CN109736021B - 一种水刺无纺布及其制备方法 - Google Patents
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Abstract
本发明保护一种水刺无纺布及其制备方法，特别地，所述水刺无纺布的主要组成成分包括：天然骨架纤维、合成纤维、合成助剂，所述天然骨架纤维选自下述纤维：苎麻落麻纤维、剑麻落麻纤维、木棉纤维；所述合成纤维选自聚对苯二甲酸‑1,3‑丙二醇酯、聚丙纶；所述合成助剂选自海藻酸钙、氧化铝，本发明提供的水刺无纺布可以有效抑制细菌、真菌生长；纤维损伤率低于0.5‰，有效解决纤维掉毛问题，触感柔软，接近纯棉布，并且耐撕扯，可机洗。
Description
技术领域
本发明涉及织物领域，特别地涉及一种水刺无纺布及其制备方法。
背景技术
无纺布(Non Woven Fabric,Nonwoven cloth)，又称不织布，是通过一定技术生产出的由定向的或随机的纤维而构成的新一代环保材料，因具有布的外观和性能而称其为布。水刺无纺布是将高压微细水流喷射到一层或多层纤维网上，使纤维相互缠结在一起形成加固并具备一定形状的织物，这种织物也被成为水刺无纺布。
水刺无纺布在生产、生活中均具备多种用途，包括但不限于医疗、卫生用无纺布，庭装饰用无纺布，服装用无纺布，工业用无纺布，农业用无纺布，其他用途等。生产无纺布的纤维原料来源广泛，包括但不限于涤纶、锦纶、丙纶、粘胶纤维、甲壳素纤维、超细纤维、天丝、蚕丝、竹纤维、木浆纤维、海藻纤维等。
水刺无纺布存在下述缺点：强度和耐久性较差；纤维按一定方向排列，容易从直角方向裂开，为解决上述技术问题，本发明提供一种水刺无纺布及其制备方法。
发明内容
为了解决上述技术问题，本发明提供一种水刺无纺布及其制备方法。
本发明是以如下技术方案实现的：
一种水刺无纺布，所述水刺无纺布的主要组成成分包括：天然骨架纤维、合成纤维、合成助剂。
进一步地，所述天然骨架纤维选自下述纤维：苎麻落麻纤维、剑麻落麻纤维、木棉纤维；所述合成纤维选自聚对苯二甲酸-1,3-丙二醇酯、聚丙纶；所述合成助剂选自海藻酸钙、氧化铝。
进一步地，所述苎麻落麻纤维为苎麻纤维在长麻纺梳理过程中产生的落麻，苎麻落麻纤维长度约为25-35mm，细度为3.8dtex；所述剑麻落麻纤维为剑麻纤维在纺织梳理过程中产生的落麻，剑麻落麻纤维长度约为18-22mm，细度为3.5dtex。
进一步地，所述水刺无纺布的主要组成成分按质量百分比具体地包括：50％苎麻落麻纤维、20％剑麻落麻纤维、13％木棉纤维、10％聚对苯二甲酸-1,3-丙二醇酯、3％聚丙纶、2％海藻酸钙、2％氧化铝。
进一步地，所述水刺无纺布的制备方法包括：步骤一、原材料准备，步骤二、制备纤维层：将准备好的纤维原料、浸泡于软化整理剂中，室温下放置24h，之后分别进行开松、除杂，使纤维包中压紧的纤维块被机械打击、撕扯松解成短纤维束，将已开松的纤维喂入纤维仓，使不同性能的纤维充分混合后，将混合后的纤维制成均匀的纤网，进入梳理工序，步骤三、梳理工序采用两梳一铺生产线，由一台梳理机输出的纤网首先喂给交叉铺网机进行铺网，紧接着由牵引机对铺叠后的纤网进行牵伸，再与另一台梳理机输出的纤网叠加成为双层纤网后送至水刺机，步骤四、由步骤三获得的双层纤网经过预湿后进行正反水刺，水刺液中溶解有合成助剂，预湿水压为1bar，水刺压力分别为35bar，控制喷射的时间为0.5-0.8min，生产线速度为31.2米/分，之后100℃烘干获得预处理纤网；步骤五、步骤四获得的预处理纤网经抗菌溶剂射流缠结，具体地，将预处理纤网送入水刺机，水刺溶液采用新型抗菌整理液，预湿水压为0.5bar，水刺压力为25bar，控制喷射的时间为5-10min，生产线速度为10米/分，之后120℃烘干获得最终产品水刺无纺布。
