CN106521956B - 一种桔瓣型超细纤维仿真皮革基布的制备方法 - Google Patents

一种桔瓣型超细纤维仿真皮革基布的制备方法 Download PDF

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CN106521956B
CN106521956B CN201710026836.2A CN201710026836A CN106521956B CN 106521956 B CN106521956 B CN 106521956B CN 201710026836 A CN201710026836 A CN 201710026836A CN 106521956 B CN106521956 B CN 106521956B
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钱晓明
赵宝宝
徐志伟
封严
邓辉
王闻宇
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Tianjin Polytechnic University
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Abstract

本发明公开了一种桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于包括以下步骤：（1）采用纺粘法制备桔瓣型复合长丝纤维，并在成网帘上铺网；（2）将纤网依次送入针刺机、水刺机进行加固，得到横截面上的纤维细度具有梯度变化的非织造布；（3）将可溶性树脂溶解，涂刮于非织造布的针刺一面，得到横截面上的树脂含量具有梯度变化的非织造布；（4）将非织造布进行含浸、固化、水煮、干燥处理，得到桔瓣型超细纤维仿真皮革基布。本发明方法生产的桔瓣型超细纤维仿真皮革基布具备纤维细度和（水性）聚氨酯含浸量在非织造布内部的梯度变化，与真皮基板的结构极其相近，具有良好的手感、垂感和质感，实现了高仿真皮革基布的目的。

