CN106087447B - 一种护理用三层覆膜提花布及其制备工艺 - Google Patents

一种护理用三层覆膜提花布及其制备工艺 Download PDF

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CN106087447B
CN106087447B CN201610652862.1A CN201610652862A CN106087447B CN 106087447 B CN106087447 B CN 106087447B CN 201610652862 A CN201610652862 A CN 201610652862A CN 106087447 B CN106087447 B CN 106087447B
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吴春英
韩东
蔡文言
赵红玉
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Abstract

本发明公开了一种护理用三层覆膜提花布及其制备工艺，该覆膜提花布，包括分别由经纱和纬纱交织形成的上表层、中间层和下表层，所述上表层由纯棉精梳纱作为经纱和40S汉麻/棉混纺纱作为纬纱交织形成，所述中间层由纯棉精梳纱作为经纱和1200D高收缩涤纶超细纤维作为纬纱交织形成，所述下表层由纯棉精梳纱作为经纱和纯棉精梳纱作为纬纱交织形成；还包括覆盖在下表层的下表面的环保防水膜层。该覆膜提花布的制备工艺包括纺纱、织造、烧毛、退浆、煮漂、加软烘干、覆膜和缝纫八个步骤。该制备工艺制备的覆膜提花布可以作为婴儿和老年人的床单、床罩、隔尿垫等使用，具有良好的柔软舒适、吸水及隔漏性能，且可以重复利用。

Description

一种护理用三层覆膜提花布及其制备工艺
技术领域
本发明涉及纺织技术领域，尤其涉及一种护理用三层覆膜提花布及其制备工艺。
背景技术
随着人们生活水平的提高，对婴幼儿和老年人的卫生护理愈加关注，尿不湿、纸尿垫成为一种不可缺少的护理用品。现有的卫生护理用品多采用纯棉制品或一次性用品。
纯棉制品虽然透气性和吸水性较好，但是没有隔漏功能，需频繁更换和清洗。而尿不湿和纸尿垫等一次性用品，使用后即丢弃，不仅浪费资源，还污染环境。同时，大部分一次性用品透气性差，影响婴幼儿和老年人的健康。
发明内容
本发明所要解决的一个技术问题是：提供一种护理用三层覆膜提花布，可以作为婴儿和老年人的床单、床罩、隔尿垫等使用，具有良好的柔软舒适、吸水及隔漏性能，且可以重复利用。
为解决上述技术问题，本发明的技术方案是：
一种护理用三层覆膜提花布，所述覆膜提花布包括分别由经纱和纬纱交织形成的上表层、中间层和下表层，所述上表层由纯棉精梳纱作为经纱和40S汉麻/棉混纺纱作为纬纱交织形成，所述中间层由纯棉精梳纱作为经纱和1200D高收缩涤纶超细纤维作为纬纱交织形成，所述下表层由纯棉精梳纱作为经纱和纯棉精梳纱作为纬纱交织形成；还包括覆盖在下表层的下表面的环保防水膜层。
作为一种改进的方案，所述上表层、中间层和下表层的经纱为60S纯棉精梳纱，所述下表层的纬纱为40S纯棉精梳纱。
作为一种改进的方案，所述上表层、中间层和下表层的经纱为80S纯棉精梳纱或120S合股纯棉精梳纱，所述下表层的纬纱为60S纯棉精梳纱。
作为一种改进的方案，所述40S汉麻/棉混纺纱中汉麻纤维和棉纤维的质量百分比分别为30％和70％。
