CN107059183B - 一种熔融粘结纱生产工艺及其在免烫面料中的应用 - Google Patents
一种熔融粘结纱生产工艺及其在免烫面料中的应用 Download PDFInfo
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Abstract
本发明公开了一种熔融粘结纱生产工艺,包括以下步骤:(1)清花工序;(2)梳棉工序;(3)精梳工序;(4)并条工序;(5)粗纱工序;(6)细纱工序;(7)络筒工序。本发明采用表面处理剂对聚乙烯纤维进行表面处理,进一步减少聚乙烯纤维在梳棉时因摩擦断裂或熔化结成小颗粒或块状的现象,并对熔融粘结纱生产工艺中的工艺参数进行了优化改进,工艺步骤简单,可操作性强,用该工艺得到的熔融粘结纱织成面料加工成服装,经熨烫后有永久挺括的性能,洗后不再需要熨烫,特别适合生产抗皱免烫衬衫。
Description
技术领域
本发明涉及纺织技术领域,尤其是涉及一种熔融粘结纱生产工艺及其在免烫面料中的应用。
背景技术
全棉服装具有吸湿透气、柔软舒适的优点,但也存在容易起皱、洗后需要熨烫的麻烦,为了避免洗后熨烫的麻烦,需要对织物进行抗皱免烫整理。目前的免烫整理方法存在一定弊端,一是免烫整理剂中含有一定量的甲醛,在整理加工及穿着过程中会释放出甲醛,对人体产生较大的危害;二是免烫整理工艺会对织物造成机械性能的降低和手感的恶化,特别是纱线线密度小于11.7dtex(50S以上)的纯棉织物,其本身强力较低,免烫整理后又进一步造成其织物的强力下降,严重时会影响穿着寿命;三是通过后整理获得的免烫功能不持久,随着使用时间的延长和洗涤次数的增加,其免烫性能会慢慢减弱甚至完全消失。
发明内容
本发明是为了解决现有技术的全棉服装所存在的上述问题,提供了一种步骤简单,可操作性强的熔融粘结纱生产工艺,用该工艺得到的熔融粘结纱织成面料加工成服装,经熨烫后有永久挺括的性能,洗后不再需要熨烫,特别适合生产抗皱免烫衬衫。
为了实现上述目的,本发明采用以下技术方案:
一种熔融粘结纱生产工艺,包括以下步骤:
(1)清花工序:以熔融粘结纱质量计,将5~10%的聚乙烯纤维以及90~95%的棉花混合后,依次在抓棉机、开棉机上开松、除杂后,经成卷机卷绕得到棉卷,其中抓棉机打手速度1300 r/min,开棉机打手速度600~650 r/min,棉卷定量为380克/米,长度为30.6米。针对棉花含杂率较高的情况,采用“多松少打、渐增开松、早落少碎、充分除杂”的工艺原则,充分除杂的同时减少纤维损伤,为梳棉工序生产出重量不匀小、棉结杂质少的生条打下良好的基础。通过限定聚乙烯纤维的含量以保证用本发明熔融粘结纱织成的面料手感,具有柔软的手感。
(2)梳棉工序:采用梳棉机对棉卷进行梳棉,梳棉工艺参数为:棉网张力牵伸1.614倍,锡林速度375r/min,刺辊速度825r/min,出条速度110m/min,盖板速度0.38m/min,锡林与盖板隔距0. 30mm、0. 20mm、0. 20mm、0. 20 mm、0.030mm,生条定量19.5g/5m。由于聚乙烯纤维熔点低,经过多次揉搓摩擦后极易熔化结成小颗粒或块状,有些块状物嵌进梳棉机的针布中,会导致梳棉棉网清晰度下降,为了减少上述现象,达到有效分梳,梳棉工序采用“轻定量、低速度、小张力牵伸、大隔距、快转移”的工艺原则,确保梳棉针齿锋利、针布状态良好,可有效保证梳理效果。适当加快盖板速度,多落盖板花,提高除杂效能,减少生条短绒含量。
