CN112726022B - 一种聚丙烯-聚乙烯复合无纺布的制备方法 - Google Patents

一种聚丙烯-聚乙烯复合无纺布的制备方法 Download PDF

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CN112726022B
CN112726022B CN202110018128.0A CN202110018128A CN112726022B CN 112726022 B CN112726022 B CN 112726022B CN 202110018128 A CN202110018128 A CN 202110018128A CN 112726022 B CN112726022 B CN 112726022B
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郑天翔
杨旭辉
苏步安
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Junfu Nonwovens Zhaoqing Co ltd
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    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
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Abstract

本发明提供一种聚丙烯‑聚乙烯复合无纺布的制备方法，所述制备方法，包括开清、梳理、铺网、针刺；所述开清、梳理步骤均加入抗静电剂。本发明在保证针刺无纺布的优良性能同时，通过添加一定比例的聚乙烯纤维（PE）来降低针刺无纺布整体的熔点，附图1的DSC（检测材料熔点）中可看出纯丙烯针刺无纺布要比PE/聚丙烯针刺无纺布熔点高出近30℃，因此在超声波焊接过程中能够使纤维充分熔融热粘合，达到焊接牢固，固定弹簧的效果。本发明通过采用两道抗静电剂的加入，以及对针刺工艺、热定型工艺的改进，避免了聚乙烯的加入对聚丙烯‑聚乙烯复合无纺布强度和布面均匀性的影响。

