CN105401336B - 采用不定岛非织造布开边料的汽车地毯 - Google Patents

采用不定岛非织造布开边料的汽车地毯 Download PDF

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CN105401336B
CN105401336B CN201510876766.0A CN201510876766A CN105401336B CN 105401336 B CN105401336 B CN 105401336B CN 201510876766 A CN201510876766 A CN 201510876766A CN 105401336 B CN105401336 B CN 105401336B
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李学彦
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Yixing (Cangzhou) Automotive Interior Parts Co.,Ltd.
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Abstract

本发明涉及一种采用不定岛非织造布开边料的汽车地毯，其特征是，包括以下步骤：（1）开松混合：将聚酯纤维60%～95%和不定岛海岛纤维开边料5%～40%经两道粗开松机开松后，送入大仓混棉机混合，再经精开松机开松；（2）梳理铺网：经精开松的混合纤维喂入梳理机，分梳形成均匀的单层棉网；铺网机将单层棉网铺成厚棉网输出；（3）针刺：铺网机输出的厚棉网由喂入机喂入到预针刺机进行预缠结加固，再经过主针刺机，得到半成品；半成品在卷绕机上形成所需克重的卷材；（4）热烘：对针刺后的卷材进行热烘，温度为120～200℃，时间为2～8分钟，使得不定岛海岛纤维外层的低密度聚乙烯熔融。本发明将不定岛非织造布开边料应用于不减量的领域，减少浪费。

