CN110438815B - 一种消声合成革的生产工艺 - Google Patents

一种消声合成革的生产工艺 Download PDF

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CN110438815B
CN110438815B CN201910550937.9A CN201910550937A CN110438815B CN 110438815 B CN110438815 B CN 110438815B CN 201910550937 A CN201910550937 A CN 201910550937A CN 110438815 B CN110438815 B CN 110438815B
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coating
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melt adhesive
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刘齐松
韦旭峰
姜海军
胡江红
方厚兵
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Zhejiang Shenteng Coated Fabrics Co ltd
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Abstract

本发明公开了一种消声合成革的生产工艺，包括：防螨面料涂布点状热熔胶与超细无纺布热压复合；束状超细纤维层涂布点状热熔胶片状胶原纤维层热压复合；防螨面料与束状超细纤维层通过点状热熔胶热压复合；防螨涂覆液涂覆至胶原纤维层的表面烘干；在胶原纤维的一侧形成花纹图案；在花纹的一侧喷涂水性PU树脂；在未烘干的水性PU膜表面喷涂消声处理液烘干后。本发明所涉及的一种消声合成革的生产工艺，使用了束状超细纤维层和胶原纤维层，使得该合成革具有接近真皮的手感和物理性质。并且在最外层表面喷涂有消声处理液，使得在使用时该合成革在摩擦时不会发出响声，并且在洗涤多次后其消声性能亦然存在，具有良好的耐洗涤性能。

Description

一种消声合成革的生产工艺
技术领域
本发明涉及合成革生产技术领域，尤其是一种消声合成革的生产工艺。
背景技术
随着人们生活水品的提高，人们逐渐追求高质量的日用产品，皮革产品的需求量越来越多，随着动物保护意识的增强，动物真皮已经不能满足人们的需求。目前，人造革产品逐渐成为未来流行的趋势，人造革已广泛用于生产箱包、服装、鞋类等产品，随着市场沙发款式日益增多，其沙发面料的物性要求也不断的在提高，尤其是电动沙发、摇椅，在使用中摩擦会出现异响，消费者不能接受。
合成革合成之后，经常需要用一些表面处理剂处理而得到具有不同性能特点的皮革，消声涂层剂是人造革中常用的表面处理剂，合成皮革经消声涂层剂处理后能明显的消除皮革间相互摩擦所产生的响声，受到人们的广泛青睐。
目前，市场上销售的合成革用消声涂层剂通常为溶剂型表处剂，对合成革处理后，会造成底层溶解，而且处理后的人造革手感较差。而且溶剂型消声剂中有机溶剂成本高气味大，易污染环境，而且存在安全隐患。
发明内容
本发明的目的是提供一种消声合成革的生产工艺，使得所生产得到的消声合成革不仅具有持久的消声功能，而且具有较好防螨抗菌效果。
为解决上述技术问题，本发明的目的是这样实现的：
本发明所涉及的一种消声合成革的生产工艺，包括如下步骤：
（1）、选择防螨面料，并采用点状热熔胶涂布设备在所选择的防螨面料的表面涂布点状热熔胶，与超细无纺布进行热压复合，为第一复合面料；热熔胶涂布量为5-10克每平方米；
