CN111016345A - 一种热塑性纤维粘合的棕丝床垫芯材及其制备方法 - Google Patents

一种热塑性纤维粘合的棕丝床垫芯材及其制备方法 Download PDF

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CN111016345A
CN111016345A CN201911119065.7A CN201911119065A CN111016345A CN 111016345 A CN111016345 A CN 111016345A CN 201911119065 A CN201911119065 A CN 201911119065A CN 111016345 A CN111016345 A CN 111016345A
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杨壁玲
吴桂林
王磊
梁海先
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Guangdong Vocational and Technical College
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Abstract

本发明公开了一种热塑性纤维粘合的棕丝床垫芯材，依次由无纺布面层、PP熔喷无纺布层、棕丝纤维层和无纺布底层组成，所述棕丝纤维层由热塑性纤维与棕丝纤维分散混合后热粘合形成网层状结构，所述热塑性纤维选自PP、PET、PA、PE或ES纤维，所述棕丝纤维选自棕榈纤维和/或椰丝纤维。采用的PP等常规材料来源广泛、价格低廉，且均为热塑性材料，可通过一定技术进行回收利用，故用于棕丝纤维的粘结与复合，具有成本优势与环保性能。

Description

一种热塑性纤维粘合的棕丝床垫芯材及其制备方法
技术领域
本发明涉及层状产品技术领域，特别是一种热塑性纤维粘合的棕丝床垫芯材，以及该棕丝床垫芯材的制备方法。
背景技术
棕丝床垫是目前最受欢迎的床垫种类之一，其主要原材料的天然特性迎合了当前消费者崇尚自然的消费心理。所采用的棕丝主要有山棕或棕榈纤维(主要为棕榈叶鞘纤维)与椰丝纤维(椰子果壳纤维)。两种纤维都是属于来源广泛、价格低廉的天然纤维资源，充分开发利用两种纤维具有积极的意义。特别是棕榈纤维，它具有不易发霉虫蛀、不易被化学腐蚀、刚度大、弹性及韧性极好、不易拉断、多孔结构等特点，用其制作的床垫产品相对椰丝纤维等床垫具备更优良的性能。
但由于棕榈纤维的纤维粗长、刚度大，将其加工成型较困难，目前一般采用梳理顺直后平铺形成一定厚度的纤维层再经由手工或机械的方式以绳索上下穿插缝编而形成棕榈纤维垫坯，为了保证固结的牢度，垫坯往往需要缝编得比较紧实，因而床垫偏硬、弹性差；椰丝纤维较之棕榈纤维细度、刚度要小，目前的主要成型工艺是利用乳胶、胶粘剂等将椰丝纤维粘合成型，一般是分薄层逐层粘合后再复合粘合成型，可以形成硬度、弹性都相对稍好的床垫。粘合的方式可使棕丝纤维粘结形成一定的网络状结构，增加床垫的弹性，是较好的成型方式。然而，目前市售椰丝床垫的粘合大多采用乳胶或胶粘剂作为粘合剂，天然乳胶虽亲肤、环保，但其粘性不足以维持床垫的稳定，且价格偏高；合成乳胶或其它价格低廉的胶粘剂，则气味大，往往含有甲醛等危害性成分，对人体健康不利。
现有专利公开的通用保健板，其由一个中间层和设置于中间层上下表面的表层组成，所述的表层为含有5％～50％的低熔点纤维与麻、涤纶、腈纶、维纶、竹炭纤维中的一种或几种，经由预成网、梳理、气流成网、针刺制成的针刺无纺布层；所述的中间层为麻纤维、5％～50％的低熔点纤维与棕纤维、椰子壳纤维、竹炭纤维、弹性化学纤维中的一种或几种，经预成网、梳理、气流成网制得的纤维网层。
另外也有也有专利也公开了类似内容的纤维床芯及其技术方法。这些专利将低熔点纤维添加至各层最后采用热烘、冷轧的方式层合粘结成保健板或纤维床芯的方法，提供了一种有效的粘结工艺方法，但其技术主要针对麻纤维等开发，采用的是梳理与气流成网的方法制备表层及中间层，而众所周知，气流成网方法适用于质轻的短纤维的成网，并且，多种纤维混合同时进行梳理或气流成网，容易出现不同纤维之间的速度差异，导致成网不匀，从而使低熔点纤维不能分散于其他纤维当中，影响粘结效果，从而影响床垫的弹性、耐用性。因此，所述技术方法不适合用于棕丝纤维特别是粗长、质硬的棕榈纤维床垫芯材的成型。
部分专利文献还公开了聚酯纤维椰棕板及其制备方法，其结构分为三层，其中上下两层采用低熔点双组份皮芯纤维和三维卷曲中空纤维，中间层采用低熔点双组份皮芯纤维和椰棕纤维，其制备工艺是先将三层材料根据配比分别进行配料、混合、梳理、铺网，然后再将三层通过工艺一体成型。该专利方法由于采用了低熔点双组份皮芯纤维作为纤维间的粘结剂，而不采用胶水，从而达到环保、无甲醒的技术效果，但同样，其中间层采用混合、梳理、铺网的方式处理低熔点双组份皮芯纤维和椰棕纤维，会由于两种纤维性能的极大差异而导致成网不匀，且三层一次一体成型的工艺，容易造成中间层的低熔点双组份皮芯纤维和椰棕纤维受热不充分，影响粘结效果而最终影响弹性、耐用性。