Description

一种聚丙烯-聚乙烯复合无纺布的制备方法
技术领域
本发明提供一种聚丙烯-聚乙烯复合无纺布的制备方法，属于无纺布技术领域。
背景技术
目前，市面上的弹簧床垫就结构而言，大致可分连结式、独立袋装、线状直立式、线状整体式及袋装线状整体式弹簧等。
其中袋装独立筒弹簧床垫将每一个独立体弹簧施压之后装填入袋，再加以连结排列而成，不同列间的弹簧袋再以粘胶或点焊互相粘合，每个弹簧体皆个别运作，独立支撑，能单独伸缩，当个别弹簧受到压力压缩时不会影响周围弹簧。
现有的袋装独立弹簧材料使用的原材料主要是聚丙烯无纺布，按工艺类型可划分为纺粘无纺布和针刺无纺布，纺粘无纺布成本低，但强力低，使用寿命短，手感硬、脆，摩擦时会产生很大噪音，影响睡眠。针刺无纺布强力高，布面摩擦系数小，因此针刺聚丙烯无纺布更适合用作弹簧包布。
但在使用超声波焊接机焊接成独立袋结构时，由于聚丙烯的熔点较高，在高速焊接的环境下，焊接点的纤维无法充分熔融导致焊接不牢，无法固定住弹簧，造成袋内弹簧的跑位变形。
聚乙烯（PE）纤维聚熔点为130℃左右，纤维形态结构与聚丙烯纤维具有优异的高温熔融流动性，化学稳定性，耐老化耐低温性，但物理强度要低于聚丙烯。
聚乙烯加入聚丙烯中，虽然可以降低针刺无纺布整体的熔点，但是会导致无纺布的强度下降，还会影响布面的均匀性。
发明内容
针对现有技术存在的不足，本发明提供一种聚丙烯-聚乙烯复合无纺布的制备方法，实现以下发明目的：降低针刺无纺布的熔点，提高复合无纺布的强度和布面均匀性。
为解决上述技术问题，本发明采取以下技术方案：
一种聚丙烯-聚乙烯复合无纺布的制备方法，述制备方法，包括开清、梳理、铺网、针刺；所述开清、梳理步骤均加入抗静电剂。
以下是对上述技术方案的进一步改进：
所述开清步骤，抗静电剂的加入量为0.8-1.2%；所述梳理步骤，抗静电剂的加入量为1.7-2.3%。
所述抗静电剂，型号为HY-5520。
所述针刺，经过预针刺下刺、主针刺上刺、主针刺下刺工序，所述预针刺下刺，针刺密度为95-105刺/cm2；所述主针刺上刺，针刺深度为11-13 mm。
所述预针刺下刺，针刺深度为10-12 mm；所述主针刺上刺，针刺密度为137-142刺/cm2；所述主针刺下刺，针刺深度6-8mm，针刺密度125-135刺/cm2。
所述预针刺用针的规格： 15×18×38×3 CBA；
主针刺用针的规格： 15×18×38×3.5 RBA；
采用的原料为聚乙烯纤维、聚丙烯纤维，质量比为13-17:83-87。
所述聚乙烯纤维的强度≥4.0 cN/dtex；所述聚丙烯纤维的强度≥5.0 cN/dtex。
所述聚乙烯纤维规格：2.5D*51mm；
聚丙烯纤维规格：3D*76mm；
所述制备方法，还包括热定型，所述热定型，温度为160-170℃，两个光辊夹持间距是0.6-0.8mm，光辊直径580-610mm，夹持压力95-105kN/m；
所述复合无纺布，熔点为140-150℃。
所述复合无纺布，纵向断裂强力≧150N，横向断裂强力≧190N。
本发明采用以上技术方案，与现有技术相比，具有以下有益效果：
（1）本发明在保证针刺无纺布的优良性能同时，通过添加一定比例的聚乙烯纤维（PE）来降低针刺无纺布整体的熔点，附图1的DSC（检测材料熔点）中可看出纯丙烯针刺无纺布要比PE/聚丙烯针刺无纺布熔点高出近30℃，因此在超声波焊接过程中能够使纤维充分熔融热粘合，达到焊接牢固，固定弹簧的效果。
（2）本发明通过采用两道抗静电剂的加入，以及对针刺工艺、热定型工艺的改进，避免了聚乙烯的加入对聚丙烯-聚乙烯复合无纺布强度和布面均匀性的影响。本发明制备的复合无纺布，克重为70-80 g/m2，纵向断裂强力为155-160 N，横向断裂强力为190-200N，纵向撕裂强力为124-130 N，横向撕裂强力为118-122 N；纵向断裂伸长率为60-65%，横向断裂伸长率为80-85%，纵向45N伸长率为12-12.5%，横向45N伸长率为21-21.5%；布面克重均匀性较高，标准偏差为3-3.5g/m2。
附图说明
图1为实施例1制备的聚丙烯-聚乙烯复合无纺布和聚丙烯无纺布的DSC对比图。
具体实施方式
实施例1一种聚丙烯-聚乙烯复合无纺布的制备方法
包括开清、梳理、铺网、针刺 、热定型；
原料：15%聚乙烯纤维+85%聚丙烯纤维；
聚乙烯纤维规格：2.5D*51mm；
聚丙烯纤维规格：3D*76mm；
聚乙烯纤维强度≥4.0 cN/dtex；
聚丙烯纤维强度≥5.0 cN/dtex。
具体步骤如下：
一、开清工序
无纺布制备的开清工艺采用两开松称重带混合式设备。
开清过程中两台抓棉机按照比例添加两种不同原料；
选用二台德国TEMAFA公司制造的抓棉机，设定的参数(涉及到的速度都是按照控制电机速度范围从0～100%表示)如下：
输棉帘：速度为20m/min；
光电控制：监测物料状态实行自动控制喂料；
均棉罗拉：速度为60rpm；
角钉帘：速度为30m/min；
剥棉打手：速度为80rpm；
活门：根据称斗填充原料达到设定的2000g后关闭，其余时间是打开状态；
秤斗：两台抓棉机都设定2000g；
秤斗活门：两台抓棉机称斗同时达到设定的2000g后打开；
混棉帘子：秤斗活门打开后运行至秤斗活门关闭时停止；
开清工序，向纤维原料中喷洒抗静电油剂， 抗静电剂型号：HY-5520，含量：12%，粘度：3 mm2/s，PH值：7.8，添加量：1%。
二、梳理工序
本次生产选用了法国进口NSC公司制造的针布罗拉梳理机，设定梳理机喂入纤维量的克重为40克每平方米，生产线速度为20m/min；
在梳理过程中，向胸锡林处喷洒抗静电油剂，抗静电剂型号：HY-5520，含量：12%，粘度：3 mm2/s，PH值：7.8，添加量：2%。
三、铺网工序
生产时铺网层数5层，铺网宽度6米，搭接系数:0.070m，铺网机输入幅宽为2.25m；
每层网的重量为20g/m2。
四、针刺工艺
针刺工序选用法国NSC公司制造的针刺机三台：预针刺下刺1台、主针刺上刺1台、主针刺下刺1台。
生产工艺参数：
① 预针刺下刺:针刺深度11mm，针刺密度100刺/cm2；
② 主针刺上刺: 针刺深度12mm，针刺密度140刺/cm2；
③主针刺下刺: 针刺深度7mm，针刺密度130刺/cm2。
预针刺用针的规格： 15×18×38×3 CBA
主针刺用针的规格： 15×18×38×3.5 RBA
上述预针刺下刺、主针刺上刺、主针刺下刺的顺序是预针刺：下刺；第一道主针刺：上刺；第二道主针刺：下刺。
五、热定型
本次生产使用热轧法工艺对产品进行进一步的加固以使产品形态能够达到所需要的施工硬挺程度，生产时的设定温度值是165℃，两个光辊夹持间距是0.7mm，光辊直径600mm，夹持压力100kN/m，生产速度19m/min，制备得到聚丙烯-聚乙烯无纺布，熔点为144℃。
对比例1
在实施例1的基础上，仅是在开清工序添加1%的抗静电剂，在梳理工序不添加抗静电剂，针刺工艺改变为：
预针刺下刺:针刺深度11mm，针刺密度85刺/cm2；
主针刺上刺: 针刺深度8mm，针刺密度140刺/cm2；
主针刺下刺: 针刺深度7mm，针刺密度130刺/cm2。
其余工艺同实施例1，制备得到聚丙烯-聚乙烯无纺布。
Figure 933270DEST_PATH_IMAGE002
4米幅宽的无纺布横幅上等间距取10个点，每个点的克重如下表： 单位(g/m2)
Figure 319252DEST_PATH_IMAGE004
可见，本发明实施例1制备的复合无纺布，布面克重分布更均匀。
除非特殊说明，本发明采用的比例均为质量比例，采用的百分比均为质量百分比。

