CN114250542B - 耐高温输送带用耐压缩芳纶浸胶帆布织物结构及其制备方法 - Google Patents
耐高温输送带用耐压缩芳纶浸胶帆布织物结构及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种耐高温输送带用耐压缩芳纶浸胶帆布织物结构及其制备方法,属于产业用纺织品的技术领域。其采用对位芳纶工业长丝和尼龙66工业长丝混合的一种用于耐高温橡胶输送带的特殊用途的机织物,其中经线采用特殊捻制方式生产的芳纶线绳。本发明耐高温输送带用耐压缩芳纶浸胶帆布织物制备得到的输送带,具有蠕变变形小,高温下尺寸稳定性好,耐高温老化性能好,耐疲劳性能好等优点,其耐压缩性能相较于目前普遍采用的直径直纬芳纶浸胶帆布输送带有很大的改善。
Description
技术领域
本发明涉及一种耐高温输送带用耐压缩芳纶浸胶帆布织物结构及其制备方法,属于产业用纺织品的技术领域。
背景技术
橡胶输送带已经普遍用于运输耐高温物料,比如水泥厂煅烧后的水泥熟料、钢铁厂的烧结矿石和高温炉渣,以及燃煤发电厂出炉的煤渣、化肥厂等高温材料等等,但运输这些高温物料,目前主要采用的耐高温输送带,其骨架材料为聚酯纤维编织的耐高温帆布,聚酯纤维在高温下会被橡胶中的胺类物质胺解,导致输送带强度下降。聚酯作为一种热塑性的材料,在高温下强度会大幅度下降,伸长大幅度增加,导致橡胶变形的增加而使得橡胶提前龟裂损坏。
为了改善上述聚酯耐高温帆布的缺陷,近年来耐高温输送带开始尝试使用芳纶浸胶帆布作为骨架材料,芳纶是一种热固性材料,具有很好的尺寸稳定性,高温下不会热收缩,也不会伸长,同时不会出现大幅度的强度下降,作为一种聚酰胺类的物质,芳纶不会被胺解,具有更好的耐化学性能,是一种十分优越的耐高温材料。但是目前广泛采用的芳纶浸胶帆布组织结构为直经直纬结构,其主经纱为多股芳纶纤维并捻而成,捻度较低,主经纱基本处于伸直状态,这种结构的芳纶浸胶帆布强度很高,同样的模量也很高,但由于客户现场的输送机械是根据低模量的聚酯输送带设计的,改用这种高模量芳纶浸胶帆布输送带,在托辊过渡展开区,两侧承受极高的张力,而中间承受压缩应力,芳纶纤维耐压缩疲劳性能差,这会导致输送带中部提前龟裂,这可能导致导致芳纶浸胶帆布出现横断等一系列问题。因此需要设计一种模量与聚酯输送带更接近的低模量芳纶浸胶帆布,使其拥有良好的耐压缩疲劳性能,能够适应客户原先为聚酯耐高温输送带设计的输送机。
钢丝绳采用捻线结构,可以降低钢丝绳的模量,因此采用一种特殊的芳纶线绳结构,让芳纶工业长丝如藤蔓装缠绕在尼龙66的芯线外面,形成类似于弹簧的效应,同时选用特殊的帆布组织结构,使得成品芳纶浸胶帆布在输送带运行方向上也能形成类似弹簧的效应,从而降低芳纶浸胶帆布的模量,使其拥有良好的耐压缩疲劳性能,避免输送带因为受到压缩应力提前断裂。
发明内容
本发明的目的是克服上述不足之处,提供一种耐高温输送带用耐压缩芳纶浸胶帆布织物结构及其制备方法,其具有强度高、变形小、耐高温性能好、耐化学性能好、强度保持率好,其耐压缩疲劳性能相对于目前的芳纶输送带有大幅度提高,在原先使用聚酯耐高温输送带的输送线上运行更安全。
本发明的技术方案,一种耐高温输送带用耐压缩芳纶浸胶帆布织物结构,其特征是:织物结构由若干个重复的单元组织构成,每个单元组织均通过经纱和纬纱交织而成;所述经纱包括两种不同的经纱,分别为主经纱和捆纱;
所述每个单元组织中的经纱包括第一捆纱、第二捆纱、第三主经纱、第四主经纱、第五捆纱和第六捆纱;所述纬纱包括第一纬纱、第二纬纱、第三纬纱、第四纬纱、第五纬纱和第六纬纱。
进一步地,所述第一捆纱位于第一纬纱、第二纬纱、第三纬纱和第六纬纱的上方,第四纬纱和第五纬纱的下方;
