CN111691064A - 一种农业可降解非织造布制造工艺 - Google Patents

一种农业可降解非织造布制造工艺 Download PDF

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CN111691064A
CN111691064A CN202010552914.4A CN202010552914A CN111691064A CN 111691064 A CN111691064 A CN 111691064A CN 202010552914 A CN202010552914 A CN 202010552914A CN 111691064 A CN111691064 A CN 111691064A
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woven fabric
slices
molten polymer
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潘全志
位守强
袁伟华
那海锋
夏佳
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JIANGYIN HUAHONG CHEMICAL FIBER CO Ltd
Jiangyin City Hua Sicheng Nonwovens Co ltd
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JIANGYIN HUAHONG CHEMICAL FIBER CO Ltd
Jiangyin City Hua Sicheng Nonwovens Co ltd
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Abstract

本发明属于纺织技术领域，具体涉及一种农业可降解非织造布制造工艺，包括以下步骤：将PP切片和PPC切片混合均匀，形成混合切片；将混合切片结晶干燥，去除切片中的水分；将混合切片进行螺杆挤压形成熔融聚合物；将熔融聚合物进行杂质过滤；将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布；对非织造布进行冷却、加固、热轧处理；将非织造布浸渍到TiO2粘胶中，通过轧机将粘胶浸润到非织造布内部；将非织造布烘干收卷。本发明通过非织造的方式制造出的可降解布，降解时长短，环保性能好。

Description

一种农业可降解非织造布制造工艺
技术领域
本发明属于纺织技术领域，具体涉及一种农业可降解非织造布制造工艺。
背景技术
无纺布是指不经过编织，而用很多带刺的针将纤维缠绕在一起，或使其部分粘着在一起而成的布料。无纺布(又称不织布)是由定向的或随机的纤维而构成。
采用聚脂(PET材质)为原料，经高温熔融、喷丝、铺网、针刺、收卷连续生产而成。因具有布的外观和某些性能而称其为布。虽为布而不经纺织故称其为无纺布。
非织造布的发展迅速，已深入到了各个领域。目前化学纤维原料中丙纶(聚丙烯PP)占63％，涤纶占23％，粘胶纤维占8％，用它们制成的非织造布难以降解，并不环保。研究发现，织物掩埋在地下后强度未下降，12个月的曝晒后也仍具有60％以上的强力。因此，非织造材料的废弃物给环境保护带来了巨大的压力，纺粘非织造布在即弃产品中使用最多，但使用之后难以降解，给我国的环境带来了巨大的压力，所以制备可生物降解非织造布成为非织造业发展的热点。
发明内容
本发明的目的在于：提供一种农业可降解非织造布制造工艺，降解率高，更具环保性能，适用范围广。
