CN109130360A - 石墨烯纤维3d微升导热散热气候层产品及制备方法 - Google Patents
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Abstract
石墨烯纤维3D微升导热散热气候层产品及制备方法,涉及经编间隔织物垫类产品。石墨烯纤维3D微升导热散热气候层产品为单独的石墨烯导热散热层织物,或由石墨烯导热散热层织物和经编间隔织物骨架稳固层、经编间隔织物通风透气层其中的一种或两种组合而成。制备石墨烯导热散热层织物;制备石墨烯分散液;浸轧;热处理;成品生产。在现有3D床垫和枕头的基础上,赋予床垫和枕头功能性多级表面层,进一步解决床垫和人体之间的闷热感,实现干爽、可洗、呼吸通风等功能,其立足于改善消费者的睡眠环境。
Description
技术领域
本发明涉及经编间隔织物垫类产品,尤其是涉及具有导热散热气候层功能,由石墨烯纤维和聚酯纤维复合编织而成的石墨烯纤维3D微升导热散热气候层产品及其制备方法。
背景技术
人们在日常生活中有三分之一的时间在睡眠中度过,而床垫和枕头是人们保障睡眠的最重要的寝具。目前市场上床垫主要有四种:棕垫、乳胶床垫、海绵床垫和弹簧床垫。枕头主要有荞麦枕、乳胶枕、纤维棉枕、记忆棉枕、太空棉枕等,市场上比较火热的保健枕也是在这些枕头的基础上添加一些具有保健功能的材料,例如决明子、茶叶、麦饭石等。市场上这些床垫和枕头虽然各有优势,但仍然存在不足之处,比如部分床垫透气性不佳,人体在睡眠过程中产生的热量无法快速扩散,导致消费者在睡眠过程中会产生一定的“闷”、“热”感。另外,人在睡眠中新陈代谢产生的废物、水蒸气等会不断通过皮肤排出,床垫不透气,这些废物不能及时散发,不利于人体健康,至今国内还没有完全满足需要的床垫和枕头类产品。福建福联精编有限公司是我国3D间隔织物领域的原创者,专注3D床垫、枕头产品的研发10年有余,其研发的3D床垫和枕头能够解决一部分现有床垫和枕头产品透气性不佳,“闷”、“热”感严重的问题。
综上所述,开发一种舒适通风透气的经编间隔织物,将其应用于床垫和枕头,以解决床品和人体之间的微环境湿热稳定性是非常必要的,能够使使用者皮肤呼吸顺畅、温湿度保持相对平衡,进一步解决人体与床垫和枕头之间“闷”、“热”感严重的问题。
发明内容
本发明的目的在于针对目前床垫等垫类产品和枕头领域存在的上述不足,提供由石墨烯纤维和聚酯纤维复合编织而成的石墨烯纤维3D微升导热散热气候层产品及其制备方法。
所述石墨烯纤维3D微升导热散热气候层产品为单独的石墨烯导热散热层织物,或由石墨烯导热散热层织物和经编间隔织物骨架稳固层、经编间隔织物通风透气层其中的一种或两种组合而成。
所述石墨烯导热散热层织物由上表面层、下表面层和中间导流层组成;上表面层和下表面层至少有一层或者两层由石墨烯纤维复丝编织而成,中间导流层是由化纤单丝、低熔点皮芯化纤丝、石墨烯单丝、石墨烯纤维复丝等中的一种或多种混合编织而成。
所述石墨烯导热散热层织物在后整理过程中采用超声加机械搅拌喷淋浸轧加热法,先让石墨烯分散液均匀吸附于石墨烯导热散热层织物上,然后经过180℃左右的高温定型处理,将石墨烯分散液固着于石墨烯导热散热层织物的上表面层、下表面层和中间导流层。
所述超声加机械搅拌喷淋浸轧加热法处理是在第一水洗池和第二水洗池设有超声波装置的浸轧设备上进行,第一水洗池和第二水洗池的底面及四周以50cm的间距间隔排列,轧辊上前方设置有喷淋装置。
所述喷淋装置的底面及四周以50cm的间距间隔铺设有超声波装置,喷淋装置设有机械搅拌系统和高温高压系统,其温度最高可为250℃,喷淋装置内装有质量体积浓度为3~5g/L的石墨烯分散液。
所述石墨烯分散液所用的石墨烯粉末为经过异氰酸酯、硅烷偶联剂、有机胺、重氮盐等试剂表面接枝功能化处理或经过聚乙烯吡咯烷酮(PVP)、十二烷基苯磺酸钠(SDBS)、木质素磺酸钠(SLS)、聚乙烯醇(PVA)、聚氧化乙烯、聚丙烯酸、聚甲基丙烯酸、聚丙烯酰胺等表面活性剂处理后的石墨烯。
