CN113862901A - Fiber felt and manufacturing process thereof - Google Patents
Fiber felt and manufacturing process thereof Download PDFInfo
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- CN113862901A CN113862901A CN202111266241.7A CN202111266241A CN113862901A CN 113862901 A CN113862901 A CN 113862901A CN 202111266241 A CN202111266241 A CN 202111266241A CN 113862901 A CN113862901 A CN 113862901A
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- 239000000835 fiber Substances 0.000 title claims abstract description 187
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 229920002748 Basalt fiber Polymers 0.000 claims abstract description 37
- 239000000463 material Substances 0.000 claims abstract description 22
- 238000002844 melting Methods 0.000 claims abstract description 7
- 230000008018 melting Effects 0.000 claims abstract description 7
- 239000004575 stone Substances 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 54
- 230000008569 process Effects 0.000 claims description 52
- 238000009960 carding Methods 0.000 claims description 26
- 229920000742 Cotton Polymers 0.000 claims description 19
- 239000010410 layer Substances 0.000 claims description 13
- 238000005086 pumping Methods 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 8
- 230000000694 effects Effects 0.000 claims description 7
- 239000002356 single layer Substances 0.000 claims description 7
- 239000010985 leather Substances 0.000 claims description 5
- 238000005303 weighing Methods 0.000 claims description 5
- 238000007599 discharging Methods 0.000 claims description 4
- 230000007246 mechanism Effects 0.000 claims description 4
- 238000004806 packaging method and process Methods 0.000 claims description 4
- 238000005096 rolling process Methods 0.000 claims description 4
- 238000007493 shaping process Methods 0.000 claims description 4
- 238000003892 spreading Methods 0.000 claims description 4
- 230000007480 spreading Effects 0.000 claims description 4
- 230000000087 stabilizing effect Effects 0.000 claims description 4
- PXXKQOPKNFECSZ-UHFFFAOYSA-N platinum rhodium Chemical compound [Rh].[Pt] PXXKQOPKNFECSZ-UHFFFAOYSA-N 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 2
- 238000009413 insulation Methods 0.000 abstract description 9
- 239000002994 raw material Substances 0.000 abstract description 5
- 238000009792 diffusion process Methods 0.000 abstract description 2
- 230000036314 physical performance Effects 0.000 abstract description 2
- 230000002265 prevention Effects 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 51
- 230000009471 action Effects 0.000 description 7
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 5
- 239000011810 insulating material Substances 0.000 description 5
- 239000005011 phenolic resin Substances 0.000 description 5
- 229920001568 phenolic resin Polymers 0.000 description 5
- 238000004321 preservation Methods 0.000 description 4
- 239000004964 aerogel Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 239000011490 mineral wool Substances 0.000 description 3
- 238000005491 wire drawing Methods 0.000 description 3
- 229910000629 Rh alloy Inorganic materials 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000011491 glass wool Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000005416 organic matter Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000009950 felting Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229920006253 high performance fiber Polymers 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000000352 supercritical drying Methods 0.000 description 1
- 231100000606 suspected carcinogen Toxicity 0.000 description 1
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—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
- D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—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
- D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43838—Ultrafine fibres, e.g. microfibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—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
- D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4391—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
- D04H1/43916—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres microcellular fibres, e.g. porous or foamed fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—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
- D04H1/44—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
- D04H1/46—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
- D04H1/498—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 entanglement of layered webs
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Nonwoven Fabrics (AREA)
Abstract
The invention belongs to the technical field of fiber felt manufacturing and discloses a fiber felt and a manufacturing process thereof. The fiber felt is a superfine basalt fiber felt, basalt fibers of the fiber felt are superfine continuous fibers formed by melting basalt stones at 1450-1500 ℃ and processing the basalt stones through a superfine fiber special kiln, the diameter of the fibers is 3-6 mu m, the fibers are processed into chopped yarns, the fibers are loosened and carded into fiber nets, lapping machines are overlapped to form a multi-layer fiber net structure, the surface and local inner layer fibers of the fiber net structure are forcedly penetrated into the fibers through a needle machine, the fibers are mutually entangled to form the fiber felt, the fibers in the multi-layer felt net are single fibers and have a three-dimensional microporous structure, the multi-layer three-dimensional staggered fiber yarns limit rapid air flowing and diffusion, the heat convection of air is reduced, and the diameter of raw materials is added to form dense gaps, so that the fiber felt has good heat insulation performance and superfine physical performance. The heat-insulating felt can completely meet the requirement of non-combustible grade A1, and is a preferred material for heat insulation, heat insulation and fire prevention.
