CN112693193A - 一种空气雾化吸水毡及其制备工艺 - Google Patents

一种空气雾化吸水毡及其制备工艺 Download PDF

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CN112693193A
CN112693193A CN202110065458.5A CN202110065458A CN112693193A CN 112693193 A CN112693193 A CN 112693193A CN 202110065458 A CN202110065458 A CN 202110065458A CN 112693193 A CN112693193 A CN 112693193A
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layer
water
absorbent
water absorption
needling
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王洪云
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Nantong Xinlvye Nonwovens Co ltd
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Nantong Xinlvye Nonwovens Co ltd
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  • Engineering & Computer Science (AREA)
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  • Wood Science & Technology (AREA)
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Abstract

本发明公开了一种空气雾化吸水毡及其制备工艺，从上至下依次包括表层、吸水树脂层、吸水纤维层、亲水无纺布层和底层，所述吸水树脂层通过胶体粘接在所述表层的下方，所述吸水纤维层通过胶体粘接在所述吸水树脂层的下方，所述亲水无纺布层通过胶体粘接在所述吸水纤维层的下方，所述吸水纤维层由聚丙烯纤维和超吸水纤维交替排列制备而成。本发明的一种空气雾化吸水毡及其制备工艺，可以有效提高原玻璃纤维薄毡材料的韧性，提高其抗拉升的能力，同时使材料具备吸湿防潮和吸收有害物质净化空气的作用。

Description

一种空气雾化吸水毡及其制备工艺
技术领域
本发明涉及一种非织造材料，具体涉及一种碳纤混合毡及其制备工艺。
背景技术
非织造材料又称非织造布、非织布、非织造织物、无纺织物或无纺布。 非织造技术是一门源于纺织，但又超越纺织的材料加工技术。它结合了纺 织、造纸、皮革和塑料四大柔性材料加工技术，并充分结合和运用了诸多 现代高新技术，如计算机控制、信息技术、高压射流、等离子体、红外、 激光技术等。无论在航天技术、环保治理、农业技术、医用保健或是人们 的日常生活等许多领域，非织造新材料已成为一种愈来愈广泛的重要产品。
随着人们对生活质量要求的提高，用作一次性用品或者医用材料的非 织造材料的舒适度是受关注比较高的方面。吸湿、蓄水、高倍亲水非织造 材料作为一次性用品，具有传统纺织品无法比拟的经济效益和性能优势。 但是，作为非织造材料原料的纤维聚合物多是非极性结构，结晶度较高且 无亲水基，因此制备成的非织造材料的吸湿性、锁水性能比较差。改善非 织造材料的吸湿、锁水性能及舒适度，对扩展非织造材料的广泛应用是一 个比较重要的方向。
发明内容
发明目的：本发明的目的是为了解决现有技术中的不足，提供一种空 气雾化吸水毡及其制备工艺，可以有效提高原玻璃纤维薄毡材料的韧性， 提高其抗拉升的能力，同时使材料具备吸湿防潮和吸收有害物质净化空气 的作用。
技术方案：本发明所述的一种空气雾化吸水毡，从上至下依次包括表 层、吸水树脂层、吸水纤维层、亲水无纺布层和底层，所述吸水树脂层通 过胶体粘接在所述表层的下方，所述吸水纤维层通过胶体粘接在所述吸水 树脂层的下方，所述亲水无纺布层通过胶体粘接在所述吸水纤维层的下方， 所述吸水纤维层由聚丙烯纤维和超吸水纤维交替排列制备而成。
