CN105970664A - 一种具有较高卫生性能品质的超细纤维合成革的加工方法 - Google Patents

一种具有较高卫生性能品质的超细纤维合成革的加工方法 Download PDF

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CN105970664A
CN105970664A CN201610281221.XA CN201610281221A CN105970664A CN 105970664 A CN105970664 A CN 105970664A CN 201610281221 A CN201610281221 A CN 201610281221A CN 105970664 A CN105970664 A CN 105970664A
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superfine
base fabric
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CN105970664B (zh
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顾宇霆
张鹏
吕天
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Anan (China) Co Ltd
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Abstract

本发明涉及超细纤维合成革技术领域，尤其是一种具有较高卫生性能品质的超细纤维合成革的加工方法，该方法通过改变常规超细纤维合成革密度均一的结构并对基布进行预处理，改变其表面致密层的微孔结构，使得制成的超细纤维合成革不但有着类似于真皮的特性而且还具有较高卫生性能品质。

Description

一种具有较高卫生性能品质的超细纤维合成革的加工方法
技术领域
本发明涉及超细纤维合成革技术领域，尤其是一种具有较高卫生性能品质的超细纤维合成革的加工方法。
背景技术
超细纤维合成革利用了超细纤维上巨大的比表面积和强烈的吸水作用，使其具有天然皮革的吸湿特征。然而天然皮革胶原纤维上具有很多活性基团，卫生性能非常好。但超细纤维合成革主要由两种组分组成，即聚酰胺和聚氨酯，其中聚酰胺纤维仅在分子链的末端才具有羧基和氨基，且聚酰胺纤维活性基团非常少，分子链的中间存在大量碳链和酰胺基，无侧链，导致合成革的透湿、透水透气汽性等卫生性能与天然皮革相比有较大差距.据相关资料显示，天然皮革的坯革透水汽量为800mg/(10cm2·24h)左右，而超细纤维合成革的透水汽量仅为400mg/(10cm2·24h)左右。这些性能的缺陷在根本上是由其分子结构与材料的差异引起的。
发明内容
本发明所要解决的技术问题是通过改变常规超细纤维合成革密度均一的结构并对基布进行预处理，改变其表面致密层的微孔结构，使得制成的超细纤维合成革不但有着类似于真皮的特性而且还具有较高卫生性能品质。
为解决上述技术问题，本生产方法是通过如下方式来实现的：
本发明所述的一种具有较高卫生性能品质的超细纤维合成革的加工方法包括如下步骤：