本发明的技术方案为：提供一种农业可降解非织造布制造工艺，包括以下步骤：
步骤1：将PP切片和PPC切片混合均匀，形成混合切片；
步骤2：将混合切片结晶干燥，去除切片中的水分；
步骤3：将混合切片进行螺杆挤压形成熔融聚合物；
步骤4：将熔融聚合物进行杂质过滤；
步骤5：将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布；
步骤6：对非织造布进行冷却处理；
步骤7：对非织造布进行加固处理；
步骤8：对非织造布进行热轧处理；
步骤9：将非织造布浸渍到二氧化钛、氧化锌组成的混合粘胶中，通过轧机将粘胶浸润到非织造布内部，所述二氧化钛与氧化锌的混合质量比例为5:2；
步骤10：将非织造布烘干收卷。
优选地，所述步骤1的具体方法为将PP切片和PPC切片按2:3均匀混合，搅拌均匀PP切片和PPC切片；所述步骤1在PP切片和PPC切片混合物中继续加入阻燃剂和增稠剂，所述阻燃剂与所述PP切片和PPC切片混合物的混合质量比为1:8，所述阻燃剂包括磷酸二氢铵、磷酸氢二胺、磷酸铵中的一种或几种，所述增稠剂为聚氨酷类非碱性增稠剂，所述增稠剂与所述PP切片和PPC切片混合物的混合质量比为1:7。
优选地，所述步骤2中进行结晶干燥的干燥温度为165℃～175℃。
优选地，所述步骤3中将混合切片进行螺杆挤压形成熔融聚合物的具体步骤为：
步骤3-1：将混合切片通过自重从料斗的出料口进入螺杆挤出机，对混合切片进行加热；
步骤3-2：混合切片间进行摩擦和被挤压、剪切，产生一定热能，混合切片在熔化区受热熔融成粘流态的熔融聚合物；
步骤3-3：将熔融聚合物压缩使其具有一定的熔体压力，向熔体管道输送。
优选地，所述步骤5中将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布的方式为采用喷丝板进行牵伸成网，所述步骤5中进行纺丝处理的工艺温度范围为215℃～235℃。
优选地，所述步骤5中对熔融聚合物的熔体压力进行检测，检测熔体压力的传感器测量范围为0～25Mpa。
优选地，还包括步骤11：在非织造布表面涂覆抗菌剂，所述抗菌剂包括异噻唑啉酮、大蒜素和甲壳素，所述异噻唑啉酮、大蒜素和甲壳素的质量比例为2:3:2。
优选地，所述步骤6中对非织造布进行冷却处理的方式为风冷；所述冷却风风温范围为8℃～12℃，吹风湿度为60～70％。
优选地，所述步骤7对非织造布进行加固处理的方式为针刺加固，所述针刺密度为50～60刺/cm2，针刺深度为5.5～7.5mm。
优选地，所述步骤8对非织造布进行热轧处理的方式为双辊热轧；上辊温度为170℃，高于聚丙烯熔点5℃；下辊温度为158℃，低于聚丙烯熔点7℃。
本发明的有益效果：
1、本发明将可光降解的二氧化钛TiO2与可生物降解的聚碳酸亚丙酯PPC同时加入到聚丙烯PP纺粘非织造布中，通过控制降解材料加入的比例可准确预计出PP纺粘非织造布的降解时间。
2、本发明将聚碳酸亚丙酯PPC与聚丙烯PP纺粘非织造布切片进行熔融共混，PPC和PP间进行化学性能、力学性能的优势互补，制备综合性能较优的可生物降解纺粘非织造布。
3、利用本发明制造工艺制造出的可降解非纺织布可便于研究聚碳酸亚丙酯PPC与二氧化钛、氧化锌加入的比例对非织造布的准确降解时间的影响。
4、本发明中纺丝处理的工艺温度范围为215℃～235℃，温度不过高既增加了熔体的流动性能，保证了喷丝的顺畅又不会因温度过高产生大量断头丝、毛丝的情况。
5、本发明纺丝处理过程中经喷丝孔喷出来的熔体细流会放出大量的凝固热，必须对此热流进行热交换，故在离开喷丝板一定距离处，有双侧的侧吹风进行冷却，使熔体的成形中凝固成丝条。在生产过程中，根据喷丝孔熔体挤出量的大小、工艺温度高低及环境温度的变化误差±1℃，决定冷却风风温的高低。根据生产经验，冷却风风温设计在8～12℃之间，吹风湿度控制在65％左右，利于对熔体进行快速合理降温。
