CN106042572A - 一种高速列车座椅用面料及其制造方法 - Google Patents

一种高速列车座椅用面料及其制造方法 Download PDF

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CN106042572A
CN106042572A CN201610527800.8A CN201610527800A CN106042572A CN 106042572 A CN106042572 A CN 106042572A CN 201610527800 A CN201610527800 A CN 201610527800A CN 106042572 A CN106042572 A CN 106042572A
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CN106042572B (zh
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范铁明
徐伯初
张夫也
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Southwest Jiaotong University
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    • B32B7/04Interconnection of layers
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    • DTEXTILES; PAPER
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    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
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    • D06M11/68Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof
    • D06M11/70Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with phosphorus or compounds thereof, e.g. with chlorophosphonic acid or salts thereof with oxides of phosphorus; with hypophosphorous, phosphorous or phosphoric acids or their salts
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Abstract

本发明公开了一种高速列车座椅用面料及其制造方法,所述面料,包括外层磷化聚酯阻燃短纤维无纺布层和内层磷化聚酯阻燃短纤维无纺布层,所述外层磷化聚酯阻燃短纤维无纺布层和内层磷化聚酯阻燃短纤维无纺布层之间设有磷化聚酯阻燃长纤维无纺布层,所述内层磷化聚酯阻燃短纤维无纺布层背面设有壳聚糖纤维和改性聚酯纤维混合无纺布层,所述改性聚酯纤维为无机硅酸盐粉末与聚酯通过熔融共混纺丝制成的聚酯纤维;所述外层磷化聚酯阻燃短纤维无纺布层,本发明的高速列车座椅用面料阻燃、抗污、抗菌能力强,舒适性高。

Description

一种高速列车座椅用面料及其制造方法
技术领域
本发明涉及一种高速列车座椅用面料及其制造方法。
背景技术
高速列车座椅面料对氧指数(阻燃性)有较高要求,同时,在日常使用时,高速列车座椅会沾染油、饮料等各种污渍,由于无法及时清洗,导致高速列车座椅面料增生了大量的细菌,此外,随着科技的进步,人们对座椅舒适度的要求也越来越高;现有技术中,多数的面料,其对氧指数(阻燃性)无法满足相关要求,同时,现有高速列车座椅面料无抗污和抗菌能力,而且舒适度较差。
发明内容
本发明的目的是为了克服上述现有技术存在的缺陷而提供了一种具有阻燃能力,同时能够抗污、抗菌、舒适性较高的高速列车座椅用面料及其制造方法。
本发明的目的可以通过以下技术方案来实现:
一种高速列车座椅用面料,包括外层磷化聚酯阻燃短纤维无纺布层和内层磷化聚酯阻燃短纤维无纺布层,所述外层磷化聚酯阻燃短纤维无纺布层和内层磷化聚酯阻燃短纤维无纺布层之间设有磷化聚酯阻燃长纤维无纺布层,所述内层磷化聚酯阻燃短纤维无纺布层背面设有壳聚糖纤维和改性聚酯纤维混合无纺布层,所述改性聚酯纤维为无机硅酸盐粉末与聚酯通过熔融共混纺丝制成的聚酯纤维;所述外层磷化聚酯阻燃短纤维无纺布层,内层磷化聚酯阻燃短纤维无纺布层和磷化聚酯阻燃长纤维无纺布层中的磷化聚酯满足下列方程组:
tanδmax≥0.176
Tα-3.77×ln(dtpf)≤135
1.334≤SG-Δn 8.64≤1.341
上述方程组中:
Tanδmax为动态粘弹性测量中损耗角正切的最大值;Tα为损耗角正切达到最大值时的温度,单位为℃;dtpf为单根纤维的细度,单位为dtex;SG为密度,单位为g/cm3;Δn是双折射;
所述磷化聚酯中磷原子的含量为800-45000ppm。
进一步的,在所述壳聚糖纤维和改性聚酯纤维混合无纺布层背面设置有阻燃隔热弹性聚酯层。
进一步的,所述壳聚糖纤维长度为42-55mm,所述改性聚酯纤维长度为42-55mm,所述壳聚糖纤维卷曲度为7-10卷曲/cm。
进一步的,所述无机硅酸盐为高岭土、蒙脱土、片状云母、锂皂土片状硅酸盐材料的一种或几种的混合物。
上述高速列车座椅用面料的制造方法,包括如下步骤:
A:制备外层磷化聚酯阻燃短纤维无纺布层和内层磷化聚酯阻燃短纤维无纺布层:
A1:以质量百分数计,将82-90%的磷化聚酯切片,4-12%的阻燃剂,2-5%的分散润滑剂和2-5%的辅料混合;
A2:将混合后的原料通过开松机开松;
A3:将开松后的混合物进行纤维梳理;
A4:用梳理后的纤维进行铺网;
A5:对铺网纤维进行成型加工,制成无纺布;
A6:将无纺布通过成卷机进行卷取,制得外层磷化聚酯阻燃短纤维无纺布层;
内层磷化聚酯阻燃短纤维无纺布层的制备方法与外层磷化聚酯阻燃短纤维无纺布层的制备方法相同;
B:制备磷化聚酯阻燃长纤维无纺布层:
B1:以质量百分数计,20-30%的超细氢氧化铝,20-30%的超细氢氧化镁、15-20%的纳米级凹凸棒土、10-20%的纳米氧化锌、2-5%的表面活性剂、3-5%的偶联剂和3-4%的抑烟剂加入高速混合机,高速混合制得复合阻燃剂;
B2:以质量百分数计,10-20%的磷化聚酯切片和10-20%的复合阻燃剂在220~250℃下进行共混造粒,制得阻燃熔喷磷化聚酯切片;
B3:将阻燃熔喷磷化聚酯切片送入螺杆挤出机中进行熔喷纺丝,熔体经螺杆到纺丝组件再到喷丝板喷出,经高速热气流牵伸后制成熔喷超细纤维,熔喷纺丝温度为240~270℃,纺丝速度为100~1000m/min,喷丝板上喷丝孔的孔径是0.2~0.35mm;
B4:通过过滤器进行过滤,再进入到纺丝箱中进行拉丝;
B5:通过成网机中进行铺网,再在热轧机中进行预热轧;
B6:通过成卷机进行卷取,制得磷化聚酯阻燃长纤维无纺布层;
C:将磷化聚酯阻燃长纤维无纺布层与内层磷化聚酯阻燃短纤维无纺布层通过倒刺机针刺覆合,形成磷化聚酯阻燃长纤维无纺布层与内层磷化聚酯阻燃短纤维无纺布层的覆合层,再将外层磷化聚酯阻燃短纤维无纺布层放在磷化聚酯阻燃长纤维无纺布层上面,通过倒刺机针刺覆合,形成磷化聚酯阻燃长纤维无纺布层、内层磷化聚酯阻燃短纤维无纺布层与外层磷化聚酯阻燃短纤维无纺布层的覆合层,通过倒刺机针刺覆合时,针刺密度控制在50-90针/平方厘米,针刺深度控制在10-12mm;
D:用分散染料对磷化聚酯阻燃长纤维无纺布层、内层磷化聚酯阻燃短纤维无纺布层与外层磷化聚酯阻燃短纤维无纺布层的覆合层进行染色处理60分钟,染色条件:以体积百分数计,染液比为1∶50,温度为145℃,染色处理后,洗涤,干燥;
E:将染色处理后的磷化聚酯阻燃长纤维无纺布层、内层磷化聚酯阻燃短纤维无纺布层与外层磷化聚酯阻燃短纤维无纺布层的覆合层浸轧整理液,整理液的组分为:280-360g/L阻燃剂FPK8002,70-120g/L防水拒油剂有机硅氟树脂,60-100g/L防紫外剂HTUV100,22-25g/L浓度为80%的磷酸,15-25g/L交链剂AF6900,二浸二轧,在100-105℃的温度热烘3-5分钟后,再在135-145℃的温度下焙烘2-5分钟;焙烘完毕后,用碳酸钠混合洗涤剂在60-65℃的温度下碱洗2-4分钟后,再在40-60℃的热水下洗4-6分钟,然后水洗、烘干;
F:制备壳聚糖纤维和改性聚酯纤维混合无纺布层:
F1:制备改性聚酯纤维:
F11:将无机硅酸盐粉碎、筛分得到具有纳米尺寸粉体,然后将得到的具有纳米尺寸粉体经硅烷偶联剂或钛酸酯偶联剂进行表面改性,以增加其与聚酯的相容性;
F12:以质量百分数计,将0.5-5%的经过经硅烷偶联剂或钛酸酯偶联剂进行表面改性的硅酸盐纳米粉体与95-99.5%的聚酯干燥后进行熔融纺丝,熔融纺丝工艺参数为:纺丝温度:260℃-300℃,纺丝速度:400-5000m/min,牵伸温度:70℃-160℃,牵伸倍数:1-5倍;纺制具有导热导湿功能的改性聚酯纤维;
F2:成网前准备;
F21:选择纤维:以质量百分数计,50-60%的壳聚糖纤维和40-50%的改性聚酯纤维开松混合;
F22:开包机开棉
a、粗开松工序:将混合后的壳聚糖纤维和改性聚酯纤维投入到输送平帘上,送入到粗开松机,制得初步开松的短纤;
b、混棉工序:通过风送和旋风分离器,使短纤均匀分布在混棉大仓进行沉积,保证棉层高度一致,通过平帘和角钉斜帘的共同作用,使其输送到精开机;所述混棉大仓的尺寸为:4100×2300×4200mm;
c、精开松工序:原料经过混棉充分混合后,喂入精开松机,在精开松机内进行充分开松和预梳理,使纤维进一步开松、拉直,通过风机喂入下道工序;
d、气压棉箱给棉:经过精开松机的纤维通过风送管道进入到气压棉箱的上棉箱,通过给棉罗拉和道夫梳理机的作用使纤维以“雪花状”落到下棉箱中,然后以均衡压力的方式把纤维定积给出;
F23:梳理:梳理机接收气压棉箱给入的纤维,进入到给棉辊后,通过双锡林双道夫梳理机的作用,梳理成均匀的5—20克/平方米双层纤维网状薄层;
F3:铺网
F31:交叉铺网:5—20克/平方米双层纤维网状薄层经过夹持碳帘的握持输送,使双层纤维网状薄层在不受外力的作用下,通过往复作用,制成网层为7—18层,棉网厚度为10—40cm的纤维网,供下道工序使用;
F32:喂入机:在针刺机前喂入,使纤维网在针刺前均匀的夹持喂入针区;
F4:针刺机加固
F41:预针刺加固:将经过梳理、铺网形成的纤维网通过单针板上针刺机预针刺工序将纤维网初步缠结定型,保证原纤维网的方向不变;
F42:主针刺加固:将经过预针刺初步缠结的纤维网通过双针板异位对刺针刺机针刺缠结;
F43:修面针刺加固:将经过主针刺加固缠结的针刺无纺布通过修面针刺机正反两面针刺,制成成型针刺无纺布;
F44:用储布张力架进行储布;
F45:用自动定长切边卷绕机进行成卷收卷;
F5:采用热收缩定型的方式降低成型针刺无纺布的热收缩率,改善性能;
G:将步骤F中制备的壳聚糖纤维和改性聚酯纤维混合无纺布层通过热烫复合机在170-180℃下与步骤E中得到的产品的内层磷化聚酯阻燃短纤维无纺布层背面有效复合在一起。
进一步的,在步骤G后设置如下步骤:
H:制备阻燃隔热弹性聚酯层:
H1:将磷系共聚型永久阻燃聚酯切片放入真空转鼓干燥设备中,在真空条件下,缓慢升温至110~145℃,进行预结晶2~6h,再转入充填式干燥塔中,升温140~165℃,干燥3~8h,达到水份含量≤30ppm;纺丝温度为255~282℃,经螺杆挤压机熔融、静态混合、过滤后,进入箱体计量泵计量,通过“C”型中空喷丝板挤出,经环吹风温度为15~25℃,环吹风速度1.5~4.5m/s的非对称环吹强风骤冷制得初生丝;将初生丝平衡、集束后,经为2.5~4.0牵伸倍数的牵伸、卷曲、切断及130~180℃松驰热定型制得2~10D的阻燃三维螺旋型卷曲中空聚酯纤维;
H2:将85~95wt%的2~10D的阻燃三维螺旋型卷曲中空聚酯纤维、15~5wt%熔点为120~180℃的涤纶短纤维混匀,再经过清花、梳棉、纵向与横向交叉铺网,之后经过热轧机或热风烘燥机将120~180℃的涤纶短纤维熔化与阻燃三维螺旋型卷曲中空聚酯纤维在120~190℃温度下热粘合,制得立体网状型的阻燃隔热弹性聚酯层;
I:将步骤H中制备的阻燃隔热弹性聚酯层通过热烫复合机在170-180℃下与步骤G中得到的产品的壳聚糖纤维和改性聚酯纤维混合无纺布层背面有效复合在一起。
进一步的,步骤H1中,磷系共聚型永久阻燃聚酯切片的磷含量为7500~8500ppm,特性粘度为0.65~0.80dl/g,熔点≥240℃,二甘醇≤3.0%,端羧基≤30mol/t。
进一步的,步骤A5中,对铺网纤维进行成型加工的方法可以为针刺法,所述针刺法包括:
A51:通过输送帘将铺网纤网不断送入针刺机中,经预针刺机与下针刺机、主针刺机进行针刺;然后经烫辊进行烫压成型,所述预针刺机针深深度为7~9mm,下针刺机针深深度为5~6mm,主针刺机针深深度为3~4mm;预针刺的针频为15~20HZ,下针刺针频为28~35HZ,主针刺针频为30~40HZ;烫辊的温度为185℃~192℃,烫压压力为0.3MPa,烫压时间为7S~9S;
A52:经过针刺成型后的无纺布送入热风炉中,进行干燥和热定型。
进一步的,步骤A5中,对铺网纤维进行成型加工的方法可以为热风法,所述热风法包括:
A51:将铺网的纤维送入烘箱,在160℃~200℃烘烤温度下进行8min~15min烘烤成型;
A52:将成型的纤维取出烘箱,用温度为10℃~20℃的冷水辊冷却施压,所施压力为0.1MPa;
A53:通过冷风机吹风冷却成型,冷风温度10℃~18℃。
与现有技术相比,本发明所述的高速列车座椅用面料,达到了如下效果:
1)、通过设置磷化聚酯阻燃层和含有磷系共聚型永久阻燃聚酯的阻燃隔热弹性聚酯层提高了面料的阻燃能力;
2)、通过浸轧整理液,实现了面料的抗污能力;
3)、通过外层采用无纺布,内层增加阻燃隔热弹性聚酯层,提高了面料的舒适度。
附图说明
下面结合附图和具体实施方式对本发明作进一步描述。
图1为本发明不含阻燃隔热弹性聚酯层面料的结构示意图。
图2为本发明含有阻燃隔热弹性聚酯层面料的结构示意图。
具体实施方式
参见图1-图2,本发明的一种高速列车座椅用面料,包括外层磷化聚酯阻燃短纤维无纺布层1和内层磷化聚酯阻燃短纤维无纺布层2,所述外层磷化聚酯阻燃短纤维无纺布层1和内层磷化聚酯阻燃短纤维无纺布层2之间设有磷化聚酯阻燃长纤维无纺布层3,所述内层磷化聚酯阻燃短纤维无纺布层2背面设有壳聚糖纤维和改性聚酯纤维混合无纺布层4,所述改性聚酯纤维为无机硅酸盐粉末与聚酯通过熔融共混纺丝制成的聚酯纤维;所述外层磷化聚酯阻燃短纤维无纺布层1,内层磷化聚酯阻燃短纤维无纺布层2和磷化聚酯阻燃长纤维无纺布层3中的磷化聚酯满足下列方程组:
tanδmax≥0.176
Tα-3.77×ln(dtpf)≤135
1.334≤SG-Δn 8.64≤1.341
上述方程组中:
Tanδmax为动态粘弹性测量中损耗角正切的最大值;Tα为损耗角正切达到最大值时的温度,单位为℃;dtpf为单根纤维的细度,单位为dtex;SG为密度,单位为g/cm3;Δn是双折射;
所述磷化聚酯中磷原子的含量为800-45000ppm。
优选的,在所述壳聚糖纤维和改性聚酯纤维混合无纺布层4背面设置有阻燃隔热弹性聚酯层5。
优选的,所述壳聚糖纤维长度为42-55mm,所述改性聚酯纤维长度为42-55mm,所述壳聚糖纤维卷曲度为7-10卷曲/cm。
优选的,所述无机硅酸盐为高岭土、蒙脱土、片状云母、锂皂土片状硅酸盐材料的一种或几种的混合物。
一种上述高速列车座椅用面料的制造方法,包括如下步骤:
A:制备外层磷化聚酯阻燃短纤维无纺布层1和内层磷化聚酯阻燃短纤维无纺布层2:
A1:以质量百分数计,将82-90%的磷化聚酯切片,4-12%的阻燃剂,2-5%的分散润滑剂和2-5%的辅料混合;
A2:将混合后的原料通过开松机开松;
A3:将开松后的混合物进行纤维梳理;
A4:用梳理后的纤维进行铺网;
A5:对铺网纤维进行成型加工,制成无纺布;
A6:将无纺布通过成卷机进行卷取,制得外层磷化聚酯阻燃短纤维无纺布层1;
内层磷化聚酯阻燃短纤维无纺布层2的制备方法与外层磷化聚酯阻燃短纤维无纺布层1的制备方法相同;
B:制备磷化聚酯阻燃长纤维无纺布层3:
B1:以质量百分数计,20-30%的超细氢氧化铝,20-30%的超细氢氧化镁、15-20%的纳米级凹凸棒土、10-20%的纳米氧化锌、2-5%的表面活性剂、3-5%的偶联剂和3-4%的抑烟剂加入高速混合机,高速混合制得复合阻燃剂;
B2:以质量百分数计,10-20%的磷化聚酯切片和10-20%的复合阻燃剂在220~250℃下进行共混造粒,制得阻燃熔喷磷化聚酯切片;
B3:将阻燃熔喷磷化聚酯切片送入螺杆挤出机中进行熔喷纺丝,熔体经螺杆到纺丝组件再到喷丝板喷出,经高速热气流牵伸后制成熔喷超细纤维,熔喷纺丝温度为240~270℃,纺丝速度为100~1000m/min,喷丝板上喷丝孔的孔径是0.2~0.35mm;
B4:通过过滤器进行过滤,再进入到纺丝箱中进行拉丝;
B5:通过成网机中进行铺网,再在热轧机中进行预热轧;
B6:通过成卷机进行卷取,制得磷化聚酯阻燃长纤维无纺布层3;