a)基布的生产制造：制备不同粗细超细纤维；按照粗细不同将超细纤维自上而下排列制成上层超细纤维较细，下层超细纤维较粗的基布；将基布至于浓硫酸和水配比的溶液中含浸，将基布经70℃烘箱中烘烤6-10min，收卷；
b)无溶剂聚氨酯的刮涂：以多NCO基预聚体、多OH基预聚体为主要原料，以WRJ-302和WRJ-514为催化剂，按照一定比例瞬间混合，并涂刮于经预处理的定型基布表面，两组分相遇，并在催化剂的作用下瞬间开始发泡，随即，基布经过一段浸入通有70℃氮气的容器当中，氮气外逸就形成了微孔结构，由此形成的微孔膜水蒸汽透过率有很大提高；之后通过70℃烘箱，在一定温度下进一步固化，交联，制成涂层后半成品；
c)涂层后半成品含浸处理：将聚氨酯，溶剂，助剂等配成具有一定固含量，粘度的浆料，注入含浸槽，将涂层后半成品通过含浸槽含浸挤压；而后进行凝固，水洗；
d)海岛纤维的开纤：将含浸后的涂层后半成品通过苯(甲苯或二甲苯)减量法进行开纤，利用海组分可以溶于热溶剂的性质，经多段溶解反复挤压去除海的组分。最终用热水水洗贝斯，除去残留的溶剂，制得开纤半成品；
e)超细纤维合成革半品的后整理及成品制造：开纤半成品进行烘干并上油烘干定型；然后经磨皮，揉皮等后整理工序获得超细纤维合成革半品；将制成的半品贝斯可通过染色、贴面、表面处理等工艺制造出优质的超细纤维合成革成品。
本发明的积极效果：本发明所述的一种具有较高卫生性能品质的超细纤维合成革的加工方法采用不同粗细纤维组成的梯度基布与表面无溶剂聚氨酯进行结合的到具有较高卫生性能品质且手感类似于真皮的密度梯度结构；将基布经硫酸进行水解处理，涂刮具有特殊微孔结构的无溶剂聚氨酯致密层，再进行含浸、减量、后整理工艺，最终形成表层密度最高，向下逐渐降低，类似于真皮的密度梯度结构；通过对基布的预处理及改变表面致密层的微孔结构，获得了较高卫生性能品质。
具体实施方式
图1为不同粗细超细纤维的制备的示意图
图2为基布的加工示意图
图3为基布的硫酸水解处理的示意图
图4为无溶剂聚氨酯的刮涂的示意图
图5为涂层后半成品含浸处理的示意图
图6为海岛纤维的开纤处理的示意图
图7为超细纤维合成革半品的后整理及成品制造
本发明所述的一种具有较高卫生性能品质的超细纤维合成革的加工方法包括如下步骤：
1、不同粗细超细纤维的制备：将海组分切片(如低密度聚乙烯、聚丙烯等切片)和岛组分切片(如聚酰胺、聚酯切片)以45/55～60/40的比例混合，通过熔融纺或者复合纺的方式纺丝，初生的丝条在内环吹风条件下冷却成形；并利用牵伸辊的牵伸作用提高丝条内部的高聚物分子的趋向一致性，此时丝条内部结构基本达到要求；为了避免断丝及静电，我们将纤维丝束经过油浴完成上油，油浴可以通过将油剂加在热水浴中，拉伸的同时进行上油，还可通过将纤维丝束拉伸后单独的上油机补充上油；在制作两种不同粗细超细纤维时，我们通过调节牵伸辊的牵伸比即通过控制不同的牵伸速度来制备不同粗细的超细纤维，一牵速度在20-40m/min，二牵速度在50-60m/min，三牵速度在60-70m/min，不同牵伸比得到不同粗细的超细纤维，牵伸比一般控制在2.8-4.0；然后通过叠丝机、卷曲机将拉伸后的纤维进行卷曲加工，增加纤维之间的抱和力，卷曲度和卷曲个数可以调节；输送过程中进行铺丝，再经过松弛热定型机的作用以后，丝条的内部结构、物理性能和丝条的外观形状就达到生产要求并稳定下来；最后将干燥定型后的丝束根据产品要求切成规定长度的短纤，成品丝通过风送管道进入打包机完成包装；纤维按照不同粗细分开打包。
