CN111531977B - 一种宽幅底布的制造方法 - Google Patents

一种宽幅底布的制造方法 Download PDF

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CN111531977B
CN111531977B CN202010394829.XA CN202010394829A CN111531977B CN 111531977 B CN111531977 B CN 111531977B CN 202010394829 A CN202010394829 A CN 202010394829A CN 111531977 B CN111531977 B CN 111531977B
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景巍巍
乐荣飞
袁飞
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Jinlun Clothing Silver Co ltd
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Abstract

本发涉及一种宽幅底布及其制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；制造方法包括涂敷胶粘剂、压延表面橡胶面、成型复合、硫化等过程。底布成品宽度最宽可达到1.60m，工艺操作简单，生产效率高，底布平整度≤0.10mm，经向强力≥10000N，经向断裂伸长率≤17%，纬向强力≥3500N，橡胶面回弹性≥48%，粘合剥离力≥30N，性价比高。

Description

一种宽幅底布的制造方法
技术领域
本发明属于复合材料领域，尤其涉及一种作为新型超宽梳棉用盖板针布的基底材料—整体硫化型高握持性、高强度宽幅底布及其制造方法。
背景技术
市场梳棉机尤其国外智能化高产梳棉机往宽幅方向发展趋势越来越明显，宽幅盖板底布（底布宽度≥1.30m）为盖板针布市场高端产品必须使用得底布材料，目前宽幅盖板底布国内基本采用拼接方式进行生产，工艺传统落后，需要将棉布折叠进行三辊压延出型，先出型其中一面，再出型另外一面，展开后进行拼接，后先进行橡胶面硫化，然后再与基层进行贴合，此工艺存在生产工艺复杂、效率低，拼接平整度差，且基部没有与橡胶面一起实现硫化，粘合剥离力不均匀现象。
整体无拼接式宽幅盖板底布，市场被进口底布占据（主要有印度、瑞士Graf公司底布）；进口底布一方面采购周期长（需求6个月），另一方面价格较高，性价比低；此外国外采用刮浆自硫化工艺进行生产，此工艺采用多次刮浆后烘箱硫化，在线进行贴合，生产工艺复杂、效率低，橡胶面回弹性低，且基部没有与橡胶面一起实现硫化，粘合剥离力不均匀现象。
发明内容
本发明的目的是克服现有技术的缺陷，提供一种宽幅底布的制造方法。
为实现上述目的，本发明采取的技术方案为：一种宽幅底布的制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；
制造方法如下：
（1）涂敷胶粘剂：首先用涂敷机对上层棉布A、中层棉布和下层棉布B根据贴合顺序依次涂敷胶粘剂，涂敷机烘箱温度控制在60~80℃，涂完后的棉布存放备用；
（2）压延表面橡胶面：将表面橡胶面用混炼胶经过开炼机热炼再经过三辊压延机压延，在上层棉布A表面贴合形成表面橡胶面，开炼机预热表面橡胶面用混炼胶温度控制为75~85℃，三辊压延机出型辊温控制在75~85℃，调整出型厚度为0.80~0.85mm；
（3）成型复合：将形成表面橡胶面的上层棉布A与步骤（1）中备用的中层棉布和下层棉布B通过成型复合机进行复合，得到初步成型盖板底布；
（4）将初步成型盖板底布经过鼓式硫化机进行硫化，熟化后制成盖板底布，控制硫化速度0.30~0.40m/min、硫化压力7~15MPa、硫化温度150~160℃。
所述表面橡胶面用混炼胶由以下重量份的原料混炼制成：泰国3号天然橡胶100份、硫磺0.9~1.5份、促进剂A 2.6~3.2份、氧化锌4~6份、硬脂酸0.5~2份、碳酸钙50~60份、钛白粉0.5~2份、酞菁绿0.05~0.1份、铬黄0.3~0.5份、苯乙烯化苯酚粉末1~2份、LY-03型防护蜡0.1~1份、环烷油0~7份。
所述棉布A、棉布B、棉布C均采用：棉布用纱：经向用长绒棉精梳纱、纬向用精梳纱；棉布纱支：经向21S/2、纬向16S；棉布密度：经向密度75~85根/英寸、纬向密度65~75根/英寸；棉布厚度0.43~0.48mm、经向断裂强力≥1600N、断裂伸长率≤17%、纬向断裂强力≥700N。
所述胶粘剂由中间层用混炼胶与汽油按质量比1：3~1：4混合制成；