作为一种改进的方案，所述上表层、中间层和下表层均包含由经纱和纬纱交织形成的底纹组织和花型组织，所述上表层的底纹组织为经面缎纹，花型组织为纬面缎纹，所述中间层的底纹组织和花型组织都为交织平纹，所述下表层的底纹组织为纬面缎纹，花型组织为经面缎纹，所述下表层的纬纱与所述上表层的经纱在所述上表层和下表层的花型组织轮廓边缘进行接结。
本发明要解决的另外一个技术问题是：提供一种护理用三层覆膜提花布的制备工艺，该制备工艺简单可靠，便于实行，制备的产品有良好的柔软舒适性能和优异的吸湿性能。
为解决上述技术问题，本发明的技术方案是：
一种护理用三层覆膜提花布的制备工艺，包括以下步骤：
①纺纱：将精梳长绒棉纱经过开松、梳理和并合卷绕成筒子，并加捻制成60S精梳纱、40S汉麻/棉混纺纱及40S精梳纱，将600D涤纶超细纤维，通过并纱制成1200D高收缩涤纶超细纤维。
②织造：将所述加捻后的纱线卷绕成筒纱，经过整经、浆纱和织造制成三层提花坯布。
③烧毛：将所述提花坯布进行烧毛，采取一正一反烧毛工艺，火口压力为10mbar，车速为100m/min。
④退浆：将烧毛后的提花坯布进行退浆。
⑤煮漂：将退浆后的提花坯布放入浴液中，加入助剂，加热至90-100℃，维持40-55min。
⑥加软烘干：将煮漂后的提花坯布松式加软烘干；
⑦覆膜：在加软烘干后的提花坯布下表层的下表面覆盖一层防渗隔漏的TPU环保膜。
⑧缝纫：将覆膜后的提花坯布缝纫制成护理用三层覆膜提花布成品。
作为一种优选的方案，40S汉麻/棉混纺纱的纺纱过程包括以下步骤：
a)开清棉工序：汉麻纤维的棉卷定量为400g/m，综合打手速度为900r/min，棉纤维的卷定量为380g/m，综合打手速度为900r/min。
b)梳棉工序：汉麻纤维的梳棉出条速度为80m/min，定量为17.5g/5m，棉纤维的梳棉出条速度为80m/min，棉生条定量为14g/5min。
c)予并条工序：汉麻纤维生条为提高伸直度，需要进行予并，予并前区×后区罗拉表面距9×19mm，出条速度为250m/min，定量为17.5g/5m。
d)并条工序：汉麻纤维与棉纤维混纺纱采取三道混并：一道并条采用FA306A并条机，3根汉麻纤维，5根棉纤维，8根并合，前区×后区罗拉中心距47×52mm，速度降到250m/min，定量16.5g/5m，二道并条采用单眼自调匀整并条机6根并合，前区×后区罗拉中心距47×52mm，速度降到250m/min，定量16.5g/5m。
e)粗纱工序：将前区×中区×后区罗拉表面距设置为12.5×23.5×33.5mm，捻系数为100，粗纱定量为4.5g/10m。
f)细纱工序：将捻系数设计为420，后区牵伸降至1.28倍，总牵伸不超过40倍，前区×后区罗拉中心距43×64mm，前罗拉速度136r/min。
g)络筒工序：将络纱速度降至1000m/min，减小张力，并使捻结强力达到原纱80％以上。
作为一种优选的方案，步骤②中，所述三层提花坯布的经密为161.2根/2.54cm,纬密为135根/2.54cm，所述上表层、中间层和下表层的经纱比例为3：1：3，纬纱比例为2：1：2。
作为一种优选的方案，所述步骤⑤中，所述浴液中，火碱浓度为30ml/L,双氧水浓度为15ml/L,所述助剂包含组分及其加入量为：精炼剂EPD-C 5ml/L、稳定剂NC 7ml/L和络合剂CD 2ml/L。
