CN109056364A - 一种具有自保洁功能的静电植绒产品及其制备方法和设备 - Google Patents

一种具有自保洁功能的静电植绒产品及其制备方法和设备 Download PDF

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CN109056364A
CN109056364A CN201811037361.8A CN201811037361A CN109056364A CN 109056364 A CN109056364 A CN 109056364A CN 201811037361 A CN201811037361 A CN 201811037361A CN 109056364 A CN109056364 A CN 109056364A
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flocking
clean
electrostatic spinning
coating
keeping function
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CN109056364B (zh
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赵丽
罗欣
孟庆荣
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Shandong Tongwei New Materials Technology Co Ltd
Weifang Qingyuan New Materials Technology Co Ltd
SHANDONG FABRIC TRENDS INTERNATIONAL Co Ltd
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Shandong Tongwei New Materials Technology Co Ltd
Weifang Qingyuan New Materials Technology Co Ltd
SHANDONG FABRIC TRENDS INTERNATIONAL Co Ltd
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Abstract

本发明提供一种具有自保洁功能的静电植绒产品的制备方法，包括涂布粘合剂、多电场植绒、固着、后处理、后整理步骤。所述的基布层处理：将作为基布的织物或无纺布进行轧光处理，所述轧光处理工艺：温度50‑100℃，压力0.1‑0.5MPa，时间：0.1‑5秒。本发明植绒面料具有自保洁功能、密度高、牢度高、手感柔软舒适的特点。

Description

一种具有自保洁功能的静电植绒产品及其制备方法和设备
技术领域
本发明涉及一种具有自保洁功能的静电植绒产品及其制备方法和设备，属于静电植绒技术领域。
技术背景
静电植绒面料以其华丽高贵的外观，柔软舒适的手感深得广大消费者的喜爱，被广泛用作沙发面料、服装面料、软包墙饰、座椅面料、铺地材料，进入了家居、家具、养老院、幼儿园、商务会所、交通、部队等领域。
但现有技术的静电植绒面料在使用过程中存在耐脏污性能差的缺点，因此需要经常清洗，给使用者带来很多不必要的麻烦，特别是在经常接触油污、废水等环境中使用时，耐脏污性能显的尤为重要。因此，发明人经过大量实践后致力于研究一种具有自保洁功能的植绒产品的静电植绒生产技术。
同时，现有的静电植绒面料普遍存在严重的掉绒现象，在使用过程中给消费者带来了诸多不便和麻烦。究其原因，主要是现有的静电植绒技术尚不成熟，绒毛植到基材上牢度不够，在运输、摩擦及使用时都会导致不同程度的掉绒。同时，现有技术的静电植绒技术植绒密度较低，也就是说，单位面积的基材上植入的绒毛量较少，导致植绒面料绒毛丰满度较差，较为单薄，即影响使用寿命，又导致视觉效果不好，无法呈现植绒面料应有的观赏价值和视觉效果。
目前市面上植绒面料主要存在的缺点：
（1）耐脏污性能较差，易吸尘沾污；
（2）植绒牢度不高，掉绒现象严重；
（3）植绒密度低，绒毛丰满度欠佳，视觉效果差，档次低。
发明内容