发明内容
因此，需要一种具有良好粘结效果的粘合剂或粘合工艺，特别是适合粗长、质硬的棕榈纤维的生产加工粘结工艺，以制备低成本、环保耐用且软硬适中的棕丝床垫芯材。
为解决上述技术问题所采用的技术方案：
一种热塑性纤维粘合的棕丝床垫芯材，依次由无纺布面层、PP熔喷无纺布层、棕丝纤维层和无纺布底层组成，所述棕丝纤维层由热塑性纤维与棕丝纤维分散混合后加热形成网层状结构，所述热塑性纤维选自PP、PET、PA、PE或ES纤维，所述棕丝纤维选自棕榈纤维和/或椰丝纤维。
进一步，所述无纺布面层和无纺布底层均由PP纤维纺丝成网再热轧粘合而成。
进一步，所述无纺布面层的规格为15～50克/平方米；所述无纺布底层的规格为15～80克/平方米。
进一步，所述PP熔喷无纺布层由PP纤维熔喷而成，规格为20～100克/平方米。
进一步，所述无纺布面层和/或所述PP熔喷无纺布层内掺杂有功能性微粒，所述功能性微粒包括活性炭粉、电气石粉；优选地，所述功能性微粒的粒径为75纳米～5微米。
另一方面，本发明还提供了制备上述热塑性纤维粘合的棕丝床垫芯材的方法，包括步骤：
1)分别制备无纺布面层、PP熔喷无纺布层、棕丝纤维层和无纺布底层；
2)将各层材料按次序铺叠，以热风喷射式热熔粘合法复合固结，即经由烘房对上、下两面以热风喷射式进行热烘，出烘房后再冷轧、冷却固结；
其中，棕丝纤维层的制备：将棕丝纤维梳理铺网形成纤维网层，将热塑性纤维梳理铺网形成热塑性纤维网层，然后将纤维网层的上下表面分别与一层热塑性纤维网层复合，采用正反面针刺法将热塑性纤维网层的热塑性纤维全部刺入纤维网层内部，然后，根据纤维网层的厚度在其上表面均匀撒入0～5％的低熔点PP粉末或PE粉末，最后采用热风穿透式热熔粘合法固结，使热塑性纤维与棕丝纤维相互交缠、粘结而形成网层状的棕丝纤维层。
进一步，所述无纺布面层由PP纤维纺丝成网，在纺丝过程中向纺丝熔体添加活性炭粉或电气石粉，再热轧粘合而成。
进一步，所述PP熔喷无纺布层在PP聚合物熔喷形成纤维的过程中，将活性炭粉或电气石粉均匀喷洒到纤维的表面并附着。
进一步，步骤2中烘房温度为140～190℃，冷轧温度为5～25℃，冷却温度为5～25℃。
与现有技术相比，本发明的有益效果是：
(1)采用的PP等常规材料来源广泛、价格低廉，且均为热塑性材料，可通过一定技术进行回收利用，故用于棕丝纤维的粘结与复合，具有成本优势与环保性能。
(2)以针刺法先将热塑性纤维刺入棕丝纤维网层内部，使得热塑性纤维与棕丝纤维相互交缠，提高了棕丝纤维网层的缠结效果，对于较粗硬的棕榈纤维或较细软的椰丝纤维均适用，且热塑性纤维可提供优良热粘结性能，故热塑性纤维与棕丝纤维经针刺、热熔粘合后，可形成相互交缠、粘结的网层结构，增加床垫芯材的弹性、柔软性与耐用性。
(3)PP等热塑性纤维质轻、无异味且抗菌、防潮，固结后不会增加棕丝纤维床垫的比重，且对人体健康无害。
(4)由于设计了第二层聚丙烯熔喷无纺布层包覆棕丝纤维层，可有效防止棕丝毛刺或对皮肤接触产生刺痒。
(5)设计的面层与底层PP纺粘无纺布包覆层，可有效保持棕丝床垫芯材作为一个整体，并增加整体固结效果与强力，提高耐用性能。
(6)通过采用含活性炭、负离子等添加物的功能性无纺布复合固结，还可赋予床垫比普通棕丝床垫更多的有益功能。
附图说明
图1是所述热塑性纤维粘合的棕丝床垫芯材的结构示意图。
图中标号分别为：1.无纺布面层；2.PP熔喷无纺布层；3.棕丝纤维层；4.无纺布底层。
具体实施方式
下面将结合具体实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1，如图1所示，一种热塑性纤维粘合的棕丝床垫芯材由以下工艺制成：
(1)采用纺丝成网技术和热轧粘合技术分别制得规格为25克/平方米的无纺布面层1，及规格为30克/平方米的无纺布底层4；
(2)采用熔喷技术制得规格为40克/平方米的PP熔喷无纺布层2；
(3)采用梳理成网技术，将棕榈纤维梳理铺网形成厚度为8cm的纤维网层，另外采用梳理成网技术将PP纤维梳理铺网形成100克/平方米的热塑性纤维网层，分别在纤维网层的上下表面覆盖一层热塑性纤维网层，然后采用正反面针刺法将热塑性纤维网层的PP纤维全部刺入纤维网层内，并在针刺后的纤维网层上表面均匀撒入一层PP粉末(含量1％)，最后送入热风吹送装置(烘房)采用热熔粘合法将其固结。热风吹送将PP粉末吹入棕丝纤维网层内部并熔融粘结，加强了粘结效果，使PP纤维与棕榈纤维相互交缠、粘结而形成较蓬松而有弹性的棕丝纤维层3，即为床垫芯材的主体；
(4)采用热风喷射式热熔粘合法经热烘、冷轧、冷却将1、2、3、4四层材料复合固结，制得一种PP纤维粘合的棕榈纤维床垫芯材。
对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。

