CN105908360B - 生态保温棉及其生产工艺 - Google Patents
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Abstract
本发明提供一种生态保温棉及其生产工艺，具有良好的防风拒水效果，而且具有一定的杀菌功能，而且保暖效果更优，生态保温棉包括保暖棉芯、防水透气层、柔软贴身层，保暖棉芯由30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维混合制造而成，防水透气层由70%胶原纤维、30%热熔纤维混合制造而成，防水透气层表面涂有纳米硅粒子处理层，处理层表面涂有氟季胺硅烷耦合剂涂层，柔软贴身层与保暖棉芯之间设置有杀菌层，柔软贴身层通过植绒的方式固定于杀菌层的内侧，柔软贴身层由长度为0.05‑0.2cm的短纤维构成，其制造工艺包括机器自动配料混合‑开松‑梳理‑铺网‑喷胶‑热定型‑成卷。
Description
技术领域
本发明涉及生态保温棉，特别涉及一种生态保温棉及其生产工艺。
背景技术
制造保暖棉的方法一般依次包括如下步骤 ：将纤维原料开松并混合，经梳棉后梳理成网并定型。目前，定型工序大多采用塑料薄膜结合针刺的方法或施加粘合剂的方法将纤维网定型。如中国专利申请ZL94101293.X描述了将纤维原料开松、梳理成网，并与聚乙烯薄膜叠加，经针刺、碾压形成复合保暖棉。中国专利ZL98203205.6描述了将纤维原料开松，形成毛绒，针刺到聚乙烯薄膜上，然后在针刺毛绒层间施加热熔胶或水溶性乳胶如乙烯一乙酸乙烯共聚乳胶液、丙烯酸共聚乳液等，制成保暖复合绒，这样制成的产品虽然保暖性好，但透气、透湿性不很理想，而且不耐水洗。
而且现有的通常使用的多为普通再生纤维（含荧光增白剂），产品手感较粗糙，水洗性能、保温性能不理想，喷胶：非100%纯丙烯酸聚合物乳液，手感较粗糙。
发明内容
本发明的目的在于克服上述技术的不足，从而提供一种生态保温棉，具有良好的防风拒水效果，而且具有一定的杀菌功能，而且保暖效果更优，许多原料来自于可再生原料，环保效果好。
发明所采用的技术方案是这样的：生态保温棉，包括保暖棉芯、粘结于所述保暖棉芯外侧的防水透气层、位于所述保暖棉芯内侧的柔软贴身层，所述防水透气层的厚度为所述保暖棉芯厚度的10%-15%，所述柔软贴身层的厚度为所述保暖棉芯厚度的30%-40%，所述保暖棉芯以重量百分比计，由30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维混合制造而成，所述防水透气层以重量百分比计，由70%胶原纤维、30%热熔纤维混合制造而成，所述防水透气层的外侧表面涂有由纳米硅粒子处理层，所述处理层的表面涂有疏水性的氟季胺硅烷耦合剂涂层，所述柔软贴身层与所述保暖棉芯之间设置有杀菌层，所述杀菌层为由竹纤维以及纳米级抗菌银离子母粒原生纤维呈经纬编织而成编织网，所述杀菌层的外侧与所述保暖棉芯相粘结，所述柔软贴身层通过植绒的方式固定于所述杀菌层的内侧，所述柔软贴身层由长度为0.05-0.2cm的短纤维构成。
本发明的目的在于克服上述技术的不足，从而提供一种生态保暖棉生产工艺。
发明所采用的技术方案是这样的：包括以下步骤：
S1：棉纤维混合，将30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维通过自动混棉机混合均匀 ；
S2：将混合后的棉纤维经过预开松机混合，均匀的开松，通过输棉风机输送给下道工序；
S3：将预开松机输送过来的原料经过主开松机的进一步精开，使原料开松得更均匀，再通过输棉风机输送到给棉机储棉仓 ；
S4：给棉机将开松混合后的纤维原料，定量、均匀地喂入梳理机 ；
