPET thoroughly resolve into micromolecule, makes composite fibre be pencil super-refinement structure; The alkaline terylene reaction residues that makes decomposition through the COPET reaction residues and the ultrasonic wave washing effect of high pressure sucktion fan centrifugal extraction hydrolysis is then cleaned out; Through the rinsing bowl washing, thoroughly wash reaction residues off again, regulate pH value at rinsing bowl at last; Make bass reach neutral requirement, send down pre-grinding skin operation to carry out the processing of pre-grinding skin again after sending down drying line oven dry then.Wherein alkali decrement speed of production is 8m/min, steam box storage cloth amount 150m, decrement oven dry back thickness requirement 1.4mm.
The Electronic Speculum figure that wet method bass process NaOH handles behind the extraction sea component sees accompanying drawing 3; The Electronic Speculum figure that amplifies 4000 times by accompanying drawing 3 finds out; An islands-in-sea type fibre thoroughly divides 37 the tiny fibers that shed after by decrement treatment, and the fineness of this fiber has reached 3.4um, near corium fabric 4um fineness requirement.
7.,
Pre-grinding skin after the decrement:
Adopt the belt decorticating mill to carry out the pre-grinding skin based on product requirement to the surface of the bass after the decrement oven dry and handle, reach surperficial velvet and the specific thickness requirement of automobile lining, the product behind the mill skin is delivered to dyeing process and is dyeed.Wherein belt machine grinds shelling skin speed 5-6m/min, and belt sand paper order is counted the positive mill of 240-320-400 skin and amounted to 3 times, and reverse side need not be handled, bass thickness 1.2mm behind the pre-grinding skin.
8.,
The pre-grinding skin is handled bass dyeing:
This operation is that the bass behind the pre-grinding skin dyes; Dyeing is to dye various colors according to the product colour needs; This patent uses the disperse dyes of conventional ultra fine dyeing to use the overflow dyeing method to reach product colouring requirement, and the product after dying is delivered to the oven dry upper wick and oiled and flame treatment.
9.,
Dyeing product oils fire-retardant:
Oiling process is after passing through the tentering drying machine drying to the bass through dyeing; Again in the solution tank that contains the environmental protection fire retarding agent that is soaked with 10-15%, carry out two and roll two and soak, shut out redundant solution with roll at last; Pick-up 80%; Dry with the tentering dryness finalization then, bake out temperature is 110-130 ℃, offers the final sanding of next procedure after the oven dry and handles.
This operation is with a certain proportion of import environmental protection fire retarding agent base cloth to be handled, thereby improves the flexibility and the physical property of superfiber leather product.Treated base cloth meets the fire-retardant requirement of product.
For the product fire resistance is further improved, adopt environmental protection import fire retardant, from the knowledge of experiment, must carry out and combination matching by two kinds of fire retardants, just can reach the optimum resistance combustion effect, so this patent environmental protection fire retarding agent HZR-3 formulation weight portion rate is following:
(1), fire retardant BC1226 3-7 part
(2), fire retardant PDP 4-8 part
(3), water H
2O 80-90 part.
Above auxiliary agent fire retardant is produced by Japan, is domesticly act as sole agent by the Shanghai trading company that fills enamel, and can buy therefrom.
Environmental protection fire retarding agent HZR-3 fire retardant collocation method is following, earlier throws soft water into surge-tank for 90 kilograms through overanxious net, and then the fire retardant BC1226 white powder that will weigh amounts to 6 kilograms and pour into surge-tank into, and turn on agitator fully stirred 30 minutes; Weigh up 7 kilograms to fire retardant PDP solution again and slowly pour in the surge-tank, the limit bevelling stirs, and stirs 30 minutes again, and it is for use to deliver to production line to the good retardant solution of allotment with all turning barrels with air pump.
10.,
The product sanding:Adopting 400-500 order roll-type decorticating mill that sanding is carried out on the surface according to product requirement handles; Rod formula mill skin speed 4-5 m/min; Reach the surperficial chamois leather velvet requirement of automobile lining, the product behind the mill skin is this patent product pencil island environmental protection flame retardant automobile chamois leather, sees accompanying drawing 4; Amplified natural corium Electronic Speculum figure that 850 times Electronic Speculum figure and accompanying drawing 5 amplify 1600 times contrasts and finds out the ultra long and slender dimension of leather, network structure, air hole structure and the cortex structure similar with corium by accompanying drawing 4.
