CN112981705A - 一种非织造复合保暖材料及其制备方法 - Google Patents

一种非织造复合保暖材料及其制备方法 Download PDF

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CN112981705A
CN112981705A CN202011609551.XA CN202011609551A CN112981705A CN 112981705 A CN112981705 A CN 112981705A CN 202011609551 A CN202011609551 A CN 202011609551A CN 112981705 A CN112981705 A CN 112981705A
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fiber
hot air
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钱幺
于晖
白楚杭
黄海铭
黄新亮
王晓梅
全冬冬
覃银红
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Wuyi University
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Abstract

本发明提供一种非织造复合保暖材料，所述材料包括由ES纤维加工成的热风非织造材料、熔喷非织造材料；所述的熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体；所述的所述ES纤维为聚乙烯/聚丙烯或聚乙烯/聚酯等双组分皮芯结构，其皮层熔点较低，芯层熔点较高。本发明利用熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，有利于提高非织造材料的静止空气含量，降低材料内部空气的流动性，以此达到提高复合材料保暖性能的效果；本发明在非织造材料的热粘合工艺过程中，具有皮芯结构的ES纤维在热风烘箱中受热熔融，与接触的熔喷层粘连，经冷却固化后形成层间粘附；而ES纤维网仍然保持蓬松状态。