进一步地，所述水刺无纺布厚度为0.65mm。
本发明的有益效果在于：水刺无纺布的纵向断裂强度≥216N，横向断裂强度≥263N，纵向断裂伸长率≥38％，横向断裂伸长率≥32％，耐撕扯性能接近纯棉布；本发明水刺无纺布吸水倍数达65-73倍，透气性高达805-834CFM，不会闷气，舒适度高，平均抑制率高达95％以上，可以有效抑制细菌、真菌生长；纤维损伤率低于0.5‰，有效解决纤维掉毛问题，触感柔软，接近纯棉布，并且耐撕扯，可机洗。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚，下面将对本发明作进一步地详细描述。下述实施例中所使用的试验方法如无特殊说明，均为常规方法；所使用的设备、原料、试剂等，如无特殊说明，均为可从常规商业途径购买得到的设备、原料、试剂。
实施例1：
所述水刺无纺布的主要组成成分包括：天然骨架纤维、合成纤维、合成助剂。所述天然骨架纤维主要选自下述纤维：苎麻落麻纤维、剑麻落麻纤维、木棉纤维；所述合成纤维主要选自聚对苯二甲酸-1,3-丙二醇酯、聚丙纶；所述合成助剂选自海藻酸钙、氧化铝。
所述苎麻落麻纤维为苎麻纤维在长麻纺梳理过程中产生的落麻，具体地包括苎麻纺纱新工艺精梳机和老工艺两道圆梳机在纺织过程中梳理下的落麻，苎麻落麻纤维长度约为25-35mm，细度为3.8dtex；所述剑麻落麻纤维为剑麻纤维在纺织梳理过程中产生的落麻，剑麻落麻纤维长度约为18-22mm，细度为3.5dtex。
组分1：所述成分按质量百分比具体地包括：66％苎麻落麻纤维、10％剑麻落麻纤维、10％木棉纤维、7％聚对苯二甲酸-1,3-丙二醇酯、3％聚丙纶、2％海藻酸钙、2％氧化铝。
组分2：所述成分按质量百分比具体地包括：50％苎麻落麻纤维、20％剑麻落麻纤维、13％木棉纤维、10％聚对苯二甲酸-1,3-丙二醇酯、3％聚丙纶、2％海藻酸钙、2％氧化铝。
组分3：所述成分按质量百分比具体地包括：45％苎麻落麻纤维、25％剑麻落麻纤维、10％木棉纤维、10％聚对苯二甲酸-1,3-丙二醇酯、5％聚丙纶、5％氧化铝。
组分4：所述成分按质量百分比具体地包括：80％苎麻落麻纤维、20％木棉纤维、3％聚对苯二甲酸-1,3-丙二醇酯、3％聚丙纶、2％海藻酸钙、2％氧化铝。
组分5：所述成分按质量百分比具体地包括：30％木棉纤维、20％粘纤、20％聚对苯二甲酸-1,3-丙二醇酯、20％聚丙纶、5％海藻酸钙、5％氧化铝。
实施例2
软化整理剂的制备：软化整理剂按质量分数包括85％粘合剂、1.5％亲水型有机硅柔软剂％、3.5％渗透剂，所述粘合剂为甲基丙烯酸缩水甘油酯、丙烯酸-2-乙基乙酯、甲基丙烯酸甲酯和丙烯酸组成的共聚乳液，共聚所用交联剂选用环氧丙烯酸酯。
新型抗菌整理液的制备：将摩尔量为0.2的3-(3’-丙烯酸丙酯)-5,5-二甲基海因与等摩尔量的三甲胺加入至100mL四氢呋喃中，将混合物搅拌10分钟至溶质溶解，获得第一混合溶液；冷却至4℃后，逐滴加入摩尔量为0.1的丙烯酰氯，搅拌后将混合溶液放置于室温下一天获得第二混合溶液，将所述第二溶液以6.58％的浓度溶于丙酮溶液获得所述新型抗菌整理液。