Claims (4)
1. the manufacturing approach of a pencil island environmental protection flame retardant automobile chamois leather is characterized in that:
This manufacturing approach may further comprise the steps:
1., fiber opening mixes: the 3.5D with 95% * 51mm terylene island fiber with figured sea-island and 5D * 51mm high-shrinkage polyester of 5% carry out shredding through the nonwoven opener; Shredding tentatively mixes two kinds of fibre transportation to mixing bale opener after becoming fritter; Deliver to fiber again through Fan pipeline and to give opener and carry out further opener, fiber block is further reduced, detect through metal detector by blower fan then; Get rid of the metal that the inside possibly be mingled with; Do not have inspection the transmitting fiber tow of metal to deliver to many storehouses mixing compartment at last, tiny fiber is fully mixed, pass to fine opener by the blower fan suction through pipeline again after mixing through mixing bunker and carry out further opener; Make fiber be split into the tiny alabastrine fiber that is, send the air pressure hopper through blower fan to by the air channel again and process fiber bat with certain volume density;
2., compound ultra fine nonwoven fabric is made: the bat that 1. above-mentioned steps makes is weighed through electronic-weighing, makes the evenly mixed and disorderly carding machine of feeding of fiber; Fiber further mixes removal of impurities through carding machine again; Fiber is thoroughly divided comb into single fiber; Fibre web through mixed and disorderly combing changes to the brute force ratio in length and breadth to some extent; The fibre web of output is held the lapping machine through double fastener again and is carried out lapping, through being folded transversally into the fibre web of certain thickness and width, gives acupuncture with becoming lace curtaining to deliver into;
A, give acupuncture:
The fibre web that adopts the elliptical orbit needing machine become lace curtaining to carry to come high fluffy not had brute force gives acupuncture, and delivering to main acupuncture then carries out main acupuncture, and wherein the pre-needling needling density is 88 thorn/cm
2, depth of needling is 8 millimeters;
B, main acupuncture
The crosspointer plate Double felting needle felting machine that is transported to the good fibre web that certain intensity is arranged of pre-needling the control of high frequency computer carries out acupuncture; Requiring set needing machine is just to sting and two of anti-thorns; Make the fiber obvolvent of fully tangling through acupuncture up and down, increase hyper-base cloth brute force and density, form the 3-D solid structure fibre web; It is compound to get into woven cloth, and wherein first needing machine needling density is 260 thorn/cm
2, depth of needling is 5 millimeters, second needing machine needling density is 400 thorn/cm
2, depth of needling is 8 millimeters;
C, woven cloth are compound
With ready 40 g/m
2The woven cloth of polyamide fibre is put into below the 3-D solid structure fibre web of the 3rd main needing machine; The high frequency needle punching machine that gets into acupuncture from top to bottom simultaneously carries out acupuncture; And then get into the 4th from bottom to top the high frequency needle punching machine of acupuncture carry out reverse side acupuncture, make the fiber obvolvent of fully tangling through acupuncture up and down, and woven cloth firmly be compound to the 3-D solid structure fibre web; Form ultra fine compound nonwoven cloth, wherein the needling density of the 3rd main needing machine is 550 thorn/cm
2, depth of needling is 6 millimeters, wherein the needling density of the 4th main needing machine is 480 thorn/cm
2, depth of needling is 10 millimeters;
D, thorn is had a shave
Ultra fine compound nonwoven cloth compound good in the C step delivered to the thorn machine is had a shave, the needing machine needling density of wherein having a shave is 800 thorn/cm
2, depth of needling is 3 millimeters, the every Gram Mass of ultra fine compound nonwoven cloth that stings is 400 g/m
2, thickness is 1.8mm;
3., compound ultra fine nonwoven fabric plates: above-mentioned compound ultra fine nonwoven fabric 2. need plate; Eliminate stress to eliminate to shrink through 120 ℃ of hot-rolling heating; Again with can setting the pressure roller in 1.2mm gap, be processed into the walking speed of 10m/min have certain thickness, density and powerful compound ultra fine nonwoven fabric;
4., the PVA impregnation is handled:
In the PVA solution of 90 ℃ of impregnator thorough impregnations, wherein the PVA solution concentration is 5% the compound ultra fine nonwoven fabric after plating, and the degree of crystallinity of PVA is 99%; Through the unnecessary PVA of roll pressed, the roll seam reaches pick-up 80%, carries out prebake through 110 ℃ of far infrared baking ovens more then; Make PVA one-step film forming just, avoid migration, and then dry through tensionless dryer; Oven temperature is set at 110-130 ℃; Because PVA oven dry heating effect shrinks high-shrinkage polyester fully, further improves compound ultra fine nonwoven fabric density, thickness is 1.8-1.9mm after the PVA drying and shaping;
5., wet method PU impregnation is handled:
Deliver to wet production line to the compound ultra fine nonwoven fabric of handling through PVA and carry out modification PU resin slurry dipping, wet method impregnation operation is to force dipping to the compound ultra fine nonwoven fabric of last operation in this operation with the wet polyurethane slurry, and wherein PU resin modulus is 55; Speed of production is 4-6m/min, and through solidifying in the coagulating basin that certain density DMF solution is housed, setting temperature is 25-30 ℃ then; Moisturizing speed is 1000kg/h; And then wash through multiple roll pressure rolling rinsing bowl, remove the PVA and the clean DMF of the inside at last through 90-100 ℃ of high-temperature water washing trough flush away, be that 115-130 ℃ of drying room formula tentering baking oven carries out dryness finalization through bake out temperature again; Product P U content after the typing is 35-40%; Thickness is 1.7-1.8 mm, becomes the semi-finished product of automobile chamois leather, i.e. bass;
