CN109154135B - 一种超细纤维面料及其制造工艺 - Google Patents

一种超细纤维面料及其制造工艺 Download PDF

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Publication number
CN109154135B
CN109154135B CN201880000055.9A CN201880000055A CN109154135B CN 109154135 B CN109154135 B CN 109154135B CN 201880000055 A CN201880000055 A CN 201880000055A CN 109154135 B CN109154135 B CN 109154135B
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fabric
island
sea
composite base
percent
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CN109154135A (zh
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钱国春
包旭旭
李梦娟
隋晓锋
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Zhejiang Meisheng New Materials Co ltd
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Zhejiang Meisheng New Materials Co ltd
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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Abstract

一种超细纤维面料，包括基体部分和表面部分，所述基体部分由定岛型海岛长丝或/和普通长丝构成，所述表面部分由短纤维构成，所述面料为基体部分和表面部分相互络合的无纺结构。一种超细纤维面料的制造工艺，其基体部分的定岛型海岛长丝或/和普通长丝通过纬编、经编或梭织工艺，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料。本超细纤维面料填补了针刺无纺布的厚度在0.5mm以下的成品规格空白，且具有非常好的双色效果，高档美观。

Description

一种超细纤维面料及其制造工艺
技术领域
本发明涉及一种超细纤维面料及其制造工艺，属于高档纺织面料技术领域。
背景技术
超纤是超细纤维PU合成革的简称，海岛型超细纤维是超细纤维的一个种类，分海岛长丝和海岛短纤(包括定岛型和不定岛型)两大类。海岛长丝一般通过机织和针织生产麂皮绒面料，用于服装、服饰的制作；海岛短纤通常通过针刺非织造生产厚型仿皮面料，主要用于制鞋、沙发、汽车内饰、服饰等。所有超纤面料一般都以实现高仿真皮为最高目的，定岛型超面料采用碱减量开纤，相对于不定岛型超纤面料采用甲苯开纤比较安全和环保。
普通的超细纤维针刺无纺布，通常做法是使超细短纤经过开包、混仓、梳理、铺网、针刺等工序，其设备投资昂贵，生产工艺条件高，能耗大，产量低，面料的平均厚度、克重控制难度高，给后续树脂含浸、染色深加工带来难度，生产的面料的厚度规格局限性较大，一般只能生产0.5-2.0mm中等厚度且无弹性规格坯布，不能直接生产0.5mm以下厚度且有弹型规格的坯布。也有厂家为追求0.5mm以下规格坯布，采用先生产1.2mm以上厚度，再采用面料横向厚度剖切片皮工艺，但这种做法的缺陷是：原先缠结一起的纤维被切开后，导致面料强度下降明显，影响后续应用。
有鉴于此，本申请人对此进行专门研究，开发出一种超细纤维面料及其制造工艺，本案由此产生。
发明内容
为了解决现有技术中存在的上述缺陷，本发明的目的是提供一种强度高、厚度薄的超细纤维面料及其制造工艺，为了实现上述目的，本发明采取的技术方案如下：
本发明为填补0.5mm以下超纤面料的规格，采用超细纤维长丝，通过针织，拉毛，刺毛工艺，生产出厚度在0.5mm以下且有弹性的坯布，再经树脂含浸、开纤、染色、磨毛等后整理，可应用到汽车内饰、服饰等领域。
一种超细纤维面料，包括基体部分和表面部分，所述基体部分由定岛型海岛长丝或/和普通长丝构成，所述表面部分由短纤维构成，所述面料为基体部分和表面部分相互络合的无纺结构。
作为优选，所述基体部分还包括涤纶高强丝，纤度为75-100D。
作为优选，所述定岛型海岛长丝为聚酯海岛长丝或/和锦纶海岛长丝，纤度为75-150D，所述普通长丝为聚酯长丝或/和锦纶长丝，纤度为50D-200D，所述短纤维为聚酯海岛短纤或/和锦纶海岛短纤。
所述超细纤维面料的成品厚度在0.5mm以下。
一种超细纤维面料的制造工艺，基体部分的定岛型海岛长丝或/和普通长丝通过纬编、经编或梭织工艺，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料，具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入75-100D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(1)中，控制线圈高度在0.2-0.3cm之间，坯布重量克重200-300g/m2，门幅为170-200cm。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，能将毛彻底拉出来，使绒毛长度在0.5-2.5cm。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上一至三层无纺针刺纤维(即短纤)，每层克重为10-20g，铺网机出网的速度为0.3-0.5m/min。