实施例3：
步骤一、原材料准备
参照实施例1所述无纺布的原料配方称量好组分1、组分2、组分3、组分4、组分5各组分原料。
步骤二、制备纤维层
将准备好的纤维原料(包括天然骨架纤维和/或合成纤维)浸泡于实施例2所述软化整理剂中，室温下放置24h，之后分别进行开松、除杂，使纤维包中压紧的纤维块被机械打击、撕扯松解成短纤维束，将已开松的纤维喂入纤维仓，使不同性能的纤维充分混合后，将混合后的纤维制成均匀的纤网，进入梳理工序。
步骤三、梳理工序采用两梳一铺生产线，由一台梳理机输出的纤网首先喂给交叉铺网机进行铺网，紧接着由牵引机对铺叠后的纤网进行牵伸，再与另一台梳理机输出的纤网叠加成为双层纤网后送至水刺机。
步骤四、由步骤三获得的双层纤网经过预湿后进行正反水刺，制备不同组分水刺无纺布过程中，水刺液不同，水刺液中分别对应的溶解有组分1、组分2、组分3、组分4、组分5中的合成助剂，预湿水压为1bar，组分1、组分2、组分3、组分4、组分5的水刺压力分别为45bar、35bar、72bar、60bar、95bar，控制喷射的时间为0.5-0.8min，生产线速度为31.2米/分，之后100℃烘干获得预处理纤网。
步骤五、步骤四获得的预处理纤网经抗菌溶剂射流缠结(原材料为组分3的预处理纤网除外)。具体地，将预处理纤网送入水刺机，水刺溶液采用新型抗菌整理液，预湿水压为0.5bar，水刺压力为25bar，控制喷射的时间为5-10min，生产线速度为10米/分，之后120℃烘干获得最终产品水刺无纺布，厚度为0.65mm，烘干至含水量为5％以下，上述射流装置工作时，用密封罩密封，密封罩内通入氮气，密封罩上部设有引风系统，可以随时抽出挥发的有机溶剂。
实施例4：
采用美国AATCC100-1996标准，抑菌率计算按照下述公式：抑菌率＝(空白对照活菌数-水刺无纺布活菌数)/空白对照样活菌数，其中空白对照选用纯棉布，经计算得到本发明的无纺材料的抑菌效果如表1所示，测试菌种选取金黄色葡萄球菌、大肠杆菌、白色念珠菌、青霉菌。
表1.抑菌效果检测
由表1可知，组分2的抗菌效果最佳，对细菌、霉菌均有抗菌作用，这是基于苎麻材料、剑麻材料经过整理后产生了较强的抗菌作用，叠加新型抗菌整理液的抗菌效果，使面料的具备极强的同时抗细菌、抗真菌效果；未经过新型抗菌整理液处理的组分3具备较弱的抗细菌效果，但基本没有抗真菌效果；不含有苎麻材料、剑麻材料的组分5，抗真菌效果显著低于含有上述成分的组分。
按FZ/T 60005-91规定进行检测纵向断裂强度、横向断裂强度、纵向断裂伸长率、横向断裂伸长率，按GB/T 9995-1997规定进行检测回潮率，结果如表2所示。
表2、性能检测
| 菌种 | 组分1 | 组分2 | 组分3 | 组分4 | 组分5 | 空白对照 |
| 纵向断裂强度 | ≥207N | ≥216N | ≥202N | ≥267N | ≥112N | ≥295N |
| 横向断裂强度 | ≥287N | ≥263N | ≥255N | ≥387N | ≥97N | ≥428N |
| 纵向断裂伸长率 | ≥28％ | ≥38％ | ≥25％ | ≥16％ | ≥23N | ≥45％ |
| 横向断裂伸长率 | ≥35％ | ≥32％ | ≥29％ | ≥21％ | ≥26N | ≥37％ |
