CN113215729B - 环保型干法骨架布及其制作工艺 - Google Patents

环保型干法骨架布及其制作工艺 Download PDF

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CN113215729B
CN113215729B CN202110490421.7A CN202110490421A CN113215729B CN 113215729 B CN113215729 B CN 113215729B CN 202110490421 A CN202110490421 A CN 202110490421A CN 113215729 B CN113215729 B CN 113215729B
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云高杰
杨丽英
云献立
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Changzhou Baipeng Textile Co ltd
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Abstract

本发明涉及一种环保型干法骨架布及其制作工艺,包括基础层和复合于基础层表面的表层纤网,基础层和表层纤网分别通过气流成网并经针刺加固连接在一起;所述基础层采用卷曲率不超过10%、长度大于20mm的第一纤维制作;所述表层纤网采用卷曲率不超过10%、长度大于20mm的第一纤维和卷曲率≥10%的第二纤维混合制作,第一纤维和第二纤维的混合比例为2‑5:1。本发明所述干法骨架布具有良好的硬度和强度,无异味无VOC释放。

Description

环保型干法骨架布及其制作工艺
技术领域
本发明属于空气净化过滤材料技术领域,具体涉及一种环保型干法骨架布及其制作工艺。
背景技术
骨架布适用于家用电器滤材(空气净化器、吸尘器等)、汽车空调滤材等,一般选用聚酯超短纤维。骨架布使用湿法工艺、浸渍工艺或干法工艺进行制造,具有高硬挺度、高透气度、克重轻等特点,是滤材的首选材料,经密褶后耐风压性极高,即便在大风量通过的情况下亦不会变形。
现有骨架布制造工艺主要存在以下优点和缺陷:
(1)第一大类湿法毡骨架布,用量最大;优点是外观好看、硬度大、强度高;缺点是采用湿法工艺制造的骨架布含有醛类粘合剂等,使用中会产生VOC、甲醛、苯类;
(2)第二大类是浸渍无纺布,靠化学整理法粘合,用量其次;优点是硬度中等偏上,价格低廉;缺点跟湿法毡一样;
(3)第三类是干法骨架布,市场使用量最小,目前还不成熟;优点是无异味,无有害VOC气体释放;缺点是外观不好看,均匀度差,会有纤维并丝,硬度一般,需要增加克重来提高硬度。
发明内容
本发明要解决的技术问题是提供一种环保型干法骨架布及其制作工艺,具有良好的硬度和强度,无异味无VOC释放。
为了解决上述技术问题,本发明采用的一种技术方案是:所述环保型干法骨架布,包括基础层和复合于基础层表面的表层纤网,基础层和表层纤网分别通过气流成网并经针刺加固连接在一起;所述基础层采用卷曲率不超过10%、长度大于20mm的第一纤维制作;所述表层纤网采用卷曲率不超过10%、长度大于20mm的第一纤维和卷曲率≥10%的第二纤维混合制作,第一纤维和第二纤维的混合比例为 2-5:1。
本发明还提供一种环保型干法骨架布的制作工艺,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%、长度大于20mm的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为2-5:1进开松并充分混合,得到表层纤网材料;
(3)精开松:分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到表层纤网;
(5)将基础层纤网和表层纤网进行针刺加固,得到骨架布。
进一步地,所述表层纤网的克重为20-40g/m2。
进一步地,所述表层纤网的厚度为1-5mm。
进一步地,所述基础层纤网的克重为100-120g/m2。
进一步地,所述基础层纤网的厚度为2-10mm。
进一步地,所述第一纤维和第二纤维的线密度为0.5~8dtex,长度为25~60mm。
进一步地,所述步骤(5)中的针刺密度150-600刺/cm2,工作温度为22-26℃,湿度控制在50-60%RH,
进一步地,所述第一纤维采用涤纶、丙纶、锦纶或维纶。
进一步地,所述第二纤维采用涤纶、丙纶、锦纶或维纶。
本发明的优点具体如下:
(1)本发明通过不卷曲的纤维和气流成网,保证制得的骨架布在不需增加克重的情况下具有良好的硬度和强度;
(2)本发明工艺过程中无异味无VOC释放;
(3)本发明骨架布的基础层主要由不卷曲的纤维通过气流成网成形,硬度和强度能够得到保证;表层纤网由不同卷曲度的纤维通过气流成网制成,整体均匀度较好,不会有纤维并丝;本发明既保证了产品的硬度和强度,也保证了外观的一致性。
具体实施方式
为了使本发明的上述目的、特征和优点能够更加明显易懂,下面对本发明的具体实施方式作进一步的说明。
在下面的描述中阐述了很多具体细节以便于充分理解本发明,但是本发明还可以采用其他不同于在此描述的其它方式来实施例,本领域技术人员可以在不违背本发明内涵的情况下做类似推广,因此本发明不受下面公开的具体实施例的限制。
总实施例:
一种环保型干法骨架布,包括基础层和复合于基础层表面的表层纤网,基础层和表层纤网分别通过气流成网并经针刺加固连接在一起;所述基础层通过气流成网成形后的克重为100-120g/m2,厚度为 2-10mm;所述表层纤网通过气流成网成形后的克重为20-40g/m2,厚度为1-5mm。所述基础层采用卷曲率不超过10%、长度大于20mm的第一纤维制作,如涤纶、丙纶、锦纶或维纶等;所述表层纤网采用卷曲率不超过10%、长度大于20mm的第一纤维和卷曲率≥10%的第二纤维混合制作,第一纤维和第二纤维的混合比例为2-5:1。
作为本实施例的优选方案,第一纤维和第二纤维的线密度为0.5~ 8dtex,长度为25~60mm。
实施例1:一种环保型干法骨架布的制作工艺,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;第一纤维的线密度为0.5dtex,长度为25mm;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为2:1进开松并充分混合,得到表层纤网材料;
(3)精开松:控制喂入纤维均匀一致,开松柔和,分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到克重为100g/m2,厚度为2mm的基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到克重为20-g/m2,厚度为1mm的表层纤网;
所述气流成网是通过气流对经过精开松后充分混合蓬松的纤维均匀分布在棉箱内进一步混合后,被加压气流输送到成网帘和成网滚筒之间上下吸风形成所需网状结构的纤网;所述气流成网的过程为:先将聚丙烯纤维输送至喂入辊,经开松后聚丙烯纤维从气流成网的成网帘落下,落在成网帘下方的成网滚筒上,并经上下吸风风机作用形成纤网;
(5)将基础层纤网和表层纤网进行针刺加固,针刺密度150刺 /cm2,工作温度为22℃,湿度控制在50%RH,得到骨架布。
实施例2:一种环保型干法骨架布的制作工艺,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;第一纤维和第二纤维的线密度为4dtex,长度为30mm;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为3:1进开松并充分混合,得到表层纤网材料;
(3)精开松:控制喂入纤维均匀一致,开松柔和,分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到克重为110g/m2,厚度为5mm的基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到克重为30g/m2,厚度为2mm的表层纤网;
所述气流成网是通过气流对经过精开松后充分混合蓬松的纤维均匀分布在棉箱内进一步混合后,被加压气流输送到成网帘和成网滚筒之间上下吸风形成所需网状结构的纤网;所述气流成网的过程为:先将聚丙烯纤维输送至喂入辊,经开松后聚丙烯纤维从气流成网的成网帘落下,落在成网帘下方的成网滚筒上,并经上下吸风风机作用形成纤网;
(5)将基础层纤网和表层纤网进行针刺加固,针刺密度300刺 /cm2,工作温度为24℃,湿度控制在55%RH,得到骨架布。
实施例3:一种环保型干法骨架布的制作工艺,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;第一纤维和第二纤维的线密度为8dtex,长度为60mm;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为5:1进开松并充分混合,得到表层纤网材料;
(3)精开松:控制喂入纤维均匀一致,开松柔和,分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到克重为120g/m2,厚度为10mm的基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到克重为40g/m2,厚度为5mm的表层纤网;
所述气流成网是通过气流对经过精开松后充分混合蓬松的纤维均匀分布在棉箱内进一步混合后,被加压气流输送到成网帘和成网滚筒之间上下吸风形成所需网状结构的纤网;所述气流成网的过程为:先将聚丙烯纤维输送至喂入辊,经开松后聚丙烯纤维从气流成网的成网帘落下,落在成网帘下方的成网滚筒上,并经上下吸风风机作用形成纤网;
(5)将基础层纤网和表层纤网进行针刺加固,针刺密度600刺 /cm2,工作温度为26℃,湿度控制在60%RH,得到骨架布。
将实施例1-实施例3制备得到的骨架布进行性能测试,所得结果见表1。
表1性能测试结果
Figure BDA0003052251120000071
Figure BDA0003052251120000081
由表1可以看出,本发明所述骨架布具有优异的强度和透气率,是一种环保型的干法骨架布。
本发明采用不卷曲的纤维和气流成网来生产,主要优点是克重不需增加即可达到更好的硬度、强度,无异味无VOC释放,均匀度更好,无纤维并丝现象。
以上对本申请所提供的一种环保型干法骨架布及其制作工艺进行了详细介绍,本文中应用了具体个例对本申请的原理及实施方式进行了阐述,以上实施例的说明只是用于帮助理解本申请的方法及其核心思想;同时,对于本领域的一般技术人员,依据本申请的思想,在具体实施方式及应用范围上均会有改变之处,综上所述,本说明书内容不应理解为对本申请的限制。

