CN109629242A - 一种水刺无纺布壁纸的制造方法 - Google Patents
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Abstract
本发明公开了一种水刺无纺布壁纸的制造方法,包括如下步骤:1)水刺工艺:以聚酯纤维长丝和聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布;(2)后整理阶段:使用浸轧工艺,将经步骤(1)后的水刺无纺布浸透含水性丙烯乳酸液的浸轧液;(3)表面涂层处理:将打底介质涂覆至经步骤(2)后的水刺无纺布,使用105目圆网上浆,通过烤箱烤干;再涂覆盖面介质,用125目圆网上浆,通过烤箱烤干后收卷,制成仿“羊绒布”成品;该方法制造的水刺无纺布受热形变小、强度高,拉伸形变小、遮盖性强、白度一致、防水效果好、纤维表面平整,是壁纸的理想材料。
Description
技术领域
本发明涉及壁纸材料,具体涉及一种水刺无纺布壁纸的制造方法。
背景技术
水刺无纺布以高分子纤维为原料,通过对纤维的开松、混合、梳理,形成一定厚度的纤网层,再喷射多股高压微细水射流至纤网层,水射流穿过纤网层后受到网帘的反弹,再次穿插纤网层。纤网层中的纤维在不同方向高压水射流的作用下,产生位移、穿插、缠结和抱合,从而使纤网得以加固而具备一定强度,最后经过后整理形成的无编织的布料。
与传统无纺纸壁纸相比,水刺无纺布容易降解,并且水刺工艺仅需要高压水射流,无需化工处理,高压用水可循环使用,所以水刺无纺布具有质量轻、防水、透气、无毒、无刺激性、抗菌、抗化学药剂、环保等优点,是做壁纸的理想材料。
但是与此同时,与无纺纸相比,水刺无纺布存在以下几个缺点:
1.与无纺纸相比强度较差,容易变形。
2.同样的厚度下克重较轻,密度小,遮盖性不够,若墙面有斑点或图案会透过水刺无纺布。
3.表面纤维蓬松,不利于壁纸图案印刷。
因此,使用无纺布作壁纸时,需要解决上述缺点。
发明内容
本发明的目的在于提供一种水刺无纺布壁纸的制造方法,通过水刺工艺,后整理阶段和表面涂层处理三个步骤制造受热形变小、高遮盖性、防水效果好、纤维表面平整的水刺无纺布壁纸。
为了解决上述技术问题,本发明采用以下技术方案:
一种水刺无纺布壁纸的制造方法,其特征在于,包括如下步骤:
(1)水刺工艺:以聚酯纤维长丝和聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布;
(2)后整理阶段:使用浸轧工艺,将经步骤(1)后的水刺无纺布浸透浸轧液,浸轧液按重量份数包括以下成分:水性丙烯乳酸液15~25份,高岭土5~15份,钛白粉10~20份,分散剂0.5~2份,消泡剂0.1~1份,防霉剂0.1~1份,防水剂2~5份,水40~60份;
(3)表面涂层处理:将打底介质涂覆至经步骤(2)后的水刺无纺布,使用105目圆网上浆,通过烤箱烤干;再涂覆盖面介质,用125目圆网上浆,通过烤箱烤干后收卷,制成仿“羊绒布”成品。
进一步,步骤(1)水刺工艺中,增加长丝的比例,增加水刺的压力,从而使纤维产生的位移、穿插、缠结和抱合更多更紧密,使水刺无纺布的强度的得到加强。
进一步,步骤(1)水刺工艺中,原料包括25~35重量%的聚酯纤维长丝和60~80重量%的聚酯纤维短丝,水刺压力为27~30bar。
进一步,步骤(2)浸轧工艺中,无纺布从浸扎液储存槽内通过,无纺布浸透并带动浸轧液运动,减少高岭土和钛白粉在浸轧液沉底,使水刺无纺布白度一致,遮盖性好。
进一步,步骤(3)中,打底介质按重量份数包括以下成分:水性丙烯酸乳液10~20份,水60~75份,透明粉3~10份,消泡剂0.1~1份,防霉剂0.1~1份,增稠剂5~10份;盖面介质按重量份数包括以下成分:水性丙烯酸乳液5~15份,水75~85份,消泡剂0.1~1份,防霉剂0.1~1份,增稠剂5~10份。
进一步,分散剂为聚丙烯酸钠盐,防水剂为含氟防水剂。
进一步,消泡剂为聚醚有机硅乳液,防霉剂为复合广谱杀菌剂。
进一步,透明粉为结晶硅铝氧化物,透明粉可以填充纤维之间的空隙,使无纺布表面变的更平整,但不影响纤维的外观效果;增稠剂为聚氨酯类缔合物,增稠剂的使用让打底介质粘度达到生产的要求。
进一步,步骤(3)中,打底介质粘度为1500~1800mPa.s;盖面介质粘度为1200~1500mPa.s。
进一步,步骤(3)中涂覆打底介质后的水刺无纺布和涂覆盖面介质的水刺无纺布均经过温度150~160℃,生产速度12m/min,长度为3米的烤箱烤干。
由于采用上述技术方案,具有以下有益效果:
1.由于壁纸需要经加热印刷图案,本发明通过改进水刺工艺和浸轧工艺,使制成的水刺无纺布壁纸受热收缩率小,强度高,拉伸形变小,符合壁纸使用要求;
2.浸轧工艺中水刺无纺布均匀浸轧,水刺无纺布遮盖性强,白度一致,防水效果佳。
3.表面涂层处理后的水刺无纺布表面纤维平整,有利于后续壁纸的加热印刷。
具体实施方式
下面通过实施例对本发明作进一步说明。
实施例1
以30重量%聚酯纤维长丝和70重量%聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布,水刺压力为28bar。将制成的水刺无纺布浸透浸轧液,浸轧液按重量份数包括以下成分:水性丙烯乳酸液20份,高岭土10份,钛白粉15份,分散剂1份,消泡剂0.5份,防霉剂0.5份,防水剂3.5份,水49.5份。将浸轧后的水刺无纺布进行表面涂层处理,进一步定型。先使用打底介质通过105目园网给水刺无纺布上浆一次,打底介质按重量份数包括以下成分:水性丙烯酸乳液15份,水70份,透明粉5份,消泡剂0.5份,防霉剂0.5份,增稠剂7份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后进行下一步。使用盖面介质通过125目园网上浆一次,盖面介质按重量份数包括以下成分:水性丙烯酸乳液10份,水80份,消泡剂0.5份,防霉剂0.5份,增稠剂9份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后收卷,即为成品仿“羊绒布”产品,其性能如表1所示。
实施例2
以25重量%聚酯纤维长丝和75重量%聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布,水刺压力为27bar。将制成的水刺无纺布浸透浸轧液,浸轧液按重量份数包括以下成分:水性丙烯乳酸液15份,高岭土5份,钛白粉10份,分散剂0.5份,消泡剂0.2份,防霉剂0.2份,防水剂2份,水60份。将浸轧后的水刺无纺布进行表面涂层处理,进一步定型。先使用打底介质通过105目园网给水刺无纺布上浆一次,打底介质按重量份数包括以下成分:水性丙烯酸乳液10份,水75份,透明粉3份,消泡剂0.2份,防霉剂0.2份,增稠剂5份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后进行下一步。使用盖面介质通过125目园网上浆一次,盖面介质按重量份数包括以下成分:水性丙烯酸乳液5份,水85份,消泡剂0.2份,防霉剂0.2份,增稠剂5份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后收卷,即为成品仿“羊绒布”产品,其性能如表1所示。
实施例3
以35重量%聚酯纤维长丝和65重量%聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布,水刺压力为30bar。将制成的水刺无纺布浸透浸轧液,浸轧液按重量份数包括以下成分:水性丙烯乳酸液25份,高岭土15份,钛白粉20份,分散剂2份,消泡剂1份,防霉剂1份,防水剂5份,水40份。将浸轧后的水刺无纺布进行表面涂层处理,进一步定型。先使用打底介质通过105目园网给水刺无纺布上浆一次,打底介质按重量份数包括以下成分:水性丙烯酸乳液20份,水60份,透明粉10份,消泡剂1份,防霉剂1份,增稠剂10份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后进行下一步。使用盖面介质通过125目园网上浆一次,盖面介质按重量份数包括以下成分:水性丙烯酸乳液15份,水75份,消泡剂1份,防霉剂1份,增稠剂10份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后收卷,即为成品仿“羊绒布”产品,其性能如表1所示。
对比例1
以20重量%聚酯纤维长丝和80重量%聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布,水刺压力为25bar。将水刺无纺布进行表面涂层处理,进一步定型。先使用打底介质通过105目园网给水刺无纺布上浆一次步,打底介质按重量份数包括以下成分:水性丙烯酸乳液15份,水70份,透明粉5份,消泡剂0.5份,防霉剂0.5份,增稠剂7份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后进行下一。使用盖面介质通过125目园网上浆一次,盖面介质按重量份数包括以下成分:水性丙烯酸乳液10份,水80份,消泡剂0.5份,防霉剂0.5份,增稠剂9份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后收卷,即为成品仿“羊绒布”产品,其性能如表1所示。