本发明为解决上述技术问题，提供一种具有自保洁功能的静电植绒产品及其制备方法和设备，实现以下发明目的：对高密度植绒面料进行功能化整理，使其具有防水、防油、防污且易去污的自保洁功能。
为了解决上述技术问题，本发明采用的技术方案是：
一种具有自保洁功能的静电植绒产品，包括上层绒毛层、中间层粘合剂层、下层基布层。所述绒毛层，其绒毛材质为聚酰胺纤维、聚酯纤维、粘胶纤维中的一种或多种混植，纤度为0.8-30D，长度为0.5-3.0mm；
所述粘合剂层，粘合剂采用丙烯酸酯、聚氨酯、环氧树脂，厚度为0.05-5mm；所述基布层，基布为织物或者无纺布，其材质为棉纤维、麻纤维、聚酯纤维、聚酰胺纤维、聚烯烃纤维、粘胶纤维中的一种或多种混织或混纺，单位面积质量为60-250g/m2。
一种具有自保洁功能的静电植绒产品的制备方法，包括涂布粘合剂、多电场植绒、固着、后处理、后整理步骤；
具体制备步骤如下：
步骤1、基布层处理：将作为基布的织物或无纺布进行轧光处理，所述轧光处理工艺：温度50-100℃，压力0.1-0.5MPa，时间：0.1-5秒。
上述工艺可以提高光滑度、均匀度、平整度和柔软性，减少涂层胶用量，提高植绒牢度。
步骤2、涂布粘合剂：调节粘合剂粘度为1.5-4.5万cps；将基布引入涂布台，均匀涂布粘合剂，
控制涂布厚度为0.05-5mm；所述粘合剂发泡倍率为0-5；所述涂布粘合剂可以为一次涂布或多次涂布，所述多次涂布粘合剂包括每次涂布粘合剂之后烘干，烘干温度为60-120℃，时间为30-90s。涂布方式可以是刮涂，辊涂，喷涂。
步骤3、多电场植绒：将涂布粘合剂的基布引入静电植绒室，对涂布粘合剂的一面进行多电场植绒，车速为5-50m/min。
所述多电场植绒为多次静电场植绒，包括直流静电场植绒和交流静电场及其脉冲静电场植绒，上述两种植绒方式可以交替或重复进行，每种方式的静电植绒次数可以为1次或多次。采用的直流静电场电压为0.5-2.5万伏，上、下电极间距为5-20cm；采用的交流静电场电压0.5-2.5万伏，频率为50-100Hz，上、下电极间距为5-20cm；所述的多次静电场植绒，每次植绒间隔时间为0.5-5s，控制总的植绒时间为10-70s。
步骤4、固着：将植绒之后的材料引入烘箱，进行高温固着，所述高温固着：温度110-160℃，时间3-10min。
上述步骤2-4的工艺可以大大提高植绒牢度和植绒密度。
步骤5、后处理：将高温固着之后的材料进行冷却、刷绒、吸绒。所述冷却：经冷却辊或冷风冷却至10-50℃；所述刷绒：由辊刷对植绒材料绒毛面进行一次或多次刷绒，目的是刷掉表面的浮绒；所述吸绒：由真空系统对刷掉的浮绒进行真空抽吸，并将浮绒回收。
步骤6、后整理：将步骤5得到的植绒面料引入给液单元对其施加整理液，然后经过焙烘、冷却、打卷。所述施加整理液，其方式可以为浸轧、喷淋、刮涂，控制带液率为50-80%；
所述整理液包括以下组分：纳米有机助剂、脂肪醇硫酸钠、聚氨酯、水；
上述整理液中各组分的浓度配比：
所述纳米有机助剂：为纳米有机硅或纳米有机氟丙烯酸乳液，浓度为40-150g/L；
所述脂肪醇硫酸钠：浓度为4-25g/L；
所述聚氨酯：浓度为5-20g/L。
优选的，所述整理液还包括：抑菌剂、阻燃剂、抗静电剂。使产品增加抗菌、阻燃、防静电的功能。
所述焙烘为柔软烘干或热风烘干，控制焙烘温度为130-150℃，焙烘时间为3-5min；所述柔软烘干在柔软烘干箱中进行，通过揉搓、热风拍打使面料具有柔软舒适的手感，自然、丰满的外观；所述热风烘干，指在烘箱中烘干。
一种具有自保洁功能的静电植绒产品的静电植绒设备，其组成单元包括进布单元、涂布单元、预烘单元、多静电场植绒单元、固着单元、冷却单元、刷绒单元、吸绒单元、给液单元、传送装置（链条式）、焙烘单元。
本发明带来的有益效果：
1. 本发明植绒面料具有自保洁功能：防水等级为4级以上，接触角为123°以上；防油等级为4级以上，防污等级为4级以上，易去污等级为4级以上；
2. 本发明植绒面料植绒密度高：上绒量160g/m2以上；
3. 本发明植绒面料植绒牢度高：按照GB/T 21196.2标准耐磨25000次不露底，经久耐用；
4. 本发明可制作手感柔软舒适，外观自然丰满的自保洁植绒产品；
5. 本发明产品可用作铺地材料、墙体装饰植绒材料、车用或船用内装饰材料、服装面料、警示材料、家具装饰等材料。