所述第二捆纱位于第三纬纱、第四纬纱、第五纬纱和第六纬纱的上方,第一纬纱和第二纬纱的下方;
所述第三主经纱位于第二纬纱、第三纬纱和第六纬纱的上方,第一纬纱、第四纬纱和第五纬纱的下方;
所述第四主经纱位于第三纬纱、第五纬纱和第六纬纱的上方,第一纬纱、第二纬纱和第四纬纱的下方;
所述第五捆纱位于第二纬纱和第三纬纱的上方,第一纬纱、第四纬纱、第五纬纱和第六纬纱的下方;
所述第六捆纱位于第五纬纱和第六纬纱的下方,第一纬纱、第二纬纱、第三纬纱和第四纬纱的上方。
所述主经纱为对位芳纶工业长丝和尼龙66工业长丝混捻而成;所述捆纱和纬纱均为尼龙66工业长丝。
进一步地,所述结构的制备方法,所述主经纱先将纤度为2200-4400dtex的对位芳纶工业长丝进行初捻,得到芳纶初捻纱,捻度为60-120捻/米;将总纤度为1400-5600dtex的尼龙66工业长丝合股加捻,得到尼龙66初捻纱,捻度为60-120捻/米;根据浸胶帆布的强度要求,将1-3股的芳纶初捻纱和1股的尼龙66初捻纱合股加捻成线绳;再浸渍浸胶液,干燥、热定型后,制备成可用于耐高温橡胶输送带的浸胶帆布。
进一步地,芳纶初捻纱超喂3%-8%,从而形成尼龙66初捻纱为芯,芳纶初捻纱缠绕在外的效果。
进一步地,所述捆纱为总纤度1400-2800dtexde 尼龙66工业长丝,其加捻捻度为60-120捻/米。
进一步地,织物的主经纱密度为30-120根/10厘米;捆纱密度与主经纱密度的比例为2:1;纬密为60-120根/10厘米。
进一步地,所述纬纱为总纤度2800-8400dtex尼龙66工业长丝合股加捻纱,捻度为120捻/米。
进一步地,经纱和纬纱交织后,再浸渍由胶乳与水性粘合剂配置而成的浸胶液,随后经过干燥和热处理,得到耐高温输送带用耐压缩芳纶浸胶帆布织物。
进一步地,所述浸胶液是由丁砒胶乳或与羧基丁苯、羧基丁腈的混合胶乳,与水性粘合剂酚醛树脂水溶液,或封闭异氰酸酯、环氧树脂、水性咪唑类固化剂的混合水溶液配置而成;浸渍水溶液的总固含量在18%-22%,其中胶乳与粘合剂的固体比例为60-85:15-40,丁砒胶乳与其他胶乳的比例为70-100:30-0。
进一步地,根据织物的厚度与单位重量,前干燥温度为90-130℃,后干燥温度为120-150℃,干燥张力为0.25cN/dtex,在各个干燥烘箱中的停留时间为2-5分钟,热定型温度为180℃,在烘箱中停留时间在2-3分钟,定型张力为0.5cN/dtex。浸胶速度应根据热定型烘箱总长度除以所需的停留时间来确定。
本发明所述的织物芯输送带,是指采用织物作为骨架材料的橡胶输送带,所运输的物料温度在100-400℃之间,输送带骨架层的受热温度小于150℃。
本发明的有益效果:本发明所述结构织造的帆布具有很高的强度,无比紧密的结构,可以有效抵御尖锐矿石的冲击和切割。具有较高的卷曲度,所生产的输送带弹性模量会大幅度下降,和多层织物芯输送带相一致,可以更好的适应原有输送机,是替代传统EP帆布的良好选择。
本发明在保证了输送带在运送大块物料和尖锐物料时能够有效抵御冲击,提高输送带的安全性,延长输送带的使用寿命。
附图说明
图1是本发明耐高温输送带用耐疲劳芳纶浸胶帆布的组织结构图。
图2是本发明耐高温输送带用耐疲劳芳纶浸胶帆布的剖面示意图。
图3是本发明耐高温输送带用耐疲劳芳纶浸胶帆布主经纱线绳结构示意图。
附图标记说明:A、主经纱、B、捆纱;C、纬纱;1、第一捆纱;2、第二捆纱;3、第三主经纱;4、第四主经纱;5、第五捆纱;6、第六捆纱;a、第一纬纱;b、第二纬纱;c、第三纬纱;d、第四纬纱;e、第五纬纱;f、第六纬纱;m、尼龙66纤维;n、对位芳纶纤维。
具体实施方式
以下对本发明的原理和特征进行描述,所举实例只用于解释本发明,并非用于限定本发明的范围。