Description

一种桔瓣型超细纤维仿真皮革基布的制备方法
技术领域
本发明涉及超细纤维合成革技术领域，具体是一种桔瓣型超细纤维仿真皮革基布的制备方法。
背景技术
目前，合成革的生产和研发一直以接近天然皮革为目的。超细纤维合成革(超纤革)作为新一代人工皮革，是最接近天然皮革的产品，但其与天然皮革还存在一定的差距，主要差别在于天然皮革基板在横截面方向上具有明显的梯度结构，其表皮层和底层在密度上具有较大的差异，表皮层密度高，底层密度低，这一特点使其表面折纹细腻，手感丰满，弯折后韧性强。
目前超纤革基布一般采用海岛型超细纤维或分裂型超细纤维，经针刺工艺或水刺工艺使超细纤维三维交联在一起，形成立体网状结构，起到骨架和支撑作用，再填充性能优异具有微孔结构的聚氨酯。利用现有技术生产出的革基布虽然呈网络立体结构，但与真皮基板的结构还有很大的区别，主要体现在横截面方向上密度没有变化，导致超纤革没有天然皮革细腻的表面效果和丰满的手感。所以要制备出高档的超纤革，首先必须生产出与天然皮革基板结构一致的革基布。
申请号201310406654.X公开了一种海岛型超细纤维仿真皮革基布的生产方法。该方法通过将针刺非织造布和湿法非织造布复合在一起，并采用水刺法进行加固，可以使基布产生横向密度的变化。该方法生产的海岛型超细纤维仿真皮革基布具有表面致密、外观平整、手感柔软等特点。但采用复合的方法制备的革基布存在剥离强度差的问题。申请号201510971519.9公开了仿真皮超细纤维合成革基布及制备方法。该方法通过在海岛型超细纤维非织造布的表面附上一层薄膜，高温下部分薄膜融化后向非织造布内部渗入，使薄膜面由外向内非织造布密度降低，能有效地减少聚氨酯在该侧的聚氨酯含浸量，使得聚氨酯在非织造布内部密度呈现由高到低的梯度变化，经过后续的减量开纤，将该薄膜除去，形成的内部结构与真皮的极其相似，制备的合成革具有良好的垂感和真皮的质感。但非织造布烫平融化薄膜需要较高的能量且其融化后向非织造布渗入的均匀性较差，并且甲苯减量或碱减量工艺，会产生大量的有机废水，不仅造成了一定的环境污染，也增加了生产成本。
发明内容
针对现有技术的不足，本发明拟解决的技术问题是，提供一种桔瓣型超细纤维仿真皮革基布的制备方法。本方法采用针刺、水刺复合开纤工艺和表面刮涂技术，实现了纤维细度和(水性)聚氨酯含浸量在非织造布内部的梯度变化，制备的革基布具有良好的手感、垂感和质感。
本发明解决所述技术问题的技术方案是，提供一种桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于包括以下步骤：
(1)复合纤维纺丝成网：首先将两种聚合物切片分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经牵伸纺丝成网；
(2)非织造布的制备：将步骤1)制得的长丝纤网依次送入针刺机和水刺机中进行加固；针刺深度5-7mm，针刺密度为50-500N/cm2，单面水刺，水针刺入非织造布的深度为0.2-0.3um，水针压力为50-280Mpa；得到横截面上的纤维细度具有梯度变化的非织造布；
(3)可溶性树脂的刮涂：将可溶性树脂溶解，调节粘度到300-3000mpa·s，制得刮涂浆料，然后将刮涂浆料涂刮于步骤2)制得的非织造布的针刺一面，浆料渗入到非织造布内部，上浆率为5-35％，干燥后得到横截面上的可溶性树脂含量具有梯度变化的非织造布；
(4)非织造布的含浸、固化、水煮和干燥处理：将步骤3)制得的非织造布进行含浸、固化、水煮和干燥处理，得到桔瓣型超细纤维仿真皮革基布。
步骤1)所述牵伸的方式为管式牵伸、宽狭缝式牵伸或窄狭缝式牵伸中的至少一种；牵伸风压力为0.1-0.8Mpa，牵伸风速度大于0且小于等于2m/s，牵伸速度为1000-6000m/min，温度为10-25℃，相对湿度为65-90％。两种聚合物切片选自PET、PA6、PP和PU中的两种，两种的质量比为70:30-50:50。
步骤2)纤网经针刺后的厚度为0.5-0.7μm、开纤率为10-50％；纤网经水刺后的厚度为0.3-0.5μm，开纤率为50-96％。
与现有技术相比，本发明有益效果在于：
(1)本发明在常规的双组份纺粘水刺技术的基础上，增加了针刺工艺，并采用单面水刺的方法，可以使非织造布的纤维细度在非织造布内部产生梯度变化，制备的非织造布具有表面致密、外观平整、手感柔软等特点，同时避免了复合革基布剥离性能差的问题；
(2)在非织造布的针刺面刮涂可溶性树脂浆料，浆料向非织造布内部渗入，由外向内密度降低，能有效地减少(水性)聚氨酯在该侧的聚氨酯含浸量，可以使(水性)聚氨酯含浸量在非织造布内部产生均匀的梯度变化，制备的非织造布具有良好的垂感和真皮的质感；
(3)同时具备纤维细度和(水性)聚氨酯含浸量在非织造布内部的梯度变化，与真皮基板的结构极其相近，制备的革基布具有良好的手感、垂感和质感；
(4)采用纺粘法纺制双组份桔瓣型复合纤维，通过针刺+水刺工艺使复合纤维的双组分进行分离开纤，并使纤维相互缠结而形成超细纤维非织造布。与目前普遍采用的海岛型复合纤维结合减量工艺制备超细纤维非织造布的加工工艺相比，中空桔瓣型纺粘水刺超细纤维非织造布的加工工艺具有工艺流程短、生产速度快、无污染、产品力学性能好等优势，而且所制备的纤维纤度可达0.075～0.175D，与真皮胶原纤维的直径相近。
具体实施方式
下面给出本发明的具体实施例。具体实施例仅用于进一步详细说明本发明，不限制本申请权利要求的保护范围。
本发明公开了一种桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于包括以下步骤：
(1)复合纤维纺丝成网：首先将两种聚合物切片分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经牵伸纺丝成网；
所述牵伸的方式为管式牵伸、宽狭缝式牵伸或窄狭缝式牵伸中的至少一种；牵伸风压力为0.1-0.8Mpa，牵伸风速度为0-2m/s，牵伸速度为1000-6000m/min，温度为10-25℃，相对湿度为65-90％；