实施例1
一种具有自保洁功能的静电植绒产品，包括上层绒毛层、中间层粘合剂层、下层基布层。所述绒毛层，其绒毛材质为PA66，纤度为1.5D，长度为1.0mm；
所述粘合剂层，粘合剂采用水性丙烯酸酯，固含量为48%，粘度为3.2万cps；
所述基布层为经纬编织面料，其材质为涤棉混纺面料，涤棉含量比为80:20，单位面积质量为100g/m2。
所述一种具有自保洁功能的静电植绒产品的制备方法，其制备步骤如下：
步骤1、基布层处理：将基布进行轧光处理，所述轧光处理工艺：温度100℃，压力0.5MPa,时间：0.5秒。
步骤2、涂布粘合剂：将基布引入涂布台，均匀涂布粘合剂，控制涂布厚度为0.3mm；所述涂布粘合剂包括两次涂布：预涂与主涂，涂布方式为刮涂。所述预涂，其粘合剂发泡倍率为5倍，涂布厚度为0.05mm；所述主涂，其粘合剂发泡倍率为2倍，涂布厚度为0.25mm；预涂之后烘干，烘干温度为80℃，时间为30s。
步骤3、多电场植绒：将涂布粘合剂的基布引入静电植绒室，对涂布粘合剂的一面进行静电场植绒，车速为50m/min；采用的绒毛纤度均为1.5D，长度均为1.0mm；
所述静电场植绒为六次静电场植绒，依次包括2次直流静电场植绒和4次交流静电场植绒；记直流静电场植绒为M，交流静电场植绒为N，M=2，N=4，即MMNNNN式静电场植绒。所述两次直流静电场：电压分别是1.2万伏、1.6万伏，上、下电极间距均为8cm；所述四次交流静电场：电压依次是1.2万伏、1.6万伏、2.0万伏、2.8万伏，频率均为50Hz，上、下电极间距均为8cm；控制单次植绒时间为6s，六次植绒间隔时间分别为0.8s、0.8s、0.8s、0.6s、0.5s。
步骤4、固着：将植绒之后的材料引入烘箱，进行高温固着，所述高温固着：温度110℃，时间8min。
步骤5、后处理：将高温固着之后的材料进行冷却、刷绒、吸绒。所述冷却：经冷却辊冷却至30℃；所述刷绒：由辊刷对植绒材料绒毛面进行三次刷绒，目的是刷掉表面的浮绒；所述吸绒：由真空系统对刷掉的浮绒进行真空抽吸，并将浮绒回收。
步骤6、后整理：将步骤5得到的植绒面料引入给液单元，对其施加整理液、焙烘、冷却、打卷。
所述施加整理液，其方式为浸轧，带液率为60%；
所述整理液包括以下组分：纳米有机氟丙烯酸乳液、脂肪醇硫酸钠、聚氨酯、水；
所述纳米有机氟丙烯酸乳液浓度为80g/L；所述脂肪醇硫酸钠，浓度为10g/L；所述聚氨酯，浓度为5g/L；
所述焙烘采用柔软烘干，焙烘温度为150℃，焙烘时间为3min；所述柔软烘干在柔软烘干箱中进行，通过揉搓、热风拍打使面料具有柔软舒适的手感，自然、丰满的外观。
本实施例产品具有优异的自保洁功能：防水等级为5级，接触角为145°，防油等级为6级，防污等级为5级，易去污等级5级；植绒密度高：上绒量为280g/m2；植绒牢度高：按照GB/T 21196.2标准磨50000次不露底。植绒面料手感柔软舒适，外观自然丰满，可用作沙发面料、座椅面料、桌布、墙布、服装用面料。
实施例2
一种具有自保洁功能的静电植绒产品，包括上层绒毛层、中间层粘合剂层、下层基布层。所述绒毛层，其绒毛材质为PA66，纤度为1.5D，长度为1.0mm；
所述粘合剂层，粘合剂采用水性丙烯酸酯，固含量为48%，粘度为3.2万cps；
所述基布层为经纬编织面料，其材质为涤棉混纺面料，涤棉含量比为80:20，单位面积质量为100g/m2。
所述一种具有自保洁功能的静电植绒产品的制备方法，其制备步骤如下：
步骤1、基布层处理：将基布进行轧光处理，所述轧光处理工艺：温度80℃，压力0.3MPa，时间：2秒。
步骤2、涂布粘合剂：
将基布引入涂布台，均匀涂布粘合剂，控制涂布厚度为0.3mm；所述涂布粘合剂包括两次涂布：预涂与主涂，涂布方式为刮涂。所述预涂，其粘合剂发泡倍率为5倍，涂布厚度为0.05mm；所述主涂，其粘合剂发泡倍率为2倍，涂布厚度为0.25mm；预涂之后烘干（预烘），烘干温度为80℃，时间为30s。
步骤3、多电场植绒：
将涂布粘合剂的基布引入静电植绒室，对涂布粘合剂的一面进行静电场植绒，车速为30m/min；
所述静电场植绒为三次植绒静电场植绒，包括3次交流静电场植绒；记直流静电场植绒为M，交流静电场植绒为N，则M=0，N=3，即NNN式静电场植绒。所述交流静电场植绒：采用的交流静电场电压1.2万伏，频率为50Hz；上、下电极间距为8cm；控制单次植绒时间为6s，三次植绒间隔时间为0.8s。