C:将磷化聚酯阻燃长纤维无纺布层3与内层磷化聚酯阻燃短纤维无纺布层2通过倒刺机针刺覆合,形成磷化聚酯阻燃长纤维无纺布层3与内层磷化聚酯阻燃短纤维无纺布层2的覆合层,再将外层磷化聚酯阻燃短纤维无纺布层1放在磷化聚酯阻燃长纤维无纺布层3上面,通过倒刺机针刺覆合,形成磷化聚酯阻燃长纤维无纺布层3、内层磷化聚酯阻燃短纤维无纺布层2与外层磷化聚酯阻燃短纤维无纺布层1的覆合层,通过倒刺机针刺覆合时,针刺密度控制在50-90针/平方厘米,针刺深度控制在10-12mm;
D:用分散染料对磷化聚酯阻燃长纤维无纺布层3、内层磷化聚酯阻燃短纤维无纺布层2与外层磷化聚酯阻燃短纤维无纺布层1的覆合层进行染色处理60分钟,染色条件:以体积百分数计,染液比为1∶50,温度为145℃,染色处理后,洗涤,干燥;
E:将染色处理后的磷化聚酯阻燃长纤维无纺布层3、内层磷化聚酯阻燃短纤维无纺布层2与外层磷化聚酯阻燃短纤维无纺布层1的覆合层浸轧整理液,整理液的组分为:280-360g/L阻燃剂FPK8002,70-120g/L防水拒油剂有机硅氟树脂,60-100g/L防紫外剂HTUV100,22-25g/L浓度为80%的磷酸,15-25g/L交链剂AF6900,二浸二轧,在100-105℃的温度热烘3-5分钟后,再在135-145℃的温度下焙烘2-5分钟;焙烘完毕后,用碳酸钠混合洗涤剂在60-65℃的温度下碱洗2-4分钟后,再在40-60℃的热水下洗4-6分钟,然后水洗、烘干;
F:制备壳聚糖纤维和改性聚酯纤维混合无纺布层4:
F1:制备改性聚酯纤维:
F11:将无机硅酸盐粉碎、筛分得到具有纳米尺寸粉体,然后将得到的具有纳米尺寸粉体经硅烷偶联剂或钛酸酯偶联剂进行表面改性,以增加其与聚酯的相容性;
F12:以质量百分数计,将0.5-5%的经过经硅烷偶联剂或钛酸酯偶联剂进行表面改性的硅酸盐纳米粉体与95-99.5%的聚酯干燥后进行熔融纺丝,熔融纺丝工艺参数为:纺丝温度:260℃-300℃,纺丝速度:400-5000m/min,牵伸温度:70℃-160℃,牵伸倍数:1-5倍;纺制具有导热导湿功能的改性聚酯纤维;
F2:成网前准备;
F21:选择纤维:以质量百分数计,50-60%的壳聚糖纤维和40-50%的改性聚酯纤维开松混合;
F22:开包机开棉
a、粗开松工序:将混合后的壳聚糖纤维和改性聚酯纤维投入到输送平帘上,送入到粗开松机,制得初步开松的短纤;
b、混棉工序:通过风送和旋风分离器,使短纤均匀分布在混棉大仓进行沉积,保证棉层高度一致,通过平帘和角钉斜帘的共同作用,使其输送到精开机;所述混棉大仓的尺寸为:4100×2300×4200mm;
c、精开松工序:原料经过混棉充分混合后,喂入精开松机,在精开松机内进行充分开松和预梳理,使纤维进一步开松、拉直,通过风机喂入下道工序;
d、气压棉箱给棉:经过精开松机的纤维通过风送管道进入到气压棉箱的上棉箱,通过给棉罗拉和道夫梳理机的作用使纤维以“雪花状”落到下棉箱中,然后以均衡压力的方式把纤维定积给出;
F23:梳理:梳理机接收气压棉箱给入的纤维,进入到给棉辊后,通过双锡林双道夫梳理机的作用,梳理成均匀的5—20克/平方米双层纤维网状薄层;
F3:铺网
F31:交叉铺网:5—20克/平方米双层纤维网状薄层经过夹持碳帘的握持输送,使双层纤维网状薄层在不受外力的作用下,通过往复作用,制成网层为7—18层,棉网厚度为10—40cm的纤维网,供下道工序使用;
F32:喂入机:在针刺机前喂入,使纤维网在针刺前均匀的夹持喂入针区;
F4:针刺机加固
F41:预针刺加固:将经过梳理、铺网形成的纤维网通过单针板上针刺机预针刺工序将纤维网初步缠结定型,保证原纤维网的方向不变;
F42:主针刺加固:将经过预针刺初步缠结的纤维网通过双针板异位对刺针刺机针刺缠结;
F43:修面针刺加固:将经过主针刺加固缠结的针刺无纺布通过修面针刺机正反两面针刺,制成成型针刺无纺布;
F44:用储布张力架进行储布;
F45:用自动定长切边卷绕机进行成卷收卷;
F5:采用热收缩定型的方式降低成型针刺无纺布的热收缩率,改善性能;
G:将步骤F中制备的壳聚糖纤维和改性聚酯纤维混合无纺布层4通过热烫复合机在170-180℃下与步骤E中得到的产品的内层磷化聚酯阻燃短纤维无纺布层2背面有效复合在一起。
优选的,在步骤G后设置如下步骤:
H:制备阻燃隔热弹性聚酯层5:
H1:将磷系共聚型永久阻燃聚酯切片放入真空转鼓干燥设备中,在真空条件下,缓慢升温至110~145℃,进行预结晶2~6h,再转入充填式干燥塔中,升温140~165℃,干燥3~8h,达到水份含量≤30ppm;纺丝温度为255~282℃,经螺杆挤压机熔融、静态混合、过滤后,进入箱体计量泵计量,通过“C”型中空喷丝板挤出,经环吹风温度为15~25℃,环吹风速度1.5~4.5m/s的非对称环吹强风骤冷制得初生丝;将初生丝平衡、集束后,经为2.5~4.0牵伸倍数的牵伸、卷曲、切断及130~180℃松驰热定型制得2~10D的阻燃三维螺旋型卷曲中空聚酯纤维;
H2:将85~95wt%的2~10D的阻燃三维螺旋型卷曲中空聚酯纤维、15~5wt%熔点为120~180℃的涤纶短纤维混匀,再经过清花、梳棉、纵向与横向交叉铺网,之后经过热轧机或热风烘燥机将120~180℃的涤纶短纤维熔化与阻燃三维螺旋型卷曲中空聚酯纤维在120~190℃温度下热粘合,制得立体网状型的阻燃隔热弹性聚酯层5;
I:将步骤H中制备的阻燃隔热弹性聚酯层5通过热烫复合机在170-180℃下与步骤G中得到的产品的壳聚糖纤维和改性聚酯纤维混合无纺布层4背面有效复合在一起。
优选的,步骤H1中,磷系共聚型永久阻燃聚酯切片的磷含量为7500~8500ppm,特性粘度为0.65~0.80dl/g,熔点≥240℃,二甘醇≤3.0%,端羧基≤30mol/t。
优选的,步骤A5中,对铺网纤维进行成型加工的方法可以为针刺法,所述针刺法包括:
A51:通过输送帘将铺网纤网不断送入针刺机中,经预针刺机与下针刺机、主针刺机进行针刺;然后经烫辊进行烫压成型,所述预针刺机针深深度为7~9mm,下针刺机针深深度为5~6mm,主针刺机针深深度为3~4mm;预针刺的针频为15~20HZ,下针刺针频为28~35HZ,主针刺针频为30~40HZ;烫辊的温度为185℃~192℃,烫压压力为0.3MPa,烫压时间为7S~9S;
A52:经过针刺成型后的无纺布送入热风炉中,进行干燥和热定型。
优选的,步骤A5中,对铺网纤维进行成型加工的方法可以为热风法,所述热风法包括:
A51:将铺网的纤维送入烘箱,在160℃~200℃烘烤温度下进行8min~15min烘烤成型;
A52:将成型的纤维取出烘箱,用温度为10℃~20℃的冷水辊冷却施压,所施压力为0.1MPa;
A53:通过冷风机吹风冷却成型,冷风温度10℃~18℃。
最后说明的是,以上实施例仅用于说明本发明的技术方案而非限制,尽管参照较佳的实施例对本发明进行了详细说明,本领域的技术人员应当理解,可以对本发明的技术方案进行修改和等同替代,而不脱离本发明技术方案的宗旨和范围,其均应涵盖在本发明的权利要求范围当中。

Claims (9)

1.一种高速列车座椅用面料,其特征在于,包括外层磷化聚酯阻燃短纤维无纺布层(1)和内层磷化聚酯阻燃短纤维无纺布层(2),所述外层磷化聚酯阻燃短纤维无纺布层(1)和内层磷化聚酯阻燃短纤维无纺布层(2)之间设有磷化聚酯阻燃长纤维无纺布层(3),所述内层磷化聚酯阻燃短纤维无纺布层(2)背面设有壳聚糖纤维和改性聚酯纤维混合无纺布层(4),所述改性聚酯纤维为无机硅酸盐粉末与聚酯通过熔融共混纺丝制成的聚酯纤维;所述外层磷化聚酯阻燃短纤维无纺布层(1),内层磷化聚酯阻燃短纤维无纺布层(2)和磷化聚酯阻燃长纤维无纺布层(3)中的磷化聚酯满足下列方程组:
tanδmax≥0.176
Tα-3.77×ln(dtpf)≤135
1.334≤SG-Δn 8.64≤1.341
上述方程组中:
Tanδmax为动态粘弹性测量中损耗角正切的最大值;Tα为损耗角正切达到最大值时的温度,单位为℃;dtpf为单根纤维的细度,单位为dtex;SG为密度,单位为g/cm3;Δn是双折射;
所述磷化聚酯中磷原子的含量为800-45000ppm。
2.根据权利要求1所述的高速列车座椅用面料,其特征在于,在所述壳聚糖纤维和改性聚酯纤维混合无纺布层(4)背面设置有阻燃隔热弹性聚酯层(5)。
3.根据权利要求1所述的高速列车座椅用面料,其特征在于,所述壳聚糖纤维长度为42-55mm,所述改性聚酯纤维长度为42-55mm,所述壳聚糖纤维卷曲度为7-10卷曲/cm。
4.根据权利要求1所述的高速列车座椅用面料,其特征在于,所述无机硅酸盐为高岭土、蒙脱土、片状云母、锂皂土片状硅酸盐材料的一种或几种的混合物。
5.一种如权利要求1~4任一项所述高速列车座椅用面料的制造方法,其特征在于:该方法包括如下步骤:
A:制备外层磷化聚酯阻燃短纤维无纺布层(1)和内层磷化聚酯阻燃短纤维无纺布层(2):
A1:以质量百分数计,将82-90%的磷化聚酯切片,4-12%的阻燃剂,2-5%的分散润滑剂和2-5%的辅料混合;
A2:将混合后的原料通过开松机开松;
A3:将开松后的混合物进行纤维梳理;
A4:用梳理后的纤维进行铺网;
A5:对铺网纤维进行成型加工,制成无纺布;
A6:将无纺布通过成卷机进行卷取,制得外层磷化聚酯阻燃短纤维无纺布层(1);
内层磷化聚酯阻燃短纤维无纺布层(2)的制备方法与外层磷化聚酯阻燃短纤维无纺布层(1)的制备方法相同;
B:制备磷化聚酯阻燃长纤维无纺布层(3):
B1:以质量百分数计,20-30%的超细氢氧化铝,20-30%的超细氢氧化镁、15-20%的纳米级凹凸棒土、10-20%的纳米氧化锌、2-5%的表面活性剂、3-5%的偶联剂和3-4%的抑烟剂加入高速混合机,高速混合制得复合阻燃剂;
B2:以质量百分数计,10-20%的磷化聚酯切片和10-20%的复合阻燃剂在220~250℃下进行共混造粒,制得阻燃熔喷磷化聚酯切片;
B3:将阻燃熔喷磷化聚酯切片送入螺杆挤出机中进行熔喷纺丝,熔体经螺杆到纺丝组件再到喷丝板喷出,经高速热气流牵伸后制成熔喷超细纤维,熔喷纺丝温度为240~270℃,纺丝速度为100~1000m/min,喷丝板上喷丝孔的孔径是0.2~0.35mm;
B4:通过过滤器进行过滤,再进入到纺丝箱中进行拉丝;
B5:通过成网机中进行铺网,再在热轧机中进行预热轧;
B6:通过成卷机进行卷取,制得磷化聚酯阻燃长纤维无纺布层(3);
C:将磷化聚酯阻燃长纤维无纺布层(3)与内层磷化聚酯阻燃短纤维无纺布层(2)通过倒刺机针刺覆合,形成磷化聚酯阻燃长纤维无纺布层(3)与内层磷化聚酯阻燃短纤维无纺布层(2)的覆合层,再将外层磷化聚酯阻燃短纤维无纺布层(1)放在磷化聚酯阻燃长纤维无纺布层(3)上面,通过倒刺机针刺覆合,形成磷化聚酯阻燃长纤维无纺布层(3)、内层磷化聚酯阻燃短纤维无纺布层(2)与外层磷化聚酯阻燃短纤维无纺布层(1)的覆合层,通过倒刺机针刺覆合时,针刺密度控制在50-90针/平方厘米,针刺深度控制在10-12mm;
D:用分散染料对磷化聚酯阻燃长纤维无纺布层(3)、内层磷化聚酯阻燃短纤维无纺布层(2)与外层磷化聚酯阻燃短纤维无纺布层(1)的覆合层进行染色处理60分钟,染色条件:以体积百分数计,染液比为1∶50,温度为145℃,染色处理后,洗涤,干燥;
E:将染色处理后的磷化聚酯阻燃长纤维无纺布层(3)、内层磷化聚酯阻燃短纤维无纺布层(2)与外层磷化聚酯阻燃短纤维无纺布层(1)的覆合层浸轧整理液,整理液的组分为:280-360g/L阻燃剂FPK8002,70-120g/L防水拒油剂有机硅氟树脂,60-100g/L防紫外剂HTUV100,22-25g/L浓度为80%的磷酸,15-25g/L交链剂AF6900,二浸二轧,在100-105℃的温度热烘3-5分钟后,再在135-145℃的温度下焙烘2-5分钟;焙烘完毕后,用碳酸钠混合洗涤剂在60-65℃的温度下碱洗2-4分钟后,再在40-60℃的热水下洗4-6分钟,然后水洗、烘干;
F:制备壳聚糖纤维和改性聚酯纤维混合无纺布层(4):
F1:制备改性聚酯纤维:
F11:将无机硅酸盐粉碎、筛分得到具有纳米尺寸粉体,然后将得到的具有纳米尺寸粉体经硅烷偶联剂或钛酸酯偶联剂进行表面改性,以增加其与聚酯的相容性;
F12:以质量百分数计,将0.5-5%的经过经硅烷偶联剂或钛酸酯偶联剂进行表面改性的硅酸盐纳米粉体与95-99.5%的聚酯干燥后进行熔融纺丝,熔融纺丝工艺参数为:纺丝温度:260℃-300℃,纺丝速度:400-5000m/min,牵伸温度:70℃-160℃,牵伸倍数:1-5倍;纺制具有导热导湿功能的改性聚酯纤维;
F2:成网前准备;
F21:选择纤维:以质量百分数计,50-60%的壳聚糖纤维和40-50%的改性聚酯纤维开松混合;
F22:开包机开棉
a、粗开松工序:将混合后的壳聚糖纤维和改性聚酯纤维投入到输送平帘上,送入到粗开松机,制得初步开松的短纤;
b、混棉工序:通过风送和旋风分离器,使短纤均匀分布在混棉大仓进行沉积,保证棉层高度一致,通过平帘和角钉斜帘的共同作用,使其输送到精开机;所述混棉大仓的尺寸为:4100×2300×4200mm;
c、精开松工序:原料经过混棉充分混合后,喂入精开松机,在精开松机内进行充分开松和预梳理,使纤维进一步开松、拉直,通过风机喂入下道工序;