Description
Technical Field
The invention belongs to the technical field of fiber felt manufacturing, and particularly relates to a fiber felt and a manufacturing process thereof.
Background
At present, the heat insulation energy-saving materials used in domestic and foreign industries and buildings mainly comprise: basalt fiber felt, rock mineral wool, glass wool, high-performance fiber and products thereof, aerogel and products thereof, organic foam heat-insulating materials and products thereof, hard heat-insulating materials and products thereof, and asbestos heat-insulating materials and products thereof. The above various thermal insulation materials all have the following defects: the existing basalt needled felt is formed by utilizing the thermosetting of phenolic resin, namely, the raw materials are melted by a cupola furnace to form a molten liquid, and the molten liquid is subjected to the working procedures of centrifugal fiber forming, cotton collecting, cotton distributing, thermosetting, subsequent cutting and the like to finally form the basalt fiber felt with certain geometric dimension. The basalt fiber felt is solidified and shaped by phenolic resin, a large amount of phenolic resin is needed to be used as a binder in the production process, the phenolic resin is organic matter, and a product solidified by the phenolic resin contains certain organic matter, so that the use temperature of the product is greatly reduced, the application range of the product is seriously influenced (the product cannot be used as long as the working temperature exceeds 400 ℃), the raw material is melted by a cupola furnace, the technological parameters are always in a large fluctuation state, and the stability of the product quality is influenced to a great extent. Rock wool presents a number of problems during application: the brittleness is large, the strength is not enough, and the material sags and is damaged and fails in heat preservation due to the self gravity in the using process; the toughness and resilience of the material are insufficient, the fiber is broken after compression or kneading, dust flies, the effective heat-preservation thickness cannot be ensured, and the due effect cannot be achieved; rock wool and ordinary glass wool are easy to age, crisp and seriously damaged. The aerogel and the products thereof are difficult to popularize due to high production cost. The organic foam material and the product have poor high temperature resistance, which can not meet the requirements of A-grade materials. The hard heat-insulating material and the product can only be used in specific occasions, and the hard heat-insulating material and the product cannot be coated on the surface of the product due to high brittleness, so that the construction is inconvenient. Asbestos-type heat-insulating energy-saving materials and suspected carcinogens of products thereof are listed as banned substances in many countries and regions in the world. Therefore, the market calls for high-performance heat-insulating energy-saving materials are higher and higher.
Compared with the traditional material, the basalt fiber needled felt does not contain any adhesive or bonding agent, so that harmful substances cannot be emitted due to heat effect in the decomposition process. The basalt fiber needled felt does not shrink during assembly and processing, which means that there is no gap between the insulation and the insulation surface. The basalt fiber mat is easy to cut and thus easy to process. The working temperature range is-200 to 650 ℃, and the material is a perfect high-performance heat-insulating energy-saving material. However, the starting material for producing the needled basalt fiber felt at present is basalt fiber with the monofilament diameter of 10-17 mu m; have limited application in the fields of flame retardancy, sound absorption and composite materials. Therefore, the preparation technology of the superfine basalt fiber needled felt with the diameter of 3-6 mu m is developed, the performance of the basalt fiber needled felt is improved to a certain extent, and the application field is expanded.
Disclosure of Invention
In order to solve the problems in the prior art, the invention aims to provide a fiber felt and a manufacturing process thereof.
