CN113290990A - 一种节能蚝基纤维复合层及其制备工艺 - Google Patents
一种节能蚝基纤维复合层及其制备工艺 Download PDFInfo
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Abstract
本发明属于蚝基纤维衍生产品领域,具体公开了一种节能蚝基纤维复合层及其制备工艺,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为3:1‑1:1所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的30‑50%;所述制备工艺包括S1分层预制、S2开松梳理、S3立体铺网、S4立体交织预定形、S5纤维层单元化、S6多单元热压成型;本发明公开的工艺填补了蚝基纤维复合材料制备工艺方面的空白,整个工艺节能环保,不使用化学胶水,无污染,使用蚝基纤维复合层制成的成品纤维垫,具有密度梯度结构,质量轻盈,弹性和支撑力好,不含有甲醛,对人体安全,具有一定的抗菌除臭效果,触感舒适。
Description
技术领域
本发明属于蚝基纤维衍生产品领域,具体公开了一种节能蚝基纤维复合层及其制备工艺。
背景技术
软垫因其较高的舒适性,已成为人们家中不可缺少的家居用品,被广泛地用作床垫、座椅垫等。软垫一般有聚氨酯海绵垫、椰棕垫、弹簧垫等种类。但是,现有的聚氨酯海绵垫原料多为TDI、MDI等石油副产品,其本身具有毒性,生产人员长期接触容易致病,而且产品透气性差,使用体验不佳;椰棕垫的制造过程中需要使用大量的胶水进行粘接,会导致甲醛含量严重超标,吸入体内会对人体造成危害;弹簧床垫则存在弹性不均衡、支撑力不均匀、易塌陷等问题,而且使用过程中声音较大,舒适度差。
纤维材料是纤维状物质通过纺织加工工艺形成的结构化材料,通常也被称为纺织材料。纤维材料的应用历史已经相当的悠久,虽然并无明确的记录说明这种材料是何时产生,但在人类古代贸易中,纤维材料始终占据着重要的地位充分说明纤维材料对人类发展的重要性。
纤维垫多采用具有天然组分的纤维原料或者聚酯纤维制成,有其他软垫难以比拟的优势,如具有良好的吸湿散湿与透气的性能,传热导热快,质地轻等优点。但是目前的纤维垫弹性不佳,易发生坍塌。。
开发新的生物基的纤维是目前纤维材料研发中的关注重点,目前中国发明申请CN202010765516.0和CN201911396605.6均公开了蚝基纤维的制备方法,与传统的聚酯纤维相比,蚝纤维既具有高强的强度和韧性,还具有抗菌、除臭、保暖、抗静电、抗紫外线等功能,能够适应不同应用场景的需求,具有很大的推广应用潜力。但是蚝纤维的生产成本较高,需要将其与其他纤维复合使用,降低其成本,发挥其优点,目前还未见有包含蚝基纤维的复合纤维材料的生产报道,市场上也没有使用蚝基纤维制备纤维垫的产品上市。
发明内容
针对以上不足,本发明公开了一种节能蚝基纤维复合层及其制备工艺,填补了蚝基纤维复合材料制备工艺方面的空白,整个工艺节能环保,极具应用潜力。
本发明的技术方案如下:
一种节能蚝基纤维复合层,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为3:1-1:1所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的 30-50%。
进一步的,上述一种节能蚝基纤维复合层,所述弹性体纤维包括天然乳胶丝、多嵌段聚氨酯纤维和蚝基纤维。
进一步的,上述一种节能蚝基纤维复合层,所述粘结纤维包括粘胶短纤维、富强纤维、粘胶丝。
进一步的,上述一种节能蚝基纤维复合层,所述节能蚝基纤维复合层的若干单元纤维层A堆叠而成;所述单元纤维层A由下至上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维。
进一步的,上述一种节能蚝基纤维复合层的制备方法,包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层A堆叠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,高温预定型;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为 11-15mm,速度为6.0-7.5m/min,针刺密度为320-480刺/cm,得到单元纤维层C;
S6多单元热压成型:将4-16个单元纤维层C堆叠在一起,放入烘箱,进行多单元热压成型。
进一步的,上述一种节能蚝基纤维复合层的制备工艺,包括以下步骤:
1).蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉。
2).配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份。
3).蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.5-0.8g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至7.6-8.0,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至80-95℃,保温5-10小时,加入7- 氨基庚酸,继续保温2-6小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至7.8-8.2,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
进一步的,上述一种节能蚝基纤维复合层的制备工艺,所述步骤 S4立体交织预定形,具体包括:将2层上述单元纤维层A堆叠在一起,使得两层粘胶短纤维靠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度高于或等于粘胶短纤维的熔点,且低于富强纤维。
进一步的,上述一种节能蚝基纤维复合层的制备工艺,所述步骤 S4立体交织预定形,具体包括:将2层上述单元纤维层A堆叠在一起,使得两层粘胶短纤维靠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度为110-150℃,加热时间2-4h。
进一步的,上述一种节能蚝基纤维复合层的制备工艺,所述S6 多单元热压成型,具体包括,将4-16个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为 220-260℃,加热时间3-6h,实现多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。