所述步骤(4)中，经针刺机针刺4次以上，经无纺针刺纤维缠结得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率控制在500-900刺/min，针板布针密度为7500针/米2，生产出厚度在0.45-1.0mm、克重为250-350g/m2，门幅为170-200cm的复合基布。
所述步骤(5)中，将复合基布进行机缸预缩，预缩时温度为130℃-180℃，所用时间为30-60min，预缩可进一步提高面料密度，可实现开纤率3％以内，同样可减少液碱使用量和液碱水洗成本，提高回弹性，改善手感。
所述步骤(6)第一次烘干和第一次定型：将复合基布放到定型机机芯烘干切边控制门幅，烘干温度在110-130℃，烘干时根据坯布密度，调节温度和车速，以坯布里外烘干烘透为合适。
所述步骤(7)树脂含浸：在树脂与水性聚氨酯的混合液中对复合基布分别进行含浸处理，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度在10％-17％的水性树脂，车速5-7m/min，以带液量120％-130％，调节压力辊压力为0.5MPa，使复合基布的水性树脂的增重量为10％±2％；所述第二次含浸：浸液浓度在12％-20％的水性聚氨酯，车速7-8m/min，以带液量120％-130％调节压力辊压力为0.5MPa，使复合基布的水性聚氨酯的增重量为8％±2％。
所述步骤(8)碱减量开纤：碱液浓度为5％，升温为5℃/min，高温区温度为96-110℃，所用时间为45-60min，开纤率18％-25％；进行中和处理时，采用柠檬酸进行，并将pH值调节到6-7，出缸后采用连续化逆流式水洗。
所述步骤(9)第二次烘干和第二次定型：含浸和碱减量开纤后进行烘干和定型，以便于磨毛。
所述步骤(10)第一次磨毛，因开纤后复合基布表面凹凸不平，经磨毛后可使复合基布均匀着色。
所述步骤(11)染色：复合基布缝头后，进缸染色、还原清洗、脱水、定型，初染色时将分散染料的始染温度控制在50～60℃，1h后逐渐升温至130℃，保温1～2h，然后充分水洗，染深色时进行还原清洗。
分散染料由高温匀染剂、扩散剂和重量百分比浓度为98％的醋酸配置而成，按照每升染料计算，所述高温匀染剂用量为0.2～1.2g/L，扩散剂用量为0.5～1g/L，醋酸用量为0.5～1.5g/L。还原清洗时，按照每升染料计算，烧碱用量为6ml/L，保险粉用量为2.5g/L，分散剂用量为0.1～0.5g/L。
所述步骤(12)第三次烘干和第三次定型：还原清洗后再次进行烘干、定型，定型时控制上述基布温度为100℃170℃，车速调至5-30米/分，车速为30-60米/分；
所述步骤(13)第二次磨毛：常规产品使布面绒毛长短一致无绒疵为合格，如客户对布面有“书写效果”需求，可以通过保留绒毛的长度以实现。
所述步骤(14)第四次烘干和第四次定型：最后根据产品需求进行定型；
所述步骤(15)检验、打卷、入库。
本发明能实现如下技术效果：
(1)本发明填补了针刺无纺布的正常生产(非增加机械片皮工序)厚度规格空白，能生产出厚度为0.5mm以下的成品；
(2)本发明生产出的面料由于在铺网时，可以选择与坯布不同性质纤维，如针织时采用涤纶高强丝，铺网时采用锦纶短纤，使铺网纤维和坯布纤维充分缠结，又由于在染色时可以只投分散染料，分散染料对锦纶短纤不上色，在面料表面就形成了白色加任意色的双色效果，也丰富了面料的表观颜色，因此本发明工艺可以实现成品面料的双色效果，采用上述留白染色的工艺使其具有非常好的双色效果，高档美观；
(3)采用75-100D涤纶高强丝和75-250D定岛型海岛长丝和10D锦纶短纤，并采用上述技术方案，使面料物性指标明显高于同厚度的针刺无纺布；
(4)因本发明的面料坯布组织有较好的回弹性，加入常规的水性树脂及水性聚氨酯50％的用量，既有皮感，同时可实现10-30％的弹性伸长率，比普通化纤面料更具仿真性，比天然皮革更具回弹性，从而扩大了面料的应用范围，可应用于有弹性伸长性需求的汽车内饰、女士春秋时装等高端面料领域，提高产品市场竞争力；
(5)本发明工艺生产的面料，保留了针织面料的悬垂性，通过针刺加入超细短纤后，增加了它的透湿度，可满足服饰领域的多种需求；还有通过针刺铺网加密，面料的隔音性有较大的提高，可增强汽车及家居内包的装饰材料的隔音功能；
(6)本发明生产工艺相比传统同规格的针刺无布，设备投入节约3/5，产能提高2倍且能耗基本持平，原料成本下降1/5，CV值控制简易，能实现高质高效量产，且所用原料合工艺均符合环保要求。
具体实施方式
为了使本发明的技术手段及其所能达到的技术效果，能够更清楚更完善的揭露，兹提供了若干个实施例详细说明，但本发明不受以下实施例的限定：
实施例1
本实施例的一种超细纤维面料，超细纤维面料的原料为以下原料组合的一种：
基体部分：75D聚酯海岛长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：75D锦纶海岛长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：75D聚酯海岛长丝、50D聚酯长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：75D聚酯海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：75D锦纶海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：75D聚酯海岛长丝、50D锦纶长丝和75D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：75D聚酯海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：75D锦纶海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