The technical scheme adopted by the invention is as follows: a process for making a fiber mat, the process comprising the steps of:
s1: cutting the single-stranded monofilament superfine basalt fiber filament produced by a superfine fiber special kiln into short-cut yarns with preset lengths by using short-cutting equipment;
s2: uniformly spreading the chopped yarns on a conveyor belt of an opener, and performing coarse opening treatment by a special opener;
s3: pumping the coarsely opened fibers to the top of the material mixing all-in-one machine through a fan, discharging wind pressure through a wind pressure relief device, enabling the fibers to orderly fall into the material mixing all-in-one machine, uniformly scattering and stacking the fibers layer by layer, and then taking the fibers out through a brad curtain;
s4: the fibers brought out by the angle nail curtain are uniformly input into a fine opener through a conveying belt to be subjected to fine opening treatment, and the fibers are further loosened;
s5: after the fine opening treatment of the fibers is finished, pumping the fibers to a last cotton bin through a fan, stabilizing the air pressure, pumping the fibers to an air pressure cotton bin through the fan from the last cotton bin, continuously conveying the fibers to a continuous leather curtain weighing instrument through the air pressure cotton bin, and automatically adjusting;
s6: the weighed fibers are input into a carding machine to be carded and finished into single fibers to form a single-layer two-dimensional thin fiber net;
s7: sending the two-dimensional thin fiber net into a lapping machine, and repeatedly lapping and processing the two-dimensional thin fiber net through a lapping mechanism to obtain a fiber net product with unit area weight and breadth;
s8: conveying the fiber web product through a bottom curtain, feeding the fiber web product into a holding input device, pressing the fiber web product to be thin, feeding the fiber web product into a pre-needling machine, and primarily entangling and shaping the fiber web product through pre-needling;
s9: guiding the fiber web product which is preliminarily entangled and shaped in the step S8 into a main needling machine through a drafting device, further needling and entangling without repeating needling through an upper needling and a lower needling, and forming a fiber felt according to the entangling effect and needling density required by the product process;
s10: and (4) after-finishing, slitting or rolling the fiber felt product, and packaging to obtain a finished product.
In the above S2, the opening process is required to be mild and the damage to the fibers is small.
In the step S4, the fibers enter the three-licker-in refined opener at the uniform speed through the conveyer belt for refined opening, and the fibers are further loosened to meet the requirements of opening picking. The process requires gentle opening action, less fiber damage and no entanglement.
The opening process in the above S2, S3, S4: the invention adopts superfine basalt fiber chopped yarn with monofilament diameter of 3-6 mu m. Due to their small monofilament diameter, fibers are easily damaged or the opening effect is poor during the initial process. The basalt fiber opening process is decomposed into two parts of coarse opening and fine opening, and the basalt fiber impregnating compound and the internal structure of the opening machine are adjusted to be beneficial to opening superfine basalt fibers.
In the step S5, the pneumatic cotton bin continuously delivers the fibers to the continuous leather curtain weighing instrument, and the weight deviation of the fibers is automatically adjusted by the self-adjusting leveling device, so that the weight difference of the delivered fibers in unit time fluctuates in a small range, and the subsequent fiber amounts delivered to the carding machine are kept consistent.
The carding process in the above S5 and S6: the carding process is used as the most critical loop in the dry-laid process of fiber materials and is the most basic and important process in the whole needling process, and the quality of the formed fiber web can directly influence the quality of a non-woven final product. As the diameter of the superfine basalt fiber is only 3-6 mu m and is extremely easy to damage in the carding process, the superfine basalt fiber carding machine improves the carding process, the fiber is tightly held by the carding machine, then is carded, opened and transferred by the opening roller with card clothing, enters the carding system device with special card clothing of the carding machine for multi-unit carding, each unit is provided with the card clothing with different types, carding and transferring of each unit are used for jointly finishing carding and stripping of the fiber, and finally a two-dimensional uniform fiber thin net is formed.
The lapping process in S7 and S8 above: lapping is to make a thick web that meets the requirements by mechanically laying thin webs together to change the areal density and thickness of the web, or simultaneously changing the direction of the fibers. The invention adopts a cross lapping mode of linear reciprocating motion, and adjusts the thickness of the needled felt by controlling the reciprocating motion frequency of the lapping machine and the conveying speed of the conveyor belt. Because the invention adopts the superfine basalt fiber chopped yarn with the diameter of 3-6 mu m as the raw material, the influence of environmental factors is larger; the influence of environmental factors on the lapping uniformity is reduced by improving the lapping workshop.
The needling process in S9 above: the needling process is to continuously puncture the laid fiber layers by using needles with extremely high needle density distributed on a needle plate, and to entangle the fibers in motion together under the action of the crochet, thereby finally preparing the needling non-woven material which is fluffy, has the thickness of 1 mm-10 mm, has uniform surface density and certain strength and can be directly used or used after finishing. The invention divides the needling process into a pre-needling process and a main needling process; meanwhile, the density of the felting needles of the pre-needling machine and the main needling machine is reduced, and the needling frequency and the needling depth are adjusted to be beneficial to the needling processing of the superfine basalt fiber chopped yarns with the diameter of 3-6 mu m.
