CN106544875A - 一种涤纶超纤面料及其制造工艺 - Google Patents

一种涤纶超纤面料及其制造工艺 Download PDF

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CN106544875A
CN106544875A CN201610963222.2A CN201610963222A CN106544875A CN 106544875 A CN106544875 A CN 106544875A CN 201610963222 A CN201610963222 A CN 201610963222A CN 106544875 A CN106544875 A CN 106544875A
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fabric
terylene
manufacturing process
mesh
temperature
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CN106544875B (zh
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钱国春
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ZHEJIANG MEISHENG NEW MATERIALS Co.,Ltd.
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ZHEJIANG MEISHENG INDUSTRY Co Ltd
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Priority to PCT/CN2017/101475 priority patent/WO2018076947A1/zh
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    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
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Abstract

本发明涉及一种涤纶超纤面料及其制造工艺，属于面料生产的技术领域，包括由上而下依次设置的上层网布、涤纶超细短纤无纺布、下层网布，上层网布和下层网布均采用2000~4000捻、75~100D/48F的高强度FDY长丝制成，涤纶超细短纤无纺布采用单丝纤度为0.15~0.25dtex的涤纶超细短纤制成。本发明一种涤纶超纤面料具有接近真皮的肤感及绒感等，同时本发明的制造工艺，整体工序短、能耗低、生产效率高。