作为一种优选的方案，所述步骤⑥中，所述松式加软烘干采用复合柔软剂,并加入中和酸调节织物pH值到4.5-7.5，烘干温度为100-140℃，速度为20m/min，所述复合柔软剂的配方和用量为：软片TF-443B 30g/L和柔软剂DA-6020g/L。
由于采用了上述技术方案，本发明的有益效果是：
本发明涉及的护理用三层覆膜提花布为机织类面料，不同于市场上常见的针织类护理面料，该覆膜提花布采用了多层毛胚布和高收缩的超细纤维，并采用不同提花组织，使得该产品退浆后产品尺寸回缩大，呈现出花型凸起的立体效果。
组织交织采用在花型轮廓外边缘处上表层花型组织的纬纱与下表层花型组织的纬纱进行表里交换接结的方式，使得三层布成为一个整体。且在花型轮廓处接结，使花型凸起更饱满，立体感更强。
同时，对提花坯布采用无张力的松式烘干(常规用于毛巾烘干)，该烘干无张力，不同于常规面料所采用的高张力的锡林烘干，使得产品最大限度的回缩，获得蓬松柔软、吸湿透气性好的效果。
采用了TPU环保膜，达到防渗隔漏的效果；正面纬纱中含有的汉麻具有抑菌抗菌性能，使得该面料兼具保健功能。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明。
实施例1
一种护理用三层覆膜提花布
所述覆膜提花布包括分别由经纱和纬纱交织形成的上表层、下表层和中间层，所述上表层由60S纯棉精梳纱作为经纱和40S汉麻/棉混纺纱作为纬纱交织形成，所述下表层由60S纯棉精梳纱作为经纱和40S纯棉精梳纱作为纬纱交织形成，所述中间层由60S纯棉精梳纱作为经纱和1200D高收缩涤纶超细纤维作为纬纱交织形成；还包括覆盖在下表层的下表面的环保防水膜层。
所述40S汉麻/棉混纺纱中汉麻纤维和棉纤维的质量百分比分别30％和70％。
所述上表层、中间层和下表层均包含由经纱和纬纱交织形成的底纹组织和花型组织，所述上表层的底纹组织为经面缎纹，花型组织为纬面缎纹，所述中间层的底纹组织和花型组织都为交织平纹，所述下表层的底纹组织为纬面缎纹，花型组织为经面缎纹，所述下表层的纬纱与所述上表层的经纱在所述上表层和下表层的花型组织轮廓边缘进行接结。
实施例2
一种护理用三层覆膜提花布
所述覆膜提花布包括分别由经纱和纬纱交织形成的上表层、下表层和中间层，所述上表层由80S纯棉精梳纱作为经纱和40S汉麻/棉混纺纱作为纬纱交织形成，所述下表层由80S纯棉精梳纱作为经纱和60S纯棉精梳纱作为纬纱交织形成，所述中间层由80S纯棉精梳纱作为经纱和1200D高收缩涤纶超细纤维作为纬纱交织形成；还包括覆盖在下表层的下表面的环保防水膜层。
所述40S汉麻/棉混纺纱中汉麻纤维和棉纤维的质量百分比分别30％和70％。
所述上表层、中间层和下表层均包含由经纱和纬纱交织形成的底纹组织和花型组织，所述上表层的底纹组织为经面缎纹，花型组织为纬面缎纹，所述中间层的底纹组织和花型组织都为交织平纹，所述下表层的底纹组织为纬面缎纹，花型组织为经面缎纹，所述下表层的纬纱与所述上表层的经纱在所述上表层和下表层的花型组织轮廓边缘进行接结。
实施例3
所述覆膜提花布包括分别由经纱和纬纱交织形成的上表层、下表层和中间层，所述上表层由120S合股纯棉精梳纱作为经纱和40S汉麻/棉混纺纱作为纬纱交织形成，所述下表层由80S纯棉精梳纱作为经纱和60S纯棉精梳纱作为纬纱交织形成，所述中间层由80S纯棉精梳纱作为经纱和1200D高收缩涤纶超细纤维作为纬纱交织形成；还包括覆盖在下表层的下表面的环保防水膜层。
