CN106192386A - 一种安全气囊面料及其加工方法 - Google Patents
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Abstract
本发明涉及一种安全气囊面料，经过精炼后，按照ASTM D 2257可萃取物质的测试方法所测得的所述安全气囊面料的异物质萃取结果在0.4％以下。本发明还涉及上述安全气囊面料的加工方法。本发明的安全气囊面料异物质萃取结果低，针抓强度高，耐磨损性能好。
Description
技术领域
本发明涉及一种安全气囊，更具体地，涉及一种安全气囊面料及其加工方法。
背景技术
安全气囊面料是安全气囊系统的重要组成部分。近年来，随着汽车的行驶速度越来越快，交通事故的发生也更加频繁，所以汽车的安全性就变得尤为重要。随着人们安全意识的提高，汽车安全气囊的安装率逐渐提高。
中国专利申请号201110090717.6描述了一种安全气囊用面料的经纬向伸长率偏差最小化工艺，包括以下步骤：1)水洗精炼：面料水洗精炼，精炼药剂为包含精炼剂、分散剂、渗透剂的NaOH溶液；组分复杂，包括精炼剂、分散剂、渗透剂等，配制程序繁琐，容易产生错误，且精炼后对非涂胶面料的针抓性能提高效果不明显。
中国专利申请号200910170195.3中描述了一种安全气囊面料的织造工艺，其工艺步骤如下：a)整经：在400-500m/min整经速度下，通过整经机将一定数量的原丝线饼均匀地卷绕在织轴上；b)喷水织机织布：在600rpm以上的织机转速下，纬纱经高压水的牵引后通过钢筘的打纬运动和综框上经纱的上下运动，使经纬纱互相交织；c)定型：在40～65m/min速度、130-200℃温度下，布料在烘箱热定型约1min时间；d)成品检验：按工艺要求进行成品的外观和性能检验。采用喷水织机织造，没有采用精炼工艺。
该发明是针对剑杆织机织造的面料，织造过程没有水的自洁，面料偏软。为了降低面料中的异物质和提高安全气囊面料针抓性能，简化加工工序，采用了一种新型精炼剂。
发明内容
本发明的目的在于提供一种异物质萃取结果低，针抓强度高，耐磨损性能好的安全气囊面料及其加工方法。
本发明的所述安全气囊面料采用一种精炼剂精炼，所述精炼剂是络合分散剂、表面活性剂以及双氧水稳定剂的复配物，经过精炼后，面料异物质萃取结果在0.4％以下，优选为0.3％以下。如果异物质萃取结果大于0.4％，则气囊爆破时候，可能带来燃烧结果偏大，对人体的伤害性大。
所述新型精炼剂是络合分散剂、表面活性剂以及双氧水稳定剂的复配物，属于阴离子性物质，pH值约为3.5-5.5，比重约为1.07-1.11g/cm3，粘度小于250mPa·s，电导率约15ms/cm。如果pH值小于3.5或大于5.5，则和NaOH溶液或水配比后，除去面料上面的异物质效果变差。如果比重大于1.11g/cm3，和NaOH溶液或水的共溶性不好，容易发生沉淀。若粘度大于250mPa·s，容易粘附在面料表面，造成二次污染。
所述新型精炼剂中包含吩的乙氧基脂肪醇，含量为13-30％；十一烷基-十一羟基聚(氧-1,2-亚乙基)，含量为7-13％；聚丙烯酸钠，含量为0.1-1％。上述含量基于精炼剂的总重量计。如果吩的乙氧基脂肪醇的含量小于13％；十一烷基-十一羟基聚(氧-1,2-亚乙基)的含量小于7％；聚丙烯酸钠的含量小于0.1％，那么其混合物对面料的渗透、润湿和融合程度变差，除去面料中异物质效果差，针抓强度低。涂胶的时候影响面料与硅胶的粘合程度，耐磨损性能下降。如果吩的乙氧基脂肪醇的含量大于30％；十一烷基-十一羟基聚(氧-1,2-亚乙基)的含量大于13％；聚丙烯酸钠的含量大于1.0％，一则成本上升，二则混合后气泡多，精炼后面料上气泡多，影响后续干燥和定型的效果。
本发明的安全气囊面料的针抓强度为300N-750N。如果面料的针抓强度小于300N，则气囊爆破时候，容易在缝制部位发生破坏，起不到对人体的保护作用。如果面料的针抓强度大于750N，则面料很硬，不容易折叠，造成气囊占用的空间变大，不符合今后发展的趋势。
本发明的安全气囊面料涂胶后的耐磨损次数在600次以上。如果涂胶后，面料的耐磨损次数小于600次，那么气囊爆破时候，折叠部位的面料相互摩擦，硅胶容易脱落，透气性能变差；同时火药爆破残留物粘附在硅胶脱落的面料处，容易烫伤面料，形成熔洞。
本发明的安全气囊面料的密度在41～60根/英寸，长丝的细度在350dtex～700dtex，所述长丝为尼龙长丝或涤纶长丝。对面料无特殊限定，涂胶和非涂胶面料都可以。
本发明的安全气囊面料的加工方法包括精炼、干燥、热定型、涂胶。精炼工序中所述精炼剂与NaOH的配方为：基于精炼药液的总重量，所述精炼剂的重量比为0.33％-0.63％，NaOH的重量比为0.38％-0.76％。精炼温度为60-95℃，干燥温度为110-130℃，热定型温度为150-200℃，涂胶温度为150-190℃。如果精炼剂重量比小于0.33％，NaOH的重量比小于0.38％，则精炼过程除去面料异物质的效果不好，针抓强度低。同时，涂胶时影响面料和硅胶的粘合程度，耐磨损性能降低。如果精炼剂重量比大于0.63％，NaOH的重量比大于0.76％，不仅会使成本上升，还会使面料的pH值增大。在一些实施例中，NaOH以32％的NaOH水溶液加入。
