CN114714730B - 可撕开成片的连续性涤纶纤维纺织布、加工设备及方法 - Google Patents
可撕开成片的连续性涤纶纤维纺织布、加工设备及方法 Download PDFInfo
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Abstract
本发明公开了可撕开成片的连续性涤纶纤维纺织布、加工设备及加工方法,采用超声波热熔技术,涤纶纤维纺织品经过金属刀模与超声波焊头作用瞬间高频产生高温把毛圈层与基层的丝线熔融在一线,形成可撕开的薄状线条熔融体,在保证基层本身韧性的同时达到熔而不断,一撕即断的效果;制备时不需要对超声波焊头或金属刀模进行预热,利用刀模和超声波焊头靠近共振产生热量,离开共振消失热量减退,来实现线状高温带的形成和温控,因此可以实现连续操作,且实现每次刀头的温度基本一致,保证各薄状线条熔融体的一致性。
Description
技术领域
本发明涉及一种纺织布,尤其是涉及一种可撕开成片的涤纶纤维纺织布,连续性的涤纶纤维纺织布上间隔地设有薄状线条熔融体,沿该薄状线条熔融体进行撕开后,可从连续的涤纶纤维纺织布上分离出可独立的纺织布。
背景技术
涤纶纤维纺织布,主要用于毛巾布、擦布、洗地布等。
涤纶纤维包括纯涤纶的和混合涤纶,混合涤纶为:单根纱线比例分为2种,一种是:80%涤纶,20%锦纶,另外一种是:85%涤纶,15%锦纶。
纺织布的组成比例:中间的基层为32-30%的全涤纶材料,两侧的毛圈层部分占比68-70%的混合型涤纶纱线。
涤纶丝、涤锦丝采用经编织造或纬编织造工艺织成坯布,经染色开纤形成的布料包含中间的基层和两侧的毛圈层。
生产企业在生产纺织布时,由于化纤布料不易撕开,将连续的涤纶纤维纺织布先行切割成片状的纺织布,成型为毛巾布、擦布或拖地布,然后将多片纺织布叠加在一起进行包装。
上述生产和包装方式,对制造型企业来说,加工及包装工序较多,生产成本较高;同时对用户来说,使用起来也不够方便。
发明内容
鉴于上述片状纺织品在生产包装及用户使用的不便利性,本发明提供一种可撕开成单片的连续性涤纶纤维纺织布,以及制备这种可撕开成单片的连续性涤纶纤维纺织布的加工设备及加工方法。
本发明解决上述技术问题所采用的技术方案为:可撕开成片的连续性涤纶纤维纺织布,包括连续延伸的涤纶纤维纺织布;
所述涤纶纤维纺织布沿长度方向上按一定间隔地设有多条薄状线条熔融体,所述薄状线条熔融体横贯涤纶纤维纺织布的宽度;
所述涤纶纤维纺织布包括由纱线编织而成的基层及设置在基层至少一侧面的毛圈层,薄状线条熔融体由所述基层与所述毛圈层经加热熔融并受压而形成,所述薄状线条熔融体的厚度小于等于所述基层的厚度;
沿所述薄状线条熔融体撕扯,可分离出独立单片的纺织布。
本发明解决上述技术问题所采用的优选的技术方案为:薄状线条熔融体呈直线、曲线、锯齿线或弯折线。
本发明解决上述技术问题所采用的优选的技术方案为:薄状线条熔融体的厚度为0.01-2毫米,所述薄状线条熔融体的宽度为1-5毫米。
本发明解决上述技术问题所采用的优选的技术方案为:单片纺织布的宽度与涤纶纤维纺织布的宽度一致,所述单片纺织布的长度为5CM-200CM。
本发明解决上述技术问题所采用的优选的技术方案为:所述涤纶纤维纺织布的两侧为热熔切边。
本发明解决上述技术问题所采用的技术方案为:所述基层的两侧面分别设有毛圈层,所述基层和两个毛圈层加热熔融后并受压形成所述薄状线条熔融体。
本发明解决上述技术问题所采用的优选的技术方案为:所述基层和毛圈层通过高频超声波加热熔融。
本发明解决上述技术问题所采用的优选的技术方案为:包括圆柱状的内芯,具有薄状线条熔融体的所述涤纶纤维纺织布卷绕于所述内芯上。