Description

采用不定岛非织造布开边料的汽车地毯
技术领域
本发明涉及一种采用不定岛非织造布开边料的汽车地毯，尤其是一种采用不定岛非织造布开边料代替低熔点纤维的汽车地毯。
背景技术
制革行业低密度聚乙烯-尼龙6混纺不定岛超细纤维是用于超细纤维超真皮革基布的专用纤维，现有的工艺流程是将岛组分通过减量去除，只留下海组分，以获得传统的纺丝工艺无法获得的超细旦纤维，也就是说只用到了岛组分。由于低密度聚乙烯和尼龙6性能差别大，因此这两种组分混纺不定岛超细纤维非织造布的裁边和废布处理一直是一个难题，开松出来的纤维一般不再用于要求较高的超真皮革生产，这种颇具技术含量的开松纤维需要一个合适的回用途径。
汽车行业用的非织造布材料比如主地毯、行李箱地毯、轮罩地毯、后搁物等，主要是聚酯纤维，为了增加硬挺度，提高热塑性，需要加入一定比例的低熔点纤维。但是低熔点纤维是完全由低熔点组分组成，本身拉伸强度低，热收缩性太大，弹性模量差，所以对非织造布设备包括开清、混合、梳理的要求也高。聚酯短纤维和低熔点短纤维经开松、混合、梳理、铺网、针刺、起绒等工序，形成杂乱排列、相互缠结的典型非织造布结构，再进入烘箱加热，低熔点纤维熔融进一步加固了纤维之间的缠结，使得整个面料更加硬挺，在加工成汽车零件的过程中具有较好的热塑性。
发明内容
本发明的目的是克服现有技术中存在的不足，提供一种采用不定岛非织造布开边料的汽车地毯，将不定岛非织造布开边料应用于不减量的领域，减少浪费。
按照本发明提供的技术方案，所述采用不定岛海岛纤维非织造布开边料的汽车地毯，其特征是，包括以下组份：聚酯纤维60%～95%、不定岛海岛纤维开边料5%～40%。
所述不定岛海岛纤维为PE-PA6不定岛海岛纤维。
所述采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是，包括以下步骤：
（1）开松混合：将聚酯纤维60%～95%和不定岛海岛纤维开边料5%～40%在开包机中经两道粗开松机开松后，送入大仓混棉机混合，再经精开松机开松；
（2）梳理铺网：经精开松的混合纤维经喂棉箱和皮带秤喂入梳理机，梳理机的锡林和工作辊对混合纤维分梳形成均匀的单层棉网，单层棉网克重为25～75g/㎡；铺网机将单层棉网铺成6～30层的厚棉网输出；
（3）针刺：铺网机输出的厚棉网由喂入机喂入到预针刺机进行预缠结加固，再经过主针刺机，得到半成品；半成品在卷绕机上形成所需克重的卷材；
（4）热烘：对针刺后的卷材进行热烘，温度为120～200℃，时间为2～8分钟，使得不定岛海岛纤维外层的低密度聚乙烯熔融。
所述针刺步骤之后还包括起绒步骤：针刺后的卷材在起绒针刺机上进行起绒，得到所需长度和密度的绒毛。
所述热烘步骤之后还包括淋膜步骤：在热烘后的汽车地毯上复合一层PE膜或EVA膜。
本发明具有以下优点：
（1）超细纤维使用过程中需要减量，去除海组分；本发明将超细纤维应用于不减量的领域，获得了和超细纤维的常规用途不同的优越性能；
（2）本发明为从裁边和废布开松出来的不定岛超细纤维重新回用找到了更适合途径，使得海岛纤维中两种组分都发挥了作用，减少浪费，实现了清洁生产；
（3）本发明降低了含低熔点纤维汽车地毯生产过程的开松混合和梳理难度，减少生产故障；
（4）本发明提高了汽车地毯的拉伸强度，降低了热收缩性；
（5）本发明使用开松回用的不定岛超细纤维，降低了汽车地毯低熔点组分的原料成本。
具体实施方式
下面结合具体实施例对本发明作进一步说明。
本发明所述汽车地毯中加入海岛纤维开边料纤维，替代原来的低熔点纤维，原来低熔点纤维受梳理机可纺性的限制，最多只能使用30%；本发明采用的不定岛海岛纤维开边料纤维可以将用量提高到40%，提高了汽车地毯可以达到的硬挺度等指标的范围。本发明主要是将超细纤维超真皮革生产过程中产生的非织造布裁边和废布开松出来的不定岛超细纤维，不经过常规的减量工序，应用到汽车主地毯、行李箱地毯、轮罩地毯、后搁物等非织造布生产中，代替汽车针刺地毯原用的低熔点纤维，获得比这种纤维的设计和常规用法更全面的优越性能。本发明采用开松回用的不定岛超细纤维，取代汽车地毯中一定含量的低熔点纤维，既能利用纤维外层的低密度聚乙烯增加地毯材料的硬挺度，提高热塑性，也发挥了这种纤维内部岛组分尼龙6的作用，提高了整个地毯材料的拉伸强度，有效降低了断裂伸长率和热收缩性，同时也相对降低了生产过程中纤维的开松混合、梳理难度。
低密度聚乙烯和尼龙6混纺的不定岛超细纤维的海组分是低密度聚乙烯，海组分是尼龙6。现在将这种未减量的海岛纤维用于汽车地毯面料，不减量，保留两种组分，而且这两种组分各自发挥自身的作用，海组分聚乙烯熔融后起到对整个地毯中的所有缠结的纤维（与聚酯短纤维安一定比例混合）加强固定的作用，岛组分尼龙起到增加非织造布拉伸强度、降低热收缩性的作用。
改进后，不定岛超细纤维取代了低熔点纤维，对整个非织造地毯面料的内部结构以及缠结没有改变，不减量的超细纤维两种组分发挥了各自的作用，使得汽车地毯的硬挺度、热塑性、拉伸强度、热收缩性等各项指标都有较大的提升。
不定岛海岛纤维的外部包覆的是低密度聚乙烯，如果不通过传统的减量流程将低密度聚乙烯保留下来，加热熔融可以起到低熔点纤维对整个无纺布结构加固的作用；纤维内部的岛组分是尼龙6，强度高，伸长率低，热收缩率低。
实施例一：一种采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是，包括以下步骤：
（1）开松混合：将聚酯纤维60%和不定岛海岛纤维开边料40%在开包机中经两道粗开松机开松后，送入大仓混棉机混合，再经精开松机开松；
（2）梳理铺网：经精开松的混合纤维经喂棉箱和皮带秤喂入梳理机，梳理机的锡林和工作辊对混合纤维分梳形成均匀的单层棉网，单层棉网克重为25g/㎡；铺网机将单层棉网铺成30层的厚棉网输出；
（3）针刺：铺网机输出的厚棉网由喂入机喂入到预针刺机进行预缠结加固，再经过主针刺机，得到半成品；半成品在卷绕机上形成所需克重的卷材；
（4）起绒步骤：针刺后的卷材在起绒针刺机上进行起绒，得到所需长度和密度的绒毛；起绒是一个可选工序，对毯面有绒感要求的汽车地毯，针刺后的卷材在起绒针刺机上利用叉形刺针进行起绒，这道工序要控制绒毛的长度和密度，控制方式是和客户的标准样品进行比对；
（5）热烘：对针刺后的卷材进行热烘，温度为120℃，时间为8分钟，使得不定岛海岛纤维外层的低密度聚乙烯熔融，对整个织物里的纤维形成粘连和加固，冷却后的地毯就比较硬挺；
（6）淋膜步骤：在热烘后的汽车地毯上复合一层PE膜或EVA膜。
实施例二：一种采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是，包括以下步骤：
（1）开松混合：将聚酯纤维95%和不定岛海岛纤维开边料5%在开包机中经两道粗开松机开松后，送入大仓混棉机混合，再经精开松机开松；
（2）梳理铺网：经精开松的混合纤维经喂棉箱和皮带秤喂入梳理机，梳理机的锡林和工作辊对混合纤维分梳形成均匀的单层棉网，单层棉网克重为75g/㎡；铺网机将单层棉网铺成6层的厚棉网输出；
（3）针刺：铺网机输出的厚棉网由喂入机喂入到预针刺机进行预缠结加固，再经过主针刺机，得到半成品；半成品在卷绕机上形成所需克重的卷材；
（4）起绒步骤：针刺后的卷材在起绒针刺机上进行起绒，得到所需长度和密度的绒毛；
（5）热烘：对针刺后的卷材进行热烘，温度为200℃，时间为2分钟，使得不定岛海岛纤维外层的低密度聚乙烯熔融；
（6）淋膜步骤：在热烘后的汽车地毯上复合一层PE膜或EVA膜。
实施例三：一种采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是，包括以下步骤：
（1）开松混合：将聚酯纤维65%和不定岛海岛纤维开边料35%在开包机中经两道粗开松机开松后，送入大仓混棉机混合，再经精开松机开松；
（2）梳理铺网：经精开松的混合纤维经喂棉箱和皮带秤喂入梳理机，梳理机的锡林和工作辊对混合纤维分梳形成均匀的单层棉网，单层棉网克重为50g/㎡；铺网机将单层棉网铺成20层的厚棉网输出；
（3）针刺：铺网机输出的厚棉网由喂入机喂入到预针刺机进行预缠结加固，再经过主针刺机，得到半成品；半成品在卷绕机上形成所需克重的卷材；
（4）起绒步骤：针刺后的卷材在起绒针刺机上进行起绒，得到所需长度和密度的绒毛；
（5）热烘：对针刺后的卷材进行热烘，温度为160℃，时间为5分钟，使得不定岛海岛纤维外层的低密度聚乙烯熔融；
（6）淋膜步骤：在热烘后的汽车地毯上复合一层PE膜或EVA膜。