Claims (3)

1.一种环保型干法骨架布的制作工艺,其特征是,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;第一纤维的线密度为0.5dtex,长度为25mm;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为2:1进开松并充分混合,得到表层纤网材料;
(3)精开松:控制喂入纤维均匀一致,开松柔和,分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到克重为100g/m2,厚度为2mm的基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到克重为20g/m2,厚度为1mm的表层纤网;
(5)将基础层纤网和表层纤网进行针刺加固,针刺密度150刺/cm2,工作温度为22℃,湿度控制在50%RH,得到骨架布。
2.一种环保型干法骨架布的制作工艺,其特征是,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;第一纤维和第二纤维的线密度为4dtex,长度为30mm;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为3:1进开松并充分混合,得到表层纤网材料;
(3)精开松:控制喂入纤维均匀一致,开松柔和,分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到克重为110g/m2,厚度为5mm的基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到克重为30 g/m2,厚度为2mm的表层纤网;
(5)将基础层纤网和表层纤网进行针刺加固,针刺密度300刺/cm2,工作温度为24℃,湿度控制在55%RH,得到骨架布。
3.一种环保型干法骨架布的制作工艺,其特征是,包括以下步骤:
(1)选择纤维:选取卷曲率不超过10%的纤维作为第一纤维,选取卷曲率≥10%的纤维作为第二纤维;第一纤维和第二纤维的线密度为8dtex,长度为60mm;
(2)粗开松:采用开松设备,将第一纤维进行初步开松作为基础层纤维材料;将第一纤维和第二纤维以混合比例为5:1进开松并充分混合,得到表层纤网材料;
(3)精开松:控制喂入纤维均匀一致,开松柔和,分别对基础层纤维材料和表层纤网材料进行精开松;
(4)将基础层纤维材料通过气流成网,得到克重为120g/m2,厚度为10mm的基础层纤网;再将表层纤网材料通过气流成网,在基础层纤网的一表面或两表面成网,得到克重为40 g/m2,厚度为5mm的表层纤网;
(5)将基础层纤网和表层纤网进行针刺加固,针刺密度600刺/cm2,工作温度为26℃,湿度控制在60%RH,得到骨架布。
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JPH0531310A (ja) * 1991-08-02 1993-02-09 Toray Ind Inc プリーツ加工性と難燃性とを有する濾材
CN101808709A (zh) * 2007-09-28 2010-08-18 东丽株式会社 滤材和过滤器单元
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