对比例2
以20重量%聚酯纤维长丝和80重量%聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布,水刺压力为25bar。将制成的水刺无纺布浸透浸轧液,浸轧液按重量份数包括以下成分:水性丙烯乳酸液40份,高岭土10份,钛白粉15份,分散剂1份,消泡剂0.5份,防霉剂0.5份,防水剂1份,水40份。将浸轧后的水刺无纺布进行表面涂层处理,进一步定型。先使用打底介质通过105目园网给水刺无纺布上浆一次,打底介质按重量份数包括以下成分:水性丙烯酸乳液15份,水70份,透明粉5份,消泡剂0.5份,防霉剂0.5份,增稠剂7份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后进行下一步。使用盖面介质通过125目园网上浆一次,盖面介质按重量份数包括以下成分:水性丙烯酸乳液10份,水80份,消泡剂0.5份,防霉剂0.5份,增稠剂9份,通过温度150-160,生产速度12米每分钟,长度为3米的烤箱烤干后收卷,即为成品仿“羊绒布”产品,其性能如表1所示。
表1:实施例1-3和对比例1-2制成的水刺无纺布性能。
通过表1可知聚酯纤维长丝比例越大,水刺压力越高,制成的水刺无纺布受热收缩率越小。浸轧工艺可有效地固定水刺无纺布纤维的位置,从而减小受热收缩。但是浸轧液中的水性丙烯酸乳液越多,水刺无纺布硬度越大,容易造成收卷布面打折,产生废品。高岭土和钛白粉可提高水刺无纺布的遮盖性和白度。
以上仅为本发明的具体实施例,但本发明的技术特征并不局限于此。任何以本发明为基础,为解决基本相同的技术问题,实现基本相同的技术效果,所作出地简单变化、等同替换或者修饰等,皆涵盖于本发明的保护范围之中。
Claims (10)
1.一种水刺无纺布壁纸的制造方法,其特征在于,包括如下步骤:
(1)水刺工艺:以聚酯纤维长丝和聚酯纤维短丝为原料,通过水刺工艺制成水刺无纺布;
(2)后整理阶段:使用浸轧工艺,将经步骤(1)后的水刺无纺布浸透浸轧液,浸轧液按重量份数包括以下成分:水性丙烯乳酸液15~25份,高岭土5~15份,钛白粉10~20份,分散剂0.5~2份,消泡剂0.1~1份,防霉剂0.1~1份,防水剂2~5份,水40~60份;
(3)表面涂层处理:将打底介质涂覆至经步骤(2)后的水刺无纺布,使用105目圆网上浆,通过烤箱烤干;再涂覆盖面介质,用125目圆网上浆,通过烤箱烤干后收卷,制成仿“羊绒布”成品。
2.根据权利要求1所述的一种水刺无纺布壁纸的制造方法,其特征在于:步骤(1)水刺工艺中,增加长丝的比例,增加水刺的压力。
3.根据权利要求2所述的一种水刺无纺布壁纸的制造方法,其特征在于:步骤(1)水刺工艺中,所述原料包括25~35重量%的聚酯纤维长丝和60~80重量%的聚酯纤维短丝,水刺压力为27~30bar。
4.根据权利要求1所述的一种水刺无纺布壁纸的制造方法,其特征在于:步骤(2)浸轧工艺中,无纺布从浸扎液储存槽内通过,无纺布浸透并带动浸轧液运动,减少浸轧液沉底。
5.根据权利要求1所述的一种水刺无纺布壁纸的制造方法,其特征在于:步骤(3)中,所述打底介质按重量份数包括以下成分:水性丙烯酸乳液10~20份,水60~75份,透明粉3~10份,消泡剂0.1~1份,防霉剂0.1~1份,增稠剂5~10份;所述盖面介质按重量份数包括以下成分:水性丙烯酸乳液5~15份,水75~85份,消泡剂0.1~1份,防霉剂0.1~1份,增稠剂5~10份。
6.根据权利要求1所述的一种水刺无纺布壁纸的制造方法,其特征在于:所述分散剂为聚丙烯酸钠盐,所述防水剂为含氟防水剂。
7.根据权利要求1或5所述的一种水刺无纺布壁纸的制造方法,其特征在于:所述消泡剂为聚醚有机硅乳液,所述防霉剂为复合广谱杀菌剂。
8.根据权利要求5所述的一种水刺无纺布壁纸的制造方法,其特征在于:所述透明粉为结晶硅铝氧化物,所述增稠剂为聚氨酯类缔合物。
9.根据权利要求1所述的一种水刺无纺布壁纸的制造方法,其特征在于:所述步骤(3)中,所述打底介质粘度为1500~1800mPa.s;所述盖面介质粘度为1200~1500mPa.s。
10.根据权利要求1所述的一种水刺无纺布壁纸的制造方法,其特征在于:所述步骤(3)中涂覆打底介质后的水刺无纺布和涂覆盖面介质的水刺无纺布均经过温度150~160℃,生产速度12m/min,长度为3米的烤箱烤干。
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