CN110385900A - 一种抗菌复合面料及其制造工艺 - Google Patents

一种抗菌复合面料及其制造工艺 Download PDF

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CN110385900A
CN110385900A CN201910667102.1A CN201910667102A CN110385900A CN 110385900 A CN110385900 A CN 110385900A CN 201910667102 A CN201910667102 A CN 201910667102A CN 110385900 A CN110385900 A CN 110385900A
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precoat
fire
antibacterial
retardant
epoxy resin
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贾正虎
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Kunshan Jumei New Technology Composite Fabric Co Ltd
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Kunshan Jumei New Technology Composite Fabric Co Ltd
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Abstract

本发明公开了一种抗菌复合面料，涉及复合面料及其制造技术领域，其技术方案要点是，包括面料层和防水膜层，所述面料层和防水膜层之间设置有胶黏层，所述防水膜层为抗菌TPU膜层；所述胶黏层包括1‑10wt%的阻燃型环氧树脂和90‑99wt%的热熔胶，且所述面料层经由阻燃整理剂进行阻燃整理。本发明的抗菌复合面料兼具阻燃抗菌特性。本发明还相应公开了一种抗菌复合面料的制造工艺，其包括面料层预处理、防水膜预处理、调胶和复合步骤，制得的复合面料具有防水透气，且兼具抗菌阻燃特性的优势。

Description

一种抗菌复合面料及其制造工艺
技术领域
本发明涉及复合面料及其制造技术领域，更具体地说，它涉及一种抗菌复合面料及其制造工艺。
背景技术
复合面料是将一层或多层纺织材料、无纺材料及其他功能材料经粘结贴合而成的一种新型材料，适合做沙发，服装等纺织品，是人们居家生活不可缺少的面料之一。
如有现有技术中授权公告号为CN205651736U的中国专利公开的一种抗菌面料即是复合面料的一种。该种复合面料包括依次复合的竹纤维层、吸汗层和亚麻纤维层，所述竹纤维层、吸汗层和亚麻纤维层的厚度均为0.4-0.6mm，吸汗层为TPU薄膜树脂。竹纤维的吸放湿性及透气性能良好，并且还具有抗菌、抑菌的功效；TPU薄膜树脂层具有较好的透湿性；亚麻纤维层具有吸湿散热、保健抑菌的特点。
但是，无论是竹纤维和亚麻纤维可燃材料，干燥状态下极易燃烧。TPU树脂同样是易燃材料，复合后使得复合面料的整体阻燃性极差，使得复合面料的应用范围受限。因而，有必要对现有技术进行改进，以设计一种兼具抗菌和阻燃性能的复合面料。
发明内容
