CN111593559A - 一种高强屏蔽布材料的生产工艺 - Google Patents
一种高强屏蔽布材料的生产工艺 Download PDFInfo
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- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/83—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
- D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
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- D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
- D06M13/02—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with hydrocarbons
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- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/01—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with natural macromolecular compounds or derivatives thereof
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- D06M15/01—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with natural macromolecular compounds or derivatives thereof
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Abstract
本发明公开了一种高强屏蔽布材料的生产工艺,其包括:在有机基材中加入油剂进行上油,制得第一混合物;对所述第一混合物进行卷绕,制得POY丝;将所述POY丝进行加热、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝;将所述DTY丝进行整经,形成经、纬股线;将经、纬股线通过喷气织机进行编织,制得胚布;将所述胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;在所述精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及通过热压机对导电布进行多次热压,热压完毕后进行磨光。本发明生产出的高强屏蔽布材料强度和布面丝条均匀度较高。
Description
领域
本发明涉及布料生产工艺,特别涉及一种高强屏蔽布材料的生产工艺。
背景
随着科学技术和电子信息工业的迅速发展,各种电子、电器设备已经遍及人们生活和工作的各个领域,给人们生活和工作带来众多便利。但电磁辐射会干扰广播、电视、通讯等设备的正常工作,还会对人体健康造成伤害。因此,研究和开发具有屏蔽电磁波作用的材料,对减少电磁辐射伤害具有重要意义。
目前电磁屏蔽布材料的制备方法主要有:金属丝与服用纱线混编、金属纤维与服用纤维混纺、共混纺丝织物等,这几种方法是在织物形成工艺上进行设计,存在屏蔽效能不高的缺点;化学镀、电镀、涂层浸渍及各种纳米后整理方式制备的电磁屏蔽布材料效能高,但是依然存在制备的电磁屏蔽布材料强度不高及布面丝条不均匀的问题。
概述
本公开涉及一种高强屏蔽布材料的生产工艺,其包括:
在有机基材中加入油剂进行上油,制得第一混合物;
对所述第一混合物进行卷绕,制得POY丝;
将所述POY丝进行加热、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝;
将所述DTY丝进行整经,形成经、纬股线;
将经、纬股线通过喷气织机进行编织,制得胚布;
将所述胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在所述精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光。
详述
在以下的说明中,包括某些具体的细节以对各个公开的实施方案提供全面的理解。然而,相关领域的技术人员会认识到,不采用一个或多个这些具体的细节,而采用其他方法、部件、材料等的情况下仍实现实施方案。