S5：梳理机将给棉机输出成型的棉梳理成网，形成均匀的单层棉网，输送给后道工序 其中：锡林速度1000-1200r/min，道夫20-25hz，工作辊10-12hz，上屏20-25hz，摇屏：25-30hz；
S6：铺网机将梳理机输出的单层棉网经过均匀的铺叠，铺设至所需的厚度以及宽度，连续不断的输送给下道工序 ；
S7:将70%胶原纤维、30%热熔纤维混合后经过铺网机均匀铺设成纤网；
S8：将铺好的纤网通过针刺机进行正反刺固处理，形成防水透气层；
S9: 通过贴合机将防水透气层与棉网进行贴合;
S10：通过五辊牵伸机，将贴合后的防水透气层与棉网进行纵向拉伸形成棉层，然后输送到喷胶部分 ；
S11：经过前、后喷胶箱在棉层正反面喷胶，胶料为纯丙烯酸聚合物乳液，前、后喷胶箱内抽真空保持负压状态，使得棉层膨松；
S12：通过烘箱，把胶定型并烘干，使棉层达到定型的效果，烘箱温度下层为 120-140℃ ,中层为140-160℃ , 上层为 160-180℃ ；
S13：在棉层外表面涂覆有纳米硅粒子处理层，在处理层的表面涂有疏水性的氟季胺硅烷耦合剂涂层；
S14：将竹纤维以及纳米级抗菌银离子母粒原生纤维进行经纬编织形成编织网；
S15：将编织网通过粘胶固定于棉层内表面，通过植绒机对编织网表面进行植绒处理：
S16：通过收卷切边机，将已定型的产品进行切边、裁剪、卷取。
通过采用前述技术方案，本发明的有益效果是：保暖棉芯中使用Sorona聚合物纤维，使用可再生原料生产，绿色环保，轻柔、蓬松、保暖，极佳的悬垂性能，而且通过使用超细保暖纤维以及三维中空保暖纤维，保暖效果更佳，通过使用竹纤维、纳米级抗菌银离子母粒原生纤维具有良好的杀菌效果，尤其是纳米级抗菌银离子母粒原生纤维采用银离子杀菌，而且在杀菌层表面通过植绒的方式具有植绒层，在提高保暖效果的同时提高舒适度，在防水透气层采用纳米硅粒子层和疏水性氟季胺硅烷耦合剂层的结合，水分子不容易通过，而气体分子可以通过，从而使织物具有拒水透气的效果。
附图说明
图1为本发明示意图；
其中：1、保暖棉芯；2、防水透气层；3、杀菌层；4、柔软贴身层。
具体实施方式
以下结合附图以及具体实施方式来进一步说明本发明。
如图1所示，本发明公开一种生态保温棉，包括保暖棉芯1、粘结于所述保暖棉芯1外侧的防水透气层2、位于所述保暖棉芯1内侧的柔软贴身层4，所述防水透气层2的厚度为所述保暖棉芯1厚度的10%-15%，所述柔软贴身层4的厚度为所述保暖棉芯1厚度的30%-40%，所述保暖棉芯1以重量百分比计，由30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维混合制造而成，所述防水透气层2以重量百分比计，由70%胶原纤维、30%热熔纤维混合制造而成，所述防水透气层2的外侧表面涂有纳米硅粒子处理层，所述处理层的表面涂有疏水性的氟季胺硅烷耦合剂涂层，所述柔软贴身层4与所述保暖棉芯1之间设置有杀菌层3，所述杀菌层3为由竹纤维以及纳米级抗菌银离子母粒原生纤维呈经纬编织而成编织网，所述杀菌层3的外侧与所述保暖棉芯1相粘结，所述柔软贴身层4通过植绒的方式固定于所述杀菌层3的内侧，所述柔软贴身层4由长度为0.05-0.2cm的短纤维构成。
生态保温棉含有30%的杜邦TMSorona聚合物纤维，杜邦TMSorona聚合物是由1,3-丙二醇（PDO）和PTA（或DMT）两种主要原料制成的。其中PDO为其关键原料，占总原料的比重为37%。PDO可以通过石化工艺制成，而美国杜邦公司则成功地利用玉米糖发酵的方法高效地制成了生产Sorona所需的PDO，从而革命性地为化纤领域注入了环保的新概念。
从玉米中获得葡萄糖，在经过基因改造的细菌作用下，经过发酵生成PDO（1，3丙二醇），经过蒸馏PDO被提纯并脱水。这时，pdo看上去是一种清澈而略带粘稠的液体。再加入TPA（对苯二甲酸），反应后，进行SORONA切片即可制得SORONA纤维。
