CN106427101B - 一种新型超高密度纤维针刺毡的制备方法 - Google Patents

一种新型超高密度纤维针刺毡的制备方法 Download PDF

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CN106427101B
CN106427101B CN201610699362.3A CN201610699362A CN106427101B CN 106427101 B CN106427101 B CN 106427101B CN 201610699362 A CN201610699362 A CN 201610699362A CN 106427101 B CN106427101 B CN 106427101B
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蒋云
陈美琴
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Wuxi yunri Intelligent Technology Co.,Ltd.
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Suzhou Qin Yun Fiber Assembly Technology Co Ltd
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Abstract

一种新型超高密度纤维针刺毡的制备方法，包括下列步骤：（1）不同结构的纤维材料裁切备用；（2）不同结构纤维材料按配比层叠预针刺，采用基布50与方格布60组合，方格布60提供Z向连接纤维，不用网胎；（3）辅助加压固化单元层10厚度，使各单元层10厚度保持一致，并与理论计算厚度一致；（4）单元层10叠层针刺，针刺密度、深度等针刺参数根据针刺毡预制体密度可调；（5）针刺毡预制体内部应力去除，有效确保预制体平整，无翘边，循环进行单元层10叠层接力针刺即可制得满足厚度尺寸和高密要求的针刺毡预制体；采用本发明制备的针刺毡预制体密度高、层间连接强度大，可应用于高温防热领域。