步骤1)中的两种聚合物切片之间的界面粘合性和相容性较差，选自PET(涤纶)、PA6(锦纶6)、PP(丙纶)和PU(氨纶)中的两种，两种的质量比为70:30-50:50；
(2)非织造布的制备：将步骤1)制得的长丝纤网依次送入针刺机(针刺深度5-7mm，针刺密度为50-500N/cm2)、水刺机进行加固(水针刺入非织造布的深度为0.2-0.3um，水针压力为50-280Mpa)，得到横截面上的纤维细度具有梯度变化的非织造布；
纤网经针刺后的厚度为0.5-0.7μm、开纤率为10-50％；
采取单面水刺，纤网经水刺后的厚度为0.3-0.5μm，开纤率为50-96％；
(3)可溶性树脂的刮涂：将可溶性树脂溶解，调节粘度到300-3000mpa·s，制得刮涂浆料，然后将刮涂浆料涂刮于步骤2)制得的非织造布的针刺一面，浆料渗入到非织造布内部，上浆率为5-35％，干燥后得到横截面上的可溶性树脂含量具有梯度变化的非织造布；
所述可溶性树脂是指固化后在高温条件下仍可溶于水的树脂，如：聚乙烯醇、水溶性聚酯等树脂中的一种；
(4)非织造布的含浸、固化、水煮和干燥处理：将步骤3)制得的非织造布进行含浸、固化、水煮和干燥处理，得到桔瓣型超细纤维仿真皮革基布。
实施例1
首先将PET/PA6(PET/PA6的质量比70:30)分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经管式牵伸纺丝成网；牵伸风压力为0.5Mpa，牵伸风速度为1m/s，牵伸速度为3000m/min，温度为20℃，相对湿度为78％；将纤网依次送入针刺机(针刺深度7mm，针刺密度为250N/cm2，针刺后的厚度为0.5μm，开纤率为30％)、水刺机(单面水刺，水针压力为150Mpa，水针刺入非织造布的深度为0.2um，开纤率为60％)进行加固，得到横截面上的纤维细度具有梯度变化的非织造布(厚度为0.4μm，克重100g/m3)；将水溶性聚酯溶解，调节粘度到800mpa·s，制得刮涂浆料，然后将刮涂浆料涂刮于非织造布的针刺一面，浆料渗入到非织造布内部，干燥后得到横截面上的树脂含量具有梯度变化的非织造布(水溶性聚酯的上浆率为8％)；将刮涂可溶性树脂后的非织造布进行含浸、固化、水煮、干燥处理，得到桔瓣型超细纤维仿真皮革基布。所制备的革基布的弯曲刚度为170mg·cm，静态悬垂系数为40％，柔软度为4.2mm，折皱回复角为145°。
实施例2
首先将PET/PA6(PET/PA6的质量比70:30)分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经宽狭缝式牵伸纺丝成网；牵伸风压力为0.5Mpa，牵伸风速度为1m/s，牵伸速度为3000m/min，温度为20℃，相对湿度为78％；将纤网依次送入针刺机(针刺深度5mm，针刺密度为150N/cm2，针刺后的厚度为0.6μm，开纤率为20％)、水刺机(单面水刺，水针压力为280Mpa，水针刺入非织造布的深度为0.3um，开纤率为80％)进行加固，得到横截面上的纤维细度具有梯度变化的非织造布(厚度为0.45μm，克重为120g/m3)；将水溶性聚酯溶解，调节粘度到800mpa·s，制得刮涂浆料，然后将刮涂浆料涂刮于非织造布的针刺一面，浆料渗入到非织造布内部，干燥后得到横截面上的树脂含量具有梯度变化的非织造布(水溶性聚酯的上浆率为8％)；将刮涂可溶性树脂后的非织造布进行含浸、固化、水煮、干燥处理，得到桔瓣型超细纤维仿真皮革基布。所制备的革基布的弯曲刚度为200mg·cm，静态悬垂系数为70％，柔软度为3.8mm，折皱回复角为155°。
实施例3
首先将PET/PA6(PET/PA6的质量比70:30)分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经窄狭缝式牵伸纺丝成网；牵伸风压力为0.5Mpa，牵伸风速度为1m/s，牵伸速度为3000m/min，温度为20℃，相对湿度为78％；将纤网依次送入针刺机(针刺深度7mm，针刺密度为250N/cm2，针刺后的厚度为0.5μm，开纤率为30％)、水刺机(单面水刺，水针压力为150Mpa，水针刺入非织造布的深度为0.2um，开纤率为60％)进行加固，得到横截面上的纤维细度具有梯度变化的非织造布(厚度为0.4μm，克重为100g/m3)；将水溶性聚酯溶解，调节粘度到500mpa·s，制得刮涂浆料，然后将刮涂浆料涂刮于非织造布的针刺一面，浆料渗入到非织造布内部，干燥后得到横截面上的树脂含量具有梯度变化的非织造布(水溶性聚酯的上浆率为20％)；将刮涂可溶性树脂后的非织造布进行含浸、固化、水煮、干燥处理，得到桔瓣型超细纤维仿真皮革基布。所制备的革基布的弯曲刚度为165mg·cm，静态悬垂系数为45％，柔软度为4.5mm，折皱回复角为160°。
实施例4
首先将PET/PA6(PET/PA6的质量比70:30)分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经管式牵伸纺丝成网；牵伸风压力为0.5Mpa，牵伸风速度为1m/s，牵伸速度为3000m/min，温度为20℃，相对湿度为78％；将纤网依次送入针刺机(针刺深度7mm，针刺密度为250N/cm2，针刺后的厚度为0.5μm，开纤率为30％)、水刺机(单面水刺，水针压力为150Mpa，水针刺入非织造布的深度为0.2um，开纤率为60％)进行加固，得到横截面上的纤维细度具有梯度变化的非织造布(厚度为0.4μm、克重为100g/m3)；将聚乙烯醇溶解，调节粘度到2000mpa·s，制得刮涂浆料，然后将刮涂浆料涂刮于非织造布的针刺一面，浆料渗入到非织造布内部，干燥后得到横截面上的树脂含量具有梯度变化的非织造布(聚乙烯醇的上浆率为5％)；将刮涂可溶性树脂后的非织造布进行含浸、固化、水煮、干燥处理，得到桔瓣型超细纤维仿真皮革基布。所制备的革基布的弯曲刚度为175mg·cm，静态悬垂系数为45％，柔软度为4.0mm，折皱回复角为145°。
本发明未述及之处适用于现有技术。

