CN112622354A - 墙布用活性炭无纺布及其制作方法 - Google Patents
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Abstract
墙布用活性炭无纺布，包括以无纺布为基层设置的活性炭，其特征在于：所述无纺布层表面均匀分布呈几何形状的凹槽单元，在每个凹槽单元内喷涂有粘胶层，且每个凹槽单元所设粘胶层表面均嵌设有活性炭颗粒群。本发明鄙弃常规制作方法，创新的通过在无纺布表面压制出凹槽单元，在凹槽单元内设置粘胶层，再通过喷沙机喷设活性炭颗粒使得活性炭颗粒均匀排布于粘胶层上，在活性炭质量分数小，活性炭无纺布的载炭量不变的情况下，大大增加了活性炭实际与空气的接触表面积，将活性炭的表面积发挥到最大，且也使得活性炭无纺布成品的重量最轻。本发明还公开了其制作方法。
Description
技术领域
本发明涉及一种墙布用活性炭无纺布，且还公开了其制作方法。
背景技术
活性炭因其表面发达的孔隙物理结构带来了其较强的吸附性能，但因活性炭为颗粒，聚集之后自身无法成型。而通过与无纺布结合使得活性炭依附于无纺布的成型性，给活性炭的的应用带来了更加广阔的应用场景。
如活性炭无纺布常被用于墙布的复合，这样使得墙布具有净化空气，除甲醛等功效。但就目前的活性炭无纺布而言，主要是将活性炭与粘合剂混合，活性炭大部分没入粘合剂内使得活性炭的吸附性能降低，而且制作活性炭无纺布时工艺也较为复杂，需要配制浸渍液，且过程需要除粘合剂外的分散剂及其他助剂的辅助。最终依据如活性炭质量分数，活性炭无纺布的载炭量等参数得到吸附值不同的活性炭无纺布。
发明内容
本发明的目的就是为了解决现有活性炭无纺布制作工艺复杂，吸附性能差，提供了一种制作工艺简单，吸附性能强的墙布用活性炭无纺布，并且还公开了其制作方法。
墙布用活性炭无纺布，包括以无纺布为基层设置的活性炭，其特征在于：所述无纺布层表面均匀分布呈几何形状的凹槽单元，在每个凹槽单元内喷涂有粘胶层，且每个凹槽单元所设粘胶层表面均嵌设有活性炭颗粒群。
所述凹槽单元的凹槽口设有粘胶用于与制作所述墙布的面料层复合。
所述凹槽单元的底部与凹槽口的高度至少0.1mm。
所述凹槽单元的底部面积不小于1mm2。
无纺布的制作方法，其特征在于：包括如下步骤：
a)按常规工艺制作或购买无纺布进行基材准备；
b)将无纺布通过一表面呈几何形状凹槽单元阵列的压辊，压制出呈几何形状凹槽单元的表面；
c)对应凹槽单元所在无纺布的表面刷上粘胶层；
d)将活性炭颗粒通过喷沙机喷在粘胶层上；
e)将无纺布晾干即可。
在步骤c与步骤d之间还设有吹风处理，所述吹风处理为冷风，且对应无纺布粘胶层表面吹风口为倾斜，并且吹风口与无纺布之间为相对运动，在吹风口吹运下使粘胶层厚度保持在10um~60um。
在步骤d与步骤e之间还设有一次吹风处理，所述吹风处理亦为冷风，吹风口为两个且前后设置，彼此吹风方向交叉与无纺布表面呈倾斜，两个吹风口与无纺布之间相对运动方向上为横向放置。
本发明的有益效果如下：
与现有技术相比，本发明鄙弃常规制作方法，创新的通过在无纺布表面压制出凹槽单元，在凹槽单元内设置粘胶层，再通过喷沙机喷设活性炭颗粒使得活性炭颗粒均匀排布于粘胶层上，在活性炭质量分数小，活性炭无纺布的载炭量不变的情况下，大大增加了活性炭实际与空气的接触表面积将活性炭的表面积发挥到最大，且也使得活性炭无纺布成品的重量最轻。
附图说明：
图1是本发明所述无纺布的结构示意图。
具体实施方式：
下面结合附图对本发明作进一步详细的阐述。
参阅图1，墙布用活性炭无纺布，包括以无纺布1为基层设置的活性炭2，所述无纺布1层表面均匀分布呈几何形状的凹槽单元3，在每个凹槽单元3内喷涂有粘胶层，且每个凹槽单元3所设粘胶层表面均嵌设有活性炭颗粒群。所述活性炭选用的颗粒大小在10um到100um之间。所述几何形状可以为圆形，三角形以及矩形，甚至可以是多边形，在本发明中，优先为图形之间最靠近能够充分排布在无纺布1表面的图形，如三角形，矩形中的正方形、长方形等。
在本发明中，因活性炭2是嵌设在粘胶层内，所以其大部分的表面都是露在外侧，大大的保证了活性炭的吸附作用。并且因为凹槽单元3的结构设置，将活性炭2划单分区域管理，凹槽槽口提供了部分在无纺布表面的强度，可以起到一定的保护凹槽单元3作用，如凹槽单元3内的活性炭颗粒群2随无纺布1在一些特殊情况下被折叠时产生的扭曲应力使部分活性炭脱离粘胶层。