（2）采用点状热熔胶涂布设备在填充有聚氨酯发泡材料的束状超细纤维层的一侧涂布点状热熔胶，与片状胶原纤维层进行热压复合，为第二复合面料；热熔胶涂布量为5-10克每平方米；
（3）采用点状热熔胶涂布设备在防螨面料与束状超细纤维层之间涂布点状热熔胶，并采用热压复合的方式将第一复合面料第二复合面料粘合，为第三复合面料；
（4）配制防螨涂覆液，将防螨涂覆液涂覆至第三复合面料的片状胶原纤维层的表面，并进行烘干，为第四复合面料；
（5）将上一步骤所制备的第四复合面料进行转移印花，在片状胶原纤维的一侧形成花纹图案，为印花复合面料；
（6）将上一步骤所制备的印花复合面料花纹的一侧涂覆一层5-8丝厚的水性PU树脂；
（7）配制消声处理液，在上一步骤未烘干的水性PU膜的表面喷涂消声处理液，烘干后，并转移印花的图案处采用真空吸花或压花工艺在表面形成图案，即得到消声合成革；
步骤（4）中，所述的防螨涂覆液中包括防螨虫整理剂SCJ-998、水性聚氨酯树脂、架桥剂、去离子水；按质量份数，防螨虫整理剂SCJ-998为10-20份，水性聚氨酯树脂为100份，架桥剂为1-3份，去离子水调节防螨涂覆液的粘度为15000-18000cps；
在多功能涂层机上采用辊上刮刀的方法将防螨涂覆液涂覆至第二复合面料的片状胶原纤维层的表面，并进行烘干；防螨涂覆剂的厚度为3-5丝，烘干温度为130-140℃，车速为10-15米每分钟；
步骤（7）中，所配制的消声处理液包括水性聚氨酯树脂、消声剂、有机硅流平剂、有机硅消泡剂、水性聚氨酯增稠剂及去离子水；按质量份数，所述水性聚氨酯为50-60份，消声剂为20-30份，有机硅流平剂为1-2份，有机硅消泡剂为0.5-1份，水性聚氨酯增稠剂0.5-1份，去离子水100份；所使用的消声剂为WTC-204；
采用喷涂设备将消声处理液涂覆至PU膜层，车速为10-15米每分钟，烘干温度为100-110℃。
作为上述方案的进一步说明，步骤（1）中，所述防螨面料所使用的是防螨长丝与竹原纤维纱线分别为经纬纱交织而成的梭织面料，面密度为100-120g/m2；所使用的防螨长丝为经纱，是含有防螨剂的聚酯长丝，细度为100D的单丝；所述的竹原纤维纱线的细度为20tex。
作为上述方案的进一步说明，所述的超细无纺布包括交叉铺网层和平行铺网层，所述的交叉铺网层为涤纶纤维，所述的平行平网层为超细纤维；所述的超细无纺布的涤纶纤维的一面与防螨面料层相复合。
作为上述方案的进一步说明，所述的束状超细纤维层所使用的是纤度在0.01旦以下的尼龙超细纤维。
作为上述方案的进一步说明，所述的胶原纤维层为由胶原纤维经天然乳胶和/或合成乳胶粘合成的片状材料；所述的胶原纤维层中胶原纤维的含量为60-70%。
本发明的有益效果是：本发明所涉及的一种消声合成革的生产工艺，使用了束状超细纤维层和胶原纤维层，使得该合成革具有接近真皮的手感和物理性质。并且在最外层表面喷涂有消声处理液，使得在使用时该合成革在摩擦时不会发出响声，并且在洗涤多次后其消声性能亦然存在，具有良好的耐洗涤性能。
具体实施方式
下面结合具体实施例对本发明进一步说明。
实施例一
本实施例所涉及的一种消声合成革的生产工艺，包括如下步骤：
步骤（1）、选择防螨面料，并采用点状热熔胶涂布设备在所选择的防螨面料的表面涂布点状热熔胶，与超细无纺布进行热压复合，为第一复合面料；热熔胶涂布量为5-10克每平方米。
在该步骤中，所使用的防螨面料中，所使用的是防螨长丝与竹原纤维纱线分别为经纬纱交织而成的梭织面料，面密度为100-120g/m2；所使用的防螨长丝为经纱，是含有防螨剂的聚酯长丝，细度为100D的单丝；所述的竹原纤维纱线的细度为20tex。