利用生化法生产的SORONA聚合物具有以下三重环保价值
1 有37%的原料来自天然可再生资源，而非石化原料，从而减少对石油资源的依赖性；
2 相同产量的Sorona聚合物，与基于石化原料的尼龙聚合物相比，Sorona在制成中比后者少消耗30%的能源；
3 相同产量的Sorona聚合物，与基于石化原料的尼龙聚合物相比，Sorona在制成中比后者少排放63%的二氧化碳（即温室效应气体）。
Sorona聚合物纤维具有出色的拉伸和回复性能，伸长15%后仍可100%回复，远高于涤纶与尼龙。
杀菌层3由竹纤维以及纳米级抗菌银离子母粒原生纤维编织而成，以下对纳米级抗菌银离子母粒原生纤维的杀菌原理进行具体叙述：
银的抗菌机理，为金属离子作用和光催化作用：
1、银的化学结构决定了银具有较高的催化能力，高氧化态银的还原势极高，足以使其周围空间产生原子氧。原子氧具有强氧化性可以灭菌；
2、Ag+可以强烈地吸引细菌体中蛋白酶上的巯基（-SH），迅速与其结合在一起，使蛋白酶丧失活性，导致细菌死亡。
3、当细菌被Ag+杀后，Ag+又由细菌尸体中游离出来，再与其它菌落接触，周而复始地进行上述过程，这也是银杀菌持久性的原因。
4、经权威机构（SGS）检测，该产品对金黄色葡萄球菌，大肠杆菌、白色念珠菌的抗菌率可达99%以上,且经150次洗涤后,抗菌率不变。
纳米硅粒子层和疏水性氟季胺硅烷耦合剂层的结合，水分子不容易通过，而气体分子可以通过，从而使织物具有拒水透气的效果，使人们在穿着的过程中感觉舒服。
在防水透气层2采用纳米硅粒子层和疏水性氟季胺硅烷耦合剂层的结合，水分子不容易通过，而气体分子可以通过，从而使织物具有拒水透气的效果。
生态保温棉生产工艺，包括以下步骤：
S1：棉纤维混合，将30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维通过自动混棉机混合均匀 ；
S2：将混合后的棉纤维经过预开松机混合，均匀的开松，通过输棉风机输送给下道工序；
S3：将预开松机输送过来的原料经过主开松机的进一步精开，使原料开松得更均匀，再通过输棉风机输送到给棉机储棉仓 ；
S4：给棉机将开松混合后的纤维原料，定量、均匀地喂入梳理机 ；
S5：梳理机将给棉机输出成型的棉梳理成网，形成均匀的单层棉网，输送给后道工序 其中：锡林速度1000-1200r/min，道夫20-25hz，工作辊10-12hz，上屏20-25hz，摇屏：25-30hz；
S6：铺网机将梳理机输出的单层棉网经过均匀的铺叠，铺设至所需的厚度以及宽度，连续不断的输送给下道工序 ；
S7:将70%胶原纤维、30%热熔纤维混合后经过铺网机均匀铺设成纤网；
S8：将铺好的纤网通过针刺机进行正反刺固处理，形成防水透气层；
S9: 通过贴合机将防水透气层与棉网进行贴合;
S10：通过五辊牵伸机，将贴合后的防水透气层与棉网进行纵向拉伸形成棉层，然后输送到喷胶部分 ；
S11：经过前、后喷胶箱在棉层正反面喷胶，胶料为纯丙烯酸聚合物乳液，前、后喷胶箱内抽真空保持负压状态，使得棉膨松，使用纯丙烯酸聚合物乳液作为胶料，环保且手感柔软；
S12：通过烘箱，把胶定型并烘干，使棉层达到定型的效果，烘箱温度下层为 120-140℃ ,中层为140-160℃ , 上层为 160-180℃ ；
S13：在棉层外表面涂覆有纳米硅粒子处理层，在处理层的表面涂有疏水性的氟季胺硅烷耦合剂涂层；
S14：将竹纤维以及纳米级抗菌银离子母粒原生纤维进行经纬编织形成编织网；
S15：将编织网通过粘胶固定于棉层内表面，通过植绒机对编织网表面进行植绒处理：
S16：通过收卷切边机，将已定型的产品进行切边、裁剪、卷取。
以上显示和描述了本发明的基本原理和主要特征及其优点，本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内，本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (2)