：75D聚酯海岛长丝、75D锦纶海岛长丝和75D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：50D聚酯长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：50D锦纶长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：50D聚酯长丝、50D锦纶长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：50D聚酯长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：50D锦纶长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：50D聚酯长丝、75D锦纶海岛长丝和75D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：50D聚酯长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：50D锦纶长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：50D锦纶长丝、75D锦纶海岛长丝和75D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤。
上述面料可以通过以下一种超细纤维面料的制造工艺，具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入75D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，克重为200-300g/m2。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上1层无纺针刺纤维，铺网机出网的速度为0.3m/min。
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为500刺/min，针板布针密度为7500针/米2，生产出厚度为0.6mm、克重为250g/m2的复合基布。
所述步骤(5)中，预缩时温度为130℃，所用时间为30min。
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为10％的水性树脂，车速5m/min，带液量120％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为12％的水性聚氨酯，车速7m/min，带液量120％-，压力辊压力为0.5MPa。
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为50℃，1h后逐渐升温至130℃，保温1h，然后充分水洗，染深色时进行还原清洗。
本实施例成品米克重为：280-290g/m2，厚度为0.50mm。
实施例2
本实施例的一种超细纤维面料，超细纤维面料的原料为以下原料组合中的一种：
基体部分：110D聚酯海岛长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：110D锦纶海岛长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：110D聚酯海岛长丝、125D聚酯长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：110D聚酯海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：110D锦纶海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：110D聚酯海岛长丝、125D锦纶长丝和85D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：110D聚酯海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：110D锦纶海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：110D聚酯海岛长丝、110D锦纶海岛长丝和85D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：125D聚酯长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：125D锦纶长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：125D聚酯长丝、125D锦纶长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：125D聚酯长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：125D锦纶长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：125D聚酯长丝、110D锦纶海岛长丝和85D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：125D聚酯长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：125D锦纶长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：125D锦纶长丝、110D锦纶海岛长丝和85D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；