6、本发明中对非织造布进行热轧处理的方式为双辊热轧；上辊温度为170℃，高于聚丙烯熔点5℃；下辊温度为158℃，低于聚丙烯熔点7℃。热轧处理方式热稳定性高，热轧温度适宜，不容易燃烧，无毒、无臭、低腐蚀。
7、本发明在非织造布表面涂覆抗菌剂，所述抗菌剂包括异噻唑啉酮、大蒜素和甲壳素，所述异噻唑啉酮、大蒜素和甲壳素的质量比例为2:3:2，异噻唑啉酮能够持久抑菌，高效低毒，大蒜素具有广泛的药理活性，抗菌谱广，对革兰氏阳性菌，革兰氏阴性菌，真菌都具有较好的抑制作用，甲壳素具有天然抑菌功效，广谱抗菌率非常高，三者同时具备良好的可降解性，在对非织造布起到抑菌保护的同时又能同非织造布一起降解。
附图说明
图1为本发明农业可降解非织造布制造工艺的流程图。
具体实施方式
下面结合附图和实施例对本发明作进一步的详细说明。可以理解的是，此处所描述的具体实施例仅用于解释本发明，而非对本发明的限定。另外还需要说明的是，为了便于描述，附图中仅示出了与本发明相关的部分而非全部结构。
请参阅图1所示，本发明提供了一种农业可降解非织造布制造工艺，包括以下步骤：
步骤1：将PP切片和PPC切片混合均匀，形成混合切片；
步骤2：将混合切片结晶干燥，去除切片中的水分；
步骤3：将混合切片进行螺杆挤压形成熔融聚合物；
步骤4：将熔融聚合物进行杂质过滤；
步骤5：将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布；
步骤6：对非织造布进行冷却处理；
步骤7：对非织造布进行加固处理；
步骤8：对非织造布进行热轧处理；
步骤9：将非织造布浸渍到二氧化钛、氧化锌组成的混合粘胶中，通过轧机将粘胶浸润到非织造布内部，所述二氧化钛与氧化锌的混合质量比例为5:2；
步骤10：将非织造布烘干收卷。
所述步骤1的具体方法为将PP切片和PPC切片按2:3均和混合，搅拌均匀PP切片和PPC切片，所述步骤1在PP切片和PPC切片混合物中继续加入阻燃剂和增稠剂，所述阻燃剂与所述PP切片和PPC切片混合物的混合质量比为1:8，所述阻燃剂包括磷酸二氢铵、磷酸氢二胺、磷酸铵中的一种或几种，所述增稠剂为聚氨酷类非碱性增稠剂，所述增稠剂与所述PP切片和PPC切片混合物的混合质量比为1:7。
所述步骤2中进行结晶干燥的干燥温度为165℃～175℃。
所述步骤3中将混合切片进行螺杆挤压形成熔融聚合物的具体步骤为：
步骤3-1：将混合切片通过自重从料斗的出料口进入螺杆挤出机，对混合切片进行加热；
步骤3-2：混合切片间进行摩擦和被挤压、剪切，产生一定热能，混合切片在熔化区受热熔融成粘流态的熔融聚合物；
步骤3-3：将熔融聚合物压缩使其具有一定的熔体压力，向熔体管道输送。
所述步骤5中将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布的方式为采用喷丝板进行牵伸成网。
所述步骤5中进行纺丝处理的工艺温度范围为215℃～235℃。
所述步骤5中对熔融聚合物的熔体压力进行检测，检测熔体压力的传感器测量范围为0～25Mpa。
所述步骤6中对非织造布进行冷却处理的方式为风冷；所述冷却风风温范围为8℃～12℃，吹风湿度为60～70％。
所述步骤7对非织造布进行加固处理的方式为针刺加固，所述针刺密度为50～60刺/cm2，针刺深度为5.5～7.5mm。
所述步骤8对非织造布进行热轧处理的方式为双辊热轧；上辊温度为170℃，高于聚丙烯熔点5℃；下辊温度为158℃，低于聚丙烯熔点7℃。
下面结合具体的实施例对本发明进行详细说明。
实施例一