采用本发明的新型精炼剂加工，使用过程不需要调配，缩短了加工工序，防止配置精炼液过程发生错误，降低生产成本。
实验方法
1.针抓强度
参照ASTM D 6479的测试方法，裁剪300mmX50mm的样品，强力机上下夹具的距离200mm。具体方法是，使样品的底部边缘与夹具的边缘线平行，样品两边边缘与夹具两边边缘对齐，拧紧夹具。以200mm/min的速度进行试验。
2.异物质萃取
按照ASTM D 2257可萃取物质的测试方法，将面料样品(重量为A)放入玻璃烧杯(重量为B)中，加入乙醚，面料中的异物质溶于乙醚，将乙醚蒸发后再称取玻璃烧杯的重量为C。
异物质萃取量(％)＝100×(C－B)/A
3.耐磨损测试
参考ISO 5981的测试方法，样品尺寸：100mm×50mm，测试仪器：Scrub测试仪，将样品放在Scrub测试仪上，进行试验，记录摩擦次数。
具体实施方式
下面结合具体实施例，进一步详细阐述本发明。应当理解，下面的实施例仅为说明本发明用，并不意图限制本发明。
除非特别指出，本发明的含量百分比皆为重量百分比。
实施例1
采用纤度为315D的聚酰胺66长丝，织造密度为60根/英寸的平纹织物，采用的新型精炼剂pH为3.5，比重为1.09g/cm3，粘度为220mPa·s，其成分吩的乙氧基脂肪醇含量15％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量8％，聚丙烯酸钠含量0.2％。精炼过程中精炼剂重量比为0.33％，NaOH(浓度32％)重量比为1.25％，精炼温度为65℃，精炼速度为20m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.28％，针抓强度经向为557N，纬向为484N。pH值为6.9。其物性结果见表1。
实施例2
采用纤度为630D的聚酰胺66长丝，织造密度为41根/英寸的平纹织物，采用的新型精炼剂pH为5.0，比重1.10g/cm3，粘度190mPa·s，其成分吩的乙氧基脂肪醇含量22％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量10％，聚丙烯酸钠含量0.6％。精炼过程中精炼剂重量比为0.5％，NaOH(浓度32％)重量比为1.5％，精炼温度为80℃，精炼速度为25m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.29％，针抓强度经向为388N，纬向为317N。pH值为6.8。其物性结果见表1。
实施例3
采用纤度为500D的聚酯长丝，织造密度为51根/英寸的平纹织物，采用的新型精炼剂pH为5.5，比重1.10g/cm3，粘度160mPa·s，其成分吩的乙氧基脂肪醇含量30％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量12％，聚丙烯酸钠含量0.9％。精炼过程中精炼剂重量比为0.6％，NaOH(浓度32％)重量比为2.3％，精炼温度为90℃，精炼速度为15m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.20％，针抓强度经向为732N，纬向为644N。pH值为6.9。其物性结果见表1。
实施例4
采用纤度为420D的聚酰胺66长丝，织造密度为46根/英寸的平纹织物，采用的新型精炼剂pH为4.5，比重1.10g/cm3，粘度190mPa·s，其成分吩的乙氧基脂肪醇含量22％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量10％，聚丙烯酸钠含量0.6％。精炼过程中精炼剂重量比为0.5％，NaOH(浓度32％)重量比为1.5％，精炼温度为80℃，精炼速度为25m/min，涂胶温度为190℃，涂胶速度为20m/min,最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.25％，针抓强度经向为413N，纬向为378N，耐磨损次数经向650次，纬向650次。其物性结果见表1。
比较例1
采用纤度为315D的聚酰胺66长丝，织造密度为60根/英寸的平纹织物，采用的精炼剂pH为3.0，比重1.05g/cm3，粘度260mPa·s，其成分吩的乙氧基脂肪醇含量15％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量8％，聚丙烯酸钠含量0.2％。精炼过程中精炼剂重量比为0.33％，NaOH(浓度32％)重量比为1.25％，精炼温度为65℃，精炼速度为20m/min，最后制得本发明的安全气囊织物，测得该气囊织物表面有杂质，异物质萃取结果为0.44％，针抓强度经向为496N，纬向为427N。pH值为6.9。其物性结果见表1。