上述超细纤维面料的制造工艺具体包括如下步骤：
(1)以实施例2-1至2-18的任一组为主要原料，并加入75-100D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，克重为200-300g/m2。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上2层无纺针刺纤维，铺网机出网的速度为0.4m/min。
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为700刺/min，针板布针密度为7500针/米2，生产出厚度在0.8mm、克重为300g/m2的复合基布。
所述步骤(5)中，预缩时温度为150℃，所用时间为45min。
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为13％的水性树脂，车速6m/min，带液量125％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为16％的水性聚氨酯，车速7.5m/min，带液量125％，压力辊压力为0.5MPa。
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为55℃，1h后逐渐升温至130℃，保温4.5h，然后充分水洗，染深色时进行还原清洗。
本实施例成品米克重为：350-360g/m2，厚度为0.48mm。
实施例3
本实施例的一种超细纤维面料，超细纤维面料的原料为以下原料组合中的一种：
基体部分：150D聚酯海岛长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：150D锦纶海岛长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：150D聚酯海岛长丝、200D聚酯长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：150D聚酯海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：150D锦纶海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：150D聚酯海岛长丝、200D锦纶长丝和100D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：150D聚酯海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：150D锦纶海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：150D聚酯海岛长丝、150D锦纶海岛长丝和100D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：200D聚酯长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：200D锦纶长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：200D聚酯长丝、200D锦纶长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：200D聚酯长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：200D锦纶长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：200D聚酯长丝、150D锦纶海岛长丝和100D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：200D聚酯长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：200D锦纶长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：200D锦纶长丝、150D锦纶海岛长丝和100D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；
上述超细纤维面料的制造工艺具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入75-100D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，克重为200-300g/m2。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上3层无纺针刺纤维，铺网机出网的速度为0.5m/min。
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为900刺/min，针板布针密度为7500针/米2，生产出厚度在1.0mm、克重为350g/m2的复合基布。
所述步骤(5)中，预缩时温度为180℃，所用时间为60min。
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为17％的水性树脂，车速7m/min，带液量130％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为20％的水性聚氨酯，车速8m/min，带液量130％，压力辊压力为0.5MPa。
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为60℃，1h后逐渐升温至130℃，保温2h，然后充分水洗，染深色时进行还原清洗。
本实施例成品米克重为：420-430g/m2，厚度为0.50mm。