针对现有技术存在的不足，本发明的目的在于提供一种抗菌复合面料，其具有兼具阻燃抗菌特性的优势。
为实现上述目的，本发明提供了如下技术方案：
一种抗菌复合面料，包括面料层和防水膜层，所述面料层和防水膜层之间设置有胶黏层，所述防水膜层为抗菌TPU膜层；所述胶黏层包括1-10wt%的阻燃型环氧树脂和90-99wt%的热熔胶，且所述面料层经由阻燃整理剂进行阻燃整理。
通过采用上述技术方案，在面料层背面复合抗菌TPU膜层后使得聚合面料具有透气防水性能，可有效阻止液体污渍渗透，同时具有一定的抑菌作用。在用于胶黏层内掺入适量阻燃型环氧树脂，可大幅提升复合面料的阻燃性能，同时由于阻燃型环氧树脂的掺入，也使得面料层和防水膜层之间的粘合牢度更高，撕裂强度和使用耐久性更好。但是，阻燃型环氧树脂的掺量不宜过高，否则容易使得复合面料板硬。
进一步地，所述热熔胶为PUR热熔胶。
PUR热熔胶是一种反应型聚氨酯热熔胶，其主要成分是端异氰酸酯预聚体，具有粘结强度高，耐温性、耐化学腐蚀性和耐老化性佳的特点。由于PUR热熔胶中含有封端的异氰酸酯，能够与环氧树脂反应，因而阻燃型环氧树脂会参与热熔胶的固化，具有提升复合面料剥离强度的作用，但同时需要严格控制阻燃型环氧树脂的掺量，以1-10wt%为宜，3-8wt%较佳，5-6wt%更优。
进一步地，所述阻燃型环氧树脂为含磷阻燃环氧树脂。
含磷阻燃环氧树脂分子中含有磷元素，具有优良的阻燃效果，相较于常规的含卤阻燃剂更环保。含磷阻燃环氧树脂可以直接选用商品性含磷阻燃型环氧树脂，如EP-1033含磷环氧树脂（广州维立纳化工）、含磷环氧树脂（EP0-128、EP0-132、EP0-342）（广州仟安化工）等；也可以以反应型含磷阻燃剂与双酚A、环氧氯丙烷等原料聚合反应得到，如参照CN200310115435.2、CN201110190789.8、CN201610740995.4等专利申请文件记载的含磷阻燃环氧树脂制备方法进行制备。
进一步地，所述面料层为机织布层、针织布层或无纺布层。
通过采用上述技术方案，根据复合面料的用途不同，可以选择不同材质和织造类型的面料作为面料层，机织布、针织布或无纺布均可。
进一步地，所述阻燃整理剂包括按重量份计的如下组分，
溶剂 10-15份
聚丙烯酸酯胶黏剂 30-35份
阻燃填料 15-20份
纳米级竹炭粉 1-5份
蜂蜡 1-5份
金银花提取液 1-3份。
阻燃整理剂中的聚丙烯酸酯胶黏剂作为粘结成分，可使得配方中的抗菌和阻燃组分牢固附着于面料层表面，比保证复合面料阻燃性的耐久性。阻燃填料优选易获取、低沉本的无机阻燃剂，不仅阻燃效果好且成本低，相对安全。纳米级竹炭粉、金银花提取液和蜂蜡，均具有抑菌和抗菌效果，具有协同提升复合面料抗菌性能的作用，其中金银花提取液可采用鲜金银花用低温萃取法或二氧化碳萃取法萃取制得。而且，纳米级竹炭粉还具有提升胶黏层粘结牢度和吸附异味的作用，蜂蜡和金银花提取液中均含天然抑菌物质和香味物质，安全抑菌、抑螨的同时，能够赋予复合面料天然的香味。此外，蜂蜡能够赋予织物一定的疏水性，提升了复合面料的耐污性能。
进一步地，所述阻燃填料为氢氧化铝、硅微粉和纳米二氧化钛按照质量比1：（0.3-0.6）：（0.1-0.2）的比例混合而成。
通过采用上述技术方案，氢氧化铝是优良的无机阻燃剂；硅微粉同样具有阻燃效果且可以提高胶黏层的附着牢度；二氧化钛同样可以提升胶黏层的附着牢度且能够吸收紫外线，提升复合面料的耐光老化性能，以氢氧化铝、硅微粉和纳米二氧化钛按照上述配比混合后作为阻燃填料可赋予复合面料优异的阻燃型，同时提升复合面料的抗撕裂强度和耐候耐老化性能。