所述40S汉麻/棉混纺纱中汉麻纤维和棉纤维的质量百分比分别30％和70％。
所述上表层、中间层和下表层均包含由经纱和纬纱交织形成的底纹组织和花型组织，所述上表层的底纹组织为经面缎纹，花型组织为纬面缎纹，所述中间层的底纹组织和花型组织都为交织平纹，所述下表层的底纹组织为纬面缎纹，花型组织为经面缎纹，所述下表层的纬纱与所述上表层的经纱在所述上表层和下表层的花型组织轮廓边缘进行接结。
实施例4
一种护理用三层覆膜提花布的制备工艺
制作实施例1所述的护理用三层覆膜提花布，包括以下步骤：
①纺纱：将精梳长绒棉纱经过开松、梳理和并合卷绕成筒子，并加捻制成60S精梳纱、40S汉麻/棉混纺纱及40S精梳纱，将600D涤纶超细纤维，通过并纱制成1200D高收缩涤纶超细纤维。
②织造：将所述加捻后的纱线卷绕成筒纱，经过整经、浆纱和织造制成三层提花坯布。所述三层提花坯布的经密为161.2根/2.54cm,纬密为135根/2.54cm，所述上表层、中间层和下表层的经纱比例为3：1：3，纬纱比例为2：1：2。
③烧毛：将所述提花坯布进行烧毛，采取一正一反烧毛工艺，火口压力为10mbar，车速为100m/min。
④退浆：将烧毛后的提花坯布进行退浆。
⑤煮漂：将退浆后的提花坯布放入浴液中，加入助剂，加热至90-100℃，维持40-55min。所述浴液中，火碱浓度为30ml/L,双氧水浓度为15ml/L,所述助剂包含组分及其加入量为：精炼剂EPD-C 5ml/L、稳定剂NC 7ml/L和络合剂CD 2ml/L。
⑥加软烘干：将煮漂后的提花坯布松式加软烘干。所述松式加软烘干采用松式震荡烘干机进行，在所述松式震荡烘干机的前区轧槽中加入复合柔软剂,并加入中和酸调节织物pH值到4.5-7.5，烘干温度为100-140℃，速度为20m/min，所述复合柔软剂的配方和用量为：软片TF-443B 30g/L和柔软剂DA-60 20g/L。
⑦覆膜：在加软烘干后的提花坯布下表层的下表面用复合机覆盖一层防渗隔漏的TPU环保膜，达到防水隔漏效果。
⑧缝纫：将覆膜后的提花坯布缝纫制成护理用三层覆膜提花布成品。
所述精炼剂EPD-C为科凯精细化工(上海)有限公司生产。
所述稳定剂NC为科凯精细化工(上海)有限公司。
所述络合剂CD为科凯精细化工(上海)有限公司生产。
所述软片TF-443B为浙江传化股份有限公司生产。
所述柔软剂DA-60为青岛欧诺思工贸有限公司生产。
其中，40S汉麻/棉混纺纱的纺纱过程包括以下步骤：
a)开清棉工序：汉麻纤维比较粗与棉纤维的差异比较大，开清棉采用“多梳少打，尽量少落”的原则，同时提高纤维的转移率，避免过多的搓揉纤维，因汉麻纤维总重量较少，A002D型抓棉机没有使用，若量较多，可采用降低打手速度，降低抓取量，采取“勤抓少抓，精细抓取“的工艺原则，原料经过人工开松后，直接由A035E混开棉机机后喂入，A035E型混开棉机降低打手速度，缩小尘棒间隔距，放大打手与尘棒隔距，减少纤维的损伤，棉卷定量400g/m，综合打手速度900r/min，棉网无破洞。
棉纤维由于杂质较多，采取“早落、多落”的原则，A002D抓棉机采用降低打手速度，降低抓取量，采取“勤抓少抓，精细抓取“的工艺原则，A035E型混开棉机加大尘棒间隔距，缩小打手与尘棒隔距，降低打手速度，FA106开棉机加大尘棒间隔距，缩小打手与尘棒隔距，降低打手速度，棉卷定量380g/m，综合打手速度900r/min，棉网无破洞。