本发明对以上实施例的成品进行测试，测试方法和测试结果如下：
1、测试方法：
透气度测量通过ISO 9237的费雷泽方法测量透气度，测量气压为125Pa
撕裂测试的测试方法：GB/T3917舌形撕破(下降速度：500mm/min上升速度：500mm/min；初始长度：100mm；环境温度：25℃；环境湿度：65％，预定伸长：70mm，峰值幅度5N；经向撕裂68.1N，纬向撕裂53.8N)
2、测试结果
表1超细纤维面料成品测试结果表
Figure GDA0002627629850000151
由上表可知：
拉伸强度≥600N；撕裂强度≥50N；符合《聚氨酯束状超细纤维合成革》的要求。
色牢度试验的测试结果：根据GB392097，摩擦牢度，干摩4级，湿摩4级。
耐洗检验GB/T3921.31997，符合要求。
PH值中性；耐水解性的试样表面无龟裂情形，经/纬向拉伸负荷超过400N/cm；经/纬向撕裂负荷超过60N/cm；干摩擦色牢度、湿摩擦色牢度、水洗摩擦牢度、日晒色牢度达3-4级。
本发明生产过程和成品的环保性，单位产品耗能量的经济性，全过程采用无张力松弛工艺和低温开纤及染色工艺，较多应用环保型节能设备并进行工艺改进，较多采用机械物理等清洁工艺替代现有化学试剂反应工艺，即使使用化学工艺也尽量考虑到生产全过程的绿色清洁，基本没有生产对环境有影响的副产品，坯布边角料循环利用，磨余毛料实现再利用，产生的三废量小且均能达标排放。
本发明成品厚度在0.5mm以下，且具有克重大、密度高、仿真皮性高、无气味等优点，因此本发明可应用到汽车内饰、高档服饰、家具装饰等领域。
以上内容是结合本发明的优选实施方式对所提供技术方案所作的进一步详细说明，不能认定本发明具体实施只局限于上述这些说明，对于本发明所属技术领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干简单推演或替换，都应当视为属于本发明的保护范围。

Claims (10)

1.一种超细纤维面料的制造工艺，以定岛型海岛长丝或/和普通长丝为主要原料，并加入涤纶高强丝，通过纬编工艺织成坯布，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料，其特征在于，具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入涤纶高强丝，通过纬编工艺织成坯布；控制线圈高度在0.2-0.3cm之间，坯布重量克重200-300g/m2，门幅为170-200cm；
(2)将步骤(1)所得的坯布进行拉毛；所述坯布经24辊强力拉毛机拉毛4次，将毛彻底拉出来，使绒毛长度在0.5-2.5cm；
(3)铺网：经成网机在步骤(2)拉毛后的制品上均匀铺上1至3层无纺针刺纤维，每层克重为10-20g，铺网机出网的速度为0.3-0.5m/min；
(4)络合：对步骤(3)铺网后的制品进行针刺，经针刺机针刺4次以上，经无纺针刺纤维缠结得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率控制在500-900刺/min，针板布针密度为7500针/米2，生产出厚度在0.45-1.0mm、克重为250-350g/m2，门幅为170-200cm的复合基布；
(5)预缩：将步骤(4)所制得的复合基布进行机缸预缩，进一步提高面料密度，预缩时温度为130℃-180℃，所用时间为30-60min；
(6)烘干定型：将步骤(5)制得的复合基布放到定型机机芯烘干切边控制门幅，烘干温度在110-130℃，烘干时根据坯布密度，调节温度和车速，以坯布里外烘干烘透为合适；
(7)含浸：在树脂与水性聚氨酯的混合液中对步骤(6)制得的复合基布分别进行含浸处理，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度在10％-17％的水性树脂，车速5-7m/min，以带液量120％-130％，调节压力辊压力为0.5MPa，使复合基布的水性树脂的增重量为10％±2％；所述第二次含浸：浸液浓度在12％-20％的水性聚氨酯，车速7-8m/min，以带液量120％-130％调节压力辊压力为0.5MPa，使复合基布的水性聚氨酯的增重量为8％±2％；
(8)对步骤(7)含浸后的复合基布进行碱减量开纤，碱液浓度为5％，升温为5℃/min，高温区温度为96-110℃，所用时间为45-60min，开纤率18％-25％；进行中和处理时，采用柠檬酸进行，并将pH值调节到6-7，出缸后采用连续化逆流式水洗；
(9)烘干定型：将步骤(8)碱减量开纤后的复合基布进行烘干和定型，以便于磨毛；
(10)将步骤(9)烘干定型后的复合基布进行第一次磨毛；
(11)染色：将步骤(10)制得的复合基布缝头后，进缸染色、还原清洗、脱水、定型，初染色时，将分散染料的始染温度控制在50～60℃，1h后逐渐升温至130℃，保温1～2h，然后充分水洗，染深色时进行还原清洗；
(12)将步骤(11)染色后的复合基布进行烘干定型，定型时控制上述基布温度为100℃-170℃，车速调至5-30米/分，车速为30-60米/分；
(13)将步骤(12)制得的复合基布进行第二次磨毛；
(14)将步骤(13)制得的复合基布进行烘干定型，根据产品需求进行定型；
(15)检验、打卷、入库。
2.根据权利要求1所述的超细纤维面料的制造工艺，其特征在于，所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上1层无纺针刺纤维，铺网机出网的速度为0.3m/min；
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为500刺/min，针板布针密度为7500针/米2，生产出厚度为0.6mm、克重为250g/m2的复合基布；
所述步骤(5)中，预缩时温度为130℃，所用时间为30min；