所述中间层用混炼胶由如下重量份数的原料混炼制成：泰国3号天然橡胶100份、硫磺1.3~1.6份、促进剂B 2.6~3.2份、氧化锌4~6份、硬脂酸0.5~2份、碳酸钙10~20份、松香4~8份、酞菁绿0.01~0.1份。
所述促进剂A为N-环己基-2-苯并噻唑次磺酰胺与2、2'-二硫代二苯并噻唑按1:1比例混合的混合物。
所述所述促进剂B为2、2'-二硫代二苯并噻唑和2一巯基苯并噻唑按1:1比例的混合物。
本发明有益效果是：底布成品宽度最宽可达到1.60m，工艺操作简单，生产效率高，底布平整度≤0.10mm，经向强力≥10000N，经向断裂伸长率≤17%，纬向强力≥3500N，橡胶面回弹性≥48%，粘合剥离力≥30N，性价比高。
具体实施方式
以下对本发明的原理和特征进行描述，所举实例只用于解释本发明，并非用于限定本发明的范围。
实施例1，一种宽幅底布的制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；所述棉布A、棉布B、棉布C采用棉布用纱：经向用长绒棉、纬向用精梳纱；棉布纱支：经向21S/2、纬向16S；棉布密度：经向密度80根/英寸、纬向密度70根/英寸；棉布厚度0.44~0.45mm、经向断裂强力1756N、断裂伸长率14.4%、纬向断裂强力853N。
制造方法如下：
（1）涂敷胶粘剂：首先用涂敷机对上层棉布A、中层棉布和下层棉布B根据贴合顺序依次涂敷胶粘剂，涂敷机烘箱温度控制在60~80℃，涂完后的棉布存放备用；其中棉布A采用两面涂敷胶粘剂正面涂敷薄层厚度为0~0.01mm、反面涂敷层厚度为0.02~0.03mm，以正反面卷绕不反粘为准，不垫衬布存放；棉布C采用两面涂敷，正反面涂敷层厚度均为0.02~0.03mm，垫卷衬布存放，棉布B仅正面涂敷，涂敷层厚度为0.02~0.03mm；
（2）压延表面橡胶面：将表面橡胶面用混炼胶经过开炼机热炼再经过三辊压延机压延，在上层棉布A表面贴合形成表面橡胶面，开炼机预热表面橡胶面用混炼胶温度控制为75~85℃，三辊压延机出型辊温控制在75~85℃，调整出型厚度为0.80~0.85mm；
（3）成型复合：将形成表面橡胶面的上层棉布A与步骤（1）中备用的中层棉布和下层棉布B通过成型复合机进行复合，得到初步成型盖板底布；
（4）将初步成型盖板底布经过直径为1.25m鼓式硫化机进行硫化，熟化后制成盖板底布，硫化工艺见表1。
所述表面橡胶面用混炼胶见表1中重量份的原料混炼制成：
所述胶粘剂由中间层用混炼胶与汽油按质量比1：3.5混合制成；
所述中间层用混炼胶由如下重量份数的原料混炼制成：泰国3号天然橡胶100份、硫磺5份、2、2'-二硫代二苯并噻唑1.5份，2-巯基苯并噻唑1.5份、氧化锌5份、硬脂酸1份、碳酸钙16份、松香6份、酞菁绿0.03份。
实施例2，一种宽幅底布的制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；所述棉布A、棉布B、棉布C采用棉布用纱：经向用长绒棉、纬向用精梳纱；棉布纱支：经向21S/2、纬向16S；棉布密度：经向密度80根/英寸、纬向密度70根/英寸；棉布厚度0.44~0.45mm、经向断裂强力1756N、断裂伸长率14.4%、纬向断裂强力853N。
制造方法同实施例1，只是表面橡胶面用混炼胶见表1中重量份的原料混炼制成；硫化工艺见表1。
所述中间层用混炼胶同实施例1。
性能检测指标见表2。
实施例3，一种宽幅底布的制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；所述棉布A、棉布B、棉布C采用棉布用纱：经向用长绒棉、纬向用精梳纱；棉布纱支：经向21S/2、纬向16S；棉布密度：经向密度80根/英寸、纬向密度70根/英寸；棉布厚度0.44~0.45mm、经向断裂强力1756N、断裂伸长率14.4%、纬向断裂强力853N。
制造方法同实施例1，只是表面橡胶面用混炼胶见表1中重量份的原料混炼制成；硫化工艺见表1。
所述中间层用混炼胶同实施例1。
性能检测指标见表2。
实施例4，一种宽幅底布的制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；所述棉布A、棉布B、棉布C采用棉布用纱：经向用长绒棉、纬向用精梳纱；棉布纱支：经向21S/2、纬向16S；棉布密度：经向密度80根/英寸、纬向密度70根/英寸；棉布厚度0.44~0.45mm、经向断裂强力1756N、断裂伸长率为14.4%、纬向断裂强力为853N。
制造方法同实施例1，只是表面橡胶面用混炼胶见表1中重量份的原料混炼制成；硫化工艺见表1。
所述中间层用混炼胶同实施例1。
性能检测指标见表2。
表1：实施例数据表
Figure DEST_PATH_IMAGE001
表2：性能检测指标
Figure 206426DEST_PATH_IMAGE002