Description

一种新型超高密度纤维针刺毡的制备方法
技术领域
本发明涉及一种纤维针刺毡的制备方法，尤其是一种新型超高密度纤维针刺毡的制备方法，属于纤维集合体技术领域。
背景技术
针刺技术源于纺织工业的短切纤维制毡工艺，是通过刺针对网胎和基布(长纤维织物)进行接力针刺，从而得到准三维网状结构织物的一种复合材料预制体成型技术。现有技术无一例外到要用到网胎作为Z向连接用纤维源头，制备的针刺毡密度低满足保温隔热需求，在高温隔热领域已批量应用。
现有技术使用短纤维经过气流或梳理成网先制成网胎，再把网胎与二维布叠层针刺制造出针刺毡。其网胎的制备采用短切纤维，该纤维在梳理或气流成网过程中易损伤，强度下降，且网胎的均匀性相比平面织物要差，网胎具有的蓬松特性使其在相同重量下比平面织物厚度要高三倍，就此说明要制备超高密度针刺毡，不能使用厚度上未经压缩的网胎等蓬松类织物。由于网胎厚度方向蓬松，在相同厚度下比平面织物的层数要少，另相邻层的网胎在针刺过程变形不一致，会出现收缩各异的情况使得针刺毡上、下层不平整，要平整就需进行裁切，损耗增加。现有针刺毡技术网胎在首次针刺时基本就已固定，后续针刺基本不会再产生Z向纤维，反复针刺反而会把纤维刺烂，使其X-Y向面内性能下降，因此现有技术只能用于制备低密度针刺毡用于保温隔热领域。
中国专利公告号CN1255600C，公告日是2006年5月10日，名称为‘一种可针刺无纺织物及准三维预制件’中公开了一种由聚丙烯晴基碳纤维预制薄层无纺织物及编织布，以及经多重交替叠层针刺形成的准三维预制件，克服了已有采用长条碳纤维前体聚丙烯晴基预氧纤维(OPF)为主叠层针刺预制件的缺陷，不足之处是采用该工艺无法制备出超高密度针刺毡预制件。中国专利公告号CN103668779A，公告日是2014年3月26日，名称为‘一种碳化硅纤维针刺毡及其制备方法’中公开了一种碳化硅纤维针刺毡及其制备方法，采用单层针刺和叠层针刺工艺，在Z向力学性能大大提高的同时，X-Y向的力学性能和热物理性能也较非针刺毡显著提高，不足之处是采用该方法制备的针刺毡密度较低，只适合应用于高温过滤、隔热等低密度复合材料领域。
发明内容
本发明要解决的技术问题就是现有技术中网胎均匀性较差，产品密度较难控制；网胎单位克重厚度高，与超高密度纤维针刺毡制备机理相悖；网胎在反复针刺过程中面内性能下降以及网胎提供Z向连接纤维不足的问题，提出一种纤维针刺毡制备新方法。
本发明一种新型超高密度纤维针刺毡制备方法包括如下步骤：
1)按设计选取一定规格的基布和方格布，把不同结构的纤维材料按配比层叠后，放在针刺毡主针刺设备的进料口处，调整其托网板与剥网板的距离为层叠物理论厚度之和加2mm，夹持固定；
2)对所述托网板与剥网板的夹持物按设定的针刺深度和密度进行针刺制成单元层；
3)在标准温、湿度条件下，对单元层先用超声波震动器去除内应力，再设定压力，对其进行辅助加压使其厚度控制在设定范围内；
4)对单元层进行裁剪修边，使其平面尺寸一致，去除表面毛糙，使其厚度尺寸一致；
5)把设定数量的单元层叠加，用托网板与剥网板夹持，所述托网板与剥网板之间的距离等于单元层理论厚度总和，而后设定针刺深度和密度对其进行叠层复合针刺，直至达到超高密度纤维针刺毡预制体厚度尺寸要求；
6)前述步骤1中，单元层基布包括单向、二维、2.5维、正交三向和三维多向等多种结构；
7)前述步骤2中，设计的针刺深度和密度是根据超高密度纤维针刺毡预制体的密度推算至单元层的针刺参数，该参数随产品密度变化可调；
8)前述步骤2中，刺针规格及型号随不同材质的纤维材料和不同密度的预制体可调；
9)前述步骤3中，对单元层辅助加压压力根据产品密度可调；
10)前述步骤5中，复合针刺时每次叠加的单元层层数及针刺参数根据产品密度可调；
11)前述单元层叠层复合针刺工艺制备的超高密度纤维针刺毡预制体形状包括：方形、圆形、截锥形、带球顶锥形及其它异形，实心或空心；
12)前述基布和方格布纤维材料的材质为碳纤维、石英纤维、玄武岩纤维、高硅氧纤维等高性能纤维。
本发明可应用于高温过滤、防热复合材料领域，还可向新型建筑材料应用领域拓展。
附图说明
图1为本发明一种新型超高密度纤维针刺毡的制备方法的单元层预针刺工艺示意图；
图2为本发明一种新型超高密度纤维针刺毡的制备方法的单元层结构组成示意图；
图3为本发明一种新型超高密度纤维针刺毡的制备方法的叠层复合针刺工艺示意图；
图4为本发明一种新型超高密度纤维针刺毡的制备方法的超高密度纤维针刺毡预制体结构示意图；
图5为本发明一种新型超高密度纤维针刺毡的制备方法的超高密度纤维针刺毡预制体制备流程结构示意图。
具体实施方式
下面结合附图与具体实施方式对本发明作进一步详细描述：
实施例：
要制备外形尺寸：(330±5)×(330±5)×(30+1)mm，厚度为压缩过的；纤维体积百分含量：40％±1％的超高密度石英纤维针刺毡。其设计及制备步骤如下：
(1)根据针刺毡外形尺寸和纤维体积百分含量设计针刺毡单元层1结构，单元层1采取2层石英平纹布5+1层石英方格布6，0°/90°铺层、针刺；石英平纹布5规格10根/cm(经密)×10根/cm(纬密)，厚度0.22mm，平方米克重198g/m2，石英方格布6采用厚度0.18mm，平方米克重100g/m2；纤维体积百分含量按40％设计，最终产品针刺毡预制体的体积密度：40％×2.2＝0.88g/cm2，针刺毡预制体重量：0.88×33×33×3＝2874.96g，作为最终检测数据。
(2)根据单元层1是由两层平纹布5和一层方格布6层叠而成，单元层1克重：2×0.33m×0.33m×198g+1×0.33m×0.33m×100g＝54.01g
需制备的单元层1数量：2874.96g÷54.01＝53.2个单元层，取整53。其制备流程如图5中所示。
(3)将两张平纹布5和一张方格布6层叠组成一个单元层1，两张平纹布5在下，方格布6在上，最底面衬塑料薄膜。
(4)裁切平纹布5和方格布6。由于单元层1在层叠针刺过程中，平纹布5与方格布6间的经、纬向不完全一致，在针刺时方格布6会出现收缩，根据试验得出其收缩量为30％，因此方格布6在裁切时要留出30％收缩余量，最终平纹布5和方格布6的裁切尺寸分别为38cm×38cm、50cm×50cm。
(5)层叠单元层1预针刺。预针刺过程中用厚度为0.08mm塑料薄膜垫底，单元层1由两张平纹布5和一张方格布6组成，方格布5在最上面，且从针刺设备进料口平行方向看，方格布5沿平纹布6左右居中，从进料口方向看，与平纹布5平齐，调整剥网板4与托网板3的间距为3mm，调整针刺密度为25针/cm2，针刺深度为9mm进行单元层1预针刺。
(6)单元层1辅助加压。将制备的单元层1放入恒温(标准温度25℃)、恒湿(相对湿度50％)的超声波振动压力箱中，以500kg/m2的压力压制1个小时，使其稳定在理论计算厚度并保持各单元层1厚度一致。
(7)单元层1修整。取出单元层1，用裁切机裁切修边，并用高速旋转刀头去除单元层1表面毛糙纤维，使其平整。
(8)单元层1叠层针刺。调整针刺深度为12mm，针刺密度为45针/cm2，剥网板4与托网板3间距为1.5mm进行叠层针刺，在叠层针刺过程中，根据理论计算每增加两层单元层1，剥网板4与托网板3间距增加1.24mm，按此规律循环针刺直至做到要求厚度。
(9)产品裁切及去应力。按330mm×330mm尺寸裁切针刺毡，使用低频率超声波设备去除针刺毡内部应力，使针刺毡平整、密实。
上述仅为本发明单个具体实施方式，但本发明的设计构思并不局限于此，凡利用此构思对本发明进行非实质性的改动，均应属于侵犯本发明保护的范围的行为。但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何形式的简单修改、等同变化与改型，仍属于本发明技术方案的保护范围。