比较例2
采用纤度为630D的聚酰胺66长丝，织造密度为41根/英寸的平纹织物，采用的精炼剂pH为5.0，比重1.15g/cm3，粘度190mPa·s，其成分吩的乙氧基脂肪醇含量35％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量15％，聚丙烯酸钠含量1.2％。精炼过程中精炼剂重量比为0.5％，NaOH(浓度32％)重量比为1.5％，精炼温度为80℃，精炼速度为25m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.46％，针抓强度经向为347N，纬向为261N。pH值为7.0，加工后面料表面有不规则水印。其物性结果见表1。
比较例3
采用纤度为500D的聚酯长丝，织造密度为51根/英寸的平纹织物，采用的精炼剂pH为5.5，比重1.10g/cm3，粘度160mPa·s，其成分吩的乙氧基脂肪醇含量30％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量12％，聚丙烯酸钠含量0.9％。精炼过程中精炼剂重量比为0.7％，NaOH(浓度32％)重量比为2.5％，精炼温度为90℃，精炼速度为15m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.40％，针抓强度经向为651N，纬向为587N，pH值为9.1。其物性结果见表1。
比较例4
采用纤度为420D的聚酰胺66长丝，织造密度为46根/英寸的平纹织物，采用的精炼剂pH为4.5，比重1.10g/cm3，粘度190mPa·s，其成分吩的乙氧基脂肪醇含量22％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量10％，聚丙烯酸钠含量0.6％。精炼过程中精炼剂重量比为0.2％，NaOH(浓度32％)重量比为1.0％，精炼温度为80℃，精炼速度为25m/min，涂胶温度为190℃，涂胶速度为20m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.40％，针抓强度经向为399N，纬向为359N，耐磨损次数经向500次，纬向500次。其物性结果见表1。
比较例5
采用纤度为420D的聚酰胺66长丝，织造密度为46根/英寸的平纹织物，采用的精炼剂pH为4.5，比重1.10g/cm3，粘度190mPa·s，其成分的吩的乙氧基脂肪醇含量10％，十一烷基-十一羟基聚(氧-1,2-亚乙基)含量5％，聚丙烯酸钠含量0.08％。精炼过程中精炼剂重量比为0.5％，NaOH(浓度32％)重量比为1.5％，精炼温度为80℃，精炼速度为25m/min，涂胶温度为190℃，涂胶速度为20m/min，最后制得本发明的安全气囊织物，测得该气囊织物的异物质萃取结果为0.39％，针抓强度经向为384N，纬向为352N，耐磨损次数经向500次，纬向500次。其物性结果见表1。
表1安全气囊面料物性表
Claims (9)
1.一种安全气囊面料，其特征在于：经过精炼后，按照ASTM D 2257可萃取物质的测试方法所测得的所述安全气囊面料的异物质萃取结果在0.4％以下。
2.根据权利要求书1所述的安全气囊面料，其特征在于，所述安全气囊面料的针抓强度为300N-750N。
3.根据权利要求书1所述的安全气囊面料，其特征在于，所述安全气囊面料的耐磨损次数在650次以上。
4.根据权利要求书1所述的安全气囊面料，其特征在于，所述安全气囊面料原丝规格为315D-630D。
5.一种方法，用于加工权利要求1所述的安全气囊面料，所述方法包括精炼阶段、涂胶阶段，其特征在于，在精炼阶段中采用的精炼剂是络合分散剂、表面活性剂以及双氧水稳定剂的阴离子性复配物，所述精炼剂的pH值为3.5-5.5，比重为1.07-1.11g/cm3，粘度小于250mPa·s。
6.根据权利要求5所述的方法，其特征在于，所述精炼剂包含吩的乙氧基脂肪醇、十一烷基-ω-羟基聚(氧-1,2-亚乙基)和聚丙烯酸钠，其中基于所述精炼剂的总重量，所述吩的乙氧基脂肪醇的含量为13-30重量％，所述十一烷基-ω-羟基聚(氧-1,2-亚乙基)的含量为7-13重量％，所述聚丙烯酸钠的含量为0.1-1重量％。
7.根据权利要6中所述的方法，其特征在于，所述精炼阶段包括精炼、干燥、热定型，基于精炼药剂的总重量，所述精炼剂的量为0.33％-0.63重量％，所述NaOH的量为0.38％-0.76重量％，精炼温度为60-95℃，干燥温度为110-130℃，热定型温度为150-200℃。
8.根据权利要7中所述的方法，其特征在于，所述NaOH以浓度为32％的NaOH水溶液加入。
9.根据权利要求5中所述的方法，其特征在于，所述涂胶阶段中的烘箱温度为150-190℃，速度为15-25m/min。
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