除非本公开中另有要求,在整体说明书和所附的权利要求中,词语“包括”、“包含”、“含有”和“具有”应解释为开放式的、含括式的意义,即“包括但不限于”。
在整体说明书中提到的“一实施方案”、“实施方案”、“在另一实施方案中”或“在某些实施方案中”意指在至少一实施方案中包括与该实施方案所述的相关的具体参考要素、结构或特征。因此,在整个说明书中不同位置出现的短语“在一实施方案中”或“在实施方案中”或“在另一实施方案中”或“在某些实施方案中”不必全部指同一实施方案,此外,具体要素、结构或特征可以任何适当的方式在一个或多个实施方案中结合。
定义
在本公开中,术语“假捻”是指把一根绳子的两端固定,在中间加捻,一边越捻越紧,就而虽另一边也越捻越紧,但捻向相反,因此在绳子上的总捻数是没有变化的,仍然为0,所以加的就叫假捻。
在本公开中,术语“上油”为改善初生丝或其成品纤维在后加工及其在后续纺织加工中的加工性能(如集束性、平滑性、抗静电性、开松性等),在制得初生丝之后或在初生丝的后加过程中,对加工中纤维施以上油剂加工工序的总称。
在本公开中,术语“卷绕”是指纺织生产中把半制品和成品按一定规律绕成各种卷装的工艺过程。
在本公开中,术语“整经”是指将一定根数的经纱按规定的长度和宽度平行卷绕在经轴或织轴上的工艺过程。
在本公开中,术语“上浆”是指将纱线用浆料进行处理,增加强度,防止或减少纱线在织造时产生断头,提高工作效率的工艺过程。
在本公开中,“涤纶PET”是合成纤维中的一个重要品种,是聚酯纤维的商品名称。它是以精对苯二甲酸(PTA)或对苯二甲酸二甲酯(DMT)和乙二醇(EG)为原料经酯化或酯交换和缩聚反应而制得的成纤高聚物-聚对苯二甲酸乙二醇酯(PET),经纺丝和后处理制成的纤维。
在本公开中,术语“平滑剂”是双氨基官能团有机硅乳液,是纺织品的柔软整理剂。
在本公开中,术语“乳化剂”是指能使两种或两种以上互不相溶的组分的混合液体形成稳定的乳状液的一类化合物。其作用原理是在乳化过程中,分散相以微滴(微米级)的形式分散在连续相中,乳化剂降低了混合体系中各组分的界面张力,并在微滴表面形成较坚固的薄膜或由于乳化剂给出的电荷而在微滴表面形成双电层,阻止微滴彼此聚集,而保持均匀的乳状液。
在本公开中,术语“D”是纺织纤维的一种单位,称“丹尼尔”,意思是:单位长度的纤维的重量,与tex互为倒数。
具体实施方式
本公开涉及一种高强屏蔽布材料的生产工艺,其包括:
在有机基材中加入油剂进行上油,制得第一混合物;
对所述第一混合物进行卷绕,制得POY丝;
将所述POY丝进行加热、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝;
将所述DTY丝进行整经,形成经、纬股线;
将经、纬股线通过喷气织机进行编织,制得胚布;
将所述胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在所述精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光。
在某些实施方案中,按重量份数计,DTY丝由50至80份有机基材、10至20份油剂制得。
在某些实施方案中,有机基材选自涤纶PET,优选为粘度为0.9dL/g的涤纶PET。
在某些实施方案中,油剂的制备方法为:于30至70℃下,将平滑剂加入反应釜中搅拌15至30min;接着,将乳化剂、添加剂加入反应釜中,搅拌3至8h;以及冷却,过滤,出料。
在某些实施方案中,按重量份数计,所述油剂由70至90份平滑剂、5至10份乳化剂、5至10份添加剂制得。
在某些实施方案中,平滑剂选自矿物油、黄油或其混合物。
在某些实施方案中,乳化剂选自是脂肪醇聚氧乙烯醚、脂肪酸聚氧乙烯醚、椰子油烷醇酰胺、失水山梨醇脂肪酸酯或其混合物。
在某些实施方案中,脂肪醇聚氧乙烯醚选自C8~C12的脂肪醇聚氧乙烯醚。
在某些实施方案中,脂肪酸聚氧乙烯醚选自C4~C12的脂肪酸聚氧乙烯醚。
在某些实施方案中,添加剂选自是抗飞溅剂、硅油或其混合物。
在某些实施方案中,抗飞溅剂选自改性聚烷撑化合物。
在某些实施方案中,硅油选自甲基硅油。
在某些实施方案中,加热温度为160至180℃。
在某些实施方案中,假捻的控制牵伸倍数为1.5至1.8。
在某些实施方案中,定型的温度为120至140℃。
在某些实施方案中,整经采用分轴整经方式,整经根纱为3400,整经车速800m/min,张力杆隔距为2mm,压辊压力为200daN。
在某些实施方案中,还包括整经后的上浆步骤。
在某些实施方案中,浆料选自天然浆料。
在某些实施方案中,天然浆料选自淀粉、海藻胶或其混合物。