Claims (5)

1.一种桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于包括以下步骤：
（1）复合纤维纺丝成网：首先将两种聚合物切片分别导入干燥塔里进行预结晶和干燥处理，经螺杆挤压机挤压熔融，熔体过滤器过滤后进入纺丝箱；然后采用桔瓣纺丝组件，在双组份纺粘设备上经牵伸纺丝成网；
（2）非织造布的制备：将步骤1）制得的长丝纤网依次送入针刺机和水刺机中进行加固；针刺深度5-7mm，针刺密度为50-500N/cm2，单面水刺，水针刺入非织造布的深度为0.2-0.3um，水针压力为50-280Mpa；得到横截面上的纤维细度具有梯度变化的非织造布；
（3）可溶性树脂的刮涂：将可溶性树脂溶解，调节粘度到300-3000mpa•s，制得刮涂浆料，然后将刮涂浆料涂刮于步骤2）制得的非织造布的针刺一面，浆料渗入到非织造布内部，上浆率为5-35%，干燥后得到横截面上的可溶性树脂含量具有梯度变化的非织造布；
（4）非织造布的含浸、固化、水煮和干燥处理：将步骤3）制得的非织造布进行含浸、固化、水煮和干燥处理，得到桔瓣型超细纤维仿真皮革基布。
2.根据权利要求1所述的桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于步骤1）所述牵伸的方式为管式牵伸、宽狭缝式牵伸或窄狭缝式牵伸中的至少一种；牵伸风压力为0.1-0.8Mpa，牵伸风速度大于0且小于等于2m/s，牵伸速度为1000-6000m/min，温度为10-25℃，相对湿度为65-90%。
3.根据权利要求1所述的桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于步骤1）中的两种聚合物切片选自PET、PA6、PP和PU中的两种，两种的质量比为70:30-50:50。
4.根据权利要求1所述的桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于步骤2）纤网经针刺后的厚度为0.5-0.7μm、开纤率为10-50%；纤网经水刺后的厚度为0.3-0.5μm，开纤率为50-96%。
5.根据权利要求1所述的桔瓣型超细纤维仿真皮革基布的制备方法，其特征在于所述可溶性树脂是聚乙烯醇或水溶性聚酯。
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