b)梳棉工序:汉麻纤维在梳棉工序采用“小定量、中隔距、低速度”的原则，放大刺辊-除尘刀隔距，降低刺辊转速，以降低对纤维的损伤，适当放大锡林-盖板隔距，梳棉出条速度80m/min，定量17.5g/5m。棉部分继续除杂，并减少纤维损伤，缩小刺辊-除尘刀隔距，降低刺辊速度，缩小锡林-盖板隔距，提高盖板速度，以多排出短绒，梳棉出条速度80m/min，棉生条定量14g/5min。
c)予并条工:汉麻纤维生条为提高伸直度，需要进行予并，予并前区×后区罗拉表面距9*19mm，出条速度250m/min，定量17.5g/5m。
d)并条工序:汉麻纤维与棉纤维混纺纱采取三道混并：一道并条采用FA306A并条机，3根汉麻纤维，5根棉纤维，8根并合，前区×后区罗拉中心距47×52mm，速度降到250m/min，定量16.5g/5m，二道并条采用单眼自调匀整并条机6根并合，前区×后区罗拉中心距47×52mm，速度降到250m/min，定量16.5g/5m。
e)粗纱工序:FA458A粗纱机配置国产超精罗拉，SKF弹簧摇架，为提高粗纱质量提供了保障，前区×中区×后区罗拉表面距12.5×23.5×33.5mm，捻系数设计100，即提高了粗纱条干，又便于细纱机牵伸，粗纱定量4.5g/10m。
f)细纱工序：EJM128K型细纱机二、三罗拉采用国产超精罗拉，前罗拉采用进口超精罗拉，采用新型上肖，65度进口软胶辊，采用∮1.9mm导纱钩，38mm钢领，捻系数设计420，后区牵伸降至1.28倍，总牵伸不超过40倍，前区×后区罗拉中心距43×64mm，前罗拉速度136r/min，成纱指标达到了较好水平，满足了用户要求。
g)络筒工序：络纱速度降至1000m/min，减小张力，多次调试捻结参数，以保证捻结强力达到原纱80％以上，电清参数棉结5.0，短粗2.3，短粗长度1.4cm，长粗1.32，长粗长度25cm，长细-18％，长细长度25cm。
以上对本发明实施例所提供的一种面料制造工艺进行了详细介绍，对于本领域的一般技术人员，依据本发明实施例的思想，在具体实施方式及应用范围上均会有改变之处，综上所述，本说明书实施例的内容不应理解为对本发明的限制。

Claims (9)

1.一种护理用三层覆膜提花布，其特征在于，所述覆膜提花布包括分别由经纱和纬纱交织形成的上表层、中间层和下表层，所述上表层由纯棉精梳纱作为经纱和40S汉麻/棉混纺纱作为纬纱交织形成，所述中间层由纯棉精梳纱作为经纱和1200D高收缩涤纶超细纤维作为纬纱交织形成，所述下表层由纯棉精梳纱作为经纱和纬纱交织形成；还包括覆盖在下表层的下表面的环保防水膜层；
所述上表层、中间层和下表层均包含由经纱和纬纱交织形成的底纹组织和花型组织，所述上表层的底纹组织为经面缎纹，花型组织为纬面缎纹，所述中间层的底纹组织和花型组织都为交织平纹，所述下表层的底纹组织为纬面缎纹，花型组织为经面缎纹，所述下表层的纬纱与所述上表层的经纱在所述上表层和下表层的花型组织轮廓边缘进行接结。
2.如权利要求1所述的护理用三层覆膜提花布，其特征在于，所述上表层、中间层和下表层的经纱为60S 纯棉精梳纱，所述下表层的纬纱为40S纯棉精梳纱。
3.如权利要求1所述的护理用三层覆膜提花布，其特征在于，所述上表层、中间层和下表层的经纱为80S纯棉精梳纱或120S合股纯棉精梳纱，所述下表层的纬纱为60S纯棉精梳纱。
4.如权利要求1所述的护理用三层覆膜提花布，其特征在于，所述40S汉麻/棉混纺纱中汉麻纤维和棉纤维的质量百分比分别为30%和70%。