所使用防螨长丝，是在100质量份中聚酯切片中加入0.05-0.15质量份的防螨剂，经挤出、切片，制成防螨纤纤维切片。再将防螨纤维切片经PET长丝纺丝设备制成所需要纤度的防螨长丝。所使用的竹原纤维纱线是以竹原纤维作为原料经纺纱设备所制成所需要纤度的竹原纤维纱线。竹原纤维具有抗菌的作用，防螨长丝具有防螨效果，所以所制备的防螨面料层不仅具有较好的防螨效果还具有较好的抗菌效果。
在本步骤中，所使用的超细无纺布包括交叉铺网层和平行铺网层，交叉铺网层为涤纶纤维，平行铺网层为超细纤维；超细无纺布的涤纶纤维的一面与防螨面料层通过点状的PU热熔胶相复合。所使用的超细纤维为海岛纤维，经高压水流的冲击，使得“海”的部分被冲散，将“岛”的部分露出，形成较超细的一面。整个超细无纺布的面密度为80-100克每平方米。
步骤（2）、采用点状热熔胶涂布设备在填充有聚氨酯发泡材料的束状超细纤维层的一侧涂布点状热熔胶，与片状胶原纤维层进行热压复合，为第二复合面料；热熔胶涂布量为5-10克每平方米。
在本实施例中，束状超细纤维层所使用的是纤度在0.01旦以下的尼龙超细纤维。束状超细纤维与天然皮革结构中束状胶原纤维结构和性能相似，所使用的尼龙束状超细纤维中细度为3.3-5.6dtex，每根纤维断面中含有300个左右的“岛”，在后道工序中用特殊方法将“海”除去，使每根单纤维分离成数百根相互不相连的超细纤维组成的纤维束，其中每根超细纤维的细度均在0.01旦以下。使用这种束状超细纤维所制备的合成革，与天然皮革的结构和性能非常相似。
在本实施例一中，所使用的胶原纤维层为由胶原纤维经天然乳胶和/或合成乳胶粘合成的片状材料，胶原纤维层中胶原纤维的含量为60-70%。胶原纤维是由蓝湿皮边角料制作，包括如下步骤：步骤一，原料选取；步骤二，裁剪；步骤三，脱脂柔软处理：将蓝湿皮碎料置于转鼓中，注水，使温度保持在35-40℃，按照蓝湿皮碎料重量计，依次加入碳酸氢钠、甲酸钠、尿素、n-十二烷基-β-D-麦芽糖苷，保温，再依次加入碱性蛋白酶、辅脱脂剂Ⅰ和辅脱脂剂Ⅱ，运行20-30min，排液，得脱脂柔软碎料；步骤四，脱水；步骤五，开松；步骤六，梳理，即得所述皮革胶原纤维。
步骤（3）、采用点状热熔胶涂布设备在防螨面料与束状超细纤维层之间涂布点状热熔胶，并采用热压复合的方式将第一复合面料第二复合面料粘合，为第三复合面料。热熔胶涂布量为5-10克每平方米。
步骤（4）、配制防螨涂覆液，将防螨涂覆液涂覆至第三复合面料的片状胶原纤维层的表面，并进行烘干，为第四复合面料。并且所配制的防螨涂覆液呈透明状。
步骤（4）中，所述的防螨涂覆液中包括防螨虫整理剂SCJ-998、水性聚氨酯树脂、架桥剂、去离子水；按质量份数，防螨虫整理剂SCJ-998为10-20份，水性聚氨酯树脂为100份，架桥剂为1-3份，去离子水调节防螨涂覆液的粘度为15000-18000cps。
在多功能涂层机上采用辊上刮刀的方法将防螨涂覆液涂覆至第二复合面料的片状胶原纤维层的表面，并进行烘干；防螨涂覆剂的厚度为3-5丝，烘干温度为130-140℃，车速为10-15米每分钟。所使用的多功能涂层机采购自奥地得J.Zimer公司。此设备是辊上刮刀式和圆网两用。辊上刮刀具有刀距可调功能，为适应不同要求的涂刮产品。辊上刮刀是采用浮刀涂刮，一般适用于在基布上涂刮成膜稍薄的工艺，经二遍涂刮后其厚度在3丝左右；浮刀式涂刮的主要优点是能提高浆料涂刮的均匀度和遮盖性，浮刀式涂刮后的烘房温度可适当提高到135℃左右，较适合大生产。工人在做被衬辊的清洁工作也较方便。
步骤（5）是将上一步骤所制备的第四复合面料进行转移印花，在片状胶原纤维的一侧形成花纹图案，为印花复合面料。
步骤（6）是将上一步骤所制备的印花复合面料花纹的一侧涂覆一层5-8丝厚的水性PU树脂。在此步骤先不需要进行烘干，形成PU树脂膜。