进一步地，所述溶剂为乙醚。
通过采用上述技术方案，能够有效溶解蜂蜡，使得蜂蜡能均匀分布于面料层表面。经加热处理后，乙醚能完全挥发，几乎无残留，不会对复合面料的使用造成影响。
本发明的目的在于提供一种抗菌复合面料制造工艺，采用该工艺制得复合面料兼具阻燃抗菌特性。
为实现上述目的，本发明提供了如下技术方案：
一种如上述任一项所述抗菌复合面料的制造工艺，包括如下步骤，
面料层预处理：在面料层表面均匀喷涂阻燃整理剂后，用红外预烘设备预烘10-15s;
防水膜预处理：对防水膜层进行电晕处理；
调胶：按照配比将热熔胶和阻燃型环氧树脂搅拌混合均匀，得阻燃型环氧树脂-热熔胶混合物；
复合：采用面料复合设备对面料层和防水膜层进行复合，复合时使面料层经由阻燃整理剂处理的一面与防水膜层经由电晕处理的一面相贴合，同时将阻燃型环氧树脂-热熔胶混合物均布于面料层和防水膜层之间；在面料层一侧给湿，打卷，静置至面料层与防水膜层粘合牢固。
通过采用上述技术方案，配合适当的设备，上述各步骤可在同一设备或生产线完成。面料层与防水膜层复合前，可以直接将调制的阻燃整理剂喷涂于面料层表面，然后红外预烘处理使得溶剂快速挥发且聚丙烯酸酯胶黏剂快速固化，将阻燃抗菌组分牢固附着于面料层；热熔胶和阻燃型环氧树脂可由单独的给胶系统混配后，在面料层与防水膜层贴合前被涂敷于两层之间。经过轧压后使得面料层与防水膜层贴合，在面料层侧喷淋适量清水后，将复合面料打卷，静置养护至热熔胶完全固化形成胶黏层即可。复合前，对防水膜层进行电晕处理，可提高防水膜层表面粗糙度，增加了胶黏层的附着牢度。按照上述工艺制得的复合面料，具有抗菌阻燃特性，且剥离强度高、耐候耐老化性佳。
综上所述，本发明具有以下有益效果：
1、在面料层背面复合抗菌TPU膜层后使得复合面料具有透气防水性能，可有效阻止液体污渍渗透，同时具有一定的抑菌作用；
2、在用于胶黏层内掺入适量阻燃型环氧树脂，可大幅提升复合面料的阻燃性能，同时由于阻燃型环氧树脂的掺入，也使得面料层和防水膜层之间的粘合牢度更高，剥离强度和使用耐久性更好；
3、选择PUR热熔胶与阻燃型环氧树脂混合，PUR热熔胶内的封端异氰酸酯能与环氧树脂反应，提升了胶黏层的粘结牢度；
4、以溶剂、聚丙烯酸酯胶黏剂、阻燃填料、蜂蜡、纳米级竹炭粉和金银花提取液配置的阻燃整理剂，可显著提升复合面料的抗菌抑菌性能和阻燃性能；
5、本发明公开的复合面料制备方法，无需单独对面料层进行阻燃剂浸渍整理，缩短了工艺流程，制得的复合面料兼具抗菌和阻燃特性。
附图说明
图1为实施例中抗菌复合面料的结构示意图；
图2为实施例中抗菌复合面料的制造系统示意图。
图中：1、面料层；2、胶黏层；3、防水膜层；4、给胶系统；5、电晕处理装置；6、红外预烘装置；7、阻燃整理剂喷涂装置；8、给湿装置；9、轧辊。
具体实施方式
以下结合附图对本发明作进一步详细说明。
实施例1：
一种抗菌复合面料，参照图1，其包括面料层1、胶黏层2和防水膜层3。其中，面料层1可选择机织布、针织布或无纺布，本实施例中选择PP无纺布；防水膜层3选择市售抗菌TPU膜。胶黏层2包含1wt%的含磷阻燃型环氧树脂EP-1033（广州维立纳化工）和998wt%的PUR热熔胶。
参照图2，具体制造工艺包括如下步骤，