2、基布的准备：准备不同粗细的超细纤维，按照粗细不同将超细纤维自上而下排列制成上层超细纤维较细，下层超细纤维较粗的基布；
将准备好的不同粗细的超细纤维分别放入开松混合机进行开松混合，并添加特定油剂(棕榈油脂、乳化剂、抗静电剂)进行包括防静电在内的可纺性的优化；将粗超细纤维先放入梳理机进行纤维梳理，梳理后的纤维通过喂入装置进入高精度的铺网机铺设成网，随后经过第一道预刺；通过另一梳理机将梳理好的细超细纤维开始在已预刺好的粗超细纤维上铺网；将厚度均匀但密度呈梯度排列的细超细纤维与粗超细纤维铺设的纤网，以恒定速度通过针刺机或水刺机，在针刺或水刺的作用下纤网内部纤维互相缠结抱和，形成结构及物理性能稳定非织造布；非织造布通过热定型固定厚度和形状，最终制成上层超细纤维较细，下层超细纤维较粗的定型基布。
3、基布的硫酸水解处理：
浓硫酸和水按照5％、15％、25％的比例配成一定溶液，当溶液温度为50℃时，将基布至于溶液中，按照不同配比控制含浸时间约5min，10min，15min，待基布完全浸透后取出，在压辊上压一次，之后，按以上步骤重复再浸泡，挤压2次，然后将基布经70℃烘箱中烘烤6-10min，收卷。
以基布的撕裂强度，断裂伸长率，透水汽性为考察指标进行取样测试。结果表明，当硫酸用量在5％至15％之间，浸泡时间为10min时，基布的撕裂强度、断裂伸长率和透水汽性增大；随着硫酸用量的继续增加，基布的抗张强度、断裂伸长率和透水汽性明显下降，主要原因是最初硫酸用量少，作用时间短时，超细纤维合成革基布表面的酰胺键断裂，紊乱的纤维互相交缠导致了物理性能提高；当硫酸用量为15％，浸泡10min时，基布的透水汽性达到最大值，相比没处理的基布提高了14％，可能是由于水解使得超细纤维合成革基布暴露的活性基团增加。
4、无溶剂聚氨酯的刮涂：
一般的无溶剂聚氨酯是十分致密的，透水汽性不好.如果我们可以选择在其成膜的过程中加入致孔剂，增加聚氨酯面层的孔隙率，则可以有效提高其透水透汽、透湿性性。本产品以多NCO基预聚体、多OH基预聚体为主要原料，以WRJ-302和WRJ-514为催化剂，按照一定比例瞬间混合，并涂刮于经预处理的定型基布表面，两组分相遇，并在催化剂的作用下瞬间开始发泡，随即，基布经过一段浸入通有70℃氮气的容器当中，氮气外逸就形成了微孔结构，由此形成的微孔膜水蒸汽透过率有很大提高；之后通过70℃烘箱，在一定温度下进一步固化，交联，制成涂层后半成品。
5、涂层后半成品含浸处理：将聚氨酯，溶剂，助剂等配成具有一定固含量，粘度的浆料，注入含浸槽，将涂层后半成品通过含浸槽含浸挤压；而后进行凝固，水洗。
6、海岛纤维的开纤：将含浸后的涂层后半成品通过苯(甲苯或二甲苯)减量法进行开纤，利用海组分可以溶于热溶剂的性质，经多段溶解反复挤压去除海的组分。最终用热水水洗贝斯，除去残留的溶剂，制得开纤半成品。
7、超细纤维合成革半品的后整理及成品制造：开纤半成品进行烘干并上油烘干定型；然后经磨皮，揉皮等后整理工序获得超细纤维合成革半品；将制成的半品贝斯可通过染色、贴面、表面处理等工艺制造出优质的超细纤维合成革成品。