步骤（7）是配制消声处理液，并且在上一步骤未烘干的水性PU膜的表面喷涂消声处理液，烘干后。并转移印花的图案处采用真空吸花或压花工艺在表面形成图案，即得到消声合成革。由真空吸花或压花工艺所形成的花纹与转移印花层上的花纹相重合，使得花纹的更为立体。
步骤（7）中，所配制的消声处理液包括水性聚氨酯树脂、消声剂、有机硅流平剂、有机硅消泡剂、水性聚氨酯增稠剂及去离子水。按质量份数，所述水性聚氨酯为50份，消声剂为20份，有机硅流平剂为1份，有机硅消泡剂为0.5份，水性聚氨酯增稠剂0.5份，去离子水100份；所使用的消声剂为WTC-204。
采用喷涂设备将消声处理液涂覆至PU膜层，车速为10米每分钟，烘干温度为100℃。
实施二
本实施例所涉及的一种消声合成革的生产工艺，与实施例一的区别在于，在步骤（3）进行点状热熔胶粘合时，束状超细纤维层与防螨面料层之间放置一层网格布。所使用的网格布为尼龙面料编织而成，面密度为5-10克每平方米，由于面密度较小，网格布具有较大的网孔，在进行粘合时，可将网格布放置于下层的防螨面料上方，再在其上涂布点状的热熔胶，在进行粘合时，束状超细纤维层与防螨面料层会粘合在一起，并将网格布置于两层之间。
另一区别在于，步骤（7）中，所配制的消声处理液包括水性聚氨酯树脂、消声剂、有机硅流平剂、有机硅消泡剂、水性聚氨酯增稠剂及去离子水。按质量份数，所述水性聚氨酯为60份，消声剂为30份，有机硅流平剂为2份，有机硅消泡剂为1份，水性聚氨酯增稠剂1份，去离子水100份；所使用的消声剂为WTC-204。
采用喷涂设备将消声处理液涂覆至PU膜层，车速为15米每分钟，烘干温度为110℃。
对实施例一与实施例二所制备的消声革，与对比例进行测试比较。所使用的对比例为市场上所购得的具有消声的合成革。
在消声方面进行测试，实施例一与实施例二及对比例在开始检测时，在相同条件下进行摩擦测试，均无响声。并对三个合成革面料洗涤后进行测试，洗涤1次后，均无响声。洗涤5次后，实施例一及实施例二无响声，对比例有轻微响声。洗涤10次后，实施例一及实施例二有轻微响声，对比例具有较大的响声。由此可见实施例一及实施例二所制备的合成革，在消声方面，经过洗涤后具有较好的消声性能。
本发明所使用的防螨虫整理剂SCJ-998的主要成分是带有活性基团的吡卟酰胺结构的氯苯咪唑类高分子化合物和以拟除虫菊酯类化合物为主的微胶囊，下纤维上的-OH、-NH-形成共价键，使得具有优异的耐洗涤性。对于防螨性能测试，只进行了尘螨、革螨和恙螨的防螨测试。对实施例一所制备的消声合成革进行测试，结果表明，该合成革对于尘螨、革螨和恙螨的驱避率均大于99%，分别为99.3%、99.5%、99.1%。洗后5次后，对于尘螨、革螨和恙螨的驱避率均大于97%，分别为97.8%、98.3%和97.5%。洗涤10次后，对于尘螨、革螨和恙螨的驱避率均大于95%，分别为95.3%、95.6%和95.4%。
而对于实施例二所制备的消声合成革，其在对于尘螨、革螨和恙螨的驱避率方面与实施例一相当，主要是因为其在制备过程中加入的网格布是起到增加强力的作用。对于防螨剂与纤维的结合不受影响。而对比例基本上不具有防螨的效果。
由上述的测试可以看出，本发明所制备的消声合成革具有良好的防螨效果。
对实施例一和实施例二及对比例所涉及的合成革，进行抗菌方面的测试。由测试结构表明，实施例一及实施例二所涉及的合成革，对灭淋球菌（WHOQ6 国际标准耐药株）、金黄色葡萄球菌（ATCC6389）、大肠杆菌（ATCC8099），等在未洗涤及洗涤5次和10次后，在该消声合成革完全不生长，抑菌率达到99%以上。而对比例基本不具有抑菌效果。