以下实施例采用原料:3340dtex的对位芳纶工业长丝,厂家为日本帝人公司,牌号为TOWRON,表面已由厂家经过预活化处理。采用1400dtex的尼龙66工业长丝,厂家为河南神马集团。
实施例1 耐高温输送带用耐压缩芳纶浸胶帆布织物结构
如图1-3所示,织物结构由若干个重复的单元组织构成,每个单元组织均通过经纱和纬纱C交织而成;所述经纱包括两种不同的经纱,分别为主经纱A和捆纱B;
所述每个单元组织中的经纱包括第一捆纱1、第二捆纱2、第三主经纱3、第四主经纱4、第五捆纱5和第六捆纱6;所述纬纱包括第一纬纱a、第二纬纱b、第三纬纱c、第四纬纱d、第五纬纱e和第六纬纱f。
所述第一捆纱1位于第一纬纱a、第二纬纱b、第三纬纱c和第六纬纱f的上方,第四纬纱d和第五纬纱e的下方;
所述第二捆纱2位于第三纬纱c、第四纬纱d、第五纬纱e和第六纬纱f的上方,第一纬纱a和第二纬纱b的下方;
所述第三主经纱3位于第二纬纱b、第三纬纱c和第六纬纱f的上方,第一纬纱a、第四纬纱d和第五纬纱e的下方;
所述第四主经纱4位于第三纬纱c、第五纬纱e和第六纬纱f的上方,第一纬纱a、第二纬纱b和第四纬纱d的下方;
所述第五捆纱位5于第二纬纱b和第三纬纱c的上方,第一纬纱a、第四纬纱d、第五纬纱e和第六纬纱f的下方;
所述第六捆纱6位于第五纬纱e和第六纬纱f的下方,第一纬纱a、第二纬纱b、第三纬纱c和第四纬纱d的上方。
所述主经纱为对位芳纶工业长丝n和尼龙66工业长丝m混捻而成;所述捆纱和纬纱均为尼龙66工业长丝。
实施例2耐高温输送带用耐压缩芳纶浸胶帆布织物的制备
(1)芳纶初捻纱:将1股3340dtex芳纶工业长丝,在环锭捻线机上加捻,捻线机为宜昌纺机的R814,加捻捻度为120捻/米,捻向Z;
(2)尼龙初捻纱:将2股1400尼龙66工业长丝在环锭捻线机上合股后加捻,捻线机为宜昌纺机的R814,加捻捻度为120捻/米,捻向Z;
(3)主经纱:主经纱为尼龙66和芳纶的混捻线绳,采用常州凯洲的KV301型上进行改制的环锭捻线机,将3股芳纶初捻纱和一股尼龙66初捻纱进行合股加捻,捻向S,捻度60捻/米,其中芳纶初捻纱比尼龙66初捻纱超喂5%,加捻后形成芳纶初捻纱螺旋形缠绕在尼龙66初捻纱的外面,得到尼龙66为芯的皮芯结构的芳纶线绳;
(4)捆纱:将1股1400dtex尼龙66工业长丝在环锭捻线机上加捻,捻线机为宜昌纺机的R814,加捻捻度为120捻/米,捻向Z;
(5)纬纱:将3股1400dtex尼龙66工业长丝在环锭捻线机上加捻,捻线机为宜昌纺机的R814,加捻捻度为120捻/米,捻向Z;
(6)织布:采用筒子架送经,将主经纱和捆纱放在定制的筒子架上,采用双经轴送经系统,捆纱和主经纱各用一个送经系统送经。织布选用定制的刚性剑杆织机,钢筘筘号为15齿/10厘米,每筘穿入主经纱6根,总根数540根;每筘穿入捆纱12根,总根数1082根。穿筘幅宽为1350cm。织布纬密为60根/10厘米;
(7)浸胶液的配置:将700公斤的固含量为40%,砒啶含量为13-14%的丁砒胶乳(山东合力),与150公斤的固含量为40%的羧基丁腈胶乳混合,再加入850公斤的软水,调配成1700公斤固含量为20%胶乳混合物。(固体物重量为340公斤);
将先后将40公斤固含量为50%的封闭异氰酸酯(常州科英)和40公斤的丙二醇缩水甘油醚环氧树脂放入220公斤的软水中进行搅拌30分钟,至彻底混合。再将上述两种混合物,混合在一起,搅拌30分钟后待用;
(8)帆布浸胶:在定制的浸胶机进行浸胶,第一次干燥温度为90℃,第二次干燥温度为130℃,干燥张力400公斤,热定型为180℃,定型张力为900公斤,浸胶后附胶量为6%。速度为6米/分,在干燥烘箱的停留时间各为5分钟,在热定型烘箱总的停留时间5分钟。浸胶后的成品幅宽为1165mm;
