CN107805937A - 氨熏法整理阻燃面料的甲醛控制工艺 - Google Patents
氨熏法整理阻燃面料的甲醛控制工艺 Download PDFInfo
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Abstract
本发明提供了一种氨熏法后整理阻燃面料的甲醛控制工艺,该工艺流程包括:浸轧阻燃整理液‑预烘工艺‑氨熏工艺‑氧化中和水洗工艺‑除甲醛工艺‑拉幅定型烘干、预缩、检验,其中,所述除甲醛工艺包括以下步骤:(1)浸轧甲醛捕捉剂;(2)洗甲醛。本发明提供的工艺通过对经过氧化中和水洗工艺的所述面料进行除甲醛工艺,不仅能够洗去所述面料上的游离甲醛,而且能捕捉残留在所述面料上的释放甲醛,且面料的阻燃性能没有降低,大大提高了面料的品质和健康使用的需求,甚至有些面料甲醛的含量达到婴幼儿使用的标准。
Description
技术领域
本发明涉及纺织服装技术领域,尤其是一种面料阻燃整理工艺中氨熏方法后甲醛含量的控制工艺。
背景技术
面料经阻燃剂整理后,想要达到耐洗涤的效果,需要使面料中纤维与阻燃剂交联在一起,通常有氨熏法和烘焙法两种方法。烘焙法采用高温焙烘的方式使阻燃剂和纤维交联,达到耐洗涤的目的。在高温焙烘过程中释放出大量溶剂中的甲醛,因此面料本身残留的甲醛就相应的较低,可以达到75PPm以下。但阻燃剂本身具有酸性,且需要加入磷酸进行催化高温交联,造成纤维强力损伤较大,而且面料损毁长度较长,通常都在100mm以上,面料损坏较严重。
而氨熏法是将面料通过充满气化的液氨的氨熏室,使得面料中纤维与阻燃剂通过NH3分子交联在一起,再使用双氧水将阻燃剂中的P3+氧化成更加稳定的P5+状态,从而达到耐洗涤的效果。虽然氨熏法所使用的阻燃剂也具有酸性,但在生产工艺过程中没有经过高温,因此面料的强力基本上没有损伤,而且损毁长度较焙烘法短。但该方法生产出的面料残留甲醛含量较焙烘法高出许多,达到1000PPm。面料上的阻燃剂分子结构中的羟甲基(-CH3-OH)断裂,会释放甲醛,众所周知,甲醛是一种具有刺激、致癌、致突变的作用,鉴于甲醛的各种危害,各国的法规或标准对纺织物的甲醛含量做了严格的规定,因此如何将氨熏法阻燃整理面料上残留的甲醛去除又不影响面料的阻燃性能是市场和生产面临的课题。
发明内容
针对上述情况,为克服现有技术之缺陷,本发明提供一种氨熏法后整理阻燃面料的甲醛控制工艺,该工艺通过对经过氧化水洗的面料进行浸轧甲醛捕捉剂、密封汽蒸的工艺流程,去除掉残留在面料上的甲醛,使面料的甲醛含量满足75~300PPm要求,而且没有影响到面料的阻燃性能。
本发明提供了一种氨熏法后整理阻燃面料的甲醛控制工艺,该工艺流程包括:浸轧阻燃整理液-预烘工艺-氨熏工艺-氧化中和水洗工艺-除甲醛工艺-拉幅定型烘干、预缩、检验,其中,所述除甲醛工艺包括以下步骤:
(1)浸轧甲醛捕捉剂:
将经过氧化水洗后的面料浸轧至浓度为1.5~3%owf的甲醛捕捉剂溶液中,轧余率为65~75%;
(2)洗甲醛:
将浸轧甲醛捕捉剂溶液的所述面料辊压传送至60~70℃的密封水蒸汽环境中,作用150~180s,再将所述面料传送至依次设置的六格温度为60~80℃的水槽中,再传送至多个冷水槽中反复辊压洗甲醛,之后烘干。
优选的,所述浸轧阻燃整理液包括:
(1)制备阻燃整理液:所述阻燃整理液由阻燃剂、柔软剂、渗透剂混合配制而成,其中所述阻燃整理液各组分的重量百分比:阻燃剂35~40%、柔软剂2~3%、渗透剂0.1~0.2%,其余为水;所述各组分的用量为阻燃剂:350~400g/L、柔软剂:20~30g/L、渗透剂:1~2g/L;
(2)将经过前处理和染色工序后的面料浸轧在调配好的所述阻燃整理液中,采用一浸一轧工序,使阻燃整理液均匀渗浸在所述面料纤维上,轧余率为85~90%。
