CN105648655A - 使用再生涤纶短纤维制造去污抑菌无纺布的方法 - Google Patents
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Abstract
本发明公开了一种使用再生涤纶短纤维制造去污抑菌无纺布的方法，向再生涤纶短纤维喷洒雾化的氢氧化钠溶液进行梳理开松，并保持周围环境PM10颗粒度小于每立方米800颗，再将纤维进行铺平处理，对被挤压过的纤维层进一步补充氢氧化钠溶液，采用水刺加固工艺，对纤维进行水刺处理，用氢氧化钠溶液对已经成型的短纤维进行再次水刺提花，继续由热二氧化碳气体烘吹，使无纺布干燥成型。本发明在制造无纺布的过程中向纤维喷洒氢氧化钠溶液，最后烘干过程采用了高温二氧化碳，和无纺布纤维表面附着的氢氧化钠分子进行化学中和反应，生产碳酸氢钠和碳酸钠晶体颗粒，具有去污络合和抑菌作用，保证了去污和抑菌效果的无纺布的具有充足的时效性，不会轻易失效。
Description
技术领域
本发明涉及一种涤纶短纤维，具体涉及一种涤纶短纤维制造无纺布的方法。
背景技术
目前，国民生产活动中产生大量的废旧涤纶纺织品，得不到及时的消耗和妥善处置，故废旧布料再生利用一直是全社会广泛关注的问题，按照材料种类进行分类和再生利用是主要的解决思路。涤纶纤维作为被广泛应用于纺织行业的化学材料，具有强度高、降解难和用量大的特点，因此提高回收利用效率、减少价值浪费和迎合市场需求，成为废旧涤纶纤维再生利用的一个方向。对于再生纤维的利用应当尽可能的考虑到其纤维来源的复杂性和携带微生物、毒素等因素，尽可能在再生利用过程中消除这样的影响。
发明内容
发明目的：本发明的目的在于针对现有技术的不足，提供一种使用再生涤纶短纤维制造去污抑菌无纺布的方法，一方面有效利用再生纺织纤维，另外一方面消除再生纤维因来源复杂造成携带微生物、毒素等可能性。
技术方案：本发明提供了一种使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：包括以下步骤：
(1)向每公斤再生涤纶短纤维喷洒雾化的重量浓度为5～15％的氢氧化钠溶液80ml～100ml，将纤维进行梳理开松，既可以杀灭再生涤纶纤维原料中的一些微生物，又减少纤维梳理开松过程的扬尘，使得周围环境PM10颗粒度小于每立方米800颗，减少生产过程对环境的污染，同时在纤维的表面可以附着氢氧化钠分子以便于与空气中的二氧化碳气体和后续处理过程热二氧化碳气体产生中和反应，生成碳酸氢钠和碳酸钠晶体颗粒；
(2)再将纤维进行铺平处理，纤维层上下分别用网面罩盖，通过上下双网夹持对称挤压纤维层使其向中心面靠近，使得铺平的纤维层单位面积的重量范围为50g/m2～200g/m2，同时控制纤维层氢氧化钠的包裹性和络合量达到1μg/m3以上；
(3)对被挤压过的纤维层进一步补充喷洒重量浓度为5～15％的氢氧化钠溶液至过量；
(4)采用转鼓与平网相结合的水刺加固工艺，对纤维进行水刺处理，使得外部纤维向中间相互缠结，形成无纺布；
(5)对无纺布进行前后牵伸，牵伸位移值控制在5cm～10cm，以保证无纺布不出现褶皱；
(6)对布面喷洒重量浓度为5％～10％的氢氧化钠溶液，对已经成型的短纤维进行再次水刺提花，进而在表面形成特定形状的花样图案同时使得花样图案中的附着更多的氢氧化钠分子；
(7)继续由温度在150℃以上的二氧化碳气体烘吹，在纤维表面生成碳酸氢钠晶体颗粒和少量碳酸钠晶体颗粒，同时在高温二氧化碳气体流动下带走水份，使无纺布干燥成型。
进一步，步骤(1)开松后的再生涤纶短纤维的纤维长度为3cm～5cm，有利于控制纤维平铺后的单位克重在50g/m2～200g/m2之间。
进一步，步骤(2)所述上下双网夹持式的网层网格孔径为0.1cm×0.1cm～0.5cm×0.5cm，铺网速度30m/min～50m/min。
进一步，步骤(3)采用转子出水头进行喷洒的氢氧化钠溶液，所述转子出水头上设有多个出水口，每个出水口对应设置一个紧贴网面转动的转子，通过转子的转动将出水口中的氢氧化钠溶液喷洒出来。