Claims (3)

1.一种宽幅底布的制造方法，其特征在于：宽幅底布由基部和其表面的橡胶面复合硫化而成；所述基部由上层棉布A、中层棉布和下层棉布B用胶粘剂粘合而成；所述中层棉布由四层棉布C用胶粘剂粘合；
制造方法如下：
（1）涂敷胶粘剂：首先用涂敷机对上层棉布A、中层棉布和下层棉布B根据贴合顺序依次涂敷胶粘剂，涂敷机烘箱温度控制在60~80℃，涂完后的棉布存放备用；
（2）压延表面橡胶面：将表面橡胶面用混炼胶经过开炼机热炼再经过三辊压延机压延，在上层棉布A表面贴合形成表面橡胶面，开炼机预热表面橡胶面用混炼胶温度控制为75~85℃，三辊压延机出型辊温控制在75~85℃，调整出型厚度为0.80~0.85mm；
（3）成型复合：将形成表面橡胶面的上层棉布A与步骤（1）中备用的中层棉布和下层棉布B通过成型复合机进行复合，得到初步成型盖板底布；
（4）将初步成型盖板底布经过鼓式硫化机进行硫化，熟化后制成盖板底布，控制硫化速度0.30~0.40m/min、硫化压力7~15MPa、硫化温度150~160℃；
所述表面橡胶面用混炼胶由以下重量份的原料混炼制成：泰国3号天然橡胶100份、硫磺0.9~1.5份、促进剂A 2.6~3.2份、氧化锌4~6份、硬脂酸0.5~2份、碳酸钙50~60份、钛白粉0.5~2份、酞菁绿0.05~0.1份、铬黄0.3~0.5份、苯乙烯化苯酚粉末1~2份、LY-03型防护蜡0.1~1份、环烷油0~7份；
所述棉布A、棉布B、棉布C均采用：棉布用纱：经向用长绒棉精梳纱、纬向用精梳纱；棉布纱支：经向21S/2、纬向16S；棉布密度：经向密度75~85根/英寸、纬向密度65~75根/英寸；棉布厚度0.43~0.48mm、经向断裂强力≥1600N、断裂伸长率≤17%、纬向断裂强力≥700N；
所述胶粘剂由中间层用混炼胶与汽油按质量比1：3~1：4混合制成；
所述中间层用混炼胶由如下重量份数的原料混炼制成：泰国3号天然橡胶100份、硫磺1.3~1.6份、促进剂B 2.6~3.2份、氧化锌4~6份、硬脂酸0.5~2份、碳酸钙10~20份、松香4~8份、酞菁绿0.01~0.1份。
2.如权利要求1所述的一种宽幅底布的制造方法，其特征在于：所述促进剂A为N-环己基-2-苯并噻唑次磺酰胺与2、2'-二硫代二苯并噻唑按1:1比例混合的混合物。
3.如权利要求1所述的一种宽幅底布的制造方法，其特征在于：所述促进剂B为2、2'-二硫代二苯并噻唑和2一巯基苯并噻唑按1:1比例的混合物。
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