所述超声加机械搅拌喷淋浸轧加热法采用两浸两轧两次热定型的处理方式,第一遍热处理采用低温低速(所述的低温低速是指其定型温度和车速相对第二遍定型处理均较低,温度为150℃左右,车速为16m/min左右),第二遍采用高温高速(所述的高温高速是指其定型温度和车速相对第一遍定型处理均较高,温度为180℃左右,车速为22m/min左右)。
所述石墨烯纤维3D微升导热散热气候层产品的厚度可为1~30cm,其中石墨烯导热散热层织物的厚度可为3~30mm。
所述石墨烯纤维为海岛型石墨烯内暖纤维,海岛型石墨烯内暖纤维的“海”组分为聚乙烯醇等水溶性纤维,“岛”组分为石墨烯纤维,石墨烯纤维中石墨烯的添加量按质量百分比可为1%~5%。
所述化纤单丝可选自涤纶单丝、丙纶单丝、锦纶单丝、乙纶单丝等其中的至少一种。
所述石墨烯导热散热层织物上表面层、下表面层的网孔形状可为圆形、三角形、菱形、矩形、六边形或无网孔平面结构等其中的至少一种。所述石墨烯导热散热层织物上表面层的网孔为1~9个/cm2,优选5个/cm2,下表面层的网孔为3~20个/cm2,优选9个/cm2;所述石墨烯导热散热层织物中间导流层的间隔丝排列方式可为l字形、V字形、X字形、1X1字形等中的至少一种。所述石墨烯导热散热层织物上表面层优选大小圆相结合的大网孔结构,下表面层采用菱形小网孔结构,中间导流层纤维的排列优选X形。
所述经编间隔织物骨架稳固层可由低熔点皮芯化纤丝和普通化学纤维混合编织,经高温定型处理后其纵、横向稳定性和Z向稳定性均十分优异。所述普通化学纤维可以是聚酯纤维、聚酰胺纤维、聚丙烯纤维等中的至少一种。
所述经编间隔织物通风透气层的上表面层网孔、下表面层网孔采用相对的方式排列,保证其具有最大的通风透气性。
所述石墨烯纤维3D微升导热散热气候层产品的制备方法包括以下步骤:
1)制备石墨烯导热散热层织物;
在步骤1)中,所述制备石墨烯导热散热层织物的具体方法可为:将石墨烯海岛丝、化纤复丝和化纤单丝经过整经工序整成可供经编机生产的盘头,通过上轴工序,将盘头放进经轴上,然后按照织造工艺的要求穿纱、挂布、织造,得石墨烯导热散热层织物。
2)制备石墨烯分散液;
在步骤2)中,所述制备石墨烯分散液的具体方法可为:将石墨烯粉末和去离子水加入喷淋装置内,开启超声波装置并辅以机械搅拌,得石墨烯分散液,供下道工序使用。
3)浸轧;
在步骤3)中,所述浸轧的具体方法可为:为了使石墨烯粉末能够均匀牢固地涂敷于石墨烯导热散热层织物中间导流层及上表面层、下表面层,采用两浸两轧的生产方式,在正式浸轧之前,先对织物进行预处理,预处理后让织物经过设有喷淋装置的喷淋区域,将制备好的石墨烯分散液均匀喷淋进织物内部,完成浸轧工序。
4)热处理;
在步骤4)中,所述热处理的方式可采用干热定型,第一遍定型采用低温低速定型的方式,第二遍定型采用高温快速定型的方式,防止织物变僵,影响舒适性。
5)成品生产。
在步骤5)中,所述成品生产可将单独一层石墨烯导热散热层织物或者单独一层石墨烯导热散热层织物与经编间隔织物骨架稳固层、经编间隔织物通风透气层其中的一种或两种组合而成的气候层产品进行成品包边加工处理,得到石墨烯纤维3D微升导热散热气候层产品。
本发明在现有3D床垫和枕头的基础上,提供一种由石墨烯纤维和聚酯纤维复合编织而成的3D经编间隔织物微升导热散热气候层产品,其赋予床垫和枕头功能性多级表面层,进一步解决床垫和人体之间的闷热感,实现干爽、可洗、呼吸通风等功能,其立足于改善消费者的睡眠环境。
本发明利用石墨烯纤维传热导热迅速的特点,结合3D经编间隔织物特有的六面透气结构,能够将人体在睡眠过程中产生的湿气和热量快速的扩散到周围大环境中,从而保证人体和床垫或枕头之间的微环境保持一定的湿热稳定性。另外,因为所述石墨烯导热散热层织物回潮率较小,仅为0.5%,而热阻为0.331m2.K/W,结合3D经编间隔织物特有的导流性能,所以石墨烯纤维3D微升导热散热气候层导湿而不吸湿,导热而不储热。利用其做成的产品本身具有维持微环境湿热相对稳定(双向调节)的功能,对人/垫间的环境具有微升2~3℃和散热的双向调节,其具有超强的传热、散热功能。