进一步，步骤(4)所述水刺加固工艺即第一级和第二级为转鼓式水刺，第三级采用平网式水刺，进一步加固无纺布纤维的缠结的牢固度，尤其在前两步中不易被水刺到位的边缘部位；每级的水刺头数为10只，每个水刺头水压为100bar～260bar。
进一步，步骤(6)使用在布面上下对称设置的高压喷射嘴喷洒高速的氢氧化钠溶液，水压控制在200bar以上。
有益效果：本发明在制造无纺布的过程中向纤维喷洒氢氧化钠溶液，氢氧化钠溶液具有一定的腐蚀性可以杀灭再生涤纶短纤维来源过程中夹带的一些微生物，起到净化作用；同时在梳理开松的过程中喷砂雾化液体溶液有利于减少作业流程中的扬尘，减少对环境的污染；在铺网过程中使用氢氧化钠溶液进行润湿挤压可以减少铺网过程中因纤维层过厚存在的空气和间隙削弱了水刺过程的效果，同时使得表面纤维和中间层纤维进一步附着更多的氢氧化钠分子；在毛坯水刺无纺布成型之后再次使用氢氧化钠溶液喷刺，则可以进一步增加成型后的无纺布表面附着更多的氢氧化钠分子，同时在无纺布表面形成一定的粗糙面花纹，增强在后期试擦应用中对污滞的去除能力；最后烘干过程采用了高温二氧化碳，一方面利用热传递和空气流动增强水分的挥发，另外一方面则是和无纺布纤维表面附着的氢氧化钠分子进行化学中和反应，生产碳酸氢钠和碳酸钠晶体颗粒，尤其是碳酸氢钠具有去污络合和抑菌作用，中和反应生成的附属产物是水，对环境不产生污染；由于使用二氧化碳同直接附着在纤维表面层的氢氧化钠分子进行化学反应，应此生产的碳酸氢钠和碳酸钠分子也会紧紧附着于纤维表面，在保存过层中不会轻易脱落，更加保证了该去污和抑菌效果的无纺布的具有充足的时效性，不会轻易失效。
附图说明
图1为本发明制造无纺布方法的操作装置示意图；
图2为转子出水头和脱水接受箱的局部放大图。
具体实施方式
下面对本发明技术方案进行详细说明，但是本发明的保护范围不局限于所述实施例。
实施例：一种使用再生涤纶短纤维制造去污抑菌无纺布的方法。首先，如图1所示，通过喷洒头1向再生涤纶短纤维喷洒氢氧化钠溶液，每公斤纤维喷洒雾化的重量浓度为5％～15％的氢氧化钠溶液80ml～100ml，在纤维的表面可以附着氢氧化钠分子以便于与空气中的二氧化碳气体和后续处理过程热二氧化碳气体产生中和反应，生成碳酸氢钠和碳酸钠晶体颗粒，同时杀灭再生涤纶纤维原料中的微生物。然后纤维通过传送带被送入高速旋转的带有尖锐齿牙的滚轮2，在滚轮2的作用下使得纤维的平均长度控制在3cm～5cm，并与氢氧化钠充分混合，潮湿的纤维减少了作业时纤维扬尘，使得周围环境PM10颗粒度小于每立方米800颗。
滚轮2作用之后，由传送带将纤维传输到上下两层分别由不同导轮收放的网层3、4之间，网层3、4的网格孔径为0.3cm×0.3cm，铺网速度40m/min，由两个压制在两层网层之外、转向相对、间距可以调节的转轮5、6带动网层3、4运动向其间的纤维层施加向纤维中心面的挤压力，使得经过压制后的纤维平铺层其单位重量范围控制在50g/m2～200g/m2，在纤维平铺层形成的同时上下两层网层被各自对应的收卷轮收卷，之后可以调换方向循环使用；形成的纤维平铺层对氢氧化钠的包裹和络合量达到1μg/m3以上。
继而处于纤维平铺层73上部且紧贴纤维平铺层73的转子出水头7和处于纤维平铺层73的下部紧贴纤维平铺层73的脱水接受箱8进行纤维平铺层73的预先润湿处理，转子出水头7如图2所示，其上设有多个出水口71，每个出水口71对应设置一个转子72，通过转子72的转动将出水口71中的氢氧化钠溶液喷洒出来。转子出水头7中各出水孔中的转子紧贴网层的移动而转动，并带出浓度为5％～15％的氢氧化钠溶液，使得纤维平铺层73中的空气和纤维间隙减少，下部的脱水接受箱8收集未被纤维平铺层73吸收的氢氧化钠溶液。
然后纤维平铺网层经过转鼓9和转鼓10两个转鼓水刺加固工艺，再经过平行水刺头11进行平网水刺处理，每级的水刺头数为10只，每个水刺头水压为100bar～260bar，以使得纤维能够向中心面趋向并相互缠结形成无纺布。
经过上一步水刺，纤维平铺层成为了毛坯水刺无纺布，调节后传导轮速度，使得毛坯水刺无纺布的各点之间被拉伸，以防止布面出现褶皱，前后位移变化在5cm～10cm之间。