Description

一种涤纶超纤面料及其制造工艺
技术领域
本发明涉及一种涤纶超纤面料及其制造工艺，属于面料生产的技术领域。
背景技术
目前市场上的汽车内饰用面料，大多采用尼龙和腈纶超细纤维制成。而采用尼龙、腈纶超细纤维所制作的车饰用面料，存在仿真皮效果差，耐光老化性能不够等缺点。
发明内容
本发明的目的是提供一种仿真皮效果好、耐光老化性能好的涤纶超纤面料及其制造工艺。
为达到上述目的，本发明所采用的技术方案为：
一种涤纶超纤面料，包括由上而下依次设置的上层网布、涤纶超细短纤无纺布、下层网布，上层网布和下层网布均采用2000~4000捻、75~100D/48F的高强度FDY长丝制成，涤纶超细短纤无纺布采用单丝纤度为0.15~0.25dtex的涤纶超细短纤制成。
本发明一种涤纶超纤面料的制造工艺，包括以下步骤：
（1）采用单丝纤度为0.15~0.25dtex的涤纶超细短纤为原料进行铺网，形成涤纶超细短纤层。
（2）对涤纶超细短纤层进行双面加筋并进行针刺，双面加筋采用由2000~4000捻、75~100D/48F的高强度FDY长丝所制成的网布。
（3）烫平，形成坯布。坯布的表观密度为0.15~0.45克每立方厘米。
（4）进入浸渍槽进行预缩，水温为90~100℃，时间为5~10min。预缩需要控制缩率，本步骤的缩率控制在12~15%。预缩可增加面料密度，达到接近真皮的高密度，可减少PU的使用量，也不减少接近于真皮的肉感，便于后期的毛感处理，使毛感更细腻。
（5）含浸水溶性树脂后进行烘干。
（6）含浸水性聚氨酯后进行烘干。
（7）开纤。
（8）水磨。
（9）揉纹：水浸湿后，进入转鼓，转鼓内的蒸汽为85~110℃，转鼓在正向120℃与反向120℃之间进行反复摆动，且转鼓在20~40s内完成整个正向到反向或反向到正向的摆角动作。揉纹可使纤维和聚氨酯之间的张力松弛，使整体柔软度更好，同时，面料可进一步收缩。
（10）染色。
（11）磨绒，得成品。
作为上述方案的进一步设置，所述步骤（2）中，针刺的车速为2~2.5m/min，针刺的频率为700 次/min。
所述步骤（3）中，烫平的车速为3~4m/min，温度为140℃。
所述步骤（5）中，水溶性树脂的黏度为0~100cps，固含量为15~20%，坯布带液量为80~120%；烘干的温度为125~135℃，车速为5~7m/min。
所述步骤（6）中，水性聚氨酯的黏度为300~1000cps，固含量为40~50%，坯布带液量为150~180%；烘干采用三节烘箱进行，第一节烘箱的温度为110~125℃，第二节烘箱的温度为145~160℃，第三节烘箱的温度为120~130℃，车速为3~5m/min。初始烘干温度要尽量低，但又要高于100℃，以便于水份蒸发，同时又不能过高，过高会使表面水性聚氨酯凝固过快。
所述步骤（7），采用浓度为10~30g/L的NaOH进行开纤，温度为85~110℃，时间为45-90min。考虑到涤纶纤维的耐碱性不强，因此采取低温低浓度开纤工艺。
所述步骤（8），先采用两根砂辊进行第一道水磨，两根砂辊的目数相同，均为150~300目；再采用一根砂辊进行第二道水磨，目数为300~400目；最后采用一根砂辊进行第三道水磨，目数为400~600目；水磨车速为5~10m/min，所有砂辊的转速为1500~2100转/min。涤纶超纤的刚性较强，粗砂先将毛感处理一致（即表面磨平），细砂起梳理作用，使表面毛感均匀、细腻。
所述步骤（10），采用分散染料进行染色，并采用低浴比一浴法，浴比为1:8到1:10，温度为120~125℃。水性聚氨酯对分散染料的亲和力较高，采用一浴法可大大降低能耗，尤其是用水量可大量节约，生产效率也高，同时还可使产品的色牢度达到较高级数。
所述步骤（11），先采用两根砂纸辊进行第一道磨绒，两根砂纸辊的目数相同，均为240~320目；再采用两根砂纸辊进行第二道磨绒，两根砂纸辊的目数相同，均为400~600目；最后采用刷毛辊进行刷毛；磨绒车速为5~8m/min，所有砂纸辊的转速为1500~2100转/min。因使用水性聚氨酯，布面的绒感与色光较好，因此省略了传统的磨皮工序，减少了工业固废的产生及处理。
本发明一种涤纶超纤面料具有接近真皮的肤感及绒感等，分散染料对涤纶纤维的亲和力更强、牢度更好，染深染艳及耐光老化性能比尼龙短纤更出色；使用水溶性聚氨酯替代了溶剂型聚氨酯，在生产过程中避免使用产生与人体及环境有害的物质，只需轻微磨绒，不需要磨皮，减少了工业固废的产生。同时本发明的制造工艺，整体工序短、能耗低、生产效率高。
本发明一种涤纶超纤面料的主要技术指标如下：⑴、耐酸汗渍色牢度（级）：变色：4，沾色：4；⑵、耐碱汗渍色牢度（级）：变色：4，沾色4级；⑶、耐皂洗色牢度（级）：变色3-4，沾色3；⑷耐摩擦色牢度（级）：干摩4，湿摩3-4；⑸耐光色牢度（变色）：3；（6）、断裂强力（N）： 经向778,纬向1030；(7)断裂伸长率（%）：经向87，纬向54；（8）、撕破强力（N）:经向45，纬向48。
具体实施方式
下面通过具体实施例对本发明作进一步说明，但本发明并不受以下实施例所限定。
实施例1
本发明一种涤纶超纤面料，包括由上而下依次设置的上层网布、涤纶超细短纤无纺布、下层网布，上层网布和下层网布均采用2000捻、75D/48F的高强度FDY长丝制成，涤纶超细短纤无纺布采用单丝纤度为0.15dtex的涤纶超细短纤制成。
本发明一种涤纶超纤面料的制造工艺，包括以下步骤：
（1）采用单丝纤度为0.15dtex的涤纶超细短纤为原料进行铺网，形成涤纶超细短纤层；
（2）对涤纶超细短纤层进行双面加筋并进行针刺，双面加筋采用由2000捻、75D/48F的高强度FDY长丝所制成的网布；
（3）烫平，形成坯布；
（4）进入浸渍槽进行预缩，水温为90℃，时间为10min；
（5）含浸水溶性树脂后进行烘干；
（6）含浸水性聚氨酯后进行烘干；
（7）开纤；
（8）水磨；
（9）揉纹：水浸湿后，进入转鼓，转鼓内的蒸汽为85℃，转鼓在正向120℃与反向120℃之间进行反复摆动，且转鼓在20s内完成整个正向到反向或反向到正向的摆角动作；
（10）染色；
（11）磨绒，得成品。
上述步骤（2）中，针刺的车速为2m/min，针刺的频率为700 次/min。
上述步骤（3）中，烫平的车速为3m/min，温度为140℃。