(3)精梳工序:在梳棉机上采用条卷—并卷工艺,将步骤(2)中的棉卷经条卷、并卷、精梳的并合后得到精梳条,其中条卷工艺参数为:并合数19根,总牵伸1.40倍,罗拉隔距6×23×19×10×23mm,条卷定量59.5g/m;并卷工艺参数为:并合数5根,总牵伸4.91倍,罗拉隔距6×25×8mm,并卷定量60.0g/m;精梳工艺参数为:并合数8根,总牵伸83.68倍,罗拉隔距3×23×15×23mm,锡林速度250钳次/min,落棉隔距10,落棉率18%,精梳条定量21.5g/5m。棉精梳准备工序采用条卷—并卷工艺,欠伸倍数小,精梳条光洁度好。经过条卷、并卷、精梳的并合后,条子并合数达到760根。充分的并合可以改善精梳条长片断均匀度。精梳工序采用适当的定量和落棉率,进一步排除棉结杂质和短绒,提高精梳条的质量。
(4)并条工序:在并条机上采用两道并合工艺将精梳条进行并合,得熟条,并条工艺参数为:熟条定量为19.5g/5m,前罗拉速度350r/min,罗拉隔距7×12mm。并条工序采用两道并合工艺,避免多道并合造成条子过熟、过烂,导致粗纱机后高架劈条和乱条现象。运用系统工程理论,采用头并总牵伸倍数小,后区牵伸倍数大,二并后区牵伸倍数小的工艺原则,二并采用带自调匀整的高速并条机,适当降低前罗拉速度,适当减小牵伸倍数和放大罗拉隔距,稳定熟条重量,减小重量波动,有效控制长短片段不匀。充分伸直弯勾纤维,进一步提高纤维的伸直平行度,总之,并条工艺的确定以稳定熟条重量,提高熟条条干均匀度为目的。
(5)粗纱工序:在粗纱机上对熟条进行牵伸、加捻和卷绕后得到粗纱线,粗纱工艺参数:定量为5.0g/10m,前罗拉速度229r/min,总牵伸7.57倍,后区牵伸1.28倍,捻系数65.6,罗拉隔距15×26×38mm。粗纱采用轻定量,牵伸倍数控制在适中的范围;为加强牵伸过程中对纤维的控制,提高粗纱条干质量,罗拉隔距不宜过大,适当降低前罗拉速度,有效控制同机台大、中、小纱和前后排粗纱张力,减小机台间的张力差异。适当增大粗纱捻系数,增强纤维间的抱合力,从而使粗纱条紧密、强力高,减少在细纱工序退绕时产生的意外牵伸而导致条干恶化,同时确保细纱工序不出牵伸硬头。
(6)细纱工序:将粗纱喂入细纱机经牵伸、抽长拉细即得细纱线,细纱工艺参数为:捻系数为370,总牵伸倍数44.72,平均锭速12464r/min,前罗拉速度196r/min,罗拉隔距18/35mm,纲领PG1,钢丝圈EMI2/0。为保证细纱生产顺利进行,采用较小的后牵伸、较大罗拉隔距和较慢锭速,使用68°软皮辊,加强对牵伸区纤维的控制,提高成纱条干质量;适当降低锭子速度,减少细纱断头;合理配置钢领钢丝圈,减少细纱毛羽;优化粗纱捻系数与细纱工艺的配置。
(7)络筒工序:使用自动络筒机,络筒机电清参数设定为:棉结N250%,短粗S180%×1.8,长粗L40%×30,长细T-35%×20,辅助H1300%×0.8,辅助H2150%×3.5,辅助H3120%×6.0。采用合理的电清参数,有效切除有害纱疵;降低络纱速度,采用适当的络纱张力,减少筒纱毛羽增长和质量指标恶化;合理调整接头参数,既要保证接头强力,又要确保接头外观质量。