本发明解决上述技术问题所采用的优选的技术方案为:具有薄状线条熔融体的所述涤纶纤维纺织布采用“Z”字形连续折叠方式堆叠于容纳器具中。
本发明解决上述技术问题所采用的技术方案为:所述基部采用经编工艺制备,所述基部包括由织线构成的环形单元,所述环形单元之间相互交织构成约束。
本发明解决上述技术问题所采用的优选的技术方案为:所述基部采用纬编工艺制备,所述基部包括由织线构成的半环形单元,相邻纬线形成的半环形单元相互交织。
本发明解决上述技术问题所采用的技术方案为:可撕开成片的连续性涤纶纤维纺织布的加工设备,包括超声波焊头和受驱动机构驱动的金属刀模,所述金属刀模包括一沿纺织布宽度方向延伸的刀棱;
所述刀棱作用于所述涤纶纤维纺织布上表面,所述超声波焊头作用于所述涤纶纤维纺织布下表面;
在驱动机构的作用下,所述金属刀模的刀棱下压通过涤纶纤维纺织布接触超声波焊头而共振,所述超声波焊头产生线状高温带;
所述涤纶纤维纺织布的基层及毛圈层在线状高温带作用下熔融,并在金属刀模和超声波焊头的挤压下形成薄状线条熔融体。
本发明解决上述技术问题所采用的优选的技术方案为:所述超声波焊头的震动频率为2000-50000次/秒,所述超声波焊头的发热温度为150-400度。
本发明解决上述技术问题所采用的优选的技术方案为:所述刀棱下压接触涤纶纤维纺织布的时间为0.02-1秒。
本发明解决上述技术问题所采用的技术方案为:可撕开成片的连续性涤纶纤维纺织布的加工方法:
连续性涤纶纤维纺织布经过超声波设备,连续性涤纶纤维纺织布的基层和毛圈层经超声波设备产生的高温熔融后并受压形成薄状线条熔融体,可分离出独立单片的纺织布。
本发明解决上述技术问题所采用的优选的技术方案为:所述超声波设备包括超声波焊头和受驱动机构驱动的金属刀模,所述金属刀模包括一沿纺织布宽度方向延伸的刀棱;
所述刀棱作用于所述涤纶纤维纺织布上表面,所述超声波焊头作用于所述涤纶纤维纺织布下表面;
在驱动机构的作用下,所述金属刀模的刀棱下压通过涤纶纤维纺织布接触超声波焊头而共振,所述超声波焊头产生线状高温带;
所述涤纶纤维纺织布的基层及毛圈层在线状高温带作用下熔融,并在金属刀模和超声波焊头的挤压下形成薄状线条熔融体。
本发明解决上述技术问题所采用的优选的技术方案为:所述超声波焊头的震动频率为2000-50000次/秒,所述超声波焊头的发热温度为150-400度。
本发明解决上述技术问题所采用的优选的技术方案为:所述刀棱与涤纶纤维纺织布的接触时间为0.02-1秒。
本发明解决上述技术问题所采用的优选的技术方案为:包括如下步骤:
(1)驱动机构驱动金属刀模下压,超声波焊头超声高频振动;
(2)所述金属刀模与超声波焊头挤压涤纶纤维纺织布并保持一定时间;
(3)去除超声发射,驱动机构驱动金属刀模回升,一道薄状线条熔融体完成制备;
(4)间隔一定周期后继续上述(1)-(3)的步骤,完成下道薄状线条熔融体的制备。
本发明解决上述技术问题所采用的优选的技术方案为:所述驱动机构的运行和超声波焊头的超声发射受一控制信号控制,以实现联动。
与现有技术相比,本发明的优点是采用一种超声波热熔技术,涤纶纤维纺织品经过刀模与超声波焊头作用瞬间高频产生高温把毛圈层与基层的丝线熔融在一线,形成可撕开的薄状线条熔融体,达到熔而不断,一撕即断的效果;
采用这种超声波共振方法,制备时不需要对超声波焊头或金属刀模进行预热,利用刀模和超声波焊头靠近共振产生热量,离开共振消失热量减退,来实现线状高温带的形成和温控,因此可以实现连续操作,且实现每次刀头的温度基本一致,保证各薄状线条熔融体的一致性。
附图说明
以下将结合附图和优选实施例来对本发明进行进一步详细描述,但是本领域技术人员将领会的是,这些附图仅是出于解释优选实施例的目的而绘制的,并且因此不应当作为对本发明范围的限制。此外,除非特别指出,附图仅示意在概念性地表示所描述对象的组成或构造并可能包含夸张性显示,并且附图也并非一定按比例绘制。