The above-described antistatic technique in S9: as the diameter of the superfine basalt fiber used in the invention is 3-6 μm, compared with the traditional 10-17 μm basalt fiber, the superfine basalt fiber has a larger specific surface area, and is more likely to generate static electricity in the processing and conveying processes, thereby influencing the preparation and performance of the basalt needled felt. Therefore, the impregnating compound for the basalt fiber needled felt is adjusted, so that the basalt fiber needled felt has more excellent antistatic performance; meanwhile, basalt fiber needled felt transmission equipment is modified, and an antistatic conveying belt is adopted, so that the generation of static electricity is reduced.
Preferably, in the S1, the single strand of the single-strand monofilament ultra-fine basalt fiber filament is 400-450 strands.
Preferably, in S1, the monofilament diameter of the single-strand monofilament ultra-fine basalt fiber filament is 3 to 6 μm.
Preferably, in S1, the preset length is 50-60 mm.
Preferably, in S1, the ultra-fine basalt fiber filaments are obtained by melting and drawing basalt stone.
Preferably, the melting temperature is 1450-.
Preferably, the wire drawing is formed by drawing a platinum rhodium alloy wire drawing bushing at a high speed.
Preferably, in S7, the web product has a thickness of 1 to 10mm in terms of weight per unit area and width.
Preferably, in the step S9, the thickness of the fiber mat is 1-2 mm.
A fiber mat obtained by the process for making a fiber mat according to any of claims 1-9.
The invention has the beneficial effects that:
the invention provides a process for preparing a fiber felt, which is a superfine basalt fiber felt, wherein basalt fiber is superfine continuous fiber formed by melting basalt stone at 1450-1500 ℃, heating the basalt stone in a furnace special for superfine fiber in a subarea manner, performing the processes of melting, clarifying, homogenizing, defoaming and the like, drawing the basalt stone into superfine continuous fiber at high speed by using a platinum-rhodium alloy wire drawing bushing, wherein the diameter of the fiber is 3-6 mu m, processing the fiber into short cut yarn with the length of 50-60mm by equipment, then opening and loosing the short cut yarn, carding the fiber into fiber nets by a carding machine, regularly overlapping the fiber nets by a lapping machine to form a multi-layer fiber net structure, leading the fiber nets to pass through a needling area of a needling machine, forcedly penetrating the surface of the fiber net and the local inner layer of the fiber net into the fiber by the action of crochet hook on the edge of the needling machine, and due to the friction action among the fibers, the fluffy fiber web is forced to be compressed, the fibers in the fiber web are mutually entangled under the action of repeated needling for many times to form a fiber felt with certain strength, density and thickness, the fibers in the multi-layer felt web are single fibers and have a three-dimensional microporous structure, the rapid flow and diffusion of air are limited by the multi-layer three-dimensional staggered fiber yarns, namely, the thermal convection of the air is reduced, and the raw materials are superfine in diameter to form dense gaps, so that the fiber felt has good heat insulation performance and physical performance.
The invention provides a production process of a superfine basalt fiber felt, the heat preservation felt prepared by the process can completely meet the requirement of non-combustible A1 grade, and is a preferred material for heat preservation, heat insulation and fire prevention. Meanwhile, the material has the characteristics of softness, folding property, coating property, easy construction and the like. The aerogel high-efficiency heat-insulation composite material can also be used as a reinforcing material, is prepared by combining a sol-gel process and a supercritical drying technology, and has extremely low heat conductivity coefficient.
Detailed Description
The present invention is further illustrated below with reference to specific examples. It will be appreciated by those skilled in the art that the following examples, which are set forth to illustrate the present invention, are intended to be part of the present invention, but not to be construed as limiting the scope of the present invention. The reagents used are all conventional products which are commercially available.