本发明的有益效果如下:
1)具有超强的导热散热性能
人体在睡眠过程中:当人体体温和湿度升高(出汗情况)时,在空气相对流动的情况下,石墨烯纤维3D微升导热散热气候层会吸收一定的热量和湿气,然后将其释放到周围环境中,人体温度和湿度适当降低,使人体保持舒适干爽的状态;
当人体体温和湿度降低时(干冷情况),在空气相对稳定的情况下,石墨烯纤维3D微升导热散热气候层可以使人体与床垫之间微环境的温度升高,对人/垫间的环境具有2~3℃的微升空间,使人体保持温暖舒适的状态。
2)超强的体温远红外功效
市场上现有的大部分产品其远红外是由添加在材料中的矿物质发射的,需要60℃以上才能激发。本发明所述石墨烯纤维3D微升导热散热气候层产品具有强大的体温产生远红外功效,即在20~35℃低温状态下,对6~14μm波长远红外光吸收率达88%以上。
3)优异的抑菌性
标准对抑菌产品的要求是抑菌率达到70%,本发明所述石墨烯纤维3D微升导热散热气候层产品抑菌率达到90%以上,具有优异的抗菌性能(针对三大常见菌种金黄色葡萄球菌、大肠杆菌、白色念珠菌)
4)手感舒适性
由于石墨烯纱线采用海岛丝形式,不影响织造的前提下,经过后整预处理后,海岛丝表面的“海”成分溶解,纤维分散成超细纤维结构,手感十分舒适。
本发明所述石墨烯纤维3D微升导热散热气候层产品具有优异的吸湿导湿性能、超过世界先进水平的强大体温产生远红外功效,促进微循环和抗菌抑菌性能,并且经多次洗涤后不衰减,且洗后速干,不变形,并且手感舒适。
附图说明
图1为组合石墨烯纤维3D微升导热散热气候层产品外观结构示意图。
图2为单层石墨烯纤维3D微升导热散热气候层织物示意图。
图3为石墨烯海岛纤维示意图。
图4为石墨烯纤维3D微升导热散热气候层织物浸轧喷淋工序示意图。
具体实施方式
以下实施例将结合图1~4对本发明作进一步的说明。
实施例1
采用空穿法编织,在karl Mayer E20机器上编织产品,针床隔距调为8mm,编织密度为14wpc。
工艺组织为:
GB1:(1-0 2-3)*3/4-5/(6-7 5-4)*4/3-2//
GB2:(6-7 5-4)*3/3-2/(1-0 2-3)*4/4-5//
GB3:0-1/0-1/3-4/3-4//
GB4:1-0/1-0/4-3/4-3//
GB5:1-0/1-2/2-3/3-4/4-5/4-3/3-2/2-1//
GB6:4-5/4-3/3-2/2-1/1-0/1-2/2-3/3-4//
采用原料及空穿:
所述石墨烯纤维3D微升导热散热气候层产品由石墨烯导热散热层织物1、经编间隔织物通风透气层2和经编间隔织物骨架稳固层3组成,示意图如图1和2所示。所述石墨烯导热散热层织物上表面层4由石墨烯海岛丝织造,网孔为大小圆结构,下表面层5由聚酯DTY织造,网孔为菱形小网孔结构,导流层6由聚酯皮芯低熔丝织造,间隔丝排列方式为“X”型。
石墨烯导热散热层织物织造完成后,开始制备石墨烯分散液,将50g石墨烯粉末和10L去离子水加入喷淋装置10内,打开超声波装置和机械搅拌装置开关,搅拌10min,即制备出浓度为5g/L的石墨烯分散液。然后对织物进行热整理前的预处理,预处理条件为:车速为30m/min,在设有超声波装置的第一水洗池11和第二水洗池12加入清洗剂,清洗剂剂量为2g/L,第三池到第五池为清水,第五池出口设置有三道轧辊,轧辊压力为3,可以除去织物上所带的多余水分。预处理完成后,织物进行喷淋浸轧处理,织物以15m/min的速度经过轧辊,轧辊上前方10cm处设置有长度20cm,宽度230cm的喷淋装置10,轧辊前后50cm范围下方及轧辊正下方均设置有长度230cm的回收槽13。喷淋装置10内外壁用不锈钢做成,中间层铺设有超声波设备。织物通过喷淋区时,石墨烯分散液以一定的速度均匀的喷洒在织物中。热处理方式采用干热定型,第一遍定型采用低温低速定型的方式,定型温度为150℃,车速为16m/min,第二遍采用高温快速的定型方式,定型温度为180℃,车速为22m/min。第一遍定型时,织物小网孔面5在下方,大网孔面4在上方,第二遍定型时,大网孔面4在下方,小网孔面5在上方,以保证石墨烯导热散热层织物热定型后具有优异的弹性。最后,将后整理完成后的石墨烯导热散热层织物和经编间隔织物骨架稳固层、经编间隔织物通风透气层进行组合,然后包边加工处理。