(9)浸胶成品检验结果:
帆布米重:1260克,断裂强度:690N/mm,断裂伸长:8.2%,10%强度下的弹性模量:16500N/mm。
本发明所制备浸胶帆布主经纱为对位芳纶纤维,强度高、变形小、耐高温性能好、耐化学性能好,而其特殊捻制的结构使得主经纱拥有类似弹簧的性能,拥有良好的耐压缩疲劳性能。
本发明制备的芳纶浸胶帆布的组织结构相比较目前普遍采用的直经直纬结构拥有更高的卷曲度,模量更低,成品输送带的模量跟传统的聚酯耐高温帆布输送带更接近,在客户原有的输送机上运行时,耐压缩疲劳性能大大提高,避免了芳纶骨架因为压缩应力而造成横断,大大提高了安全性和使用寿命。
以上所述仅为本发明的较佳实施例,并不用于限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种耐高温输送带用耐压缩芳纶浸胶帆布织物结构的制备方法,其特征是:织物结构由若干个重复的单元组织构成,每个单元组织均通过经纱和纬纱交织而成;所述经纱包括两种不同的经纱,分别为主经纱和捆纱;
所述每个单元组织中的经纱包括第一捆纱、第二捆纱、第三主经纱、第四主经纱、第五捆纱和第六捆纱;所述纬纱包括第一纬纱、第二纬纱、第三纬纱、第四纬纱、第五纬纱和第六纬纱;
制备方法具体为:所述主经纱先将纤度为2200-4400dtex的对位芳纶工业长丝进行初捻,得到芳纶初捻纱,捻度为60-120捻/米;将总纤度为1400-5600dtex的尼龙66工业长丝合股加捻,得到尼龙66初捻纱,捻度为60-120捻/米;根据浸胶帆布的强度要求,将1-3股的芳纶初捻纱和1股的尼龙66初捻纱合股加捻成线绳;
所述第一捆纱位于第一纬纱、第二纬纱、第三纬纱和第六纬纱的上方,第四纬纱和第五纬纱的下方;
所述第二捆纱位于第三纬纱、第四纬纱、第五纬纱和第六纬纱的上方,第一纬纱和第二纬纱的下方;
所述第三主经纱位于第二纬纱、第三纬纱和第六纬纱的上方,第一纬纱、第四纬纱和第五纬纱的下方;
所述第四主经纱位于第三纬纱、第五纬纱和第六纬纱的上方,第一纬纱、第二纬纱和第四纬纱的下方;
所述第五捆纱位于第二纬纱和第三纬纱的上方,第一纬纱、第四纬纱、第五纬纱和第六纬纱的下方;
所述第六捆纱位于第五纬纱和第六纬纱的下方,第一纬纱、第二纬纱、第三纬纱和第四纬纱的上方;
芳纶初捻纱超喂3%-8%,从而形成尼龙66初捻纱为芯,芳纶初捻纱缠绕在外的效果。
2.如权利要求1所述结构的制备方法,其特征是:所述主经纱为对位芳纶工业长丝和尼龙66工业长丝混捻而成;所述捆纱和纬纱均为尼龙66工业长丝。
3.如权利要求1所述结构的制备方法,其特征是:所述捆纱为总纤度1400-2800dtexde尼龙66工业长丝,其加捻捻度为60-120捻/米。
4.如权利要求1所述结构的制备方法,其特征是:所述纬纱为总纤度2800-8400dtex尼龙66工业长丝合股加捻纱,捻度为120捻/米。
5.如权利要求1所述结构的制备方法,其特征是:经纱和纬纱交织后,再浸渍由胶乳与水性粘合剂配置而成的浸胶液,随后经过干燥和热处理,得到耐高温输送带用耐压缩芳纶浸胶帆布织物。
6.如权利要求5所述结构的制备方法,其特征是:所述浸胶液是总固含量为18%-22%,其中胶乳与粘合剂的固体比例为60-85:15-40。
7.如权利要求5所述结构的制备方法,其特征是:根据织物的厚度与单位重量,前干燥温度为90-130℃,后干燥温度为120-150℃,干燥张力为0.25cN/dtex,在各个干燥烘箱中的停留时间为2-5分钟,热定型温度为180℃,在烘箱中停留时间在2-3分钟,定型张力为0.5cN/dtex。
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