作为优选,步骤(1)中的聚乙烯纤维为经表面处理后的聚乙烯纤维,所述经表面处理后的聚乙烯纤维通过以下方法制得:将聚乙烯纤维置于表面处理剂中剪切分散30~60min后,于70~90℃下烘干即可,所述表面处理剂由以下质量百分比的组分组成:40~50%聚四氟乙烯分散乳液,0.3~0.5%硬脂酸聚氧乙烯酯,0.1~0.3%抗静电剂,0.1~0.3%硅烷偶联剂KH-550,0.05~0.1%纳米氧化铝,余量为水。由于聚乙烯纤维熔点低,经过多次揉搓摩擦后极易熔化结成小颗粒或块状,有些块状物嵌进梳棉机的针布中,会导致梳棉棉网清晰度下降,除了通过控制梳棉工序的工艺参数以减少上述现象,本发明中对聚乙烯纤维进行表面处理在形成一层保护膜,减少聚乙烯纤维在梳棉时因摩擦断裂或熔化结成小颗粒或块状的现象,其中聚四氟乙烯分散乳液为成膜剂,成膜后耐高温并能提高聚乙烯纤维的抗拉性能,硬脂酸聚氧乙烯酯能使聚四氟乙烯分散乳液成膜更为柔软、均匀,硅烷偶联剂KH-550为分散,使纳米氧化铝均匀分散,纳米氧化铝具有优异的导热性,可避免热量的堆积而造成聚乙烯纤维熔化,抗静电剂无特殊要求,可为阳离子型如季铵盐、胺盐等,阴离子型如磷酸盐、磺酸盐等,非离子型如多元醇、多元醇脂肪酸酯、聚氧化乙烯附加物等,两性型如季铵内盐、丙胺酸盐等。
一种通过上述熔融粘结纱生产工艺得到的熔融粘结纱在免烫面料中的应用。具体应用方法为将熔融粘结纱织成面料后,通过熨烫使得其中的聚乙烯纤维熔融与棉纤维相互粘结,待冷却即形成硬挺的面料,洗后无需再熨烫。
因此,本发明具有如下有益效果:
(1)通过控制纱线中聚乙烯纤维的含量以保证用本发明熔融粘结纱织成的面料手感,使其具有柔软的手感;
(2)对熔融粘结纱生产工艺中的工艺参数进行了优化改进,工艺步骤简单,可操作性强,用该工艺得到的熔融粘结纱织成面料加工成服装,经熨烫后有永久挺括的性能,洗后不再需要熨烫,特别适合生产抗皱免烫衬衫;
(3)采用表面处理剂对聚乙烯纤维进行表面处理,进一步减少聚乙烯纤维在梳棉时因摩擦断裂或熔化结成小颗粒或块状的现象。
具体实施方式
下面通过具体实施方式对本发明做进一步的描述。
实施例1
(1)清花工序:以熔融粘结纱质量计,将5%的经表面处理后的聚乙烯纤维以及95%的棉花混合后,依次在抓棉机、开棉机上开松、除杂后,经成卷机卷绕得到棉卷,其中抓棉机打手速度1300 r/min,开棉机打手速度600r/min,棉卷定量为380g/m,长度为30.6m,经表面处理后的聚乙烯纤维通过以下方法制得:将聚乙烯纤维置于表面处理剂中剪切分散30min后,于70℃下烘干即可,表面处理剂由以下质量百分比的组分组成:40%聚四氟乙烯分散乳液,0.3%硬脂酸聚氧乙烯酯,0.1%抗静电剂(季铵盐),0.1%硅烷偶联剂KH-550,0.05%纳米氧化铝,余量为水;
(2)梳棉工序:采用梳棉机对棉卷进行梳棉,梳棉工艺参数为:棉网张力牵伸1.614倍,锡林速度375r/min,刺辊速度825r/min,出条速度110m/min,盖板速度0.38m/min,锡林与盖板隔距0. 30mm、0. 20mm、0. 20mm、0. 20 mm、0.030mm,生条定量19.5g/5m;
(3)精梳工序:在梳棉机上采用条卷—并卷工艺,将步骤(2)中的棉卷经条卷、并卷、精梳的并合后得到精梳条,其中条卷工艺参数为:并合数19根,总牵伸1.40倍,罗拉隔距6×23×19×10×23mm,条卷定量59.5g/m;并卷工艺参数为:并合数5根,总牵伸4.91倍,罗拉隔距6×25×8mm,并卷定量60.0g/m;精梳工艺参数为:并合数8根,总牵伸83.68倍,罗拉隔距3×23×15×23mm,锡林速度250钳次/min,落棉隔距10,落棉率18%,精梳条定量21.5g/5m;