Claims (4)

1.一种具有较高卫生性能品质的超细纤维合成革的加工方法，其特征在于：包括如下步骤：
a)基布的生产制造：制备不同粗细超细纤维；按照粗细不同将超细纤维自上而下排列制成上层超细纤维较细，下层超细纤维较粗的基布；将基布至于浓硫酸和水配比的溶液中含浸，将基布经70℃烘箱中烘烤6-10min，收卷；
b)无溶剂聚氨酯的刮涂：以多NCO基预聚体、多OH基预聚体为主要原料，以WRJ-302和WRJ-514为催化剂，按照一定比例瞬间混合，并涂刮于经预处理的定型基布表面，两组分相遇，并在催化剂的作用下瞬间开始发泡，随即，基布经过一段浸入通有70℃氮气的容器当中，氮气外逸就形成了微孔结构，由此形成的微孔膜水蒸汽透过率有很大提高；之后通过70℃烘箱，在一定温度下进一步固化，交联，制成涂层后半成品；
c)涂层后半成品含浸处理：将聚氨酯，溶剂，助剂等配成具有一定固含量，粘度的浆料，注入含浸槽，将涂层后半成品通过含浸槽含浸挤压；而后进行凝固，水洗；
d)海岛纤维的开纤：将含浸后的涂层后半成品通过苯(甲苯或二甲苯)减量法进行开纤，利用海组分可以溶于热溶剂的性质，经多段溶解反复挤压去除海的组分。最终用热水水洗贝斯，除去残留的溶剂，制得开纤半成品；
e)超细纤维合成革半品的后整理及成品制造：开纤半成品进行烘干并上油烘干定型；然后经磨皮，揉皮等后整理工序获得超细纤维合成革半品；将制成的半品贝斯可通过染色、贴面、表面处理等工艺制造出优质的超细纤维合成革成品。
2.根据权利要求1所述的一种具有较高卫生性能品质的超细纤维合成革的加工方法，其特征在于：步骤a中制备不同粗细超细纤维的方法包括：将海组分切片和岛组分切片以45/55～60/40的比例混合，通过熔融纺或者复合纺的方式纺丝，初生的丝条在内环吹风条件下冷却成形；并利用牵伸辊的牵伸作用提高丝条内部的高聚物分子的趋向一致性，此时丝条内部结构基本达到要求；为了避免断丝及静电，将纤维丝束经过油浴完成上油，油浴可以通过将油剂加在热水浴中，拉伸的同时进行上油，还可通过将纤维丝束拉伸后单独的上油机补充上油；
在制作两种不同粗细超细纤维时，我们通过调节牵伸辊的牵伸比即通过控制不同的牵伸速度来制备不同粗细的超细纤维，牵伸速度分别设定在20-40m/min、50-60m/min和60-70m/min，可得到不同粗细的超细纤维，牵伸比一般控制在2.8-4.0；然后通过叠丝机、卷曲机将拉伸后的纤维进行卷曲加工，增加纤维之间的抱和力，卷曲度和卷曲个数可以调节；输送过程中进行铺丝，再经过松弛热定型机的作用以后，丝条的内部结构、物理性能和丝条的外观形状就达到生产要求并稳定下来；最后将干燥定型后的丝束根据产品要求切成规定长度的短纤，成品丝通过风送管道进入打包机完成包装；纤维按照不同粗细分开打包。
3.根据权利要求1所述的一种具有较高卫生性能品质的超细纤维合成革的加工方法，其特征在于：步骤a中按照粗细不同将超细纤维自上而下排列制成上层超细纤维较细，下层超细纤维较粗的基布的方法包括：将准备好的不同粗细的超细纤维分别放入开松混合机进行开松混合，并添加棕榈油脂、乳化剂、抗静电剂等特定油剂进行包括防静电在内的可纺性的优化；将粗超细纤维先放入梳理机进行纤维梳理，梳理后的纤维通过喂入装置进入高精度的铺网机铺设成网，随后经过第一道预刺；通过另一梳理机将梳理好的细超细纤维开始在已预刺好的粗超细纤维上铺网；将厚度均匀但密度呈梯度排列的细超细纤维与粗超细纤维铺设的纤网，以恒定速度通过针刺机或水刺机，在针刺或水刺的作用下纤网内部纤维互相缠结抱和，形成结构及物理性能稳定非织造布；非织造布通过热定型固定厚度和形状，最终制成上层超细纤维较细，下层超细纤维较粗的定型基布。
4.根据权利要求1所述的一种具有较高卫生性能品质的超细纤维合成革的加工方法，其特征在于：步骤a中将基布置于硫酸中含浸处理包括：将浓硫酸和水按照5％、15％、25％的比例配成一定溶液，当溶液温度为50℃时，将基布至于溶液中，按照不同配比控制含浸时间控制在5min、10min、15min，待基布完全浸透后取出，在压辊上压一次，之后，按以上步骤重复再浸泡，挤压2次，然后将基布经70℃烘箱中烘烤6-10min，收卷。
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CN109023717A (zh) * 2018-08-16 2018-12-18 吉安市三江超纤无纺有限公司 一种多层超纤仿真皮革基布制造方法
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CN111501363A (zh) * 2020-05-12 2020-08-07 明新孟诺卡(江苏)新材料有限公司 一种高仿真超纤制备方法
CN113403856A (zh) * 2021-05-27 2021-09-17 安安(中国)有限公司 一种超高防水透气性能的超细纤维合成革的加工方法
CN114481455A (zh) * 2022-04-14 2022-05-13 天津齐邦新材料有限公司 一种长丝超细纤维面膜布及其制备方法
CN114481455B (zh) * 2022-04-14 2022-06-28 天津齐邦新材料有限公司 一种长丝超细纤维面膜布及其制备方法

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