Description

一种非织造复合保暖材料及其制备方法
技术领域
本发明涉及保温材料技术领域，尤其是一种非织造复合保暖材料及其制备方法。
背景技术
随着人们对保暖材料性能需求的不断提高，非织造保暖材料的品种也越来越多，新型非织造保暖材料的研发也得到重视，已经从传统的天然保暖材料到混合型的保暖材料，并且由复合型材料逐渐开始代替单一结构的传统保暖材料。
优化后的复合型材料结构，可以使原来厚重的材料变得更加的轻薄，多种材料混合起来的保温材料不仅可以得到更好的保温性能，而且能达到多功能的目的，满足消费者对保暖材料各方面的需求。根据保暖机理可知，要想获得较好的保暖效果，纤维材料中必须包含更多的静止空气，但是作为纺织材料而言，也不能牺牲透气和透湿性能。
因此，可以采用超细纤维层包裹更多的静止空气，能防止空气对流，增加保温隔热效果。目前，欧美等一些国家就已开发了中空纤维和超细纤维为主的保暖材料，该材料制作出的衣物具有高强度和高的保暖性，现已朝着轻便、舒适方向发展。熔喷非织造布是一种超细纤维非织造布，在过滤，吸油、保暖、防水等方面的性能优异，在保暖材料中广泛应用，但是熔喷纤维的严重缺陷是强力较低，通常需要与其他非织造材料结合使用。
由于单一材料已很难使保暖材料的性能得以提高和突破，因此复合保暖材料成为人们研究的方向。这种复合型材料是指由不同的材料结合在一起形成结构较为复杂的多层材料或多组分混合材料。
例如，专利ZL201510488170.3提供一种绒球状保温棉制品的制造方法，将绒球状保温棉包含在两层面料之间，利用超声波粘合将其复合。专利 CN201611104317.5提供一种新型轻薄复合保暖材料，材料为三层结构，里层为非织造保暖层，中间层为涂层织物，外层为面料层。
专利CN201210311067.8公开了一种由面料层、保暖层和弹性体中间层构成的复合保暖材料，虽然兼顾了弹性回复性能、保暖、吸湿性能，但未考虑三者之间的复合方式及复合牢度。
专利CN 201210570645.X公开了一种熔喷纤维与木棉纤维在线复合的制造方法及其保暖材料，在线复合过程中，利用熔喷纤维与木棉纤维二者自粘接，形成稳定的复合结构，实现二者纤维的优势互补；虽然依靠熔喷纤维层的熔喷纤维自身余温而产生粘接，但是熔喷纤维与木棉纤维之间因为组分不同，难以较好地粘结。
专利ZL201310526669.X选用低熔点纤维和其他纤维，通过梳理形成单网，沿单网表面至少一部分长度喷涂相变材料，将单网层层铺叠，进行热定型加固，从而形成保暖材料。该专利描述的方法复杂，层数较多，实际中实现难度较大，并且相变材料的相变升温效果未必会好。
因此，研制开发良好保温性能的保暖非织造材料，达到兼顾保暖性能、透气透湿性能、和轻薄性，进一步为了增加材料内部静止空气的含量，并且较好地控制内部空气的流动是非常关键和十分必要的。
发明内容
针对现有技术的不足，本发明提供一种非织造复合保暖材料及其制备方法，本发明利用熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，有利于提高非织造材料的静止空气含量，以此增加材料的保暖性能。
并且本发明通过物理方法制备复合保暖材料，工艺简单易行，不适应化学粘合剂，环保无污染，所制备的非织造材料可应用于保温隔热、吸音等材料中。
本发明的技术方案为：一种非织造复合保暖材料，所述的材料包括由ES纤维加工成的热风非织造材料、熔喷非织造材料；
所述的熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体；
所述的所述ES纤维为聚乙烯(PE)/聚丙烯(PP)或聚乙烯(PE)/聚酯(PET) 等双组分皮芯结构，其皮层熔点较低，芯层熔点较高。
进一步的，所述的复合保暖材料为多层结构，多层结构复合材料由ES纤维粘合形成，或在ES纤维粘合的基础上经过超声波粘合加以复合。
进一步的，所述的复合材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构。
进一步的，所述的复合材料的层数为3～10层，结构上为对称或不对称结构，得到多层结构的克重为50～500g/m2。
进一步的，所述的ES纤维的细度为0.5D～10D，长度为20-60mm，皮层熔点在90～135℃之间。
进一步的，所述的热风非织造材料的克重为10～100g/m2。
进一步的，所述的熔喷非织造材料为聚丙烯(PP)、聚酯(PET)或二者构成的双组份熔喷，材料的克重为10～80g/m2，纤维平均直径0.5～10μm。
本发明还提供一种非织造复合保暖材料的制备方法，所述的方法为由ES纤维受热熔融、冷却固化后粘结而成，采用热风非织造工艺、或烘箱加热制得；并且在此基础上增加超声波粘合工艺，加固层间复合效果。
进一步的，所述的非织造复合保暖材料的制备方法，具体包括以下步骤：
S1)、ES纤维网的制备
将ES短纤维进行开松、混合、梳理、铺网，得到一定克重的蓬松纤维网，所得纤网克重为10～100g/m2；
S2)、纤维网的铺叠
将克重为10～100g/m2的熔喷非织造材料与克重为10～100g/m2ES纤维网按照一定层数铺叠，实现厚度与克重的要求；
S3)、纤维网的加固
上述得到的纤维网经过热风粘合工艺或烘箱加热进行加固，ES纤维网的皮层在热风烘箱内受热熔融，烘箱温度设置为90～150℃，加热时间为5～15min；然后输出至室温环境冷却固化，得到复合非织造材料；或增加超声波粘合工艺，增加粘合牢度。
进一步的，步骤S1)中，所述ES纤维为聚乙烯(PE)/聚丙烯(PP)或聚乙烯(PE)/聚酯(PET)等双组分皮芯结构，皮层熔点较低，芯层熔点较高。