进一步的，所述吸水树脂层包括吸水树脂小球和棉布。
进一步的，所述棉布有两层且四周相互缝合，所述两层棉布之间设置 多条相互平行的缝合线使两层棉布之间形成多条相互平行的通道，所述吸 水树脂小球大量分布在所述通道内。
进一步的，所述亲水无纺布层中碳纤维的细度为2.2dtex。
进一步的，所述表层的面密度为100-150克每平方米，吸水树脂层的 面密度为30-50克每平方米，吸水纤维层的面密度为40-60克每平方米， 亲水无纺布层的面密度为20-30克每平方米，底层的面密度为100-150克 每平方米。
进一步的，所述表层、吸水树脂层、吸水纤维层、亲水无纺布层和底 层相互之间通过非水溶性的高分子胶体进行粘接。
进一步的，所述表层上表面以及底层下表面涂覆有聚四氟乙烯涂层。
本发明还公开了上述一种空气雾化吸水毡的制备工艺，包括如下步骤：
(1)原料选取，采用吸水纤维，亲水无纺织布为原料；
(2)将上述原料按一定比例进行称重；
(3)切断：将上述原料纤维切断；
(4)开松：将上述原料纤维分别经过开包机进行纤维的初步开包，然 后输送至预开松机，然后输送至混棉机，最后输送至主开松机；
(5)成网：成网梳理工序采用单锡林、双道夫罗拉式梳理机进行，然 后采用交叉式铺网机进行均匀铺网；
(6)针刺成毡：预刺刺针和主刺刺针采用Y型针，预刺向下刺的针 刺深度为9-11mm，向下刺的主针刺深度为7-9mm，针刺成毡即可；
(7)将针刺成毡的各层与吸水树脂、表层以及底层铺设成网，且相互 之间通过高分子胶体进行粘接。
有益效果：本发明的一种空气雾化吸水毡及其制备工艺，可以有效提 高原玻璃纤维薄毡材料的韧性，提高其抗拉升的能力，同时使材料具备吸 湿防潮和吸收有害物质净化空气的作用。
附图说明
图1为本发明空气雾化吸水毡的结构剖视图；
图2为本发明亲水无纺布层的结构剖视图。
具体实施方式
下面详细描述本发明的实施方式，所述实施方式的示例在附图中示出。 下面通过参考附图描述的实施方式是示例性的，仅用于解释本发明，而不 能解释为对本发明的限制。
如图1所示的一种空气雾化吸水毡，从上至下依次包括表层1、吸水 树脂层2、吸水纤维层3、亲水无纺布层4和底层5，所述吸水树脂层2通 过胶体粘接在所述表层1的下方，所述吸水纤维层3通过胶体粘接在所述 吸水树脂层2的下方，所述亲水无纺布层4通过胶体粘接在所述吸水纤维 层3的下方，所述吸水纤维层3由聚丙烯纤维31和超吸水纤维32交替排列制备而成。
作为上述实施例的进一步优化：
本实施例中优选地，所述吸水树脂层2包括吸水树脂小球和棉布。所 述棉布有两层且四周相互缝合，所述两层棉布之间设置多条相互平行的缝 合线使两层棉布之间形成多条相互平行的通道，所述吸水树脂小球大量分 布在所述通道内。吸水树脂小球通过放入通道内而形成吸水树脂层，这样 当吸水树脂失效后可以拆开并更换吸水树脂有效提高材料的寿命，同时使 吸水树脂小球均匀分布。
本实施例中优选地，所述表层1的面密度为100-150克每平方米，吸 水树脂层2的面密度为30-50克每平方米，吸水纤维层3的面密度为40-60 克每平方米，亲水无纺布层4的面密度为20-30克每平方米，底层5的面 密度为100-150克每平方米。
本实施例中优选地，所述表层1、吸水树脂层2、吸水纤维层3、亲水 无纺布层4和底层5相互之间通过非水溶性的高分子胶体进行粘接。
本实施例中优选地，所述表层1上表面以及底层5下表面涂覆有聚四 氟乙烯涂层。
上述一种空气雾化吸水毡的制备工艺，包括如下步骤：
(1)原料选取，采用吸水纤维，亲水无纺织布为原料；
(2)将上述原料按一定比例进行称重；
(3)切断：将上述原料纤维切断；
开松好的纤网的均匀度较差，最终致使高端车内饰阻燃材料的力学性 能不稳定；若针刺工艺配置不好，则会造成针刺针损伤纤维，最终使制备 出的高端车内饰阻燃材料在特定的工艺下，拉伸和耐磨性能达不到最大值， 甚至会出现大幅度下降的可能。可见纤维之间的开松、混合、梳理和针刺 工艺对最终产品性能的影响很大，工艺之间的合理配置是高端车内饰材料 优良性能的必要条件。
(4)开松：将上述原料纤维分别经过开包机进行纤维的初步开包，然 后输送至预开松机，然后输送至混棉机，最后输送至主开松机。