6., bass carries out the alkali decrement treatment: this operation is to carry out the alkali decrement to the bass behind the wet method impregnation PU to extract out, contains bass to be immersed in 8% the NaoH solution and floods, and pick-up is 100%; Get into then in 100 ℃ the steam box and carry out chemical reaction, making the sea part in NaoH and the islands-in-sea type fibre is that alkaline terylene carries out the complete hydrolysis reaction, and makes alkaline terylene thoroughly resolve into micromolecule; Make composite fibre be pencil super-refinement structure; Clean out with the alkaline terylene reaction residues that the ultrasonic wave washing effect makes decomposition through the alkaline terylene reaction residues of high pressure sucktion fan centrifugal extraction hydrolysis then, wash through rinsing bowl again, thoroughly wash reaction residues off; Regulate pH value at rinsing bowl at last; Make bass reach neutral requirement, send down pre-grinding skin operation to carry out the processing of pre-grinding skin again after sending down drying line oven dry then, wherein alkali decrement speed of production is 8m/min; Steam box storage cloth amount 150m, decrement oven dry back thickness requirement 1.4mm;
7., pre-grinding skin after the decrement:
Adopting the belt decorticating mill to carry out the pre-grinding skin according to product requirement to the surface of the bass after the decrement oven dry handles; Reach the surperficial velvet and the specific thickness requirement of automobile lining; Product behind the mill skin is delivered to dyeing process dyeing; Wherein belt machine grinds shelling skin speed 5-6m/min; Belt sand paper order is counted the positive mill of 240-320-400 skin and is amounted to 3 times; Reverse side need not be handled, bass thickness 1.2mm behind the pre-grinding skin;
8., the pre-grinding skin is handled bass dyeing:
This operation is that the bass behind the pre-grinding skin dyes; Dyeing is based on product colour need dye various colors; This patent uses the disperse dyes of conventional ultra fine dyeing to use the overflow dyeing method to reach product colouring requirement, and the product after dying is delivered to the oven dry upper wick and oiled and flame treatment;
9., dyeing product oils fire-retardant:
Oiling process is after the bass through dyeing is passed through the tentering drying machine drying; Again in the solution tank that contains the environmental protection fire retarding agent that is soaked with 10-15%; Carrying out two rolls two and soaks; Shut out redundant solution with roll at last; Pick-up 80%; Dry with the tentering dryness finalization then, bake out temperature is 110-130 ℃, offers the final sanding of next procedure after the oven dry and handles;
10., product sanding: adopt 400-500 order roll-type decorticating mill that sanding is carried out on the surface according to product requirement and handle; Rod formula mill skin speed 4-5 m/min; Reach the surperficial chamois leather velvet requirement of automobile lining, the product behind the mill skin is this patent product island environmental protection flame retardant automobile chamois leather.
2. the manufacturing approach of a kind of pencil according to claim 1 island environmental protection flame retardant automobile chamois leather; It is characterized in that: the 5. middle DMF aqueous solution of described wet method PU impregnation treatment process solidifies and adopts different DMF Pressure, Concentration, Temperature condition control, makes the PU on the impregnation compound nonwoven cloth produce the distinctive porous ductile structure of leather with minute aperture; Bass thickness requirement 1.7-1.8mm after the wet method drying and shaping, resin content 35% in the bass, and wet processing is confirmed speed of production 5.5m/min, gives water speed 1000kg/h, 25 ℃ of temperature, PU resin concentration 20%; DMF coagulating basin concentration ladder, first solidifies concentration 28%, the second setting temperature 15%, the three solidifies concentration 10%.
3. the manufacturing approach of a kind of pencil according to claim 1 island environmental protection flame retardant automobile chamois leather is characterized in that: the wet polyurethane slurry PU raw material of said wet method PU impregnation treatment process in 5. form and the amount portion rate following:
DMF:65-69 part
Modified polyurethane resin: 20-24 part
Foam stabilizer AR600:0.4-0.6 part
Accelerant A R120:1-2 part
Blowing agent AR100:3-4 part
Abscess mediator agent S-25:0.6-0.8 part
Mill base: 3-5 part.
4. the manufacturing approach of a kind of pencil according to claim 1 island environmental protection flame retardant automobile chamois leather is characterized in that: described dyeing product oil fire-retardant operation 9. in the environmental protection fire retarding agent ratio of weight and number following:
Fire retardant BC1226 3-7 part
Fire retardant PDP 4-8 part
Water H
2O 80-90 part.
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Application publication date: 20120801 Assignee: Fujian Topsun Superfine Fibre Co., Ltd. Assignor: Jilin runze Microfiber Technology Co., Ltd. Contract record no.: 2012350000192 Denomination of invention: Manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather License type: Exclusive License Record date: 20121226 |
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Address after: Xingtai Industrial Park of Changtai Economic Development Zone, Fujian city of Zhangzhou province 363900 Patentee after: Fujian Topsun Superfine Fibre Co., Ltd. Address before: Xingtai Industrial Park Economic Development Zone, Changtai County, Fujian city of Zhangzhou province 363000 Patentee before: Fujian Topsun Superfine Fibre Co., Ltd. |