CN106319963A - 一种机器人防护面料及其制备方法 - Google Patents
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Abstract
本发明公开了一种耐污、易洗涤,且具有永久导电性能的机器人防护面料及其制备方法。所述机器人防护面料,含有质量百分比为2‑10%的导电纤维成分,经8‑10%质量百分比的三防剂和1‑3%质量百分比的交联剂和3‑6%质量百分比的催化剂混合液,采用一浸一轧处理,经120℃烘干和160℃烘焙,形成5次洗涤后三防性能不低于3级的耐污、耐洗机器人防护服面料产品。
Description
技术领域
本发明涉及纺织面料应用技术领域,具体涉及一种具有抗静电性能和耐污、易洗涤的纺织面料及其制备方法。
背景技术
近年来,工业机器人产业迅猛发展,在各行各业中机器人被越来越多的使用,当前市场上广泛使用的工业机器人有喷涂机器人、耐高温机器人、焊接机器人、清洗机器人、搬运机器人等。这些机器人长期处在极端恶劣的生产环境中,不仅容易受到环境侵蚀,影响外观和正常使用,其自身的使用寿命也受到威胁。尤其是机器人外接皮线、传动关节处等相对易被破坏的部位,更需要特别的安全保护。如喷涂机器人在正常工作中要受到雾化喷漆的影响,不仅使表面附着油漆影响美观,同时,雾化的液滴容易侵入机器人的连接关节处,附着在表面,影响机器的正常使用,另外,雾化的油漆液滴在空气中具有一定的浓度,在接触到静电时,容易发生爆炸,具有较高的危险性。因此,喷涂机器人在使用中往往安装防护服,一方面保持设备清洁,不受喷涂材料的侵蚀,另一方面,防护服增加了抗静电功能,使设备表面不积存电荷,有效减少甚至避免了静电威胁带来的安全隐患。
当前市场上的喷涂机器人防护服多采用针织面料,经一定的抗静电整理,使其具有一定的抗静电性。抗静电整理面料在使用初期性能较好,但经过一段时间的使用后,面料受到长期摩擦和不断的洗涤,其表面的抗静电整理层逐渐脱落,其抗静电性能也越来越差,甚至消失,从而导致材料不能继续使用。由于喷涂机器人长期处于工作环境,每天接触大量的油漆物质,每天都需要对沾染的油漆进行洗涤,因此抗静电性的耐久性成为提高材料使用寿命的关键问题。同时,面料沾染大量的油漆,清洁洗涤也非常的繁琐,为了提高面料的防油污性能,往往考虑为面料添加三防功能,但经过抗静电处理的面料再次进行后处理,无论抗静电性还是三防性能都无法获得良好的效果,如何使抗静电性和三防性能兼得,而不影响面料的正常使用,减少洗涤次数,提高使用效率,降低喷涂机器人防护服清洁工作中耗用的人力和物力,成为防护服使用单位关心的问题。
本发明结合喷涂机器人的工况环境,设计开发了一种具有耐久性抗静电性能和耐污易清洁打理的新型面料,其抗静电性不会随着洗涤次数的增加而降低,同时面料不易沾污便于清洁,不需要每天洗涤,只需在每天使用后简单擦拭既可,可有效延长洗涤间隔期,减少人力物力的耗用。
发明内容
一种耐污、易洗涤,且具有永久导电性能的机器人防护面料,面料采用三防剂、交联剂, 共同处理,形成防水、防油、防污保护层。
所述的机器人防护面料,三防剂优选美国明尼苏达矿务及制造业公司(3M)公司的PM930三防整理剂,比例为8-10%,交联剂优选石家庄市联邦科特化工有限公司的HPA-3交联剂,比例为1-3%,催化剂采用石家庄市联邦科特化工有限公司的CS-200与市售磷酸和冰醋酸的混合物,比例为3-6%,面料经一浸一轧处理,采用120℃、2.5min进行烘干,再经过160℃、3min进行烘焙。
所述的机器人防护面料,所选用的催化剂为CS-200、磷酸和冰醋酸的混合物,三种药剂的比例为2:1:1。
所述的机器人防护面料,三防整理后面料中药剂含量为4.5-6.5%,其中三防剂与交联剂的比例为3:1-8:1。