首先原料要经过YYKB-110开包机进行纤维的初步开包，并经角钉帘输 送YYKS-150型预开松机，其中为了防止输送纤维时掉毛和产生静电而缠 绕，喂入得平帘采用皮帘输入，同时角钉帘表面包覆丁腈橡胶防静电专用 皮帘，这样把原料和木帘棒隔开，防止纤维和木帘棒的缠绕；然后，原料经 过预开松机输送到YYHM-220型大仓混棉机，4种原料在仓里进行进一步的 混合，而后进入YYKS-150型主开松机。纤维开松根据纤维的细度、类型、性能等选用分步开松，先将腈纶纤维和锦纶纤维开松混合，再与碳纤维、 预氧丝开松混合。开松后再经混合，可以将不同等级、不同品种的纤维混 合均匀。分步法的开松混合更加细致，混合的均匀性更佳。
(5)成网：成网梳理工序采用单锡林、双道夫罗拉式梳理机进行，然 后采用交叉式铺网机进行均匀铺网；
经过开松与混合之后，纤维原料进入梳理工序，梳理工序是纤维成网 的关键工序，纤维的梳理工序采用YYSL-185型单锡林、双道夫罗拉式梳 理机进行，本设备适用于1.5D-20Dx25mm-76m的化学纤维梳理成网，单 锡林高速梳理，双道夫出棉多、降低了电能、产量高。YYSL-185型梳理 机的4根090mm罗拉，包缠金属针布，分上、下两组配对，其中第一对上 罗拉轴承座及传动齿轮为尼龙件具有金属检测功能，并有倒车和自停报警 功能；锡林直径中为1230mm,两道夫直径中为492mm,工作辊直径φ为155mm,剥毛辊直径φ为122mm,刺辊直径φ为295mm。原料经过锡林、 工作辊、剥取辊的分梳和剥取作用之后，初始的原料成单根纤维薄网状态， 其面密度一般在25g/m2左右，针刺工序中需要的纤维网一般需要进一步的 铺网来增加厚度和平方米克重。
采用YYPW-300型交叉式铺网机，该铺网机铺网往复分六断速精准控 制，将纤网不匀率控制到最低。根据250g/m2克重及纤维网均匀要求确定 铺网层数为10层。
(6)针刺成毡：预刺刺针和主刺刺针采用Y型针，预刺向下刺的针 刺深度为9-11mm，向下刺的主针刺深度为7-9mm，针刺成毡即可。
针刺工艺参数的不同，对制备出来的非织造材料性能有很大的影响。 本课题首先对影响产品性能的主要针刺工艺参数进行分析，根据不同的原 料性能指标和产品的性能要求，合理设置针刺工艺参数，以制得性能更优 的产品。
针刺加固是一种典型的机械加固方法，针刺加固的基本原理:用截面为 三角形或其他形状且其棱上带有钩齿的金属针，对蓬松的纤网进行反复穿 刺。当数以万计的刺针刺入纤网时，刺针棱上的齿钧就会钩住纤网上下表 层和里层的纤维，随着刺针的刺入运动，被刺针的棱钩住的纤维发生了位 移的变化，即钩住的纤维在纤维网截面内进行穿插运动，使纤维在运动的 过程中相互交织和缠结在一起。由于刺针对纤网摩擦力的作用和纤网中纤 维上下位移变动对纤网产生了一定的挤压，使得因压缩而变薄。刺针刺入 纤网一定深度后回升，此时的刺针是做顺向运动，刺针沟槽中的纤维脱离 刺针近似垂直状态滞留在纤网之中，就像销钉一样钉入纤网，使已经压缩 的纤维不再回复原状，这样刺针往复的运动就使纤网制成了又一定厚度和 强度的复合材料。
①刺针：刺针是针刺机中最为重要的一个机件，其规格和质量直接影 响无纺布的外观和质量，因此对刺针的形状、规格、选材和制造精度的选 择尤为重要。本发明预刺刺针和主刺刺针的刚度均为HV635，此剌针的加 工经过渗氦处理，机械性能强韧、耐磨、使用寿命长。采用Y型针，该针 切入角呈弧形，能避免损伤纤维，同时齿钩带的纤维量均匀。由于切入槽 不深，刺针不易断，则织物结构和外观质量和拉伸强度较均匀。预刺刺针 规格15x18x36x3R28-333YP3.2,主刺刺针规格15x28x36x3M24-222Y.P3.2。 从预刺刺针和主刺刺针的规格中可以看出，预刺刺针钩刺针体单棱上有三 个齿钩，而主刺刺针的钩刺针体的单棱有两个齿钩。
②针刺深度:针刺深度指刺针针尖到托网板上表面之间的距离，即刺针 穿过纤网后伸出网外的长度。当选用的刺针一定后，刺针深度大时，针刺 带动的纤维大，纤维间的穿插缠结效果充分。但是针刺深度要适当，深度 过分大了会使纤维的损伤较大，造成纤维的断裂较多，使得织物的强度降 低，同时也会使针折断较多。制备内饰阻燃材料的平方米克重为250g/m2， 结合上述分析预刺向下刺得针刺深度设定在9-11mm,向下刺得主刺针刺深度设定7-9mm范围内，同时向上刺得针刺深度分别降低4mm.