优选的,所述阻燃整理液还包括醋酸,所述醋酸的浓度为0.2~1g/L,其中所述阻燃整理液各组分的重量百分比:阻燃剂35~40%、柔软剂2~3%、渗透剂0.1~0.2%、醋酸0.02%~0.1%,其余为水;所述阻燃剂为四羟甲基氯化磷和尿素的聚合物,所述柔软剂为聚乙烯类聚合物,优选地所述柔软剂为聚乙烯乳液,所述渗透剂为脂肪醇聚氧乙烯醚。
优选的,所述预烘工艺是将浸轧阻燃整理液后的面料在车速为20~30m/min、并依次穿过预烘机的两节烘箱进行预烘处理,所述两节烘箱设定预烘温度均为80~85℃,使所述面料的含潮率控制在12~14%范围内。
优选的,所述氨熏工艺是将预烘后的所述面料以车速为20~30m/min通过氨熏机对所述面料进行氨熏处理,氨熏流量为65~75m3/h。
优选的,所述氧化中和水洗工艺是将氨熏后的所述面料传送至平幅皂洗机中,经过浸轧200~250g/l双氧水的氧化液,轧余率为60~65%,透空氧化60~90秒,之后进入两格30~40g/l烧碱溶液进行中和,在四格75~85℃,两格55~65℃,两格35~45℃下水洗,最后冷水洗,烘筒烘干落布。
优选的,所述拉幅定型烘干、预缩、检验是将水洗过的所述面料经过辊轮辊压后进入烘箱,依次设置的6~8节烘箱内热风循环上下喷气对所述面料做烘干处理,每节烘箱温度为120~150℃,所述面料传送的车速为20~30m/min,然后从烘箱出来后依次进行冷风冷却、脱铗收缩,进入检验设备检验面料质量,最后打卷出布。
本发明提供了一种棉系列面料阻燃整理工艺中氨熏方法后甲醛含量的控制工艺,该工艺通过对经过氧化中和水洗工艺的所述面料进行除甲醛工艺,不仅能够洗去所述面料上的游离甲醛,而且能捕捉残留在所述面料上的释放甲醛,经过除甲醛工艺处理后的所述面料甲醛含量满足75~300ppm要求,而且面料的阻燃性能没有降低,大大提高了面料的品质和健康使用的需求,甚至有些面料甲醛的含量达到婴幼儿使用的标准。
附图说明
图1为本发明生产阻燃面料流程图。
具体实施方式
下面将参考附图1并结合具体实施方式来详细说明本发明,但并非是对本发明保护范围的限定实施例中所涉及的工艺方法,如无特别说明则为常规方法或步骤,所用药品除特别说明外,均为市售,本发明中使用的甲醛捕捉剂为市售。
本发明提供了一种氨熏法后整理阻燃面料的甲醛控制工艺,该工艺流程包括:浸轧阻燃整理液-预烘工艺-氨熏工艺-氧化中和水洗工艺-除甲醛工艺-拉幅定型烘干、预缩、检验,其中,
浸轧阻燃整理液包括:
(1)制备阻燃整理液:所述阻燃整理液由阻燃剂、柔软剂、渗透剂混合配制而成,其中所述阻燃整理液各组分的重量百分比:阻燃剂35~40%、柔软剂2~3%、渗透剂0.1~0.2%,其余为水,所述各组分的用量为阻燃剂:350~400g/L、柔软剂:20~30g/L、渗透剂:1~2g/L,所述阻燃剂为四羟甲基氯化磷和尿素的聚合物,所述柔软剂为聚乙烯类聚合物,优选地所述柔软剂为聚乙烯乳液,所述渗透剂为脂肪醇聚氧乙烯醚,所述阻燃整理液还包括醋酸,所述醋酸的浓度为0.2~1g/L,其重量所占百分比为0.02~0.1%,阻燃整理液呈酸性。
(2)将经过前处理和染色工序后的面料浸轧在调配好的所述阻燃整理液中,采用一浸一轧工序,使阻燃整理液均匀渗浸在所述面料纤维上,轧余率85~90%。轧余率也叫带液率,是织物上带的液体重量与织物本身重量的百分比,具体来说是经过浆槽带上溶液后,经过轧辊轧过后布面上带的溶液重量和浸轧前原来织物重量的百分比。
预烘工艺:将浸轧阻燃整理液后的面料在车速为20~30m/min、并依次穿过预烘机的两节烘箱进行预烘处理,所述两节烘箱设定预烘温度均为80~85℃,使所述面料的含潮率控制在12~14%范围内。