Claims (5)

1.一种聚丙烯-聚乙烯复合无纺布的制备方法，其特征在于：所述制备方法，包括开清、梳理、铺网、针刺；
所述开清、梳理步骤均加入抗静电剂；所述抗静电剂，型号为HY-5520；
所述开清步骤，抗静电剂的加入量为0.8-1.2%；所述梳理步骤，抗静电剂的加入量为1.7-2.3%；
所述针刺，经过预针刺下刺、主针刺上刺、主针刺下刺工序；
所述预针刺下刺，针刺密度为95-105刺/cm2；所述主针刺上刺，针刺深度为11-13 mm；
所述预针刺下刺，针刺深度为10-12 mm；所述主针刺上刺，针刺密度为137-142刺/cm2；
所述主针刺下刺，针刺深度6-8mm，针刺密度125-135刺/cm2；
采用的原料为聚乙烯纤维、聚丙烯纤维，质量比为13-17:83-87。
2.根据权利要求1所述的一种聚丙烯-聚乙烯复合无纺布的制备方法，其特征在于：所述聚乙烯纤维的强度≥4.0 cN/dtex；所述聚丙烯纤维的强度≥5.0 cN/dtex。
3.根据权利要求1所述的一种聚丙烯-聚乙烯复合无纺布的制备方法，其特征在于：所述制备方法，还包括热定型，所述热定型，温度为160-170℃。
4.根据权利要求1所述的一种聚丙烯-聚乙烯复合无纺布的制备方法，其特征在于：所述复合无纺布，熔点为140-150℃。
5.根据权利要求1所述的一种聚丙烯-聚乙烯复合无纺布的制备方法，其特征在于：所述复合无纺布，纵向断裂强力≧150N，横向断裂强力≧190N。
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