③针刺密度:针刺密度指单位面积维网内所受到的刺针数。针刺密度 大，织物的强力也会提高，若针刺密度过大，则会造成断针，从而影响产 品质量.课题选取预刺机植针密度4000针/m2,输出速度1.35m/min,针刺频 率346针/min；主刺机植针密度7000针/m2,输出速度1.35m/min,针刺频 率666针/min。则预刺机针刺密度为102.5针/cm2,主刺机针刺密度为345.3 针/cm2。
(7)将针刺成毡的各层与吸水树脂、表层以及底层铺设成网，且相互 之间通过高分子胶体进行粘接。
本发明的一种空气雾化吸水毡及其制备工艺，可以有效提高原玻璃纤 维薄毡材料的韧性，提高其抗拉升的能力，同时使材料具备吸湿防潮和吸 收有害物质净化空气的作用。
以上所述，仅是本发明的较佳实施例而已，并非对本发明作任何形式 上的限制，虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发 明，任何熟悉本专业的技术人员，在不脱离本发明技术方案范围内，当可 利用上述揭示的技术内容作出些许更动或修饰为等同变化的等效实施例， 但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施 例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (7)

1.一种空气雾化吸水毡，其特征在于：从上至下依次包括表层（1）、吸水树脂层（2）、吸水纤维层（3）、亲水无纺布层（4）和底层（5），所述吸水树脂层（2）通过胶体粘接在所述表层（1）的下方，所述吸水纤维层（3）通过胶体粘接在所述吸水树脂层（2）的下方，所述亲水无纺布层（4）通过胶体粘接在所述吸水纤维层（3）的下方，所述吸水纤维层（3）由聚丙烯纤维（31）和超吸水纤维（32）交替排列制备而成。
2.根据权利要求1所述的一种空气雾化吸水毡，其特征在于：所述吸水树脂层（2）包括吸水树脂小球和棉布。
3.根据权利要求2所述的一种空气雾化吸水毡，其特征在于：所述棉布有两层且四周相互缝合，所述两层棉布之间设置多条相互平行的缝合线使两层棉布之间形成多条相互平行的通道，所述吸水树脂小球大量分布在所述通道内。
4.根据权利要求1所述的一种空气雾化吸水毡，其特征在于：所述表层（1）的面密度为100-150克每平方米，吸水树脂层（2）的面密度为30-50克每平方米，吸水纤维层（3）的面密度为40-60克每平方米，亲水无纺布层（4）的面密度为20-30克每平方米，底层（5）的面密度为100-150克每平方米。
5.根据权利要求1所述的一种空气雾化吸水毡，其特征在于：所述表层（1）、吸水树脂层（2）、吸水纤维层（3）、亲水无纺布层（4）和底层（5）相互之间通过非水溶性的高分子胶体进行粘接。
6.根据权利要求1所述的一种空气雾化吸水毡，其特征在于：所述表层（1）上表面以及底层（5）下表面涂覆有聚四氟乙烯涂层。
7.根据权利要求1-6任意一项所述的一种空气雾化吸水毡的制备工艺，其特征在于：包括如下步骤：
（1）原料选取，采用吸水纤维，亲水无纺织布为原料；
（2）将上述原料按一定比例进行称重；
（3）切断：将上述原料纤维切断；
（4）开松：将上述原料纤维分别经过开包机进行纤维的初步开包，然后输送至预开松机，然后输送至混棉机，最后输送至主开松机；
（5）成网：成网梳理工序采用单锡林、双道夫罗拉式梳理机进行，然后采用交叉式铺网机进行均匀铺网；
（6）针刺成毡：预刺刺针和主刺刺针采用Y型针，预刺向下刺的针刺深度为9-11mm，向下刺的主针刺深度为7-9mm，针刺成毡即可；
（7）将针刺成毡的各层与吸水树脂、表层以及底层铺设成网，且相互之间通过高分子胶体进行粘接。
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