Example 1:
a process for making a fiber mat, the process comprising the steps of:
s1: cutting single-stranded monofilaments (400 monofilaments with the diameter of 3 mu m) produced by a superfine fiber special kiln into short-cut yarns with the preset length of 50mm by using short-cutting equipment;
s2: uniformly spreading the chopped yarns on a conveyor belt of an opener, and performing coarse opening treatment by using a special opener, wherein the opening process needs to be moderate and soft, and the damage to fibers needs to be small;
s3: pumping the coarsely opened fibers to the top of the material mixing all-in-one machine through a fan, discharging wind pressure through a wind pressure relief device, enabling the fibers to enter the material mixing all-in-one machine in sequence, enabling the uniform fibers to be scattered and stacked layer by layer, then taking the fibers out through a brad curtain, and outputting the fibers onto a finely opened conveying belt;
s4: the fibers enter a three-licker-in roller fine opener at uniform speed through a conveying belt for fine opening, and the fibers are further loosened to meet the requirements of opening and picking. The process requires that the opening action is soft and proper, the fiber damage is small, and the entanglement phenomenon cannot occur;
s5: after the opening process of the fibers is finished, pumping the fibers to a last cotton bin through a fan, stabilizing air pressure, pumping the fibers to an air pressure cotton bin through the fan from the last cotton bin, continuously conveying the fibers to a continuous leather curtain weighing instrument through the air pressure cotton bin, and automatically adjusting the weight deviation of the fibers through a self-adjusting leveling device, so that the weight difference of the conveyed fibers in unit time fluctuates in a very small range, and the fibers input into a carding machine are kept consistent;
s6: the fibers are input into a carding machine for carding, so that the opened fibers are carded into single fibers in the carding process to form a single-layer two-dimensional thin fiber net;
s7: repeatedly overlapping and paving the single-layer fiber net output by the carding machine through a lapping mechanism to obtain a fiber net product with unit area weight and breadth, wherein the thickness of the product is 1 mm;
s8: conveying the laid fiber net product through a bottom curtain, feeding the fiber net product into a holding input device, thinning the fiber net product, feeding the fiber net product into a pre-needling machine, and primarily entangling and shaping the fiber net product through pre-needling;
s9: guiding the preliminarily entangled and shaped fiber web product into a main needling machine through a drafting device, further needling and entangling through the non-repeated needling of an upper needling and a lower needling to achieve the entanglement effect and needling density required by the product process, and forming the fiber felt with the thickness of 1 mm;
s10: and (4) performing after-treatment, slitting or rolling on the fiber felt product, and packaging to obtain a finished product.
Example 2:
a process for making a fiber mat, the process comprising the steps of:
s1: cutting single-stranded monofilaments (450 strands with the monofilament diameter of 6 mu m) produced by a superfine fiber special kiln into short cut yarns with the preset length of 60mm by using short cutting equipment;
s2: uniformly spreading the chopped yarns on a conveyor belt of an opener, and performing coarse opening treatment by using a special opener, wherein the opening process needs to be moderate and soft, and the damage to fibers needs to be small;
s3: pumping the coarsely opened fibers to the top of the material mixing all-in-one machine through a fan, discharging wind pressure through a wind pressure relief device, enabling the fibers to enter the material mixing all-in-one machine in sequence, enabling the uniform fibers to be scattered and stacked layer by layer, then taking the fibers out through a brad curtain, and outputting the fibers onto a finely opened conveying belt;
s4: the fibers enter a three-licker-in roller fine opener at uniform speed through a conveying belt for fine opening, and the fibers are further loosened to meet the requirements of opening and picking. The process requires that the opening action is soft and proper, the fiber damage is small, and the entanglement phenomenon cannot occur;
s5: after the opening process of the fibers is finished, pumping the fibers to a last cotton bin through a fan, stabilizing air pressure, pumping the fibers to an air pressure cotton bin through the fan from the last cotton bin, continuously conveying the fibers to a continuous leather curtain weighing instrument through the air pressure cotton bin, and automatically adjusting the weight deviation of the fibers through a self-adjusting leveling device, so that the weight difference of the conveyed fibers in unit time fluctuates in a very small range, and the fibers input into a carding machine are kept consistent;
s6: the fibers are input into a carding machine for carding, so that the opened fibers are carded into single fibers in the carding process to form a single-layer two-dimensional thin fiber net;
s7: enabling the single-layer two-dimensional thin fiber net to enter a lapping machine, and repeatedly lapping the single-layer fiber net output by the carding machine through a lapping mechanism to obtain a fiber net product with unit area weight and breadth, wherein the product thickness is 10 mm;
s8: conveying the laid fiber net product through a bottom curtain, feeding the fiber net product into a holding input device, thinning the fiber net product, feeding the fiber net product into a pre-needling machine, and primarily entangling and shaping the fiber net product through pre-needling;
s9: guiding the preliminarily entangled and shaped fiber web product into a main needling machine through a drafting device, further needling and entangling through the non-repeated needling of an upper needling and a lower needling to achieve the entanglement effect and needling density of the product process requirement, and forming the fiber felt with the thickness of 2 mm;
s10: and (4) performing after-treatment, slitting or rolling on the fiber felt product, and packaging to obtain a finished product.