实施例2
采用空穿法编织,在karl Mayer E20机器上编织产品,针床隔距调为15mm,编织密度为22wpc。
工艺组织为
GB1:(1-0 2-3)*2/4-5/(6-7 5-4)*2/3-2//
GB2:(6-7 5-4)*2/3-2/(1-0 2-3)*2/4-5//
GB3:0-1/0-1/3-4/3-4//
GB4:1-0/1-0/4-3/4-3//
GB5:1-0/1-2/2-3/3-4/4-5/4-3/3-2/2-1//
GB6:4-5/4-3/3-2/2-1/1-0/1-2/2-3/3-4//
采用原料及空穿:
所述石墨烯纤维3D微升导热散热气候层产品由单独的石墨烯导热散热层织物组成,示意图如图2,其上表面层4由石墨烯聚酯海岛丝7织造,网孔为大小圆结构,下表面层5由聚酯DTY织造,网孔为菱形小网孔结构,导流层6由聚酯皮芯低熔丝织造,间隔丝排列方式为“X”型。所述海岛丝7由“海”组分8水溶性聚乙烯醇纤维和“岛”组分9石墨烯纤维组成。石墨烯导热散热层织物织造完成后,开始制备石墨烯分散液,将30g石墨烯粉末和10L去离子水加入喷淋装置10内,打开超声波装置和机械搅拌装置开关,搅拌10min,即制备出浓度为3g/L的石墨烯分散液。然后对织物进行热整理前的预处理,预处理条件为:车速为30m/min,在设有超声波装置的第一水洗池11和第二水洗12池加入清洗剂,清洗剂剂量为2g/L,第三池到第五池为清水,第五池出口设置有三道轧辊,轧辊压力为3,可以除去织物上所带的多余水分。预处理完成后,织物进行喷淋浸轧处理,织物以15m/min的速度经过轧辊,轧辊上前方10cm处设置有长度20cm,宽度230cm的喷淋装置10,轧辊前后50cm范围下方及轧辊正下方均设置有长度230cm的回收槽14。喷淋装置内外壁用不锈钢做成,中间层铺设有超声波设备。织物通过喷淋区时,石墨烯分散液以一定的速度均匀的喷洒在织物中。热处理方式采用干热定型,第一遍定型采用低温低速定型的方式,定型温度为150℃,车速为12m/min,第二遍采用高温快速的定型方式,定型温度为170℃,车速为18m/min。第一遍定型时,织物小网孔面5在下方,大网孔面4在上方,第二遍定型时,大网孔面4在下方,小网孔面5在上方,以保证石墨烯导热散热层织物热定型后具有优异的弹性。最后,将后整理完成后的石墨烯导热散热层织物进行成品包边加工处理。
Claims (10)
1.石墨烯纤维3D微升导热散热气候层产品,其特征在于为单独的石墨烯导热散热层织物,或由石墨烯导热散热层织物和经编间隔织物骨架稳固层、经编间隔织物通风透气层其中的一种或两种组合而成;所述石墨烯导热散热层织物由上表面层、下表面层和中间导流层组成;上表面层和下表面层至少有一层或者两层由石墨烯纤维复丝编织而成,中间导流层是由化纤单丝、低熔点皮芯化纤丝、石墨烯单丝、石墨烯纤维复丝中的一种或多种混合编织而成。
2.如权利要求1所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述石墨烯导热散热层织物在后整理过程中采用超声加机械搅拌喷淋浸轧加热法,先让石墨烯分散液均匀吸附于石墨烯导热散热层织物上,然后经过高温定型处理,将石墨烯分散液固着于石墨烯导热散热层织物的上表面层、下表面层和中间导流层;所述高温定型处理的温度可为180℃。
3.如权利要求2所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述超声加机械搅拌喷淋浸轧加热法处理是在第一水洗池和第二水洗池设有超声波装置的浸轧设备上进行,第一水洗池和第二水洗池的底面及四周以50cm的间距间隔排列,轧辊上前方设置有喷淋装置;