步骤1：将PP切片和PPC切片按2:3混合均匀，搅拌均匀PP切片和PPC切片形成混合切片；所述步骤1在PP切片和PPC切片混合物中继续加入阻燃剂和增稠剂，所述阻燃剂与所述PP切片和PPC切片混合物的混合质量比为1:8，所述阻燃剂包括磷酸二氢铵、磷酸氢二胺、磷酸铵中的一种或几种，所述增稠剂为聚氨酷类非碱性增稠剂，所述增稠剂与所述PP切片和PPC切片混合物的混合质量比为1:7；
步骤2：将混合切片结晶干燥，去除切片中的水分，干燥温度为165℃；
步骤3：将混合切片进行螺杆挤压形成熔融聚合物；
步骤3包括以下具体步骤：
步骤3-1：将混合切片通过自重从料斗的出料口进入螺杆挤出机，对混合切片进行加热；
步骤3-2：混合切片间进行摩擦和被挤压、剪切，产生一定热能，混合切片在熔化区受热熔融成粘流态的熔融聚合物；
步骤3-3：将熔融聚合物压缩使其具有一定的熔体压力，向熔体管道输送。
步骤4：将熔融聚合物进行杂质过滤；
步骤5：将过滤掉杂质的熔融聚合物进行纺丝处理，采用喷丝板进行牵伸成网，使得熔融聚合物形成成网的非织造布；纺丝处理的工艺温度范围为215℃，对熔融聚合物的熔体压力进行检测，检测熔体压力的传感器测量范围为0～25Mpa。
步骤6：对非织造布进行冷却处理；进行冷却处理的方式为风冷；所述冷却风风温范围为8℃，吹风湿度为60％。
步骤7：对非织造布进行加固处理，进行加固处理的方式为针刺加固，所述针刺密度为50刺/cm2，针刺深度为5.5mm。
步骤8：对非织造布进行热轧处理，进行热轧处理的方式为双辊热轧；上辊温度为170℃，高于聚丙烯熔点5℃；下辊温度为158℃，低于聚丙烯熔点7℃。
步骤9：将非织造布浸渍到二氧化钛、氧化锌组成的混合粘胶中，通过轧机将粘胶浸润到非织造布内部，所述二氧化钛与氧化锌的混合质量比例为5:2；
步骤10：将非织造布烘干收卷。
本实施一制造出的农业可降解非织造布的相关性能见表1。
表1
Figure BDA0002543230310000081
Figure BDA0002543230310000091
实施二
实施二与实施一不同之处在于步骤1中PP切片和PPC切片的比例为1:1，步骤2中的干燥温度为175℃；步骤5中纺丝处理的工艺温度范围为235℃；步骤6中冷却风风温范围为12℃，吹风湿度为70％；步骤7中针刺密度为60刺/cm2，针刺深度为7.5mm。
本实施二制造出的农业可降解非织造布的相关性能见表2。
表2
序号 性能种类 性能数据
1 单位面积质量(g/m<sup>2</sup>) 72
2 断裂强度(MPa)≥ 21
3 最大拉力时延伸率/％≥ 34
4 透光性％≥ 79
5 保温性(较无覆盖地表温度提升℃) 5
6 保湿性(％)≥ 82
7 弃后90天PPC降解率(％)≥ 36
8 弃后6个月TiO<sub>2</sub>降解率(％)≥ 55
实施例三
实施例三与实施一的不同之处在于在于步骤1中PP切片和PPC切片的比例为3:2，步骤2中的干燥温度为170℃；步骤5中纺丝处理的工艺温度范围为225℃；步骤6中冷却风风温范围为10℃，吹风湿度为65％；步骤7中针刺密度为55刺/cm2，针刺深度为6.0mm。
本实施三制造出的农业可降解非织造布的相关性能见表3。
表3
序号 性能种类 性能数据
1 单位面积质量(g/m<sup>2</sup>) 71
2 断裂强度(MPa)≥ 25
3 最大拉力时延伸率/％≥ 36
4 透光性％≥ 82
5 保温性(较无覆盖地表温度提升℃) 5
6 保湿性(％)≥ 80
7 弃后90天PPC降解率(％)≥ 36
8 弃后6个月TiO<sub>2</sub>降解率(％)≥ 53
实施例四
实施例四与实施例三不同的是，在步骤1后还有步骤11：在非织造布表面涂覆抗菌剂，所述抗菌剂包括异噻唑啉酮、大蒜素和甲壳素，所述异噻唑啉酮、大蒜素和甲壳素的质量比例为2:3:2。