d、气压棉箱给棉:经过精开松机的纤维通过风送管道进入到气压棉箱的上棉箱,通过给棉罗拉和道夫梳理机的作用使纤维以“雪花状”落到下棉箱中,然后以均衡压力的方式把纤维定积给出;
F23:梳理:梳理机接收气压棉箱给入的纤维,进入到给棉辊后,通过双锡林双道夫梳理机的作用,梳理成均匀的5—20克/平方米双层纤维网状薄层;
F3:铺网
F31:交叉铺网:5—20克/平方米双层纤维网状薄层经过夹持碳帘的握持输送,使双层纤维网状薄层在不受外力的作用下,通过往复作用,制成网层为7—18层,棉网厚度为10—40cm的纤维网,供下道工序使用;
F32:喂入机:在针刺机前喂入,使纤维网在针刺前均匀的夹持喂入针区;
F4:针刺机加固
F41:预针刺加固:将经过梳理、铺网形成的纤维网通过单针板上针刺机预针刺工序将纤维网初步缠结定型,保证原纤维网的方向不变;
F42:主针刺加固:将经过预针刺初步缠结的纤维网通过双针板异位对刺针刺机针刺缠结;
F43:修面针刺加固:将经过主针刺加固缠结的针刺无纺布通过修面针刺机正反两面针刺,制成成型针刺无纺布;
F44:用储布张力架进行储布;
F45:用自动定长切边卷绕机进行成卷收卷;
F5:采用热收缩定型的方式降低成型针刺无纺布的热收缩率,改善性能;
G:将步骤F中制备的壳聚糖纤维和改性聚酯纤维混合无纺布层(4)通过热烫复合机在170-180℃下与步骤E中得到的产品的内层磷化聚酯阻燃短纤维无纺布层(2)背面有效复合在一起。
6.根据权利要求5所述的高速列车座椅用面料的制造方法,其特征在于,在步骤G后设置如下步骤:
H:制备阻燃隔热弹性聚酯层(5):
H1:将磷系共聚型永久阻燃聚酯切片放入真空转鼓干燥设备中,在真空条件下,缓慢升温至110~145℃,进行预结晶2~6h,再转入充填式干燥塔中,升温140~165℃,干燥3~8h,达到水份含量≤30ppm;纺丝温度为255~282℃,经螺杆挤压机熔融、静态混合、过滤后,进入箱体计量泵计量,通过“C”型中空喷丝板挤出,经环吹风温度为15~25℃,环吹风速度1.5~4.5m/s的非对称环吹强风骤冷制得初生丝;将初生丝平衡、集束后,经为2.5~4.0牵伸倍数的牵伸、卷曲、切断及130~180℃松驰热定型制得2~10D的阻燃三维螺旋型卷曲中空聚酯纤维;
H2:将85~95wt%的2~10D的阻燃三维螺旋型卷曲中空聚酯纤维、15~5wt%熔点为120~180℃的涤纶短纤维混匀,再经过清花、梳棉、纵向与横向交叉铺网,之后经过热轧机或热风烘燥机将120~180℃的涤纶短纤维熔化与阻燃三维螺旋型卷曲中空聚酯纤维在120~190℃温度下热粘合,制得立体网状型的阻燃隔热弹性聚酯层(5);
I:将步骤H中制备的阻燃隔热弹性聚酯层(5)通过热烫复合机在170-180℃下与步骤G中得到的产品的壳聚糖纤维和改性聚酯纤维混合无纺布层(4)背面有效复合在一起。
7.根据权利要求6所述的高速列车座椅用面料的制造方法,其特征在于,步骤H1中,磷系共聚型永久阻燃聚酯切片的磷含量为7500~8500ppm,特性粘度为0.65~0.80dl/g,熔点≥240℃,二甘醇≤3.0%,端羧基≤30mol/t。
8.根据权利要求5所述的高速列车座椅用面料的制造方法,其特征在于,步骤A5中,对铺网纤维进行成型加工的方法为针刺法,所述针刺法包括:
A51:通过输送帘将铺网纤网不断送入针刺机中,经预针刺机与下针刺机、主针刺机进行针刺;然后经烫辊进行烫压成型,所述预针刺机针深深度为7~9mm,下针刺机针深深度为5~6mm,主针刺机针深深度为3~4mm;预针刺的针频为15~20HZ,下针刺针频为28~35HZ,主针刺针频为30~40HZ;烫辊的温度为185℃~192℃,烫压压力为0.3MPa,烫压时间为7S~9S;
A52:经过针刺成型后的无纺布送入热风炉中,进行干燥和热定型。
9.根据权利要求5所述的高速列车座椅用面料的制造方法,其特征在于,步骤A5中,对铺网纤维进行成型加工的方法为热风法,所述热风法包括:
A51:将铺网的纤维送入烘箱,在160℃~200℃烘烤温度下进行8min~15min烘烤成型;
A52:将成型的纤维取出烘箱,用温度为10℃~20℃的冷水辊冷却施压,所施压力为0.1MPa;
A53:通过冷风机吹风冷却成型,冷风温度10℃~18℃。
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