A面料层预处理：按照乙醚12.5kg、聚丙烯酸酯胶黏剂32.5kg、阻燃填料17.5kg、纳米级竹炭粉2.5kg、蜂蜡2.5kg和金银花提取液1.5kg的比例配置阻燃整理剂，其中阻燃填料由氢氧化铝粉末、硅微粉和纳米二氧化钛按照质量比1：0.35：0.15的比例混合而成。然后借助阻燃整理剂喷涂装置7将阻燃整理剂均匀喷涂于作为面料层1的PP无纺布表面。面料层1的运行方向上设置红外预烘装置6，喷涂阻燃整理剂后的面料层1运行至红外预烘装置6时，在红外加热作用下预烘13s，乙醚挥发、聚丙烯酸酯胶黏剂固化，使得阻燃填料、纳米级竹炭粉、蜂蜡及金银花提取液均匀固着于面料层1表面。
B防水膜预处理：在作为防水膜层3的抗菌TPU膜运行方向上设置电晕处理装置5，利用电晕处理装置5对抗菌TPU膜进行电晕处理，使得抗菌TPU膜表面粗糙，利于后续与面料层1复合时热熔胶的附着。抗菌TPU膜选择高透气型的抗菌TPU膜，可赋予复合面料优良的防水、透气和抗菌性能。
C调胶：热熔胶和含磷阻燃型环氧树脂的涂布需要借助给胶系统4进行，给胶系统4将含磷阻燃型环氧树脂EP-1033和熔融的PUR热熔胶混合均匀后，均匀涂布于面料层1与防水膜层3之间。在轧辊9的轧压作用下，面料层1与防水膜层3初步复合。
D复合：面料层1层与防水膜层3复合时，面料层1经由阻燃整理剂处理的一面与防水膜层3经由电晕处理的一面相贴合。经由轧辊9轧压后，借助给湿装置8向面料层1表面均匀喷淋水雾，在后续轧辊9的轧压下面料层1层均匀吸湿。随后，对初步复合并给湿的面料层1和防水膜层3打卷，静置，养护至面料层1与防水膜层3粘合牢固即可。
实施例2-4：
实施例2-4均涉及一种抗菌复合面料，且均以实施例1为基础，与实施例1的区别仅在于胶黏层2中PUR热熔胶和含磷阻燃型环氧树脂EP-1033的占比不同：
实施例2的胶黏层2包含5wt%的含磷阻燃型环氧树脂EP-1033，余量为PUR热熔胶；
实施例3的胶黏层2包含6wt%的含磷阻燃型环氧树脂EP-1033，余量为PUR热熔胶；
实施例4的胶黏层2包含10wt%的含磷阻燃型环氧树脂EP-1033，余量为PUR热熔胶。
实施例5-6
实施例5-6均涉及一种抗菌复合面料，且均以实施例2为基础，与实施例2的区别仅在于：阻燃剂整理剂的配比不同，具体如表1所示，
表1.实施例5-6中阻燃整理剂的组分配比表
表1中阻燃填料均由氢氧化铝粉末、硅微粉和纳米二氧化钛按照质量比1：0.35：0.15的比例混合而成。
实施例7-8
实施例7-8均涉及一种抗菌复合面料，且均以实施例2为基础，与实施例2的区别仅在于阻燃填料的组成不同：
实施例7中阻燃填料由氢氧化铝粉末、硅微粉和纳米二氧化钛按照质量比1：0.3：0.1的比例混合而成；
实施例8中阻燃填料由氢氧化铝粉末、硅微粉和纳米二氧化钛按照质量比1：0.6：0.2的比例混合而成。
对照例1
一种复合面料，其与实施例2的区别仅在于：胶黏层中不含有含磷阻燃型环氧树脂EP-1033。
对照例2
一种复合面料，其与实施例2的区别仅在于：面料层未经过阻燃整理剂处理。
对照例3
一种复合面料，包括面料层、胶黏层和防水膜层，面料层为PP无纺布、胶黏层为PUR热熔胶层、防水膜层为TPU膜层。
性能测试
1、拉伸断裂强力测试：实验仪器为YG065型电子织物强力试验仪，参照标准ISO9073-3-1989《纺织品 非织造布试验方法 第三部分：拉伸强力及伸长测定》；
2、剥离强度试验：参照GB8808-1998《软质复合塑料材料剥离试验方法》进行；
3、抗菌性实验：参照GB/T20944.1-2007《纺织品 抗菌性能的评价 第1部分：琼脂平皿扩散法》进行；以金黄色葡萄球菌和大肠杆菌作为实验菌种，实验菌液浓度为1ｘ108CFU/ml，。