上述步骤（5）中，水溶性树脂的黏度为50cps，固含量为15%，坯布带液量为80%；烘干的温度为125℃，车速为5m/min。
上述步骤（6）中，水性聚氨酯的黏度为300cps，固含量为40%，坯布带液量为150%；烘干采用三节烘箱进行，第一节烘箱的温度为110℃，第二节烘箱的温度为145℃，第三节烘箱的温度为120℃，车速为3m/min。
上述步骤（7），采用浓度为10g/L的NaOH进行开纤，温度为85℃，时间为90min。
上述步骤（8），先采用两根砂辊进行第一道水磨，两根砂辊的目数相同，均为150目；再采用一根砂辊进行第二道水磨，目数为300目；最后采用一根砂辊进行第三道水磨，目数为400目；水磨车速为5m/min，所有砂辊的转速为1500转/min。
上述步骤（10），采用分散染料进行染色，并采用低浴比一浴法，浴比为1:8，温度为120℃。
上述步骤（11），先采用两根砂纸辊进行第一道磨绒，两根砂纸辊的目数相同，均为240目；再采用两根砂纸辊进行第二道磨绒，两根砂纸辊的目数相同，均为400目；最后采用刷毛辊进行刷毛；磨绒车速为5m/min，所有砂纸辊的转速为1500转/min。
实施例2
本发明一种涤纶超纤面料，包括由上而下依次设置的上层网布、涤纶超细短纤无纺布、下层网布，上层网布和下层网布均采用3000捻、90D/48F的高强度FDY长丝制成，涤纶超细短纤无纺布采用单丝纤度为0.2dtex的涤纶超细短纤制成。
本发明一种涤纶超纤面料的制造工艺，包括以下步骤：
（1）采用单丝纤度为0.2dtex的涤纶超细短纤为原料进行铺网，形成涤纶超细短纤层；
（2）对涤纶超细短纤层进行双面加筋并进行针刺，双面加筋采用由3000捻、90D/48F的高强度FDY长丝所制成的网布；
（3）烫平，形成坯布；
（4）进入浸渍槽进行预缩，水温为95℃，时间为8min；
（5）含浸水溶性树脂后进行烘干；
（6）含浸水性聚氨酯后进行烘干；
（7）开纤；
（8）水磨；
（9）揉纹：水浸湿后，进入转鼓，转鼓内的蒸汽为102℃，转鼓在正向120℃与反向120℃之间进行反复摆动，且转鼓在30s内完成整个正向到反向或反向到正向的摆角动作；
（10）染色；
（11）磨绒，得成品。
上述步骤（2）中，针刺的车速为2.2m/min，针刺的频率为700 次/min。
上述步骤（3）中，烫平的车速为3.5m/min，温度为140℃。
上述步骤（5）中，水溶性树脂的黏度为0cps，固含量为18%，坯布带液量为100%；烘干的温度为130℃，车速为6m/min。
上述步骤（6）中，水性聚氨酯的黏度为600cps，固含量为45%，坯布带液量为160%；烘干采用三节烘箱进行，第一节烘箱的温度为118℃，第二节烘箱的温度为150℃，第三节烘箱的温度为125℃，车速为4m/min。
上述步骤（7），采用浓度为20g/L的NaOH进行开纤，温度为100℃，时间为60min。
上述步骤（8），先采用两根砂辊进行第一道水磨，两根砂辊的目数相同，均为220目；再采用一根砂辊进行第二道水磨，目数为350目；最后采用一根砂辊进行第三道水磨，目数为500目；水磨车速为8m/min，所有砂辊的转速为1800转/min。
上述步骤（10），采用分散染料进行染色，并采用低浴比一浴法，浴比为1:9，温度为122℃。
上述步骤（11），先采用两根砂纸辊进行第一道磨绒，两根砂纸辊的目数相同，均为280目；再采用两根砂纸辊进行第二道磨绒，两根砂纸辊的目数相同，均为500目；最后采用刷毛辊进行刷毛；磨绒车速为6m/min，所有砂纸辊的转速为1800转/min。
实施例3
本发明一种涤纶超纤面料，包括由上而下依次设置的上层网布、涤纶超细短纤无纺布、下层网布，上层网布和下层网布均采用4000捻、100D/48F的高强度FDY长丝制成，涤纶超细短纤无纺布采用单丝纤度为0.25dtex的涤纶超细短纤制成。
本发明一种涤纶超纤面料的制造工艺，包括以下步骤：
（1）采用单丝纤度为0.25dtex的涤纶超细短纤为原料进行铺网，形成涤纶超细短纤层；
（2）对涤纶超细短纤层进行双面加筋并进行针刺，双面加筋采用由4000捻、100D/48F的高强度FDY长丝所制成的网布；
（3）烫平，形成坯布；
（4）进入浸渍槽进行预缩，水温为100℃，时间为5min；
（5）含浸水溶性树脂后进行烘干；
（6）含浸水性聚氨酯后进行烘干；
（7）开纤；
（8）水磨；
（9）揉纹：水浸湿后，进入转鼓，转鼓内的蒸汽为110℃，转鼓在正向120℃与反向120℃之间进行反复摆动，且转鼓在40s内完成整个正向到反向或反向到正向的摆角动作；
（10）染色；
（11）磨绒，得成品。
上述步骤（2）中，针刺的车速为2.5m/min，针刺的频率为700 次/min。
上述步骤（3）中，烫平的车速为4m/min，温度为140℃。
上述步骤（5）中，水溶性树脂的黏度为0cps，固含量为20%，坯布带液量为120%；烘干的温度为135℃，车速为7m/min。
上述步骤（6）中，水性聚氨酯的黏度为1000cps，固含量为50%，坯布带液量为180%；烘干采用三节烘箱进行，第一节烘箱的温度为125℃，第二节烘箱的温度为160℃，第三节烘箱的温度为130℃，车速为5m/min。
上述步骤（7），采用浓度为30g/L的NaOH进行开纤，温度为110℃，时间为45min。
上述步骤（8），先采用两根砂辊进行第一道水磨，两根砂辊的目数相同，均为300目；再采用一根砂辊进行第二道水磨，目数为400目；最后采用一根砂辊进行第三道水磨，目数为600目；水磨车速为10m/min，所有砂辊的转速为2100转/min。
上述步骤（10），采用分散染料进行染色，并采用低浴比一浴法，浴比为1:10，温度为125℃。
上述步骤（11），先采用两根砂纸辊进行第一道磨绒，两根砂纸辊的目数相同，均为320目；再采用两根砂纸辊进行第二道磨绒，两根砂纸辊的目数相同，均为600目；最后采用刷毛辊进行刷毛；磨绒车速为8m/min，所有砂纸辊的转速为2100转/min。
以上所有实施例中，上层网布和下层网布均采用平纹组织，高强度FDY长丝的强度范围为6～7 g/d。
上述实施例仅用于解释说明本发明的发明构思，而非对本发明权利保护的限定，凡利用此构思对本发明进行非实质性的改动，均应落入本发明的保护范围。