5.如权利要求1所述的护理用三层覆膜提花布的制备工艺，其特征在于，包括以下步骤：
①纺纱：将精梳长绒棉纱经过开松、梳理和并合卷绕成筒子，并加捻制成60S精梳纱、40S汉麻/棉混纺纱及40S精梳纱，将600D涤纶超细纤维，通过并纱制成1200D高收缩涤纶超细纤维；
②织造：将步骤①加捻后的纱线卷绕成筒纱，经过整经、浆纱和织造制成三层提花坯布；
③烧毛：将所述提花坯布进行烧毛，采取一正一反烧毛工艺，火口压力为10 mbar，车速为100m/min；
④退浆：将烧毛后的提花坯布进行退浆；
⑤煮漂：将退浆后的提花坯布放入浴液中，加入助剂，加热至90-100℃，维持40-55min；
⑥加软烘干：将煮漂后的提花坯布松式加软烘干；
⑦覆膜：在加软烘干后的提花坯布下表层的下表面覆盖一层防渗隔漏的TPU环保膜；
⑧缝纫：将覆膜后的提花坯布缝纫制成护理用三层覆膜提花布成品。
6.如权利要求5所述的护理用三层覆膜提花布的制备工艺，其特征在于，所述步骤①中，40S汉麻/棉混纺纱的纺纱过程包括以下步骤：
a)开清棉工序：汉麻纤维的棉卷定量为400g/m，综合打手速度为900r/min，棉纤维的卷定量为380g/m，综合打手速度为900r/min；
b)梳棉工序：汉麻纤维的梳棉出条速度为80m/min，定量为17.5g/5m，棉纤维的梳棉出条速度为80m/min，棉生条定量为14g/5min；
c)予并条工序：汉麻纤维生条为提高伸直度，需要进行予并，予并前区×后区罗拉表面距9×19mm，出条速度为250m/min，定量为17.5g/5m；
d)并条工序：汉麻纤维与棉纤维混纺纱采取三道混并：一道并条采用3根汉麻纤维，5根棉纤维，8根并合，前区×后区罗拉中心距47×52mm，速度降到250m/min，定量16.5g/5m，二道并条采用６根并合，前区×后区罗拉中心距47×52mm，速度降到250m/min，定量16.5g/5m；
e) 粗纱工序：将前区×中区×后区罗拉表面距设置为12.5×23.5×33.5mm，捻系数为100，粗纱定量为4.5g/10m；
f)细纱工序：将捻系数设计为420，后区牵伸降至1.28倍，总牵伸不超过40倍，前区×后区罗拉中心距43×64mm，前罗拉速度136r/min；
g)络筒工序：将络纱速度降至1000m/min，减小张力，并使捻结强力达到原纱80%以上。
7.如权利要求5所述的护理用三层覆膜提花布的制备工艺，其特征在于，步骤②中，所述三层提花坯布的经密为161.2根/2.54cm,纬密为135根/2.54cm，所述上表层、中间层和下表层的经纱比例为3：1：3，纬纱比例为2：1：2。
8.如权利要求5所述的护理用三层覆膜提花布的制备工艺，其特征在于，所述步骤⑤中，所述浴液中，火碱浓度为30mL /L,双氧水浓度为15mL /L, 所述助剂包含组分及其加入量为：精炼剂EPD-C 5mL /L、稳定剂NC 7mL /L和络合剂CD 2mL /L。
9.如权利要求5所述的护理用三层覆膜提花布的制备工艺，其特征在于，所述步骤⑥中，所述松式加软烘干采用复合柔软剂,并加入中和酸调节织物pH值到4.5-7.5，烘干温度为100-140℃，速度为20m/min，所述复合柔软剂的配方和用量为：软片TF-443B 30g/L和柔软剂DA-60 20g/L。
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