由表2结果可知，组分2的水刺无纺布的纵向断裂强度≥216N，横向断裂强度≥263N，纵向断裂伸长率≥38％，横向断裂伸长率≥32％，可见组分2的水刺无纺布耐撕扯性能接近纯棉布；不含有苎麻材料、剑麻材料的组分5不耐撕扯，苎麻材料、剑麻材料含量较高的组分4耐撕扯但是柔软度较差，综合表1、表2结果，组分2的水刺无纺布性能最优、抗菌效果最强。
本发明组分2的水刺无纺布吸水倍数达65-73倍，透气性高达805-834CFM，不会闷气，舒适度高，平均抑制率高达95％以上，可以有效抑制细菌、真菌生长；纤维损伤率低于0.5‰，有效解决纤维掉毛问题，触感柔软，接近纯棉布，并且耐撕扯，可机洗。
以上所揭露的仅为本发明较佳实施例而已，当然不能以此来限定本发明之权利范围，因此依本发明权利要求所作的等同变化，仍属本发明所涵盖的范围。
Claims (3)
1.一种水刺无纺布，其特征在于，所述水刺无纺布的主要组成成分按质量百分比具体为50%苎麻落麻纤维、20%剑麻落麻纤维、13%木棉纤维、10%聚对苯二甲酸-1,3-丙二醇酯、3%聚丙纶、2%海藻酸钙、2%氧化铝，所述苎麻落麻纤维为苎麻纤维在长麻纺梳理过程中产生的落麻，苎麻落麻纤维长度为25-35mm，细度为3.8 dtex；所述剑麻落麻纤维为剑麻纤维在纺织梳理过程中产生的落麻，剑麻落麻纤维长度为18-22mm，细度为3.5 dtex，所述水刺无纺布对细菌、霉菌均有抗菌作用，所述对于细菌、霉菌的抗菌作用源自抗菌整理液对苎麻落麻纤维、麻落麻纤维、木棉纤维的抗菌整理，所述抗菌整理液的制备方法为将摩尔量为0.2的3-(3’-丙烯酸丙酯)-5,5-二甲基海因与等摩尔量的三甲胺加入至100 mL四氢呋喃中，将混合物搅拌10分钟至溶质溶解，获得第一混合溶液；冷却至4℃后，逐滴加入摩尔量为0.1的丙烯酰氯，搅拌后将混合溶液放置于室温下一天获得第二混合溶液，将所述第二混合溶液以6.58%的浓度溶于丙酮溶液获得所述抗菌整理液。
2.根据权利要求1所述的水刺无纺布，其特征在于，所述水刺无纺布的制备方法包括：步骤一、原材料准备，步骤二、制备纤维层：将准备好的纤维原料、浸泡于软化整理剂中，室温下放置24h，之后分别进行开松、除杂，使纤维包中压紧的纤维块被机械打击、撕扯松解成短纤维束，将已开松的纤维喂入纤维仓，使不同性能的纤维充分混合后，将混合后的纤维制成均匀的纤网，进入梳理工序，步骤三、梳理工序采用两梳一铺生产线，由一台梳理机输出的纤网首先喂给交叉铺网机进行铺网，紧接着由牵引机对铺叠后的纤网进行牵伸，再与另一台梳理机输出的纤网叠加成为双层纤网后送至水刺机，步骤四、由步骤三获得的双层纤网经过预湿后进行正反水刺，水刺液中溶解有合成助剂，预湿水压为1bar，水刺压力分别为35bar，控制喷射的时间为0.5-0.8min，生产线速度为31.2米/分，之后100℃烘干获得预处理纤网；步骤五、步骤四获得的预处理纤网经抗菌溶剂射流缠结，具体地，将预处理纤网送入水刺机，水刺溶液采用抗菌整理液，预湿水压为0.5bar，水刺压力为25bar，控制喷射的时间为5-10min，生产线速度为10米/分，之后120℃烘干获得最终产品水刺无纺布。
3.根据权利要求1所述的水刺无纺布，其特征在于，所述水刺无纺布厚度为0.65 mm。
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