进一步的,使用上述节能蚝基纤维复合层制成的纤维垫制品。
本发明至少具有如下有益效果:
本发明公开了一种节能蚝基纤维复合层及其制备工艺,填补了蚝基纤维复合材料制备工艺方面的空白,通过开松、梳理、铺网、预定型等步骤首先形成具有多层结构的单元纤维层,再通过对叠置的多个单元纤维层进行热压,综合了弹性体纤维和粘结纤维的优点,整个工艺节能环保,不使用化学胶水,无污染,能耗低,使用蚝基纤维复合层制成的成品纤维垫,具有密度梯度结构,质量轻盈,弹性和支撑力好,不含有甲醛,对人体安全,具有一定的抗菌除臭效果,触感舒适。
附图说明
附图1为本发明所述节能蚝基纤维复合层的制备工艺流程;
附图2为实施例1-4中单元纤维层A的结构示意图;
附图3为实施例1-3中单元纤维层B的结构示意图;
附图4为实施例4中单元纤维层B的结构示意图;
附图5为实施例1中节能蚝基纤维复合层的结构示意图。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。所述实验材料没有特殊说明均可自商业渠道购得。
本发明所述节能蚝基纤维复合层的制备工艺流程,如附图1所示:
包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层堆叠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,高温预定型;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为 11-15mm,速度为6.0-7.5m/min,针刺密度为320-480刺/cm,得到单元纤维层C;
S6多单元热压成型:将4-16个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为 220-260℃,加热时间3-6h。进行多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。
所述步骤蚝基纤维层由以下步骤制备:
1)蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉。
2)配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份。
3)蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.5-0.8g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至7.6-8.0,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至80-95℃,保温5-10小时,加入7- 氨基庚酸,继续保温2-6小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至7.8-8.2,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
实施例1
如附图2、3、5所示的一种节能蚝基纤维复合层,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为3:1,所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的30%,按各自的重量百分数计,所述弹性体纤维包括天然乳胶丝40%、多嵌段聚氨酯纤维30%和蚝基纤维30%;所述粘结纤维包括粘胶短纤维50%、富强纤维25%、粘胶丝25%;所述节能蚝基纤维复合层的由若干单元纤维层A堆叠而成;所述单元纤维层 A由下至上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维。
上述一种节能蚝基纤维复合层的制备工艺,包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层堆叠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度为110℃,加热时间2h,高温预定型;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为 11mm,速度为6.0m/min,针刺密度为320刺/cm,得到单元纤维层C;
S6多单元热压成型:将4个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为220℃,加热时间3h。进行多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。所述成品节能蚝基纤维复合层厚度为3-5cm。
所述步骤蚝基纤维层由以下步骤制备:
1)蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉。
2)配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份。
3)蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.5g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至7.6,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至80℃,保温5小时,加入7-氨基庚酸,继续保温2小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至7.8,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
实施例2
如附图2、3所示一种节能蚝基纤维复合层,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为2:1,所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的40%,按各自的重量百分数计,所述弹性体纤维包括天然乳胶丝30%、多嵌段聚氨酯纤维30%和蚝基纤维40%;所述粘结纤维包括粘胶短纤维50%、富强纤维25%、粘胶丝25%;所述节能蚝基纤维复合层的由若干单元纤维层A堆叠而成;所述单元纤维层A由下至上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维。