氨熏工艺:将预烘后的所述面料以车速为20~30m/min通过氨熏机对所述面料进行氨熏处理,氨熏流量为65~75m3/h。氨熏的过程中,NH3分子将阻燃剂和面料上的纤维交联在一起,有利于阻燃剂附着在所述面料上,使布料具有阻燃的功能。
氧化中和水洗工艺:将氨熏后的所述面料传送至平幅皂洗机中,经过浸轧200~250g/l双氧水的氧化液,轧余率为60~65%,透空氧化60~90秒,之后进入两格30~40g/l烧碱溶液进行中和,在四格75~85℃,两格55~65℃,两格35~45℃下水洗,最后冷水洗,烘筒烘干落布。在氧化过程中,双氧水会将阻燃剂(四羟甲基氯化磷和尿素的聚合体)中的P3+氧化为P5+,从而使布料达到耐洗涤的效果。碱洗是为了中和阻燃剂经过氧化产生的酸,高温水洗、低温水洗、冷水洗是为了洗去所述布料上残留的游离甲醛、氨气、双氧水、碱等其他沉积其上的杂质。
除甲醛工艺包括以下步骤:
(1)浸轧甲醛捕捉剂:
将经过氧化水洗后的面料浸轧至浓度为1.5~3%owf的甲醛捕捉剂溶液中,面料出所述甲醛捕捉剂的轧余率为65~75%;
(2)洗甲醛:
将所述面料辊压传送至60~70℃的密封水蒸汽环境中,作用150~180s,再将所述面料传送至依次设置的六格温度为60~80℃的水槽中,再传送至多个冷水槽中反复辊压洗甲醛,之后烘干,洗去面料上的甲醛捕捉剂、游离甲醛、以及其他杂质等。
在本发明的技术方案中,所述甲醛捕捉剂为硫酸氢钠,亚硫酸氢钠,尿素,乙烯脲,保险粉的混合物,其中硫酸氢钠、亚硫酸氢钠、尿素、乙烯脲、保险粉,是采购于新乡市天顺纺织有限公司。本发明采用阻燃剂分子结构中的羟甲基(-CH3-OH)不稳定,在高温等其他状态下极易断裂,产生甲醛,因此申请申请人采用甲醛捕捉剂将羟甲基进行醚化,使其该基团活性降低,不再断裂产生甲醛,从而达到降低甲醛的释放量。
拉幅定型烘干、预缩、检验:将水洗过的所述面料经过辊轮辊压后进入烘箱,依次设置的6~8节烘箱内热风循环上下喷气对所述面料做烘干处理,每节烘箱温度为120~150℃,所述面料传送的车速为20~30m/min,然后从烘箱出来后依次进行冷风冷却、脱铗收缩,进入检验设备检验面料质量,最后打卷出布。
实施例1
以240g/m2全棉20*16 128*60灰色纱卡为例
本实施例选择生产240g/m2全棉20*16 128*60灰色纱卡,其生产工艺步骤如下:
(一)浸轧阻燃整理液包括:
(1)制备阻燃整理液:将阻燃剂40%、柔软剂3%、渗透剂0.2%、醋酸为0.05%、其余为水混合制成阻燃整理液,其中,阻燃剂为四羟甲基氯化磷和尿素的聚合物,柔软剂为聚乙烯乳液,渗透剂为脂肪醇聚氧乙烯醚;
(2)将经过前处理和染色工序后的面料浸轧在调配好的所述阻燃整理液中,采用一浸一轧工序,使阻燃整理液均匀渗浸在所述面料纤维上,轧余率90%。
(二)预烘工艺:将浸轧阻燃整理液后的面料在车速为25m/min、并依次穿过预烘机的两节烘箱进行预烘处理,所述两节烘箱设定预烘温度均为85℃,使所述面料的含潮率控制在13%。
(三)氨熏工艺:将预烘后的所述面料以车速为25m/min通过氨熏机对所述面料进行氨熏处理,氨熏流量为70m3/h。
(四)氧化中和水洗工艺:将氨熏后的所述面料传送至平幅皂洗机中,经过浸轧250g/l双氧水的氧化液,轧余率为65%,透空氧化90秒,之后进入两格30g/l烧碱溶液进行中和,在四格80℃,两格65℃,两格40℃下水洗,最后冷水洗,烘筒烘干落布。
(五)除甲醛工艺包括以下步骤:
(1)浸轧甲醛捕捉剂:
将经过氧化水洗后的面料浸轧至浓度为2%owf的甲醛捕捉剂溶液中,面料出所述甲醛捕捉剂的轧余率为70%;
(2)洗甲醛:
将所述面料辊压传送至65℃的密封水蒸汽环境中,并作用160s,再将所述面料传送至依次设置的六格温度为70℃的水槽中,再传送至多个冷水槽中反复辊压洗甲醛,之后烘干;