4、阻燃性试验：参照GB/T5455-2014《纺织品 燃烧性能 垂直方向 损毁长度、阴燃和续燃时间的测定》
分别对实施例1-8和对照例1-3的复合面料进行测试，试验结果记录如下：
表2.拉伸断裂强力、剥离强度实验结果表
表3.抗菌性试验结果表
表4.阻燃性试验结果表
由表2试验数据可知：在胶黏层2内掺加适量阻燃型环氧树脂可显著提升复合面料的剥离强度，对复合面料的拉伸断裂强力同样有提升作用。而且，由实施例2-3的试验数据可知阻燃型环氧树脂的掺量以5-6wt%最为适宜。对比实施例2和对照例1-2 的试验数据可知，在胶黏层2内掺假阻燃型环氧树脂和对面料层1进行阻燃整理，可以协同提升复合面料的拉伸断裂强力和剥离强度。
由表3试验数据可知：阻燃整理剂内掺加蜂蜡、金银花提取液和纳米级竹炭粉对复合面料的抗菌性具有显著提升作用。
由表4的试验数据可知：在胶黏层2内掺加阻燃型环氧树脂和用特定配方的阻燃整理剂对面料层1进行处理，可显著提升复合面料的阻燃性能，使得复合面料兼具抗菌阻燃特性。
上述具体实施例仅仅是对本发明的解释，其并不是对本发明的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本发明的权利要求范围内都受到专利法的保护。

Claims (8)

1.一种抗菌复合面料，包括面料层(1)和防水膜层(3)，所述面料层(1)和防水膜层(3)之间设置有胶黏层(2)，其特征在于：所述防水膜层(3)为抗菌TPU膜层；所述胶黏层(2)包括1-10wt%的阻燃型环氧树脂和90-99wt%的热熔胶，且所述面料层(1)经由阻燃整理剂进行阻燃整理。
2.根据权利要求1所述的一种抗菌复合面料，其特征在于：所述热熔胶为PUR热熔胶。
3.根据权利要求1所述的一种抗菌复合面料，其特征在于：所述阻燃型环氧树脂为含磷阻燃环氧树脂。
4.根据权利要求1所述的一种抗菌复合面料，其特征在于：所述面料层(1)为机织布层、针织布层或无纺布层。
5. 根据权利要求1所述的一种抗菌复合面料，其特征在于：所述阻燃整理剂包括按重量份计的如下组分，
溶剂 10-15份
聚丙烯酸酯胶黏剂 30-35份
阻燃填料 15-20份
纳米级竹炭粉 1-5份
蜂蜡 1-5份
金银花提取液 1-3份。
6.根据权利要求5所述的一种抗菌复合面料，其特征在于：所述阻燃填料为氢氧化铝、硅微粉和纳米二氧化钛按照质量比1：（0.3-0.6）：（0.1-0.2）的比例混合而成。
7.根据权利要求5所述的一种抗菌复合面料，其特征在于：所述溶剂为乙醚。
8.一种如权利要求1-7任一项所述抗菌复合面料的制造工艺，其特征在于：包括如下步骤，
面料层预处理：在面料层(1)表面均匀喷涂阻燃整理剂后，用红外预烘设备预烘10-15s;
防水膜预处理：对防水膜层(3)进行电晕处理；
调胶：按照配比将热熔胶和阻燃型环氧树脂搅拌混合均匀，得阻燃型环氧树脂-热熔胶混合物；
复合：采用面料复合设备对面料层(1)和防水膜层(3)进行复合，复合时使面料层(1)经由阻燃整理剂处理的一面与防水膜层(3)经由电晕处理的一面相贴合，同时将阻燃型环氧树脂-热熔胶混合物均布于面料层(1)和防水膜层(3)之间；在面料层(1)一侧给湿，打卷，静置至面料层(1)与防水膜层(3)粘合牢固。
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Application publication date: 20191029