本实施四制造出的农业可降解非织造布的相关性能见表4。
表4
Figure BDA0002543230310000101
Figure BDA0002543230310000111
上述实施例一至四中应用到的螺杆挤出机的作用是把高聚物熔融后以匀质、恒定的温度和稳定的压力输出高聚物熔体。聚合物切片靠自重从料斗的出料口进入螺杆挤出机。由于螺杆的转动，切片沿着螺槽向前运动。螺杆套筒外侧安装有加热元件，通过套筒将热量传递给切片。同时，螺杆挤出机内切片的摩擦和被挤压、剪切，亦产生一定的由机械能转化成的热能。聚合物切片在熔化区受热熔融成粘流态的聚合物，并被挤出机压缩而具有一定的熔体压力，向熔体管道输送。
对混合切片进行加热时的加热区域温度见表4。
表4
Figure BDA0002543230310000112
在进行纺丝处理时，由于纺丝泵的转速是生产线产量及产品定量计算及其它工艺参数如冷却风量、拉伸风量、设备线速度设定的基础依据，因此要求纺丝泵调节范围要大，转速变化率(精差率)小，调速平稳。纺丝泵的每转排量在10～100cm3/r之间变化，其调速范围为9.5～105cm3/r，精差率小于0.001，能以0.1r/min为单位进行速度设定。
在聚丙烯纺粘法非织造布生产过程中，熔体压力一般控制在6～10MPa之间，因此为保证正常生产，在纺丝箱体上都安装有测量范围为0～25MPa的熔体压力传感器，以测量熔体压力。为了保持熔体的粘度不会因散热、降温而变大，影响熔体的流动，纺丝泵除了有良好的保温措施外，还像其出入口管道一样，设置了必要的加热装置，自动控制熔体的温度，对于聚丙烯熔体，这个温度应在200℃以上。
纺丝组件是由喷丝板、熔体分配板、熔体过滤材料及组装套的结合件、密封件组成，其主要作用是将计量泵送来的熔体进行最后一次过滤，混合均匀后分配到每一个喷丝孔中，形成均匀的细流。采用的是德国卡尔菲休的喷丝板，单独的整条矩形喷丝板，喷丝板纺丝孔数在孔以上，利用一条窄缝进行牵伸，成网均匀，布面均匀度很好。
纺丝箱体主要由加热管、导热板、分配管、组件等组成。纺丝箱体通过导热油循环加热，加热体为油炉。为节省能源，保证生产所需的工艺温度，纺丝箱体应进行保温保护，以防热量流失。根据生产要求，为了增加熔体的流动性能，保证喷丝的顺畅，纺丝箱体的温度应稍高些。但过高的箱体温度会发生大量的断头丝、毛丝，不利于生产的顺利进行。纺丝箱体通常的工艺温度范围为190℃～265℃，常用温度为225℃±10℃。
非织造布的应用范围如下：
①露地浮面覆盖，保温；②塑料大棚内的浮面覆盖；③棚内或温室的二道保温幕；④塑料棚的棚外保温层；⑤温室、大棚内的防滴水层；⑥容器的垫底材料以及无土栽培中的衬底；⑦防暴雨台风；⑧防病虫害、防鸟。目前已成功地应用于几十种农作物上，包括胡罗卜、洋葱、西红柿、草莓、罗马甜瓜、黄瓜、豆类作物、马铃薯、毛豆、卷心菜、白菜、菠菜、芹菜、姜类蔬菜、韭菜、茶树、烟草和果树等。其中露地和大棚内的浮面覆盖、棚或温室的二道幕使用最普遍。纺粘非织造布在农业中的应用正在不断开拓扩大，用量也在不断增长。上海、广东等省市的农用丰收布的销量近年来都大幅度提高，用于浮面覆盖的数量也大幅增长。本发明制造出的农业可降解非织造布具有广阔的应用空间及应用范围。
注意，上述仅为本发明的较佳实施例及所运用技术原理。本领域技术人员会理解，本发明不限于这里所述的特定实施例，对本领域技术人员来说能够进行各种明显的变化、重新调整和替代而不会脱离本发明的保护范围。因此，虽然通过以上实施例对本发明进行了较为详细的说明，但是本发明不仅仅限于以上实施例，在不脱离本发明构思的情况下，还可以包括更多其他等效实施例，而本发明的范围由所附的权利要求范围决定。

Claims (10)