(六)拉幅定型烘干、预缩、检验:将水洗过的所述面料经过辊轮辊压后进入烘箱热风循环上下喷气烘干处理,所述烘箱有8节烘筒,每节烘筒温度为140℃,所述面料传送的车速为25m/min,然后从烘箱出来后依次进行冷风冷却、脱铗收缩,进入检验设备检验面料质量,最后打卷出布。
经测试,本实施例生产的240g/m2全棉20*16 128*60灰色纱卡甲醛含有率为100PPm,且阻燃性能优异。
实施例2
以300g/m2全棉16*10 108*56深蓝直贡为例
本实施例选择生产300g/m2全棉16*10 108*56深蓝直贡,其生产工艺步骤如下:
(一)浸轧阻燃整理液包括:
(1)制备阻燃整理液:将阻燃剂35%、柔软剂3%、渗透剂0.12%混合制成阻燃整理液,其余为溶剂水,其中,阻燃剂为四羟甲基氯化磷和尿素的聚合物,柔软剂为聚乙烯乳液,渗透剂为脂肪醇聚氧乙烯醚;
(2)将经过前处理和染色工序后的面料浸轧在调配好的所述阻燃整理液中,采用一浸一轧工序,使阻燃整理液均匀渗浸在所述面料纤维上,轧余率90%。
(二)预烘工艺:将浸轧阻燃整理液后的面料在车速为22m/min、并依次穿过预烘机的两节烘箱进行预烘处理,所述两节烘箱设定预烘温度均为85℃,使所述面料的含潮率控制在12~14%范围内。
(三)氨熏工艺:将预烘后的所述面料以车速为23m/min通过氨熏机对所述面料进行氨熏处理,氨熏流量为72m3/h。
(四)氧化中和水洗工艺::将氨熏后的所述面料传送至平幅皂洗机中,经过浸轧250g/l双氧水的氧化液,轧余率为65%,透空氧化90秒,之后进入两格40g/l烧碱溶液进行中和,在四格85℃,两格60℃,两格40℃下水洗,最后冷水洗,烘筒烘干落布。
(五)除甲醛工艺包括以下步骤:
(1)浸轧甲醛捕捉剂:
将经过氧化水洗后的面料浸轧至浓度为1.8%owf的甲醛捕捉剂溶液中,面料出所述甲醛捕捉剂的轧余率为73%;
(2)洗甲醛:
将所述面料辊压传送至70℃的密封水蒸汽环境中,并作用180s,再将所述面料传送至依次设置的六格温度为65℃的水槽中,再传送至多个冷水槽中反复辊压洗甲醛,之后烘干。
(六)拉幅定型烘干、预缩、检验:将水洗过的所述面料经过辊轮辊压后再进入烘箱热风循环上下喷气烘干处理,所述烘箱有8节烘筒,每节烘筒温度为160℃,所述面料传送的车速为20m/min,然后从烘箱出来后依次进行冷风冷却、脱铗收缩,进入检验设备检验面料质量,最后打卷出布。
经测试,本实施例生产的300g/m2全棉16*10 108*56深蓝色直贡甲醛含有率为70PPm,且阻燃性能优异,提升了面料的品质和健康使用需求。
对比实施例
以240g/m2全棉20*16 128*60灰色纱卡
本实施例选择240g/m2全棉20*16 128*60灰色纱卡,且不对该全棉灰色20*16 128*60纱卡做除甲醛处理,其生产工艺步骤如下:
(一)浸轧阻燃整理液包括:
(1)制备阻燃整理液:将阻燃剂40%、柔软剂3%、渗透剂0.2%、醋酸为0.05%、其余为溶剂水混合制成阻燃整理液,其中,阻燃剂为四羟甲基氯化磷和尿素的聚合物,柔软剂为聚乙烯乳液,渗透剂为脂肪醇聚氧乙烯醚;
(2)将经过前处理和染色工序后的面料浸轧在调配好的所述阻燃整理液中,采用一浸一轧工序,使阻燃整理液均匀渗浸在所述面料纤维上,轧余率90%。
(二)预烘工艺:将浸轧阻燃整理液后的面料在车速为25m/min、并依次穿过预烘机的两节烘箱进行预烘处理,所述两节烘箱设定预烘温度均为85℃,使所述面料的含潮率控制在13%范围内。
(三)氨熏工艺:将预烘后的所述面料以车速为25m/min通过氨熏机对所述面料进行氨熏处理,氨熏流量为70m3/h。
(四)氧化中和水洗工艺:将氨熏后的所述面料传送至平幅皂洗机中,经过浸轧250g/l双氧水的氧化液,轧余率为65%,透空氧化90秒,之后进入两格30g/l烧碱溶液进行中和,在四格80℃,两格65℃,两格40℃下水洗,最后冷水洗,烘筒烘干落布。