在某些实施方案中,浆料选自合成浆料。
在某些实施方案中,合成浆料选自聚乙二醇、聚乙烯醇、聚丙烯酸酯或其混合物。
在某些实施方案中,喷气织机采用环形喷嘴。
在某些实施方案中,环形喷嘴的气压为2.4至2.6kgf/cm2,纺织速度为680至720m/min;热压条件为:140至160℃,20至30s。
下文中,本公开将通过如下实施例进行详细解释以便更好地理解本申请的各个方面及其优点。然而,应当理解,以下的实施例是非限制性的而且仅用于说明本公开的某些实施方案。
实施例
实施例1
于30℃下,将70份矿物油加入反应釜中搅拌15min;接着,将5份C8~C12的脂肪醇聚氧乙烯醚、5份改性聚烷撑化合物加入反应釜中,搅拌3h;以及冷却,过滤,出料;
在50份粘度为0.9dL/g的涤纶PET中加入10份油剂进行上油,制得第一混合物;对第一混合物进行卷绕,制得POY丝;
将POY丝进行加热至160℃、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝,其中:假捻的控制牵伸倍数为1.5,所述定型的温度为120℃;
将DTY丝进行整经,形成经、纬股线,其中:整经采用分轴整经方式,整经根纱为3400,整经车速800m/min,张力杆隔距为2mm,压辊压力为200daN;
上浆,其中:浆料选自淀粉;
将经、纬股线通过喷气织机进行编织,制得胚布,其中:喷气织机采用环形喷嘴,环形喷嘴的气压为2.4kgf/cm2,纺织速度为680m/min;
将胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光,生产出一种高强屏蔽布材料,其中:热压条件为:140℃,20s。
实施例2
于45℃下,将75份黄油加入反应釜中搅拌20min;接着,将7份C8~C12的脂肪醇聚氧乙烯醚、7份改性聚烷撑化合物加入反应釜中,搅拌5h;以及冷却,过滤,出料;
在60份粘度为0.9dL/g的涤纶PET中加入13份油剂进行上油,制得第一混合物;对第一混合物进行卷绕,制得POY丝;
将POY丝进行加热至165℃、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝,其中:假捻的控制牵伸倍数为1.6,所述定型的温度为125℃;
将DTY丝进行整经,形成经、纬股线,其中:整经采用分轴整经方式,整经根纱为3400,整经车速800m/min,张力杆隔距为2mm,压辊压力为200daN;
上浆,其中:浆料选自海藻胶;
将经、纬股线通过喷气织机进行编织,制得胚布,其中:喷气织机采用环形喷嘴,环形喷嘴的气压为2.5kgf/cm2,纺织速度为690m/min;
将胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光,生产出一种高强屏蔽布材料,其中:热压条件为:145℃,23s。
实施例3
于60℃下,将80份平滑剂黄油加入反应釜中搅拌25min;接着,将9份乳化剂乳化剂C4~C12的脂肪酸聚氧乙烯醚、9份甲基硅油加入反应釜中,搅拌7h;以及冷却,过滤,出料;
在70份粘度为0.9dL/g的涤纶PET中加入16份油剂进行上油,制得第一混合物;对第一混合物进行卷绕,制得POY丝;
将POY丝进行加热至170℃、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝,其中:假捻的控制牵伸倍数为1.7,所述定型的温度为130℃;
将DTY丝进行整经,形成经、纬股线,其中:整经采用分轴整经方式,整经根纱为3400,整经车速800m/min,张力杆隔距为2mm,压辊压力为200daN;
上浆,其中:浆料选自聚乙烯醇;
将经、纬股线通过喷气织机进行编织,制得胚布,其中:喷气织机采用环形喷嘴,环形喷嘴的气压为2.6kgf/cm2,纺织速度为700m/min;
将胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光,生产出一种高强屏蔽布材料,其中:热压条件为:155℃,26s。
实施例4
于70℃下,将90份黄油加入反应釜中搅拌30min;接着,将10份C4~C12的脂肪酸聚氧乙烯醚、10份改性聚烷撑化合物加入反应釜中,搅拌8h;以及冷却,过滤,出料;
在80份粘度为0.9dL/g的涤纶PET中加入20份油剂进行上油,制得第一混合物;对第一混合物进行卷绕,制得POY丝;
将POY丝进行加热至180℃、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝,其中:假捻的控制牵伸倍数为1.8,所述定型的温度为140℃;