Claims (3)

1.一种采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是，包括以下步骤：
（1）开松混合：将聚酯纤维60%～95%和不定岛海岛纤维开边料5%～40%在开包机中经两道粗开松机开松后，送入大仓混棉机混合，再经精开松机开松；所述不定岛海岛纤维为PE-PA6不定岛海岛纤维；
（2）梳理铺网：经精开松的混合纤维经喂棉箱和皮带秤喂入梳理机，梳理机的锡林和工作辊对混合纤维分梳形成均匀的单层棉网，单层棉网克重为25～75g/㎡；铺网机将单层棉网铺成6～30层的厚棉网输出；
（3）针刺：铺网机输出的厚棉网由喂入机喂入到预针刺机进行预缠结加固，再经过主针刺机，得到半成品；半成品在卷绕机上形成所需克重的卷材；
（4）热烘：对针刺后的卷材进行热烘，温度为120～200℃，时间为2～8分钟，使得不定岛海岛纤维外层的低密度聚乙烯熔融。
2.如权利要求1所述的采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是：所述针刺步骤之后还包括起绒步骤：针刺后的卷材在起绒针刺机上进行起绒，得到所需长度和密度的绒毛。
3.如权利要求1所述的采用不定岛海岛纤维非织造布开边料的汽车地毯的生产工艺，其特征是：所述热烘步骤之后还包括淋膜步骤：在热烘后的汽车地毯上复合一层PE膜或EVA膜。
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