上述一种节能蚝基纤维复合层的制备工艺,包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层堆叠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度为130℃,加热时间3h,高温预定型;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为 13mm,速度为6.0m/min,针刺密度为400刺/cm,得到单元纤维层C;
S6多单元热压成型:将8个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为240℃,加热时间4.5h,实现多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。所述成品节能蚝基纤维复合层厚度为4-6cm。
所述步骤蚝基纤维层由以下步骤制备:
1)蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉。
2)配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份。
3)蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.65g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至7.8,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至90℃,保温8小时,加入7-氨基庚酸,继续保温4小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至8.0,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
实施例3
如附图2、3所示的一种节能蚝基纤维复合层,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为1:1,所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的50%,按各自的重量百分数计,所述弹性体纤维包括天然乳胶丝25%、多嵌段聚氨酯纤维25%和蚝基纤维50%;所述粘结纤维包括粘胶短纤维50%、富强纤维25%、粘胶丝25%;所述节能蚝基纤维复合层的由若干单元纤维层A堆叠而成;所述单元纤维层A 由下至上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维。
上述一种节能蚝基纤维复合层的制备工艺,包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层堆叠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度为150℃,加热时间4h,高温预定型;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为 15mm,速度为7.5m/min,针刺密度为480刺/cm,得到单元纤维层C;
S6多单元热压成型:将16个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为260℃,加热时间6h,实现多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。所述成品节能蚝基纤维复合层厚度为5-7cm。
所述步骤蚝基纤维层由以下步骤制备:
1)蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉。
2)配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份。
3)蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.8g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至8.0,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至95℃,保温5小时,加入7-氨基庚酸,继续保温6小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至8.2,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
实施例4
如附图2、4所示的一种节能蚝基纤维复合层,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为2:1,所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的40%,按各自的重量百分数计,所述弹性体纤维包括天然乳胶丝30%、多嵌段聚氨酯纤维30%和蚝基纤维40%;所述粘结纤维包括粘胶短纤维50%、富强纤维25%、粘胶丝25%;所述节能蚝基纤维复合层的由若干单元纤维层A堆叠而成;所述单元纤维层 A由下至上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维。
上述一种节能蚝基纤维复合层的制备工艺,包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层A堆叠在一起,使得两层粘胶短纤维靠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度为 130℃,加热时间3h;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为 13mm,速度为6.0m/min,针刺密度为400刺/cm,得到单元纤维层C;
S6多单元热压成型:将8个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为240℃,加热时间4.5h,实现多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。所述成品节能蚝基纤维复合层厚度为4-6cm。
所述步骤蚝基纤维层由以下步骤制备:
1)蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉。