以上详细描述了本发明的较佳具体实施例。应当理解，本领域的普通技术人员无需创造性劳动就可以根据本发明的构思做出诸多修改和变化。因此，凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案，皆应在由权利要求书所确定的保护范围内。

Claims (5)

1.一种消声合成革的生产工艺，其特征在于，包括如下步骤：
（1）、选择防螨面料，并采用点状热熔胶涂布设备在所选择的防螨面料的表面涂布点状热熔胶，与超细无纺布进行热压复合，为第一复合面料；热熔胶涂布量为5-10克每平方米；
（2）采用点状热熔胶涂布设备在填充有聚氨酯发泡材料的束状超细纤维层的一侧涂布点状热熔胶，与片状胶原纤维层进行热压复合，为第二复合面料；热熔胶涂布量为5-10克每平方米；
（3）采用点状热熔胶涂布设备在防螨面料与束状超细纤维层之间涂布点状热熔胶，并采用热压复合的方式将第一复合面料第二复合面料粘合，为第三复合面料；
（4）配制防螨涂覆液，将防螨涂覆液涂覆至第三复合面料的片状胶原纤维层的表面，并进行烘干，为第四复合面料；
（5）将上一步骤所制备的第四复合面料进行转移印花，在片状胶原纤维的一侧形成花纹图案，为印花复合面料；
（6）将上一步骤所制备的印花复合面料花纹的一侧涂覆一层5-8丝厚的水性PU树脂；
（7）配制消声处理液，在上一步骤未烘干的水性PU膜的表面喷涂消声处理液，烘干后，并转移印花的图案处采用真空吸花或压花工艺在表面形成图案，即得到消声合成革；
步骤（4）中，所述的防螨涂覆液中包括防螨虫整理剂SCJ-998、水性聚氨酯树脂、架桥剂、去离子水；按质量份数，防螨虫整理剂SCJ-998为10-20份，水性聚氨酯树脂为100份，架桥剂为1-3份，去离子水调节防螨涂覆液的粘度为15000-18000cps；
在多功能涂层机上采用辊上刮刀的方法将防螨涂覆液涂覆至第二复合面料的片状胶原纤维层的表面，并进行烘干；防螨涂覆剂的厚度为3-5丝，烘干温度为130-140℃，车速为10-15米每分钟；
步骤（7）中，所配制的消声处理液包括水性聚氨酯树脂、消声剂、有机硅流平剂、有机硅消泡剂、水性聚氨酯增稠剂及去离子水；按质量份数，所述水性聚氨酯为50-60份，消声剂为20-30份，有机硅流平剂为1-2份，有机硅消泡剂为0.5-1份，水性聚氨酯增稠剂0.5-1份，去离子水100份；所使用的消声剂为WTC-204；
采用喷涂设备将消声处理液涂覆至PU膜层，车速为10-15米每分钟，烘干温度为100-110℃。
2.如权利要求1所述的消声合成革的生产工艺，其特征在于，步骤（1）中，所述防螨面料所使用的是防螨长丝与竹原纤维纱线分别为经纬纱交织而成的梭织面料，面密度为100-120g/m2；所使用的防螨长丝为经纱，是含有防螨剂的聚酯长丝，细度为100D的单丝；所述的竹原纤维纱线的细度为20tex。
3.如权利要求1所述的消声合成革的生产工艺，其特征在于，所述的超细无纺布包括交叉铺网层和平行铺网层，所述的交叉铺网层为涤纶纤维，所述的平行铺网层为超细纤维；所述的超细无纺布的涤纶纤维的一面与防螨面料层相复合。
4.如权利要求1所述的消声合成革的生产工艺，其特征在于，所述的束状超细纤维层所使用的是纤度在0.01旦以下的尼龙超细纤维。
5.如权利要求1所述的消声合成革的生产工艺，其特征在于，所述的胶原纤维层为由胶原纤维经天然乳胶和/或合成乳胶粘合成的片状材料；所述的胶原纤维层中胶原纤维的含量为60-70%。
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CN205636310U (zh) * 2016-05-17 2016-10-12 清远市金昌人造革有限公司 一种具有透气性的超纤人造皮革
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