将DTY丝进行整经,形成经、纬股线,其中:整经采用分轴整经方式,整经根纱为3400,整经车速800m/min,张力杆隔距为2mm,压辊压力为200daN;
上浆,其中:浆料选自聚丙烯酸酯;
将经、纬股线通过喷气织机进行编织,制得胚布,其中:喷气织机采用环形喷嘴,环形喷嘴的气压为2.6kgf/cm2,纺织速度为720m/min;
将胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光,生产出一种高强屏蔽布材料,其中:热压条件为:160℃,30s。
实施例5
为了进一步验证本发明生产的一种高强屏蔽布材料,对实施例1-4的高强屏蔽布材料的性能进行了研究,其性能参数如表1所示。
表1实施例1-4的高强屏蔽布材料的性能参数
从表1中可知,采用粘度为0.9dg/L的涤纶PET及油剂为原料,制备出的DTY丝强度较高,进而减少了镀铜镀镍和织造上浆退浆步骤中布面强度的降低,大幅提高了织造的效率与速度,不易使得单根纤维断裂,使得布面成品率得以提高,可达99.99%的布面产出效率;制备出的DTY丝均匀度较好,进而使得布面丝条均匀平整,在镀铜镀镍份过程中,铜镍小分子均匀涂覆在布面的每个缝隙内,使得铜镍的均匀镀层达到平整均匀,从而提高了屏蔽布材料布面的强度及均匀度。与普通的强性布相比,本发明生产出的屏蔽布材料的强度大约提高了28至30%。
综上所述:通过先将金属镍镀在胚布上,接着在镍上再镀上高导电性的铜层,最后在铜层上再电镀上防氧化防腐蚀的镍金属,制得导电布,铜和镍结合提供了极佳的导电性和良好的电磁屏蔽效果。
同时,采用粘度为0.9dg/L的涤纶PET及油剂为原料,制备出的DTY丝强度较高,均匀度较好,进而提高布面的强度及布面丝条的均匀度。
从前述中可以理解,尽管为了示例性说明的目的描述了本公开的具体实施方案,但是在不偏离本公开的精神和范围的条件下,本领域所述技术人员可以作出各种变形或改进、这些变形或修改都应落入本公开所附权利要求的范围。
Claims (10)
1.一种高强屏蔽布材料的生产工艺,其包括:
在有机基材中加入油剂进行上油,制得第一混合物;
对所述第一混合物进行卷绕,制得POY丝;
将所述POY丝进行加热、假捻、定型、上油和卷绕步骤,制得纤度为5D的DTY丝;
将所述DTY丝进行整经,形成经、纬股线;
将经、纬股线通过喷气织机进行编织,制得胚布;
将所述胚布浸泡在精炼剂、漂白剂的溶液后,进行洗净、脱水步骤,制得精炼白布;
在所述精炼白布上用真空镀法镀镍,再连续电镀铜和镍,制得导电布;以及
通过热压机对导电布进行多次热压,热压完毕后进行磨光。
2.如权利要求1所述的生产工艺,其中按重量份数计,DTY丝由50至80份有机基材、10至20份油剂制得。
3.如权利要求1所述的生产工艺,其中:所述有机基材选自涤纶PET,优选为粘度为0.9dL/g的涤纶PET。
4.如权利要求1所述的生产工艺,其中所述油剂的制备方法为:
于30至70℃下,将平滑剂加入反应釜中搅拌15至30min;
接着,将乳化剂、添加剂加入反应釜中,搅拌3至8h;以及
冷却,过滤,出料。
5.如权利要求4所述的生产工艺,其中按重量份数计,所述油剂由70至90份平滑剂、5至10份乳化剂、5至10份添加剂制得。
6.如权利要求5所述的生产工艺,所述平滑剂选自矿物油、黄油或其混合物;所述乳化剂选自是脂肪醇聚氧乙烯醚、脂肪酸聚氧乙烯醚、椰子油烷醇酰胺、失水山梨醇脂肪酸酯或其混合物,优选所述脂肪醇聚氧乙烯醚选自C8~C12的脂肪醇聚氧乙烯醚,优选所述脂肪酸聚氧乙烯醚选自C4~C12的脂肪酸聚氧乙烯醚;所述添加剂选自是抗飞溅剂、硅油或其混合物,优选所述抗飞溅剂选自改性聚烷撑化合物,优选所述硅油选自甲基硅油。
7.如权利要求1所述的生产工艺,其中:所述加热温度为160至180℃,所述假捻的控制牵伸倍数为1.5至1.8,所述定型的温度为120至140℃。
8.如权利要求1所述的生产工艺,其中所述整经采用分轴整经方式,整经根纱为3400,整经车速800m/min,张力杆隔距为2mm,压辊压力为200daN。
9.如权利要求8所述的生产工艺,其还包括整经后的上浆步骤,优选浆料选自天然浆料,更优选所述天然浆料选自淀粉、海藻胶或其混合物;优选浆料选自合成浆料,更优选所述合成浆料选自聚乙二醇、聚乙烯醇、聚丙烯酸酯或其混合物。
10.如权利要求1至9中任一权利要求所述的生产工艺,其中所述喷气织机采用环形喷嘴,环形喷嘴的气压为2.4至2.6kgf/cm2,纺织速度为680至720m/min;热压条件为:140至160℃,20至30s。
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