另外，上述结构只涉及到粘胶层与活性炭并不涉及其他的辅助试剂，降低了成本，也缩减了很大部分的制作步骤。
进一步，作为对本发明的改进，所述凹槽单元3的凹槽口设有粘胶4用于与制作所述墙布的面料层复合。在本发明中，凹槽单元3的凹槽口设置粘胶4为活性炭无纺布提供了进一步使用的空间，而且在复合其他面料层时并不影响到凹槽单元3内活性炭颗粒群与空气接触的空间。
进一步，作为对本发明的改进，所述凹槽单元3的底部与凹槽口的高度至少0.1mm。
在本发明中，底部与凹槽口的高度的限定，为活性炭颗粒群嵌入粘胶层后暴露在空气中的表面积提供了空间。
进一步，作为对本发明的改进，所述凹槽单元3的底部面积不小于1mm2。
在本发明中，底部面积不应设置的过大，也不应设置的过小，过小会影响到压辊的加工，压辊加过无纺布时无纺布的成型效果，以及保证压辊压一次就能成型的加工目的。
无纺布的制作方法，包括如下步骤：
a)按常规工艺制作或购买无纺布进行基材准备；
b)将无纺布通过一表面呈几何形状凹槽单元阵列的压辊，压制出呈几何形状凹槽单元的表面；
c)对应凹槽单元所在无纺布的表面刷上粘胶层；
d)将活性炭颗粒通过喷沙机喷在粘胶层上；
e)将无纺布晾干即可。
在上述步骤中，无纺布通常为自行生产，这样在后期可以与压辊以及喷沙机等直接整合成一套生产设备，这样方便一次性生产活性炭无纺布。
无纺布通过转辊从一端带往另一端，其开始段上设置压辊，所述压辊表面设有呈几何形状的的凹凸，视压制效果情况可增加或调整压辊的加热功能。
粘胶层的粘胶可由刷胶转辊进行接触刷胶，亦可由喷枪进行刷胶，胶层厚度应控制在合理范围，不能过厚，因此在凹槽，厚度以凹槽槽口边沿进行计算，通常保持在高于凹槽槽口边沿1毫米左右。
活性炭颗粒通过喷沙机喷在粘胶层时，需要根据无纺布收卷速度以及喷沙时的强弱度进行调节，调试时以喷沙机的喷沙口向下喷时，以每凹槽单元内所喷活性炭颗粒填充三分之一为宜。喷沙时，无纺布在上，喷沙机的喷沙口向上喷，这样未嵌入的活性炭颗粒会自动掉落，掉落的活性炭颗粒回收后再置入喷沙机内使用。
进一步，作为对本发明的改进，在步骤c与步骤d之间还设有吹风处理，所述吹风处理为冷风，且对应无纺布粘胶层表面吹风口为倾斜，并且吹风口与无纺布之间为相对运动，在吹风口吹运下使粘胶层厚度保持在10um~60um。
在本发明中，吹风口设置为一整排横向跨越无纺布，倾斜之后可使凹槽单元内过多的粘胶吹出，从而使其粘胶层的厚度在凹槽单元内可以保持在10um~60um之间，使得活性炭在嵌入时可以保证每颗活性炭大部分的表面露在空间中。
进一步，作为对本发明的改进，在步骤d与步骤e之间还设有一次吹风处理，所述吹风处理亦为冷风，吹风口为两个且前后设置，彼此吹风方向交叉与无纺布表面呈倾斜，两个吹风口与无纺布之间相对运动方向上为横向放置。
在该步骤中，可以将未嵌入粘胶层的活性炭吹出凹槽单元甚至是无纺布。
Claims (7)
1.墙布用活性炭无纺布，包括以无纺布为基层设置的活性炭，其特征在于：所述无纺布层表面均匀分布呈几何形状的凹槽单元，在每个凹槽单元内喷涂有粘胶层，且每个凹槽单元所设粘胶层表面均嵌设有活性炭颗粒群。
2.根据权利要求1所述的墙布用活性炭无纺布，其特征在于：所述单元的凹槽口设有粘胶用于与制作所述墙布的面料层复合。
3.根据权利要求1所述的墙布用活性炭无纺布，其特征在于：所述凹槽凹槽单元的底部与凹槽口的高度至少0.1mm。
4.根据权利要求1所述的墙布用活性炭无纺布，其特征在于：所述凹槽单元的底部面积不小于1mm2。
5.无纺布的制作方法，其特征在于：包括如下步骤：
a)按常规工艺制作或购买无纺布进行基材准备；
b)将无纺布通过一表面呈几何形状凹槽单元阵列的压辊，压制出呈几何形状凹槽单元的表面；
c)对应凹槽单元所在无纺布的表面刷上粘胶层；
d)将活性炭颗粒通过喷沙机喷在粘胶层上；
e)将无纺布晾干即可。
6.根据权利要求5所述的无纺布的制作方法，其特征在于：在步骤c与步骤d之间还设有吹风处理，所述吹风处理为冷风，且对应无纺布粘胶层表面吹风口为倾斜，并且吹风口与无纺布之间为相对运动，在吹风口吹运下使粘胶层厚度保持在10um~60um。
7.根据权利要求5所述的无纺布的制作方法，其特征在于：在步骤d与步骤e之间还设有一次吹风处理，所述吹风处理亦为冷风，吹风口为两个且前后设置，彼此吹风方向交叉与无纺布表面呈倾斜，两个吹风口与无纺布之间相对运动方向上为横向放置。
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