Claims (7)

1.一种新型超高密度纤维针刺毡的制备方法，其特征是包括下列步骤：
一、根据针刺毡外形尺寸和纤维体积百分含量设计针刺毡单元层(1)结构，按设计选取一定规格的基布(5)和方格布(6)，且所述方格布(6)在裁切时要留出30％收缩余量；把不同结构的纤维材料按配比层叠后，放在针刺毡主针刺设备的进料口处，调整其托网板(3)与剥网板(4)的距离为层叠物理论厚度之和加2mm，夹持固定，且两张基布(5)在下，方格布(6)在上层叠组成一个单元层(1)，最底面衬塑料薄膜；
二、对所述托网板(3)与剥网板(4)的夹持物按设定的针刺深度和密度进行针刺制成单元层(1)，设计的针刺深度和密度是根据超高密度纤维针刺毡预制体的密度推算至单元层(1)的针刺参数，该针刺参数随超高密度纤维针刺毡预制体密度变化可调；
三、在标准温度25℃、相对湿度50％的条件下，对单元层(1)先用超声波震动器去除内应力，再设定压力，对其进行辅助加压使其厚度控制在设定范围内；
四、对单元层(1)进行裁剪修边，使其平面尺寸一致，去除表面毛糙，使其厚度尺寸一致；
五、把设定数量的单元层(1)叠加，用托网板(3)与剥网板(4)夹持，所述托网板(3)与剥网板(4)之间的距离等于单元层(1)理论厚度总和，而后设定针刺深度和密度对其进行叠层复合针刺，直至达到超高密度纤维针刺毡预制体厚度尺寸要求。
2.根据权利要求1所述的新型超高密度纤维针刺毡的制备方法，其特征是步骤一中，基布(5)的结构包括单向、二维、2.5维、正交三向和三维多向。
3.根据权利要求1所述的新型超高密度纤维针刺毡的制备方法，其特征是步骤二中，刺针(2)规格及型号随不同材质的纤维材料和不同密度的超高密度纤维针刺毡预制体可调。
4.根据权利要求1所述的新型超高密度纤维针刺毡的制备方法，其特征是步骤三中，对单元层(1)辅助加压压力根据超高密度纤维针刺毡预制体密度可调。
5.根据权利要求1所述的新型超高密度纤维针刺毡的制备方法，其特征是步骤五中，复合针刺时每次叠加的单元层(1)层数及针刺参数根据超高密度纤维针刺毡预制体密度可调。
6.根据权利要求1所述的新型超高密度纤维针刺毡的制备方法，其特征是单元层(1)叠层复合针刺工艺制备的超高密度纤维针刺毡预制体形状包括：方形、圆形、截锥形、带球顶锥形，实心或空心。
7.根据权利要求1所述的新型超高密度纤维针刺毡的制备方法，其特征是所述的基布(5)和方格布(6)纤维材料的材质为碳纤维、石英纤维、玄武岩纤维、高硅氧纤维。
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