步骤4、固着：将植绒之后的材料引入烘箱，进行高温固着。所述高温固着：温度130℃，时间6min；
步骤5、后处理：将高温固着之后的材料进行冷却、刷绒、吸绒。所述冷却：经冷却辊冷却至20℃；所述刷绒：由辊刷对植绒材料绒毛面进行两次刷绒，目的是刷掉表面的浮绒；所述吸绒：由真空系统对刷掉的浮绒进行真空抽吸，并将浮绒回收；
步骤6、后整理：将步骤5得到的植绒面料引入给液单元，对其施加整理液、焙烘、冷却、打卷。
所述施加整理液，其方式为浸轧，带液率为60%；
所述整理液包括以下组分：纳米有机氟丙烯酸乳液、脂肪醇硫酸钠、聚氨酯、水；
所述纳米有机氟丙烯酸乳液浓度为80g/L；所述脂肪醇硫酸钠，浓度为10g/L；所述聚氨酯，浓度为5g/L；
所述焙烘采用柔软烘干，焙烘温度为130℃，焙烘时间为5min；所述柔软烘干在柔软烘干箱中进行，通过揉搓、热风拍打使面料具有柔软舒适的手感，自然、丰满的外观。
本实施例产品具有优异的自保洁功能：防水等级为4.5级，接触角为136°，防油等级为5级，防污等级为4级，易去污等级4.5级；植绒密度高：上绒量为160g/m2；植绒牢度高：按照GB/T 21196.2标准磨50000次不露底。植绒面料手感柔软舒适，外观自然丰满，可用作沙发面料、座椅面料、桌布、墙布、服装用面料。
实施例3
一种具有自保洁功能的静电植绒产品，包括上层绒毛层、中间层粘合剂层、下层基布层。所述绒毛层，其绒毛材质为PA66，
纤度为25D，长度为3mm；
所述粘合剂层，粘合剂采用水性丙烯酸酯，粘度为3.8万cps；
所述基布层，基布无纺布，其材质为聚丙烯纤维，单位面积质量为200g/m2。
所述一种具有自保洁功能的静电植绒产品的制备方法，其制备步骤如下：
步骤1、基布层处理：将基布进行轧光处理，所述轧光处理工艺：温度100℃，压力0.5MPa,时间：0.5秒；
步骤2、涂布粘合剂：将基布引入涂布台，均匀涂布粘合剂，控制涂布厚度为1mm；所述涂布粘合剂为一次刮涂。
步骤3、多电场植绒：将涂布粘合剂的基布引入静电植绒室，对涂布粘合剂的一面进行静电场植绒，车速为25m/min。
所述静电场植绒为六次静电场植绒，依次包括2次直流静电场植绒和4次交流静电场植绒；记直流静电场植绒为M，交流静电场植绒为N，M=2，N=4，即MMNNNN式静电场植绒。所述两次直流静电场：电压分别是1.6万伏、1.8万伏，上、下电极间距为8cm；所述四次交流静电场：电压依次是1.8万伏、2.0万伏、2.5万伏、3.2万伏，频率均为50Hz，上、下电极间距均为8cm；控制单次植绒时间为6s，六次植绒间隔时间分别为1.0 s、1.2s、1.2s、1.4s、1.6s。
步骤4、固着：将植绒之后的材料引入烘箱，进行高温固着，所述高温固着：温度160℃，时间10min。
步骤5、后处理：将高温固着之后的材料进行冷却、刷绒、吸绒。所述冷却：经冷却辊和冷风冷却至20℃；所述刷绒：由辊刷对植绒材料绒毛面进行三次刷绒，目的是刷掉表面的浮绒；所述吸绒：由真空系统对刷掉的浮绒进行真空抽吸，并将浮绒回收。
步骤6、后整理：将步骤5得到的植绒面料引入给液单元，对其施加整理液、焙烘、冷却、打卷。
所述施加整理液，其方式为对绒毛面进行刮涂，刮涂厚度为1mm；
所述整理液为纳米有机硅、脂肪醇硫酸钠、聚氨酯、水的混合溶液；经发泡机发泡至3.5倍；其中，纳米有机硅浓度为100g/L；脂肪醇硫酸钠，浓度为8g/L；聚氨酯，浓度为10g/L；
所述焙烘：采用热风烘干，在烘箱中进行，焙烘温度为150℃，焙烘时间为3.5min。
本实施例产品具有优异的自保洁功能：防水等级为4级，接触角为123°，防油等级为5级，防污等级为4级，易去污等级4级；植绒密度高：上绒量为280g/m2；植绒牢度高：按照GB/T 21196.2标准磨65000次不露底。植绒面料优异的自保洁性能及高耐磨性能，可以用于铺地材料中，铺设在养老院、幼儿园、船舶、客车、办公室等对空气要求高、客流量大的领域。
实施例4 一种具有自保洁功能的静电植绒产品的制备设备
所述设备的组成单元包括进布单元、涂布单元、预烘单元、多静电场植绒单元、固着单元、冷却单元、刷绒单元、吸绒单元、给液单元、传送装置（链条式）、焙烘单元；
