CN105926157B - 生态棉及其生产工艺 - Google Patents
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Abstract
本发明提供一种生态棉及其生产工艺,保暖效果更优,生态棉包括保暖棉芯、3D植绒层、柔软贴身层,保暖棉芯由30%Sorona聚合物纤维、60%超细保暖纤维、10%原生棉纤维混合制造而成,3D植绒层包括弹性基布、设置于弹性基布表面的3D植绒面层、设置于弹性基布与保暖棉芯之间的真空棉填充层,柔软贴身层包括与保暖棉芯固定的金属铝箔膜层、设置于金属铝箔膜层表面的平面植绒内衬,3D植绒面层以及平面植绒内衬均由长度为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
本发明涉及生态棉,特别涉及一种生态棉及其生产工艺。
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,从而提供一种生态棉,保暖效果更优,许多原料来自于可再生原料,环保效果好,而且强度以及柔软性极好。
发明所采用的技术方案是这样的:生态棉,包括保暖棉芯、设置于所述保暖棉芯外侧的3D植绒层、设置于所述保暖棉芯内侧的柔软贴身层,所述3D植绒层的厚度为所述保暖棉芯厚度的20%-30%,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、60%超细保暖纤维、10%原生棉纤维混合制造而成,所述3D植绒层包括弹性基布、通过3D植绒的方式设置于所述弹性基布表面的3D植绒面层、设置于所述弹性基布与所述保暖棉芯之间的真空棉填充层,所述弹性基布的边缘部与所述保暖棉芯相缝制连接,所述柔软贴身层包括与所述保暖棉芯通过针刺固定的金属铝箔膜层、通过平面植绒设置于所述金属铝箔膜层表面的平面植绒内衬,所述3D植绒面层以及所述平面植绒内衬均由长度为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,从而提供一种生态棉生产工艺。
发明所采用的技术方案是这样的,生态棉生产工艺:包括以下步骤:
S1:棉纤维混合,将30%Sorona聚合物纤维、60%超细保暖纤维、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:通过五辊牵伸机,将棉网进行纵向拉伸形成棉层,然后输送到喷胶部分 ;
S8: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;
S9: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℃ ;
S10:通过针刺将金属铝箔膜层与棉层一侧面固定,并且在金属铝箔膜层表面通过平面植绒加工平面植绒内衬;
S11:在棉层另一侧面铺设真空棉,而后覆上弹性基布进行包裹,将弹性基布的边缘与棉层通过缝制连接,在弹性基布的表面通过3D植绒的方式加工3D植绒面层;
S12: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,保暖效果更佳,通过在保暖棉芯的内侧设置金属铝箔膜层,用金属铝箔膜层的反射作用,将人体所散发的热量反射回人体,从而产生高效保暖效果,而且在金属铝箔膜层表面设置平面植绒内衬,在保证强度的同时提高柔软性能,在保暖棉芯的另一侧设置真空棉填充层以及3D植绒面层,3D植绒面层能够形成图案,增加美感,此外真空棉填充层能够在提高保暖效果的同时提高舒适度。
附图说明
图1为本发明示意图;
其中:1、保暖棉芯;2、金属铝箔膜层;3、平面植绒内衬;4、真空棉填充层;5、3D植绒面层;6、弹性基布。
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棉,包括保暖棉芯1、设置于所述保暖棉芯1外侧的3D植绒层、设置于所述保暖棉芯1内侧的柔软贴身层,所述3D植绒层的厚度为所述保暖棉芯1厚度的20%-30%,所述柔软贴身层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、60%超细保暖纤维、10%原生棉纤维混合制造而成,所述3D植绒层包括弹性基布6、通过3D植绒的方式设置于所述弹性基布6表面的3D植绒面层5、设置于所述弹性基布6与所述保暖棉芯1之间的真空棉填充层4,所述弹性基布6的边缘部与所述保暖棉芯1相缝制连接,所述柔软贴身层包括与所述保暖棉芯1通过针刺固定的金属铝箔膜层2、通过平面植绒设置于所述金属铝箔膜层2表面的平面植绒内衬3,所述3D植绒面层5以及所述平面植绒内衬3均由长度为0.05-0.2cm的短纤维构成。
生态棉含有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。
高比例超细保暖纤维能有效的留存住更多的隔绝空气并反射由人体辐射出的热量,保温性能优异,通过在保暖棉芯1的内侧设置金属铝箔膜层2,用金属铝箔膜层2的反射作用,将人体所散发的热量反射回人体,从而产生高效保暖效果,而且在金属铝箔膜层2表面设置平面植绒内衬3,在保证强度的同时提高柔软性能,在保暖棉芯1的另一侧设置真空棉填充层4以及3D植绒面层5,3D植绒面层5能够形成图案,增加美感,此外真空棉填充层4能够在提高保暖效果的同时提高舒适度。
生态棉生产工艺,包括以下步骤:
S1:棉纤维混合,将30%Sorona聚合物纤维、60%超细保暖纤维、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:通过五辊牵伸机,将棉网进行纵向拉伸形成棉层,然后输送到喷胶部分 ;
S8: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;
S9: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℃ ;
S10:通过针刺将金属铝箔膜层2与棉层一侧面固定,并且在金属铝箔膜层2表面通过平面植绒加工平面植绒内衬3;
S11:在棉层另一侧面铺设真空棉,而后覆上弹性基布6进行包裹,将弹性基布6的边缘与棉层通过缝制连接,在弹性基布6的表面通过3D植绒的方式加工3D植绒面层5;
S12: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.生态棉,其特征在于:包括保暖棉芯、设置于所述保暖棉芯外侧的3D植绒层、设置于所述保暖棉芯内侧的柔软贴身层,所述3D植绒层的厚度为所述保暖棉芯厚度的20%-30%,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、60%超细保暖纤维、10%原生棉纤维混合制造而成,所述3D植绒层包括弹性基布、通过3D植绒的方式设置于所述弹性基布表面的3D植绒面层、设置于所述弹性基布与所述保暖棉芯之间的真空棉填充层,所述弹性基布的边缘部与所述保暖棉芯相缝制连接,所述柔软贴身层包括与所述保暖棉芯通过针刺固定的金属铝箔膜层、通过平面植绒设置于所述金属铝箔膜层表面的平面植绒内衬,所述3D植绒面层以及所述平面植绒内衬均由长度为0.05-0.2cm的短纤维构成。
2.上述权利要求1中生态棉生产工艺,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、60%超细保暖纤维、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:通过五辊牵伸机,将棉网进行纵向拉伸形成棉层,然后输送到喷胶部分 ;
S8: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;
S9: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℃ ;
S10:通过针刺将金属铝箔膜层与棉层一侧面固定,并且在金属铝箔膜层表面通过平面植绒加工平面植绒内衬;
S11:在棉层另一侧面铺设真空棉,而后覆上弹性基布进行包裹,将弹性基布的边缘与棉层通过缝制连接,在弹性基布的表面通过3D植绒的方式加工3D植绒面层;
S12: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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