2)配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份。
3)蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.65g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至7.8,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至90℃,保温8小时,加入7-氨基庚酸,继续保温4小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至8.0,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
测试例1
取实施例1-4的节能蚝基纤维复合层为原料按照现有技术制备得到25cm的纤维垫(实施例1-4),与市售的聚丙烯纤维制得的纤维垫(对比例)进行性能对比,数据见表1所示。
测试内容为
1压缩回复率:将纤维垫压缩75%所须的能量与从75%起的恢复所须能量的比率。压缩回复率越大,表示回弹性越好。
2压缩应力比:纤维垫压缩25%时的应力与压缩65%时的应力的比率。相对于压缩量,表示压缩到相应程度,应力(反拨力)的变化。这个数值越小时,纤维垫突然下沉时,身体摇晃变大,无法达到安定舒适的躺卧效果。
3压缩耐久性硬度保持率(A)测试法:以每分钟60次的速度压缩试样至原厚度的50%,连续重复8万次。
4压缩耐久性硬度保持率(B)测试法:以0.8kg/cm的压力重压试样15秒→除压10秒→重复360次。
表1纤维性能测试
从上表1可以看出,实施例1~4相对于对比例的压缩回复率结果明显更加优秀,压缩应力比亦显示了更良好的结果,展现了更优异的综合回弹性,特别的实施例4由于其结果是将两个单元纤维层A反向的粘结,显示了更加优异的效果。同时,根据两种硬度保持率测试法测试下得到的数据显示,拥有密度梯度结构的实施例-4使得纤维垫具有多级缓冲性能,因此对外来的重压它也不易老化,能够长久保持当初的构造与弹性,具备更优秀的压缩耐久性。
以上仅为本发明的较佳实施例而已,不能以此限定本发明的保护范围,即大凡依本发明权利要求书及发明内容所做的简单的等效变化与修改,皆仍属于本发明专利申请的保护范围。
Claims (10)
1.一种节能蚝基纤维复合层,其特征在于,所述蚝基纤维复合层包括弹性体纤维和粘结纤维;所述弹性体纤维与所述粘结纤维的质量比为3:1-1:1所述弹性体纤维中包含有蚝基纤维,所述蚝基纤维占所述弹性体纤维的30-50%。
2.根据权利要求1所述的一种节能蚝基纤维复合层,其特征在于,所述弹性体纤维包括天然乳胶丝、多嵌段聚氨酯纤维和蚝基纤维。
3.根据权利要求2所述的一种节能蚝基纤维复合层,其特征在于,所述粘结纤维包括粘胶短纤维、富强纤维、粘胶丝。
4.根据权利要求3所述的一种节能蚝基纤维复合层,其特征在于,所述节能蚝基纤维复合层的若干单元纤维层A堆叠而成;所述单元纤维层A由下至上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维。
5.如权利要求4所述的一种节能蚝基纤维复合层的制备工艺,包括以下步骤:
S1分层预制:制备蚝基纤维层、粘胶丝纤维层、多嵌段聚氨酯纤维纤维层、富强纤维纤维层、天然乳胶丝纤维层和粘胶短纤维纤维层;
S2开松梳理:将上述纤维层分别进行开松和梳理,形成松软的结构;
S3立体铺网:将上述纤维层按照由下之上依次为蚝基纤维、粘胶丝、多嵌段聚氨酯纤维、富强纤维、天然乳胶丝和粘胶短纤维的次序松软的铺设在一起,组成疏松的单元纤维层A;
S4立体交织预定形:将2层上述单元纤维层A堆叠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,高温预定型;
S5纤维层单元化:将上述单元纤维层B冷却到室温后,采用针刺方式进行纤维层单元化,其包括正面针刺和反面针刺,针刺深度为11-15mm,速度为6.0-7.5m/min,针刺密度为320-480刺/cm,得到单元纤维层C;
S6多单元热压成型:将4-16个单元纤维层C堆叠在一起,放入烘箱,进行多单元热压成型。
6.根据权利要求5所述的节能蚝基纤维复合层的制备工艺,其特征在于,所述蚝基纤维层由以下步骤制备:
1)蚝壳的预处理步骤
将蚝壳清洗干净后进行高温煅烧,冷却后,进行粉碎处理,得到蚝壳粉;
2)配料
准确称取蚝壳粉3份、聚酰胺树脂97份、7-氨基庚酸0.15份;
3)蚝纤维的制备
步骤一:将蚝壳粉和壳聚糖溶于乙酸水溶液中,形成壳聚糖浓度为0.5-0.8g/mL的反应液;
步骤二:向反应液中加入尿素,将反应液的pH调节至7.6-8.0,此时,反应液转化为凝胶状溶液;
步骤三:加热凝胶状溶液至80-95℃,保温5-10小时,加入7-氨基庚酸,继续保温2-6小时,本步骤过程中持续搅拌;
步骤四:将步骤三得到的混合液的pH值调节至7.8-8.2,然后向混合液中添加氯乙酸,使壳聚糖转化为羧甲基壳聚糖;
步骤五:加入去离子水,超声使羧甲基壳聚糖充分溶解,过滤,使用去离子水对滤渣进行冲洗,滤去洗液,保留滤渣备用;
步骤六:向滤渣中添加丁酮,进行研磨,充分分散,将研磨后的混合浆液与聚酯充分混合,经过造粒、纺丝,编织成蚝基纤维层。
7.根据权利要求5所述的一种节能蚝基纤维复合层的制备工艺,其特征在于,所述步骤S4立体交织预定形,具体包括:将2层上述单元纤维层A堆叠在一起,使得两层粘胶短纤维靠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度高于或等于粘胶短纤维的熔点,且低于富强纤维。
8.根据权利要求7所述的一种节能蚝基纤维复合层的制备工艺,其特征在于,所述步骤S4立体交织预定形,具体包括:将2层上述单元纤维层A堆叠在一起,使得两层粘胶短纤维靠在一起,形成单元纤维层B,不施加压力的情况下,放入烘箱,向烘箱中通入循环热空气,所述循环热空气的温度为110-150℃,加热时间2-4h。
9.根据权利要求5所述的一种节能蚝基纤维复合层的制备工艺,其特征在于,S6多单元热压成型,具体包括,将4-16个单元纤维层C堆叠在一起,放入烘箱,向烘箱中通入循环热氮气,所述循环热氮气的温度为220-260℃,加热时间3-6h,实现多单元热压成型,叠置的单元纤维层C相互粘接在一起,冷却后形成密度梯度结构,在烘箱出口端得到成品节能蚝基纤维复合层。
10.一种纤维垫,其特征在于,由权利要求1-3所述的节能蚝基纤维复合层制成。
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