所述的链条式：链条上设置有针板、布夹；
所述多静电场植绒单元：
包括直流静电场植绒箱，箱内设置有静电发生器、电极板、绒毛储存器、落绒仓；
还包括交流静电场植绒箱，箱内设置有静电发生器、变频器、电极板、绒毛储存器、落绒仓、打击辊（一个或多个）
所述的植绒箱采用密闭式箱体；
所述直流静电场植绒箱与交流静电场植绒箱的数量均可以为一个或多个；
所述冷却单元：包括冷风箱、冷却辊筒；
所述刷绒单元：包括刷绒辊（一个或多个）；
所述吸绒单元：包括真空吸绒装置（一个或多个）；
所述给液单元：包括储液槽和轧辊；
所述焙烘单元：柔软烘干箱或热风定型机。
除特殊说明的外，本发明所述的百分数均为质量百分数，所述的比值均为质量比。
最后应说明的是：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，尽管参照前述实施例对本发明进行了详细说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换。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 (10)

1.一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：包括涂布粘合剂、多电场植绒、固着、后处理、后整理步骤。
2.根据权利要求1所述的一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：所述的基布层处理：将作为基布的织物或无纺布进行轧光处理，所述轧光处理工艺：温度50-100℃，压力0.1-0.5MPa，时间：0.1-5秒。
3.根据权利要求1所述的一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：所述的涂布粘合剂：将基布引入涂布台，均匀涂布粘合剂，控制涂布厚度为0.05-2mm；所述粘合剂发泡倍率为0-5；所述涂布粘合剂可以为一次涂布或多次涂布，涂布方式可以是刮涂，辊涂，喷涂。
4.根据权利要求3所述的一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：所述的多次涂布：每次涂布粘合剂之后烘干，烘干温度为60-120℃，时间为30-90s。
5.根据权利要求1所述的一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：所述的多电场植绒：将涂布粘合剂的基布引入静电植绒室，对涂布粘合剂的一面进行多电场植绒，车速为5-50m/min。
6.根据权利要求1所述的一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：所述多电场植绒为多次静电场植绒，包括直流静电场植绒和交流静电场植绒，上述两种植绒方式可以交替或重复进行，每种方式的静电植绒次数可以为1次或多次；采用的直流静电场电压为0.5-2.5万伏，上、下电极间距为5-20cm；采用的交流静电场电压0.5-2.5万伏，频率为50-100Hz，上、下电极间距为5-20cm；所述的多次静电场植绒，每次植绒间隔时间为0.5-5s，控制总的植绒时间为10-70s。
7.根据权利要求1所述的一种具有自保洁功能的静电植绒产品的制备方法，其特征在于：所述的固着：温度110-160℃，时间3-10min。
8.一种具有自保洁功能的静电植绒产品，其特征在于：所述产品依次包括上层绒毛层、中间层粘合剂层、下层基布层；所述绒毛层，其绒毛材质为聚酰胺纤维、聚酯纤维、粘胶纤维中的一种或多种混植；所述绒毛：纤度为0.8-30D，长度为0.5-3.0mm。
9.根据权利要求1所述的一种具有自保洁功能的静电植绒产品，其特征在于：所述粘合剂层，粘合剂为丙烯酸酯、聚氨酯、环氧树脂中的一种或多种，粘合剂的粘度为1.5-4.5万cps。
10.根据权利要求1所述的一种具有自保洁功能的静电植绒产品，其特征在于：所述基布层，基布采用织物或者无纺布，其材质为棉纤维、麻纤维、聚酯纤维、聚烯烃纤维、粘胶纤维中的一种或多种混织或混纺，所述基布的单位面积质量为60-250g/m2。
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