图1为卷绕成型的可撕开成片的连续性涤纶纤维纺织布的示意图;
图2为可撕开成片的连续性涤纶纤维纺织布的撕扯成片过程示意图;
图3为可撕开成片的连续性涤纶纤维纺织布的局部剖面图;
图4为可撕开成片的连续性涤纶纤维纺织布的经编工艺的基层图;
图5为可撕开成片的连续性涤纶纤维纺织布的纬编工艺的基层图;
图6为可撕开成片的连续性涤纶纤维纺织布的加工示意图。
具体实施方式
以下将参考附图来详细描述本发明的优选实施例。本领域中的技术人员将领会的是,这些描述仅为描述性的、示例性的,并且不应被解释为限定了本发明的保护范围。
应注意到:相似的标号在下面的附图中表示类似项,因此,一旦某一项在一个附图中被定义,则在随后的附图中可能不再对其进行进一步定义和解释。
在本发明的描述中,需要说明的是,术语“前”、“后”等指示的方位或位置关系为基于附图所示的方位或位置关系,或者是该发明产品使用时惯常摆放的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。
如图1-3所示,可撕开成片的连续性涤纶纤维纺织布包括连续延伸的涤纶纤维纺织布A,该涤纶纤维纺织布A由纱线编织而成的基层1及设置在基层1至少一侧面的毛圈层2。
如图4所示,基层1采用经编工艺制备;如图5所示,基层1采用纬编工艺制备。上述两种工艺制备的基层1具有由织线构成的环形单元a或半环形单元b。
采用经编工艺制备的基层经线上的环形单元a环环相扣,纬线上的环形单元a的一引出线穿过相邻纬线上的环形单元a,另一引出线用以环绕形成对角线位置的环形单元a。从而使得相邻环形单元a之间相互交织构成约束。
采用纬编工艺制备的基层的织线呈波浪形弯曲,形成纬线上的相邻的正反向间隔的半环形单元b。相邻纬线形成的半环形单元b相互交织。
相互交织的环形单元a或半环形单元b使整个基层1具有抗撕拉性能,进而使得该涤纶纤维纺织布更加耐用。
而毛圈层2的毛圈编织单元凸出于基层1的表面,且呈矩阵方式排列于基层1的表面。每个毛圈编织单元与基层1的环形单元a或半环形单元b进一步交织,使得基层1和毛圈层2结合起来,在提高该涤纶纤维纺织布吸水、清洁能力的同时更增进了布料的强度。
如图1-3所示,连续性涤纶纤维纺织布沿长度方向上间隔设有多条薄状线条熔融体3。
薄状线条熔融体3可以横贯涤纶纤维纺织布的宽度,也可以交错形成网格状,从而将长条状的涤纶纤维纺织布分隔形成若干个纺织布单元M。
这些薄状线条熔融体3由基层1与毛圈层2经加热熔融并受压而形成,且薄状线条熔融体3的厚度小于等于基层1的厚度。薄状线条熔融体3内凹于涤纶纤维纺织布表面,从视觉上便可获悉其所处位置。
应当被理解的是,通过热熔加压,一来薄状线条熔融体3处的纤维本身的韧性受到热破坏而变脆;二来该处的基层1的环形单元a之间的约束以及毛圈编制单元和基层1的环形单元a的约束均受到破坏;三来该处薄状线条熔融体3内凹而使得应力更加集中以形成撕裂缺口。也就是说,薄状线条熔融体3容易受力断裂。
据此,使用者沿薄状线条熔融体3撕扯,可分离出独立单片的纺织布。也可视待清洁物的多寡,以撕取方式即可自行决定布体的大小长度,而不需通过刀器或利刃来剪裁。
优选地,薄状线条熔融体3可以呈直线、曲线、锯齿线或弯折线。在本实施例中,薄状线条熔融体3贯穿涤纶纤维纺织布的宽度且按一定间隔地分布于长条状的涤纶纤维纺织布上,从而将涤纶纤维纺织布分成相同大小的纺织布单元M,以便于用户取用。
优选地,基层1的材质为全涤纶,毛圈层2的材质为由涤纶和锦纶形成的混合型涤纶。其中基层1占比30-32%,毛圈层2占比68-70%。