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为10％的水性树脂，车速5m/min，带液量120％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为12％的水性聚氨酯，车速7m/min，带液量120％，压力辊压力为0.5MPa；
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为50℃，1h后逐渐升温至130℃，保温1h，然后充分水洗，染深色时进行还原清洗。
3.根据权利要求1所述的超细纤维面料的制造工艺，其特征在于，所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上3层无纺针刺纤维，铺网机出网的速度为0.5m/min；
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为900刺/min，针板布针密度为7500针/米2，生产出厚度在1.0mm、克重为350g/m2的复合基布；
所述步骤(5)中，预缩时温度为180℃，所用时间为60min；
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为17％的水性树脂，车速7m/min，带液量130％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为20％的水性聚氨酯，车速8m/min，带液量130％，压力辊压力为0.5MPa；
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为60℃，1h后逐渐升温至130℃，保温2h，然后充分水洗，染深色时进行还原清洗。
4.一种采用权利要求1-3任一项所述制造工艺所制得的超细纤维面料，其特征在于：包括基体部分和表面部分，所述基体部分包括定岛型海岛长丝或/和普通长丝，所述表面部分由短纤维构成，所述面料为经过拉毛处理的基体部分和表面部分相互络合的无纺结构。
5.如权利要求4所述的超细纤维面料，其特征在于：所述基体部分还包括涤纶高强丝，其涤纶高强丝的纤度为75-100D。
6.如权利要求4所述的超细纤维面料，其特征在于：所述定岛型海岛长丝为聚酯海岛长丝或/和锦纶海岛长丝，纤度为75-150D。
7.如权利要求4所述的超细纤维面料，其特征在于：所述普通长丝为聚酯长丝或/和锦纶长丝，纤度为50D-200D。
8.如权利要求4所述的超细纤维面料，其特征在于：所述短纤维为聚酯海岛短纤或/和锦纶海岛短纤。
9.如权利要求4所述的超细纤维面料，其特征在于：所述超细纤维面料的成品厚度在0.5mm以下。
10.一种超细纤维面料的制造工艺，以定岛型海岛长丝或/和普通长丝为主要原料，并加入涤纶高强丝，通过纬编工艺织成坯布，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料，其特征在于，具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入涤纶高强丝，通过纬编工艺织成坯布；控制线圈高度在0.2-0.3cm之间，坯布重量克重200-300g/m2，门幅为170-200cm；
(2)将步骤(1)所得的坯布进行拉毛；所述坯布经24辊强力拉毛机拉毛4次，将毛彻底拉出来，使绒毛长度在0.5-2.5cm；
(3)铺网：经成网机在步骤(2)拉毛后的制品上均匀铺上2层无纺针刺纤维，每层克重为10-20g，铺网机出网的速度为0.4m/min；
(4)络合：对步骤(3)铺网后的制品进行针刺，经针刺机针刺4次以上，经无纺针刺纤维缠结得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为700刺/min，针板布针密度为7500针/米2，生产出厚度在0.8mm、克重为300g/m2，门幅为170-200cm的复合基布；
(5)预缩：将步骤(4)所制得的复合基布进行机缸预缩，进一步提高面料密度，预缩时温度为150℃，所用时间为45min；
(6)烘干定型：将步骤(5)制得的复合基布放到定型机机芯烘干切边控制门幅，烘干温度在110-130℃，烘干时根据坯布密度，调节温度和车速，以坯布里外烘干烘透为合适；
(7)含浸：在树脂与水性聚氨酯的混合液中对步骤(6)制得的复合基布分别进行含浸处理，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度在13％的水性树脂，车速6m/min，以带液量125％，调节压力辊压力为0.5MPa，使复合基布的水性树脂的增重量为10％±2％；所述第二次含浸：浸液浓度在16％的水性聚氨酯，车速7.5m/min，以带液量125％调节压力辊压力为0.5MPa，使复合基布的水性聚氨酯的增重量为8％±2％；
(8)对步骤(7)含浸后的复合基布进行碱减量开纤，碱液浓度为5％，升温为5℃/min，高温区温度为96-110℃，所用时间为45-60min，开纤率18％-25％；进行中和处理时，采用柠檬酸进行，并将pH值调节到6-7，出缸后采用连续化逆流式水洗；
(9)烘干定型：将步骤(8)碱减量开纤后的复合基布进行烘干和定型，以便于磨毛；
(10)将步骤(9)烘干定型后的复合基布进行第一次磨毛；
(11)染色：将步骤(10)制得的复合基布缝头后，进缸染色、还原清洗、脱水、定型，初染色时，将分散染料的始染温度控制在55℃，1h后逐渐升温至130℃，保温4.5h，然后充分水洗，染深色时进行还原清洗；
(12)将步骤(11)染色后的复合基布进行烘干定型，定型时控制上述基布温度为100℃-170℃，车速调至5-30米/分，车速为30-60米/分；
(13)将步骤(12)制得的复合基布进行第二次磨毛；
(14)将步骤(13)制得的复合基布进行烘干定型，根据产品需求进行定型；
(15)检验、打卷、入库。
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