所述的机器人防护面料,面料成分中含有质量百分比2%-10%的导电纤维材料。
所述的机器人防护面料,含有的导电纤维材料包含不锈钢长丝、导电长丝或导电短纤维。
所述的机器人防护面料,经5次洗涤后三防性能不低于3级。
具体实施方式
喷涂机器人防护面料一般采用针织罗纹结构,大圆机织造,根据实际用途情况,对总针根数和纱支进行调节,本发明中采用1*1细针罗纹,180g/m2的坯布克重,32s单纱或长丝纱,19G针筒,34寸门幅,总针根数为2040针。在加工过程中,选择常规阻燃涤纶短纤纱或长丝纱,以及具有导电性能的不锈钢长丝,铜离子、银离子导电长丝或加入导电纤维的短纤维纱,按照比例倒筒后,按顺序依次喂入针织大圆机,采用常规罗纹织物的加工工艺进行织造,形成180g/m2,175cm幅宽的针织坯布。
针织坯布下机后,在后整理机中进行后整理,首先配置三防整理液,三防整理液中选用的三防整理剂为美国明尼苏达矿务及制造业公司(3M)公司生产的PM930三防整理剂,交联剂为石家庄市联邦科特化工有限公司生产的HPA-3交联剂,催化剂为按比例配置的催化剂混合物,其中含有石家庄市联邦科特化工有限公司生产的CS-200、市售的磷酸和冰醋酸,催化剂中三种药剂的比例为2:1:1。
设计成品含固率为4-5%,其中三防剂与交联剂的比例为3:1-8:1,设计面料带液率为50-65%,根据设计面料带液率调整设备压辊压力,根据加工面料数量估算三防整理液重量如下:
三防整理液重量≥坯布重量*0.05/0.08,
三防整理液重量≥设备最低充液量,
二者取较大值为三防整理液最低重量,实际加工中根据实际情况多配置部分备用。
三防整理液的配置:
根据计算的三防整理液重量,计算三防整理剂、交联剂、催化剂和水的重量,在配液容器中注入足够数量的水,分别加入三防整理剂、交联剂,和按照比例配置的催化剂成分,充分搅拌,溶解。
三防整理加工:
三防整理液配置完成后注入后整理设备中,面料在设备中经一浸一轧处理后,带液面料进入连续烘箱中,经120℃烘干2.5min,烘干后的面料再经过连续烘箱,经160℃烘焙3min。
面料在设备中经过浸渍,使三防整理液中的药剂充分而均匀地分布在面料内外,经过压辊的挤压,面料带液率达到50-65%,其中的三防剂的有效成分留存约4-5%。挤压后的面料经过120℃烘箱烘干2.5min后,一方面织物中的水分挥发,另一方面,三防整理液中的三防剂通过交联剂与织物纤维结构中的大分子相结合,使三防剂与纤维形成稳固的化学结构,从而达到三防和耐水洗的性能。由于交联剂在三防剂和织物纤维大分子的结合过程中起到桥梁的作用,交联剂与三防剂和织物纤维大分子直接的结合必须充分而稳固,才能保证三防性能的有效性、耐久性和耐洗涤性。为了保证交联剂的充分反应,在三防整理液中加入催化剂,高温状态有利于催化剂快速而有效地催化反应的进行,因此,在面料烘干后,再次选用更高的温度160℃,更长的时间3min,对面料进行烘焙,面料在烘焙过程中,催化作用更加快速,交联剂与织物纤维大分子和三防剂的结合反应更快速、充分而稳固,从而使面料的三防性能大幅度提高,三防性能、耐久性和耐洗涤性也明显提高。
测试方法
导电性的测试:
面料比电阻的测试采用GB 12014-2009《防静电服》标准中附录A方法测试织物点对点电阻,并对照其中4.1.2的点对点电阻技术要求,评价面料比电阻的水平。
三防性能的测试:
面料三防性能的测试采用GB 4745-2012《纺织品防水性能的检测和评价沾水法》,通过对织物防水性的测试进行评价,最高为5级,3级以上为合格。
洗涤方法:
喷涂机器人防护服的洗涤方法采用GB 8629-2001《纺织品试验用家庭洗涤和干燥程序》5A程序进行洗涤。
实施例:
下面结合实施例对本发明做进一步描述。
实施例1:
采用不锈钢长丝与阻燃涤纶长丝,采用大圆机罗纹织造,织造后不锈钢长丝的重量百分比为10%,织物克重180g/m2,门幅175cm,选用PM930三防整理剂8%,HPA-3交联剂1%,CS-200、磷酸、冰醋酸以2:1:1混合而成的催化剂3%,一浸一轧,烘干120℃,2.5min,烘焙160℃,3min。
加工完成的面料采用GB 12014-2009测试比电阻为3.21*106Ω,GB 4745-2012测试防水性能为4.5级,经5次洗涤后测试比电阻为3.14*106Ω,三防性能为3级。
实施例2:
采用不锈钢长丝与阻燃涤纶长丝,采用大圆机罗纹织造,织造后不锈钢长丝的重量百分比为5%,织物克重180g/m2,门幅175cm,选用PM930三防整理剂10%,HPA-3交联剂3%,CS-200、磷酸、冰醋酸以2:1:1混合而成的催化剂6%,一浸一轧,烘干120℃,2.5min,烘焙160℃,3min。
加工完成的面料采用GB 12014-2009测试比电阻为3.55*106Ω,GB 4745-2012测试防水性能为5级,经5次洗涤后测试比电阻为4.03*106Ω,三防性能为4级。
实施例3:
采用含有10%导电纤维的短纤纱与阻燃涤纶长丝,采用大圆机罗纹织造,织造后导电纤维的重量百分比为2%,织物克重180g/m2,门幅175cm,选用PM930三防整理剂9%,HPA-3交联剂2.5%,CS-200、磷酸、冰醋酸以2:1:1混合而成的催化剂4.5%,一浸一轧,烘干120℃,2.5min,烘焙160℃,3min。
加工完成的面料采用GB 12014-2009测试比电阻为7.83*106Ω,GB 4745-2012测试防水性能为4.5级,经5次洗涤后测试比电阻为7.12*106Ω,三防性能为3.5级。
对比例1
100%涤纶长丝,采用大圆机罗纹织造,织物克重180g/m2,门幅175cm,进行抗静电整理,整理后采用GB 12014-2009测试比电阻为7.64*106Ω,GB 4745-2012测试防水性能为2.5级,经5次洗涤后,测试比电阻为6.27*1014Ω,防水性能2级。
实施例1 | 实施例2 | 实施例3 | 对比例1 | |
水洗前比电阻 | 3.21*106Ω | 4.03*106Ω | 7.83*106Ω | 7.64*106Ω |
5次水洗后比电阻 | 3.14*106Ω | 3.55*106Ω | 7.12*106Ω | 6.27*1014Ω |
水洗前三防性能 | 4.5 | 5 | 4.5 | 2.5 |
5次水洗后三防性 | 3 | 4 | 3.5 | 2 |
Claims (7)
1.一种耐污、易洗涤,且具有永久导电性能的机器人防护面料,其特征在于,所述面料采用三防剂、交联剂、催化剂,共同处理,形成防水、防油、防污保护层。
2.如权利要求1所述的机器人防护面料,三防剂优选PM930,比例为8-10%,交联剂优选HPA-3,比例为1-3%,催化剂采用CS-200、磷酸、冰醋酸混合物,比例为3-6%,面料经一浸一轧处理,采用120℃、2.5min进行烘干,再经过160℃、3min进行烘焙。
3.如权利要求2所述的机器人防护面料,其特征在于,所选用的催化剂为CS-200、磷酸和冰醋酸的混合物,三种药剂的比例为2:1:1。
4.如权利要求2所述的机器人防护面料,其特征在于,三防整理后面料中药剂含量为4.5-6.5%,其中三防剂与交联剂的比例为3:1-8:1。
5.如权利要求1或2所述的机器人防护面料,其特征在于,面料成分中含有质量百分比2%-10%的导电纤维材料。
6.如权利要求5所述的机器人防护面料,其特征在于,所述导电纤维材料包含不锈钢长丝、导电长丝或导电短纤维。
7.如权利要求6所述的机器人防护面料,其特征在于,所述面料经5次洗涤后三防性能不低于3级。
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