1.生态保温棉，其特征在于：包括保暖棉芯、粘结于所述保暖棉芯外侧的防水透气层、位于所述保暖棉芯内侧的柔软贴身层，所述防水透气层的厚度为所述保暖棉芯厚度的10%-15%，所述柔软贴身层的厚度为所述保暖棉芯厚度的30%-40%，所述保暖棉芯以重量百分比计，由30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维混合制造而成，所述防水透气层以重量百分比计，由70%胶原纤维、30%热熔纤维混合制造而成，所述防水透气层的外侧表面涂有纳米硅粒子处理层，所述处理层的表面涂有疏水性的氟季胺硅烷耦合剂涂层，所述柔软贴身层与所述保暖棉芯之间设置有杀菌层，所述杀菌层为由竹纤维以及纳米级抗菌银离子母粒原生纤维呈经纬编织而成编织网，所述杀菌层的外侧与所述保暖棉芯相粘结，所述柔软贴身层通过植绒的方式固定于所述杀菌层的内侧，所述柔软贴身层由长度为0.05-0.2cm的短纤维构成。
2.上述权利要求1中的生态保温棉生产工艺，其特征在于：包括以下步骤：
S1：棉纤维混合，将30%Sorona聚合物纤维、30%超细保暖纤维、30%三维中空保暖纤维、10%原生棉纤维通过自动混棉机混合均匀 ；
S2：将混合后的棉纤维经过预开松机混合，均匀的开松，通过输棉风机输送给下道工序；
S3：将预开松机输送过来的原料经过主开松机的进一步精开，使原料开松得更均匀，再通过输棉风机输送到给棉机储棉仓 ；
S4：给棉机将开松混合后的纤维原料，定量、均匀地喂入梳理机 ；
S5：梳理机将给棉机输出成型的棉梳理成网，形成均匀的单层棉网，输送给后道工序其中：锡林速度1000-1200r/min，道夫20-25hz，工作辊10-12hz，上屏20-25hz，摇屏：25-30hz；
S6：铺网机将梳理机输出的单层棉网经过均匀的铺叠，铺设至所需的厚度以及宽度，连续不断的输送给下道工序 ；
S7:将70%胶原纤维、30%热熔纤维混合后经过铺网机均匀铺设成纤网；
S8：将铺好的纤网通过针刺机进行正反刺固处理，形成防水透气层；
S9: 通过贴合机将防水透气层与棉网进行贴合;
S10：通过五辊牵伸机，将贴合后的防水透气层与棉网进行纵向拉伸形成棉层，然后输送到喷胶部分 ；
S11：经过前、后喷胶箱在棉层正反面喷胶，胶料为纯丙烯酸聚合物乳液，前、后喷胶箱内抽真空保持负压状态，使得棉层膨松；
S12：通过烘箱，把胶定型并烘干，使棉层达到定型的效果，烘箱温度下层为 120-140℃,中层为140-160℃ , 上层为 160-180℃ ；
S13：在棉层外表面涂覆有纳米硅粒子处理层，在处理层的表面涂有疏水性的氟季胺硅烷耦合剂涂层；
S14：将竹纤维以及纳米级抗菌银离子母粒原生纤维进行经纬编织形成编织网；
S15：将编织网通过粘胶固定于棉层内表面，通过植绒机对编织网表面进行植绒处理：
S16：通过收卷切边机，将已定型的产品进行切边、裁剪、卷取。
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| CN104260538A (zh) * | 2014-09-28 | 2015-01-07 | 江阴新嘉美服饰有限公司 | 抗菌棉织物超疏水涂层面料 |
| CN104354422A (zh) * | 2014-10-14 | 2015-02-18 | 江阴市悦达印染有限公司 | 使用性能好防水保暖面料 |
| CN105544094A (zh) * | 2015-12-27 | 2016-05-04 | 福建省晋江市恒丰喷胶棉织造有限公司 | 抗菌喷胶棉及其制造工艺 |
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