Claims (9)

1.一种热塑性纤维粘合的棕丝床垫芯材，其特征在于：依次由无纺布面层、PP熔喷无纺布层、棕丝纤维层和无纺布底层组成，所述棕丝纤维层由热塑性纤维与棕丝纤维分散混合后经热粘合形成网层状结构，所述热塑性纤维选自PP、PET、PA、PE或ES纤维，所述棕丝纤维选自棕榈纤维和/或椰丝纤维。
2.根据权利要求1所述的热塑性纤维粘合的棕丝床垫芯材，其特征在于：所述无纺布面层和无纺布底层均由PP纤维纺丝成网再热轧粘合而成。
3.根据权利要求2所述的热塑性纤维粘合的棕丝床垫芯材，其特征在于：所述无纺布面层的规格为15～50克/平方米；所述无纺布底层的规格为15～80克/平方米。
4.根据权利要求1所述的热塑性纤维粘合的棕丝床垫芯材，其特征在于：所述PP熔喷无纺布层由PP纤维熔喷而成，规格为20～100克/平方米。
5.根据权利要求2～4任一项所述的热塑性纤维粘合的棕丝床垫芯材，其特征在于：所述无纺布面层和/或所述PP熔喷无纺布层内掺杂有功能性微粒，所述功能性微粒包括活性炭粉、电气石粉；优选地，所述功能性微粒的粒径为75纳米～5微米。
6.一种热塑性纤维粘合的棕丝床垫芯材的制备方法，其特征在于，包括步骤：
1)分别制备无纺布面层、PP熔喷无纺布层、棕丝纤维层和无纺布底层；
2)将各层材料按次序铺叠，经由烘房对上、下两面以热风喷射式进行热烘，出烘房后再冷轧、冷却固结；
其中，棕丝纤维层的制备：将棕丝纤维梳理铺网形成纤维网层，将热塑性纤维梳理铺网形成热塑性纤维网层，然后将纤维网层的上下表面分别与一层热塑性纤维网层复合，采用正反面针刺法将热塑性纤维网层的热塑性纤维全部刺入纤维网层内部，然后根据纤维网层的厚度在其上表面均匀撒入0～5％的低熔点PP粉末或PE粉末，最后采用热风穿透式热熔粘合法固结，使热塑性纤维与棕丝纤维相互交缠、粘结而形成网层状的棕丝纤维层。
7.根据权利要求6所述的热塑性纤维粘合的棕丝床垫芯材的制备方法，其特征在于，所述无纺布面层由PP纤维纺丝成网，在纺丝过程中向纺丝熔体添加活性炭粉或电气石粉，再热轧粘合而成。
8.根据权利要求6所述的热塑性纤维粘合的棕丝床垫芯材的制备方法，其特征在于，所述PP熔喷无纺布层在PP聚合物熔喷形成纤维的过程中，将活性炭粉或电气石粉均匀喷洒到纤维的表面并附着。
9.根据权利要求6所述的热塑性纤维粘合的棕丝床垫芯材的制备方法，其特征在于，步骤2中烘房温度为140～190℃，冷轧温度为5～25℃，冷却温度为5～25℃。
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