被牵引伸长的毛坯水刺成布进入布面上下对齐排布的压力为100bar～150bar的高压喷射嘴12，向布面喷出高速重量浓度为5％～10％的氢氧化钠溶液，对已经成型的短纤维毛坯水刺无纺布进行水刺提花，进而在其表面形成花样图案，同时使得花样图案中的附着更多的氢氧化钠分子，高速水压控制在200bar以上。
水刺提花的短纤维水刺无纺布，继续由热二氧化碳烘干口13和热二氧化碳吹风口14喷出温度在150℃以上的热二氧化碳气体对无纺布烘吹，在其表面生成一层具有去污和杀菌效果的碳酸氢钠晶体颗粒和少量碳酸钠晶体颗粒，同时在高温和气体流动的作用下带走更多水份，使得水刺无纺布能够干燥成型，最终由收卷轮15对成品带有抑菌和清洁功能的水刺无纺布成品收卷。
实施例2：与实施例1步骤大致相同，所不同的是，喷洒头1连接有储罐16，储罐16中灌装与氢氧化钠具有同样性质的其他碱溶液，并在喷洒头1、转子出水头7和高压喷射嘴12也使用同样性质的碱溶液，同时烘干口13和吹风口14吹出的热干燥气体根据需要调整为热空气、热氮气或者热二氧化碳气体，对应的无纺布表面产生的将是其他特殊功能的盐类晶体微粒。
Claims (6)
1.一种使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：包括以下步骤：
（1）向每公斤再生涤纶短纤维喷洒雾化的重量浓度为5～15%的氢氧化钠溶液80ml～100ml，将纤维进行梳理开松，并保持周围环境PM10颗粒度小于每立方米800颗；
（2）再将纤维进行铺平处理，纤维层上下分别用网面罩盖，通过上下双网夹持对称挤压纤维层使其向中心面靠近，使得铺平的纤维层单位面积的重量范围为50g/m2～200g/m2，同时控制纤维层氢氧化钠的包裹性和络合量达到1μg/m3以上；
（3）对被挤压过的纤维层进一步补充喷洒重量浓度为5～15%的氢氧化钠溶液至过量；
（4）采用转鼓与平网相结合的水刺加固工艺，对纤维进行水刺处理，使得外部纤维向中间相互缠结，形成无纺布；
（5）对无纺布进行前后牵伸，牵伸位移值控制在5cm~10cm；
（6）对布面喷洒重量浓度为5%～10%的氢氧化钠溶液，对已经成型的短纤维进行再次水刺提花，进而在表面形成花样图案同时使得花样图案中的附着更多的氢氧化钠分子；
（7）继续由温度在150℃以上的二氧化碳气体烘吹，在纤维表面生成碳酸氢钠晶体颗粒和碳酸钠晶体颗粒，同时在高温二氧化碳气体流动下带走水份，使无纺布干燥成型。
2.根据权利要求1所述的使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：步骤（1）开松后的再生涤纶短纤维的纤维长度为3cm~5cm。
3.根据权利要求1所述的使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：步骤（2）所述上下双网夹持式的网层网格孔径为0.1cm×0.1cm~0.5cm×0.5cm，铺网速度30m/min~50m/min。
4.根据权利要求1所述的使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：步骤（3）采用转子出水头进行喷洒的氢氧化钠溶液，所述转子出水头上设有多个出水口，每个出水口对应设置一个紧贴网面转动的转子，通过转子的转动将出水口中的氢氧化钠溶液喷洒出来。
5.根据权利要求1所述的使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：步骤（4）所述水刺加固工艺即第一级和第二级为转鼓式水刺，第三级采用平网式水刺；每级的水刺头数为10只，每个水刺头水压为100bar~260bar。
6.根据权利要求1所述的使用再生涤纶短纤维制造去污抑菌无纺布的方法，其特征在于：步骤（6）使用在布面上下对称设置的高压喷射嘴喷洒高速的氢氧化钠溶液，水压控制在200bar以上。
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