Claims (10)

1.一种涤纶超纤面料，其特征在于：包括由上而下依次设置的上层网布、涤纶超细短纤无纺布、下层网布，上层网布和下层网布均采用2000~4000捻、75~100D/48F的高强度FDY长丝制成，涤纶超细短纤无纺布采用单丝纤度为0.15~0.25dtex的涤纶超细短纤制成。
2.如权利要求1所述一种涤纶超纤面料的制造工艺，其特征在于包括以下步骤：
（1）采用单丝纤度为0.15~0.25dtex的涤纶超细短纤为原料进行铺网，形成涤纶超细短纤层；
（2）对涤纶超细短纤层进行双面加筋并进行针刺，双面加筋采用由2000~4000捻、75~100D/48F的高强度FDY长丝所制成的网布；
（3）烫平，形成坯布；
（4）进入浸渍槽进行预缩，水温为90~100℃，时间为5~10min；
（5）含浸水溶性树脂后进行烘干；
（6）含浸水性聚氨酯后进行烘干；
（7）开纤；
（8）水磨；
（9）揉纹：水浸湿后，进入转鼓，转鼓内的蒸汽为85~110℃，转鼓在正向120℃与反向120℃之间进行反复摆动，且转鼓在20~40s内完成整个正向到反向或反向到正向的摆角动作；
（10）染色；
（11）磨绒，得成品。
3.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（2）中，针刺的车速为2~2.5m/min，针刺的频率为700 次/min。
4.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（3）中，烫平的车速为3~4m/min，温度为140℃。
5.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（5）中，水溶性树脂的黏度为0~100cps，固含量为15~20%，坯布带液量为80~120%；烘干的温度为125~135℃，车速为5~7m/min。
6.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（6）中，水性聚氨酯的黏度为300~1000cps，固含量为40~50%，坯布带液量为150~180%；烘干采用三节烘箱进行，第一节烘箱的温度为110~125℃，第二节烘箱的温度为145~160℃，第三节烘箱的温度为120~130℃，车速为3~5m/min。
7.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（7），采用浓度为10~30g/L的NaOH进行开纤，温度为85~110℃，时间为45-90min。
8.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（8），先采用两根砂辊进行第一道水磨，两根砂辊的目数相同，均为150~300目；再采用一根砂辊进行第二道水磨，目数为300~400目；最后采用一根砂辊进行第三道水磨，目数为400~600目；水磨车速为5~10m/min，所有砂辊的转速为1500~2100转/min。
9.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（10），采用分散染料进行染色，并采用低浴比一浴法，浴比为1:8到1:10，温度为120~125℃。
10.如权利要求2所述一种涤纶超纤面料的制造工艺，其特征在于：所述步骤（11），先采用两根砂纸辊进行第一道磨绒，两根砂纸辊的目数相同，均为240~320目；再采用两根砂纸辊进行第二道磨绒，两根砂纸辊的目数相同，均为400~600目；最后采用刷毛辊进行刷毛；磨绒车速为5~8m/min，所有砂纸辊的转速为1500~2100转/min。
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