所述喷淋装置的底面及四周以50cm的间距间隔铺设有超声波装置,喷淋装置设有机械搅拌系统和高温高压系统,其温度最高为250℃,喷淋装置内装有质量体积浓度为3~5g/L的石墨烯分散液。
4.如权利要求2所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述石墨烯分散液所用的石墨烯粉末为经过异氰酸酯、硅烷偶联剂、有机胺、重氮盐试剂表面接枝功能化处理或经过聚乙烯吡咯烷酮、十二烷基苯磺酸钠、木质素磺酸钠、聚乙烯醇、聚氧化乙烯、聚丙烯酸、聚甲基丙烯酸、聚丙烯酰胺表面活性剂处理后的石墨烯。
5.如权利要求2所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述超声加机械搅拌喷淋浸轧加热法采用两浸两轧两次热定型的处理方式,第一遍热处理采用低温低速,第二遍采用高温高速;
所述石墨烯纤维3D微升导热散热气候层产品的厚度可为1~30cm,其中石墨烯导热散热层织物的厚度可为3~30mm。
6.如权利要求1所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述化纤单丝选自涤纶单丝、丙纶单丝、锦纶单丝、乙纶单丝其中的至少一种;
所述石墨烯导热散热层织物上表面层、下表面层的网孔形状为圆形、三角形、菱形、矩形、六边形或无网孔平面结构其中的至少一种;所述石墨烯导热散热层织物上表面层的网孔为1~9个/cm2,优选5个/cm2,下表面层的网孔为3~20个/cm2,优选9个/cm2;所述石墨烯导热散热层织物中间导流层的间隔丝排列方式可为l字形、V字形、X字形、1X1字形中的至少一种;所述石墨烯导热散热层织物上表面层优选大小圆相结合的大网孔结构,下表面层采用菱形小网孔结构,中间导流层纤维的排列优选X形。
7.如权利要求1所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述经编间隔织物骨架稳固层由低熔点皮芯化纤丝和化学纤维混合编织;所述化学纤维选自聚酯纤维、聚酰胺纤维、聚丙烯纤维中的至少一种。
8.如权利要求1所述石墨烯纤维3D微升导热散热气候层产品,其特征在于所述经编间隔织物通风透气层的上表面层网孔、下表面层网孔采用相对的方式排列。
9.如权利要求1~8所述石墨烯纤维3D微升导热散热气候层产品的制备方法,其特征在于包括以下步骤:
1)制备石墨烯导热散热层织物;
2)制备石墨烯分散液;
3)浸轧;
4)热处理;
5)成品生产。
10.如权利要求9所述石墨烯纤维3D微升导热散热气候层产品的制备方法,其特征在于在步骤1)中,所述制备石墨烯导热散热层织物的具体方法为:将石墨烯海岛丝、化纤复丝和化纤单丝经过整经工序整成供经编机生产的盘头,通过上轴工序,将盘头放进经轴上,然后按照织造工艺的要求穿纱、挂布、织造,得石墨烯导热散热层织物;
在步骤2)中,所述制备石墨烯分散液的具体方法为:将石墨烯粉末和去离子水加入喷淋装置内,开启超声波装置并辅以机械搅拌,得石墨烯分散液,供下道工序使用;
在步骤3)中,所述浸轧的具体方法为:在浸轧之前,先对织物进行预处理,预处理后让织物经过设有喷淋装置的喷淋区域,将制备好的石墨烯分散液均匀喷淋进织物内部,完成浸轧工序;
在步骤4)中,所述热处理的方式采用干热定型,第一遍定型采用低温低速定型的方式,第二遍定型采用高温快速定型的方式,防止织物变僵,影响舒适性;
在步骤5)中,所述成品生产将单独一层石墨烯导热散热层织物或者单独一层石墨烯导热散热层织物与经编间隔织物骨架稳固层、经编间隔织物通风透气层其中的一种或两种组合而成的气候层产品进行成品包边加工处理,得到石墨烯纤维3D微升导热散热气候层产品。
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