(4)并条工序:在并条机上采用两道并合工艺将精梳条进行并合,得熟条,并条工艺参数为:熟条定量为19.5g/5m,前罗拉速度350r/min,罗拉隔距7×12mm;
(5)粗纱工序:在粗纱机上对熟条进行牵伸、加捻和卷绕后得到粗纱线,粗纱工艺参数:定量为5.0g/10m,前罗拉速度229r/min,总牵伸7.57倍,后区牵伸1.28倍,捻系数65.6,罗拉隔距15×26×38mm;
(6)细纱工序:将粗纱喂入细纱机经牵伸、抽长拉细即得细纱线,细纱工艺参数为:捻系数为370,总牵伸倍数44.72,平均锭速12464r/min,前罗拉速度196r/min,罗拉隔距18/35mm,纲领PG1,钢丝圈EMI2/0;
(7)络筒工序:使用自动络筒机,络筒机电清参数设定为:棉结N250%,短粗S180%×1.8,长粗L40%×30,长细T-35%×20,辅助H1300%×0.8,辅助H2150%×3.5,辅助H3120%×6.0。
实施例2
(1)清花工序:以熔融粘结纱质量计,将10%的经表面处理后的聚乙烯纤维以及90%的棉花混合后,依次在抓棉机、开棉机上开松、除杂后,经成卷机卷绕得到棉卷,其中抓棉机打手速度1300 r/min,开棉机打手速度650 r/min,棉卷定量为380g/m,长度为30.6m,经表面处理后的聚乙烯纤维通过以下方法制得:将聚乙烯纤维置于表面处理剂中剪切分散60min后,于90℃下烘干即可,表面处理剂由以下质量百分比的组分组成:50%聚四氟乙烯分散乳液,0.5%硬脂酸聚氧乙烯酯,0.3%抗静电剂(磷酸盐),0.3%硅烷偶联剂KH-550,0.1%纳米氧化铝,余量为水;
(2)梳棉工序:采用梳棉机对棉卷进行梳棉,梳棉工艺参数为:棉网张力牵伸1.614倍,锡林速度375r/min,刺辊速度825r/min,出条速度110m/min,盖板速度0.38m/min,锡林与盖板隔距0. 30mm、0. 20mm、0. 20mm、0. 20 mm、0.030mm,生条定量19.5g/5m;
(3)精梳工序:在梳棉机上采用条卷—并卷工艺,将步骤(2)中的棉卷经条卷、并卷、精梳的并合后得到精梳条,其中条卷工艺参数为:并合数19根,总牵伸1.40倍,罗拉隔距6×23×19×10×23mm,条卷定量59.5g/m;并卷工艺参数为:并合数5根,总牵伸4.91倍,罗拉隔距6×25×8mm,并卷定量60.0g/m;精梳工艺参数为:并合数8根,总牵伸83.68倍,罗拉隔距3×23×15×23mm,锡林速度250钳次/min,落棉隔距10,落棉率18%,精梳条定量21.5g/5m;
(4)并条工序:在并条机上采用两道并合工艺将精梳条进行并合,得熟条,并条工艺参数为:熟条定量为19.5g/5m,前罗拉速度350r/min,罗拉隔距7×12mm;
(5)粗纱工序:在粗纱机上对熟条进行牵伸、加捻和卷绕后得到粗纱线,粗纱主工艺参数:定量为5.0g/10m,前罗拉速度229r/min,总牵伸7.57倍,后区牵伸1.28倍,捻系数65.6,罗拉隔距15×26×38mm;
(6)细纱工序:将粗纱喂入细纱机经牵伸、抽长拉细即得细纱线,细纱工艺参数为:捻系数为370,总牵伸倍数44.72,平均锭速12464,前罗拉速度196r/min,罗拉隔距18/35mm,纲领PG1,钢丝圈EMI2/0;
(7)络筒工序:使用自动络筒机,络筒机电清参数设定为:棉结N250%,短粗S180%×1.8,长粗L40%×30,长细T-35%×20,辅助H1300%×0.8,辅助H2150%×3.5,辅助H3120%×6.0。