The present invention is not limited to the above alternative embodiments, and any other products in various forms can be obtained by the present invention, and the present invention is within the protection scope of the present invention. The above embodiments should not be construed as limiting the scope of the present invention, and it will be understood by those skilled in the art that modifications may be made to the technical solutions described in the above embodiments, or equivalent substitutions may be made to some or all of the technical features thereof, without departing from the scope of the present invention, and at the same time, such modifications or substitutions may not make the essence of the corresponding technical solutions depart from the scope of the embodiments of the present invention.
Claims (10)
1. The manufacturing process of the fiber felt is characterized by comprising the following steps:
s1: cutting the single-stranded monofilament superfine basalt fiber filament produced by a superfine fiber special kiln into short-cut yarns with preset lengths by using short-cutting equipment;
s2: uniformly spreading the chopped yarns on a conveyor belt of an opener, and performing coarse opening treatment by a special opener;
s3: pumping the coarsely opened fibers to the top of the material mixing all-in-one machine through a fan, discharging wind pressure through a wind pressure relief device, enabling the fibers to orderly fall into the material mixing all-in-one machine, uniformly scattering and stacking the fibers layer by layer, and then taking the fibers out through a brad curtain;
s4: the fibers brought out by the angle nail curtain are uniformly input into a fine opener through a conveying belt to be subjected to fine opening treatment, and the fibers are further loosened;
s5: after the fine opening treatment of the fibers is finished, pumping the fibers to a last cotton bin through a fan, stabilizing the air pressure, pumping the fibers to an air pressure cotton bin through the fan from the last cotton bin, continuously conveying the fibers to a continuous leather curtain weighing instrument through the air pressure cotton bin, and automatically adjusting;
s6: the weighed fibers are input into a carding machine to be carded and finished into single fibers to form a single-layer two-dimensional thin fiber net;
s7: sending the two-dimensional thin fiber net into a lapping machine, and repeatedly lapping and processing the two-dimensional thin fiber net through a lapping mechanism to obtain a fiber net product with unit area weight and breadth;
s8: conveying the fiber web product through a bottom curtain, feeding the fiber web product into a holding input device, pressing the fiber web product to be thin, feeding the fiber web product into a pre-needling machine, and primarily entangling and shaping the fiber web product through pre-needling;
s9: guiding the fiber web product which is preliminarily entangled and shaped in the step S8 into a main needling machine through a drafting device, further needling and entangling without repeating needling through an upper needling and a lower needling, and forming a fiber felt according to the entangling effect and needling density required by the product process;
s10: and (4) after-finishing, slitting or rolling the fiber felt product, and packaging to obtain a finished product.
2. The process of claim 1, wherein in the step S1, the number of the single strands of the single-strand monofilament ultra-fine basalt fiber filament is 400-450.
3. The process of claim 2, wherein in the step S1, the monofilament diameter of the single-strand monofilament ultra-fine basalt fiber filament is 3 to 6 μm.
4. The process of claim 1, wherein the predetermined length in S1 is 50-60 mm.
5. The process of claim 1, wherein in the step S1, the ultra-fine basalt fiber filament is obtained from basalt stone material by melting and drawing.
6. The process of claim 5, wherein the melting temperature is 1450-1500 ℃.
7. The process of claim 5, wherein the wire is drawn at high speed using a platinum rhodium bushing.
8. The process of claim 1, wherein the web product of weight per unit area and width in S7 has a thickness of 1-10 mm.
9. The process of claim 1, wherein in step S9, the thickness of the fiber mat is 1-2 mm.
10. A fibrous mat, characterized in that a finished product is obtained by the process for the manufacture of a fibrous mat according to any of the preceding claims 1-9.
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