进一步的，步骤S1)中，所述的ES纤维的细度为0.5D～10D，长度为 20-60mm，皮层熔点在90～135℃之间。
进一步的，步骤S2)中，所述的熔喷非织造材料为聚丙烯(PP)、聚酯(PET) 或二者构成的双组份熔喷，纤维平均直径0.5～10μm。
进一步的，步骤S3)中，所述的复合保暖材料为多层结构，多层结构复合材料由ES纤维粘合形成，或在ES纤维粘合的基础上经过超声波粘合加以复合。
进一步的，步骤S3)中，所述的复合材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构。
进一步的，步骤S3)中，所述的复合材料的层数为3～10层，结构上为对称或不对称结构，得到多层结构的克重为50～500g/m2。
本发明的有益效果为：
1、本发明利用熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，有利于提高非织造材料的静止空气含量，降低材料内部空气的流动性，以此达到提高复合材料保暖性能的效果；
2、本发明在非织造材料的热粘合工艺过程中，具有皮芯结构的ES纤维在热风烘箱中受热熔融，与接触的熔喷层粘连，经冷却固化后形成层间粘附；而 ES纤维网仍然保持蓬松状态。
附图说明
图1为本发明实施例1的非织造复合保暖材料的结构示意图；
图2为本发明实施例2的非织造复合保暖材料的结构示意图；
图3为本发明实施例3的非织造复合保暖材料的结构示意图；
图4为本发明实施例4的非织造复合保暖材料的结构示意图；
图中，1-熔喷非织造材料，2-ES纤维热风非织造材料。
具体实施方式
下面结合附图对本发明的具体实施方式作进一步说明：
实施例1
如图1所示，本实施例提供一种非织造复合保暖材料，本实施例所述非织造复合保暖材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构，层数为5层，熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，得到5层结构的总克重为150g/m2。
其中，本实施例所述的ES纤维为聚乙烯(PE)/聚丙烯(PP)双组分皮芯结构，皮层熔点为130℃芯层熔点较高；ES纤维细度为2D，长度为38mm。热风非织造材料的克重为30g/m2。
本实施例中，所述的熔喷非织造材料成分为聚丙烯(PP)，材料的克重为30 g/m2，熔喷纤维平均直径7μm。
实施例2
如图2所示，本实施例提供一种非织造复合保暖材料，本实施例所述非织造复合保暖材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构，层数为3层，熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，得到3层结构的总克重为160g/m2。
其中，本实施例所述的ES纤维为聚乙烯(PE)/聚丙烯(PP)双组分皮芯结构，皮层熔点为130℃芯层熔点较高；ES纤维细度为7D，长度为38mm。热风非织造材料的克重为70g/m2。
本实施例中，所述的熔喷非织造材料成分为聚酯(PET)，材料的克重为45 g/m2，熔喷纤维平均直径3μm。
实施例3
如图3所示，本实施例提供一种非织造复合保暖材料，本实施例所述非织造复合保暖材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构，层数为7层，熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，得到7层结构的总克重为220g/m2。
其中，本实施例所述的ES纤维为聚乙烯(PE)/聚丙烯(PP)双组分皮芯结构，皮层熔点为130℃芯层熔点较高；ES纤维细度为5D，长度为50mm。
热风非织造材料的克重为40g/m2。
本实施例中，所述的熔喷非织造材料成分为聚丙烯(PP)，材料的克重为30 g/m2，熔喷纤维平均直径5μm。
实施例4
如图4所示，本实施例提供一种非织造复合保暖材料，本实施例所述非织造复合保暖材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构，层数为10层，熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体，得到10层结构的总克重为230g/m2。
其中，本实施例所述的ES纤维为聚乙烯(PE)/聚酯(PET)双组分皮芯结构，皮层熔点为130℃芯层熔点较高；ES纤维细度为4D，长度为20mm。热风非织造材料的克重为20g/m2。
本实施例中，所述的熔喷非织造材料成分为聚酯(PET)，材料的克重为 25g/m2，熔喷纤维平均直径5μm。
实施例5
本实施例提供一种非织造复合保暖材料的制备方法，所述的方法包括如下步骤：
S1)、ES纤维网的制备；
将ES短纤维进行开松、混合、梳理、铺网，得到一定克重的蓬松纤维网，所得纤网克重为30g/m2；
S2)、纤维网的铺叠
将克重为30g/m2的熔喷非织造材料与克重为30g/m2ES纤维网按照一定层数铺叠，得到总克重为150g/m2；
S3)、纤维网的加固
将上述得到的纤维网经过热风粘合工艺或烘箱加热进行加固，ES纤维网的皮层在热风烘箱内受热熔融，烘箱温度设置为140℃，加热时间为5min；然后输出至室温环境冷却固化，得到复合非织造材料；或增加超声波粘合工艺，增加粘合牢度。
上述实施例和说明书中描述的只是说明本发明的原理和最佳实施例，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。