实施例3
(1)清花工序:以熔融粘结纱质量计,将8%的经表面处理后的聚乙烯纤维以及92%的棉花混合后,依次在抓棉机、开棉机上开松、除杂后,经成卷机卷绕得到棉卷,其中抓棉机打手速度1300 r/min,开棉机打手速度630 r/min,棉卷定量为380g/m,长度为30.6m,经表面处理后的聚乙烯纤维通过以下方法制得:将聚乙烯纤维置于表面处理剂中剪切分散40min后,于80℃下烘干即可,表面处理剂由以下质量百分比的组分组成:45%聚四氟乙烯分散乳液,0.4%硬脂酸聚氧乙烯酯,0.2%抗静电剂(丙胺酸盐),0.2%硅烷偶联剂KH-550,0.07%纳米氧化铝,余量为水;
(2)梳棉工序:采用梳棉机对棉卷进行梳棉,梳棉工艺参数为:棉网张力牵伸1.614倍,锡林速度375r/min,刺辊速度825r/min,出条速度110m/min,盖板速度0.38m/min,锡林与盖板隔距0. 30mm、0. 20mm、0. 20mm、0. 20 mm、0.030mm,生条定量19.5g/5m;
(3)精梳工序:在梳棉机上采用条卷—并卷工艺,将步骤(2)中的棉卷经条卷、并卷、精梳的并合后得到精梳条,其中条卷工艺参数为:并合数19根,总牵伸1.40倍,罗拉隔距6×23×19×10×23mm,条卷定量59.5g/m;并卷工艺参数为:并合数5根,总牵伸4.91倍,罗拉隔距6×25×8mm,并卷定量60.0g/m;精梳工艺参数为:并合数8根,总牵伸83.68倍,罗拉隔距3×23×15×23mm,锡林速度250钳次/min,落棉隔距10,落棉率18%,精梳条定量21.5g/5m;
(4)并条工序:在并条机上采用两道并合工艺将精梳条进行并合,得熟条,并条工艺参数为:熟条定量为19.5g/5m,前罗拉速度350r/min,罗拉隔距7×12mm;
(5)粗纱工序:在粗纱机上对熟条进行牵伸、加捻和卷绕后得到粗纱线,粗纱工艺参数:定量为5.0g/10m,前罗拉速度229r/min,总牵伸7.57倍,后区牵伸1.28倍,捻系数65.6,罗拉隔距15×26×38mm;
(6)细纱工序:将粗纱喂入细纱机经牵伸、抽长拉细即得细纱线,细纱工艺参数为:捻系数为370,总牵伸倍数44.72,平均锭速12464,前罗拉速度196r/min,罗拉隔距18/35mm,纲领PG1,钢丝圈EMI2/0;
(7)络筒工序:使用自动络筒机,络筒机电清参数设定为:棉结N250%,短粗S180%×1.8,长粗L40%×30,长细T-35%×20,辅助H1300%×0.8,辅助H2150%×3.5,辅助H3120%×6.0。
通过本发明得到的熔融粘结纱具体应用方法为:将熔融粘结纱织成面料后,通过熨烫使得其中的聚乙烯纤维熔融与棉纤维相互粘结,待冷却即形成硬挺的面料,用于该面料制成的衣物洗后无需再熨烫。
以上所述的实施例只是本发明的一种较佳的方案,并非对本发明作任何形式上的限制,在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。
Claims (2)
1.一种熔融粘结纱生产工艺,其特征在于,包括以下步骤:
(1)清花工序:以熔融粘结纱质量计,将5~10%的聚乙烯纤维以及90~95%的棉花混合后,依次在抓棉机、开棉机上开松、除杂后,经成卷机卷绕得到棉卷,其中抓棉机打手速度1300r/min,开棉机打手速度600~650 r/min,棉卷定量为380g/m,长度为30.6m;聚乙烯纤维为经表面处理后的聚乙烯纤维,所述经表面处理后的聚乙烯纤维通过以下方法制得:将聚乙烯纤维置于表面处理剂中剪切分散30~60min后,于70~90℃下烘干即可,所述表面处理剂由以下质量百分比的组分组成:40~50%聚四氟乙烯分散乳液,0.3~0.5%硬脂酸聚氧乙烯酯,0.1~0.3%抗静电剂,0.1~0.3%硅烷偶联剂KH-550,0.05~0.1%纳米氧化铝,余量为水;
(2)梳棉工序:采用梳棉机对棉卷进行梳棉,梳棉工艺参数为:棉网张力牵伸1.614倍,锡林速度375r/min,刺辊速度825r/min出条速度110m/min,盖板速度0.38m/min,锡林与盖板隔距0. 30mm、0. 20mm、0. 20mm、0. 20 mm、0.030mm,生条定量19.5g/5m;
(3)精梳工序:在梳棉机上采用条卷—并卷工艺,将步骤(2)中的棉卷经条卷、并卷、精梳的并合后得到精梳条,其中条卷工艺参数为:并合数19根,总牵伸1.40倍,罗拉隔距6×23×19×10×23mm,条卷定量59.5g/m;并卷工艺参数为:并合数5根,总牵伸4.91倍,罗拉隔距6×25×8mm,并卷定量60.0g/m;精梳工艺参数为:并合数8根,总牵伸83.68倍,罗拉隔距3×23×15×23mm,锡林速度250钳次/min,落棉隔距10,落棉率18%,精梳条定量21.5g/5m;
(4)并条工序:在并条机上采用两道并合工艺将精梳条进行并合,得熟条,并条工艺参数为:熟条定量为19.5g/5m,前罗拉速度350r/min,罗拉隔距7×12mm;
(5)粗纱工序:在粗纱机上对熟条进行牵伸、加捻和卷绕后得到粗纱线,粗纱工艺参数:定量为5.0g/10m,前罗拉速度229r/min,总牵伸7.57倍,后区牵伸1.28倍,捻系数65.6,罗拉隔距15×26×38mm;
(6)细纱工序:将粗纱喂入细纱机经牵伸、抽长拉细即得细纱线,细纱工艺参数为:捻系数为370,总牵伸倍数44.72,平均锭速12464r/min,前罗拉速度196r/min,罗拉隔距18/35mm,纲领PG1,钢丝圈EMI2/0;
(7)络筒工序:使用自动络筒机,络筒机电清参数设定为:棉结N250%,短粗S180%×1.8,长粗L40%×30,长细T-35%×20,辅助H1300%×0.8,辅助H2150%×3.5,辅助H3120%×6.0。
2.一种通过如权利要求1所述的熔融粘结纱生产工艺得到的熔融粘结纱在免烫面料中的应用。
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CN104805557A (zh) * | 2015-05-19 | 2015-07-29 | 江苏工程职业技术学院 | 新型超舒适吸湿强韧高分子量聚乙烯纤维/粘胶混纺纱的生产方法 |
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CN103696066A (zh) * | 2013-12-19 | 2014-04-02 | 吴江明敏制衣有限公司松陵分公司 | 一种抗菌复股纱 |
CN104805557A (zh) * | 2015-05-19 | 2015-07-29 | 江苏工程职业技术学院 | 新型超舒适吸湿强韧高分子量聚乙烯纤维/粘胶混纺纱的生产方法 |
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