1.一种农业可降解非织造布制造工艺，其特征在于，包括以下步骤：
步骤1：将PP切片和PPC切片混合均匀，形成混合切片；
步骤2：将混合切片结晶干燥，去除切片中的水分；
步骤3：将混合切片进行螺杆挤压形成熔融聚合物；
步骤4：将熔融聚合物进行杂质过滤；
步骤5：将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布；
步骤6：对非织造布进行冷却处理；
步骤7：对非织造布进行加固处理；
步骤8：对非织造布进行热轧处理；
步骤9：将非织造布浸渍到二氧化钛、氧化锌组成的混合粘胶中，通过轧机将粘胶浸润到非织造布内部，所述二氧化钛与氧化锌的混合质量比例为5:2；
步骤10：将非织造布烘干收卷。
2.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤1的具体方法为将PP切片和PPC切片按2:3均匀混合，搅拌均匀PP切片和PPC切片；所述步骤1在PP切片和PPC切片混合物中继续加入阻燃剂和增稠剂，所述阻燃剂与所述PP切片和PPC切片混合物的混合质量比为1:8，所述阻燃剂包括磷酸二氢铵、磷酸氢二胺、磷酸铵中的一种或几种，所述增稠剂为聚氨酷类非碱性增稠剂，所述增稠剂与所述PP切片和PPC切片混合物的混合质量比为1:7。
3.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤2中进行结晶干燥的干燥温度为165℃～175℃。
4.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤3中将混合切片进行螺杆挤压形成熔融聚合物的具体步骤为：
步骤3-1：将混合切片通过自重从料斗的出料口进入螺杆挤出机，对混合切片进行加热；
步骤3-2：混合切片间进行摩擦和被挤压、剪切，产生一定热能，混合切片在熔化区受热熔融成粘流态的熔融聚合物；
步骤3-3：将熔融聚合物压缩使其具有一定的熔体压力，向熔体管道输送。
5.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤5中将过滤掉杂质的熔融聚合物进行纺丝处理，使得熔融聚合物形成成网的非织造布的方式为采用喷丝板进行牵伸成网；所述步骤5中进行纺丝处理的工艺温度范围为215℃～235℃。
6.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，还包括步骤11：在非织造布表面涂覆抗菌剂，所述抗菌剂包括异噻唑啉酮、大蒜素和甲壳素，所述异噻唑啉酮、大蒜素和甲壳素的质量比例为2:3:2。
7.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤5中对熔融聚合物的熔体压力进行检测，检测熔体压力的传感器测量范围为0～25Mpa。
8.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤6中对非织造布进行冷却处理的方式为风冷；所述冷却风风温范围为8℃～12℃，吹风湿度为60～70％。
9.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤7对非织造布进行加固处理的方式为针刺加固，所述针刺密度为50～60刺/cm2，针刺深度为5.5～7.5mm。
10.根据权利要求1所述的农业可降解非织造布制造工艺，其特征在于，所述步骤8对非织造布进行热轧处理的方式为双辊热轧；上辊温度为170℃，高于聚丙烯熔点5℃；下辊温度为158℃，低于聚丙烯熔点7℃。
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