(五)拉幅定型烘干、预缩、检验:将水洗过的所述面料经过辊轮辊压后进入烘箱热风循环上下喷气烘干处理,所述烘箱有8节烘筒,每节烘筒温度为140℃,所述面料传送的车速为25m/min,然后从烘箱出来后依次进行冷风冷却、脱铗收缩,进入检验设备检验面料质量,最后打卷出布。
经测试,本实施例生产的240g/m2全棉20*16 128*60灰色纱卡甲醛含有率为1000PPm,是实施例1生产的布料甲醛含量的10倍,大大降低了布料的健康使用标准,但阻燃性能与实施例1基本上一致。
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种氨熏法后整理阻燃面料的甲醛控制工艺,该工艺流程包括:浸轧阻燃整理液-预烘工艺-氨熏工艺-氧化中和水洗工艺-除甲醛工艺-拉幅定型烘干、预缩、检验,其特征在于,所述除甲醛工艺包括以下步骤:
(1)浸轧甲醛捕捉剂:
将经过氧化水洗后的面料浸轧至浓度为1.5~3%owf的甲醛捕捉剂溶液中,轧余率为65~75%;
(2)洗甲醛:
将浸轧甲醛捕捉剂溶液的所述面料辊压传送至60~70℃的密封水蒸汽环境中,作用150~180s,再将所述面料传送至依次设置的六格温度为60~80℃的水槽中,再传送至多个冷水槽中反复辊压洗甲醛,之后烘干。
2.根据权利要求1所述的工艺,其特征在于,所述浸轧阻燃整理液包括:
(1)制备阻燃整理液:所述阻燃整理液由阻燃剂、柔软剂、渗透剂混合配制而成,其中所述阻燃整理液各组分的重量百分比:阻燃剂35~40%、柔软剂2~3%、渗透剂0.1~0.2%,其余为水;所述各组分的用量为阻燃剂:350~400g/L、柔软剂:20~30g/L、渗透剂:1~2g/L;
(2)将经过前处理和染色工序后的面料浸轧在调配好的所述阻燃整理液中,采用一浸一轧工序,使阻燃整理液均匀渗浸在所述面料纤维上,轧余率为85~90%。
3.根据权利要求2所述的工艺,其特征在于,所述阻燃整理液还包括醋酸,所述醋酸的浓度为0.2~1g/L,其中所述阻燃整理液各组分的重量百分比:阻燃剂35~40%、柔软剂2~3%、渗透剂0.1~0.2%、醋酸0.02%~0.1%,其余为水;所述阻燃剂为四羟甲基氯化磷和尿素的聚合物,所述柔软剂为聚乙烯类聚合物,优选地所述柔软剂为聚乙烯乳液,所述渗透剂为脂肪醇聚氧乙烯醚。
4.根据权利要求1所述的工艺,其特征在于,所述预烘工艺是将浸轧阻燃整理液后的面料在车速为20~30m/min、并依次穿过预烘机的两节烘箱进行预烘处理,所述两节烘箱设定预烘温度均为80~85℃,使所述面料的含潮率控制在12~14%范围内。
5.根据权利要求1所述的工艺,其特征在于,所述氨熏工艺是将预烘后的所述面料以车速为20~30m/min通过氨熏机对所述面料进行氨熏处理,氨熏流量为65~75m3/h。
6.根据权利要求1所述的工艺,其特征在于,所述氧化中和水洗工艺是将氨熏后的所述面料传送至平幅皂洗机中,经过浸轧200~250g/l双氧水的氧化液,轧余率为60~65%,透空氧化60~90秒,之后进入两格30~40g/l烧碱溶液进行中和,在四格75~85℃,两格55~65℃,两格35~45℃下水洗,最后冷水洗,烘筒烘干落布。
7.根据权利要求1所述的工艺,其特征在于,所述拉幅定型烘干、预缩、检验是将水洗过的所述面料经过辊轮辊压后进入烘箱,依次设置的6~8节烘箱内热风循环上下喷气对所述面料做烘干处理,每节烘箱温度为120~150℃,所述面料传送的车速为20~30m/min,然后从烘箱出来后依次进行冷风冷却、脱铗收缩,进入检验设备检验面料质量,最后打卷出布。
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