Claims (10)

1.一种非织造复合保暖材料，其特征在于，所述的材料包括由ES纤维加工成的热风非织造材料、熔喷非织造材料；
所述的熔喷非织造材料作为超细纤维层，包覆热风非织造材料并与之粘合为一整体；
所述的所述ES纤维为聚乙烯(PE)/聚丙烯(PP)或聚乙烯(PE)/聚酯(PET)双组分皮芯结构，其皮层熔点较低，芯层熔点较高。
2.根据权利要求1所述的一种非织造复合保暖材料，其特征在于：所述的复合保暖材料为多层结构，多层结构复合材料由ES纤维粘合形成，或在ES纤维粘合的基础上经过超声波粘合加以复合。
3.根据权利要求1所述的一种非织造复合保暖材料，其特征在于：所述的复合材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构；
所述的复合材料的层数为3～10层，结构上为对称或不对称结构，得到多层结构的克重为50～500g/m2。
4.根据权利要求1所述的一种非织造复合保暖材料，其特征在于：所述的ES纤维的细度为0.5D～10D，长度为20-60mm，皮层熔点在90～135℃之间；
所述的热风非织造材料的克重为10～100g/m2。
5.根据权利要求1所述的一种非织造复合保暖材料，其特征在于：所述的熔喷非织造材料为聚丙烯(PP)、聚酯(PET)或二者构成的双组份熔喷，材料的克重为10～80g/m2，纤维平均直径0.5～10μm。
6.一种非织造复合保暖材料的制备方法，其特征在于，所述的方法为由ES纤维受热熔融、冷却固化后粘结而成，采用热风非织造工艺、或烘箱加热制得；并且在此基础上增加超声波粘合工艺，加固层间复合效果。
7.根据权利要求6所述的一种非织造复合保暖材料的制备方法，其特征在于，所述的非织造复合保暖材料的制备方法，具体包括以下步骤：
S1)、ES纤维网的制备
将ES短纤维进行开松、混合、梳理、铺网，得到一定克重的蓬松纤维网，所得纤网克重为10～100g/m2；
S2)、纤维网的铺叠
将克重为10～100g/m2的熔喷非织造材料与克重为10～100g/m2ES纤维网按照一定层数铺叠，实现厚度与克重的要求；
S3)、纤维网的加固
上述得到的纤维网经过热风粘合工艺或烘箱加热进行加固，ES纤维网的皮层在热风烘箱内受热熔融，烘箱温度设置为90～150℃，加热时间为5～15min；然后输出至室温环境冷却固化，得到复合非织造材料；或增加超声波粘合工艺，增加粘合牢度。
8.根据权利要求7所述的一种非织造复合保暖材料的制备方法，其特征在于，步骤S1)中，所述ES纤维为聚乙烯(PE)/聚丙烯(PP)或聚乙烯(PE)/聚酯(PET)双组分皮芯结构，皮层熔点较低，芯层熔点较高；
所述的ES纤维的细度为0.5D～10D，长度为20-60mm，皮层熔点在90～135℃之间。
9.根据权利要求7所述的一种非织造复合保暖材料的制备方法，其特征在于，步骤S2)中，所述的熔喷非织造材料为聚丙烯(PP)、聚酯(PET)或二者构成的双组份熔喷，纤维平均直径0.5～10μm。
10.根据权利要求7所述的一种非织造复合保暖材料的制备方法，其特征在于，步骤S3)中，所述的复合保暖材料为多层结构，多层结构复合材料由ES纤维粘合形成，或在ES纤维粘合的基础上经过超声波粘合加以复合；
所述的复合材料是由ES纤维热风非织造材料和熔喷非织造材料间隔铺叠形成的多层结构；
所述的复合材料的层数为3～10层，结构上为对称或不对称结构，得到多层结构的克重为50～500g/m2。
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