如图所示,毛圈层2的毛圈编织单元的矩阵方式排布将形成纵向毛圈间隔线,而薄状线条熔融体3平行于纵向毛圈间隔线。薄状线条熔融体3两侧的毛圈编织单元熔融收缩且产生倒伏,使得薄状线条熔融体3两侧的毛圈层2自薄状线条熔融体3逐渐又薄变厚。
如图1-3所示,纵向的薄状线条熔融体3间隔的纺织布单元M从整体连续性涤纶纤维纺织布分离后形成的单片纺织布,单片纺织布的宽度与长条状的涤纶纤维纺织布的宽度一致,单片纺织布的长度为5CM-200CM。
优选地,基层1的两侧面分别设有毛圈层2,基层1和两个毛圈层2加热熔融后并受压形成薄状线条熔融体3。薄状线条熔融体3位于涤纶纤维纺织布的厚度的中线,以在涤纶纤维纺织布的两个表面形成内凹的线槽。
如图所示,薄状线条熔融体3的厚度为0.01-2毫米,宽度为1-5毫米。0.01-2毫米即使得薄状线条熔融体3在无外力撕扯状态下具有连接两侧纺织布单元M的能力,使得涤纶纤维纺织布保持连续性,又保证连接强度处于能够被使用者撕扯后断裂的范围内,方便用户撕扯分离出独立单片的纺织布。同时薄状线条熔融体3的宽度也影响其连接强度,另外1-5毫米的宽度范围使得薄状线条熔融体3可视且不至于浪费布料。
此外,连续性涤纶纤维纺织布的两侧通过热熔切边收口,可防止织布跑丝。在连续性涤纶纤维纺织布上的任一薄状线条熔融体3被撕拉分离纺织布单元M后,薄状线条熔融体3的一部分残留在剩余连续性涤纶纤维纺织布的外边缘,依旧起到收口作用。
为了便于收纳和取用连续性涤纶纤维纺织布,本实施例提供了一种连续性涤纶纤维纺织布的放置形态,即卷筒式涤纶纤维纺织布,当然也可以为折叠抽拉式等其他的放置形态。
如图1所示,卷筒式涤纶纤维纺织布包括内芯4及卷绕在内芯4外的上述具有薄状线条熔融体3的连续延伸的涤纶纤维纺织布A,内心4为圆柱形的纸筒。
应当说明的是,撕扯后残留在外边缘的薄状线条熔融体3硬、薄且边缘毛糙,而涤纶纤维纺织布的外表面因为毛圈层2的原因导致表面毛糙,残留在外边缘的薄状线条熔融体3与涤纶纤维纺织布的外表面之间可以保持较大的摩擦力,甚至残留在外边缘的薄状线条熔融体3可以扎在涤纶纤维纺织布的外表面的毛圈层2内,因此在残留在外边缘的薄状线条熔融体3可以附着在涤纶纤维纺织布的外表面,使卷筒式涤纶纤维纺织布保持稳定卷绕形状,而不容易脱落、散乱。
本实施例还提供了用于制备上述涤纶纤维纺织布的加工设备。该加工设备为超声波设备,主要涉及在纺织而成的长条状的纶纤维纺织布上间隔制备薄状线条熔融体3。
如图6所示,加工设备包括超声波焊头10和受驱动机构驱动的金属刀模20。超声波焊头10包括超声波发射装置和焊头,超声波发射装置将220V的交流电转换为高频的超声波讯号,然后连接到换能器转化为高频振动以驱使头部发生高频率的超声震动。焊头具有承载涤纶纤维纺织布的搁置表面,且涤纶纤维纺织布在这一搁置表面上实现传送。
金属刀模20包括一沿纺织布宽度方向延伸的刀棱s,在驱动机构的作用下,金属刀模20的刀棱s下移接触涤纶纤维纺织布的表面,从而金属刀模20与涤纶纤维纺织布下方的超声波焊头10发生共振,超声波焊头10的头部产生线状高温带。线状高温带的宽度与刀棱s的宽度一致,这一线状高温带熔融该处的涤纶纤维纺织布的基层1及毛圈层2,同时刀棱s和头部挤压这部分熔融物以形成薄状线条熔融体3。即,基层1和毛圈层2通过高频超声波加热熔融形成薄状线条熔融体3。
同理,涤纶纤维纺织布的两侧的热熔切边也可以采用此种方式制备。
优选地驱动机构可以为受气压传动系统控制的气缸。实际作业时,电源启动一触发控制信号,控制信号使气压传动系统运行使气缸加压驱动金属刀模下降,同时控制信号使超声波焊头10的超声波发射装置发射超声波以使焊头超声震动,金属刀模下压与超声波焊头挤压涤纶纤维纺织布并保持一定时间,去除超声发射,气压传动系统退压,金属刀模回升,一道薄状线条熔融体3制备完成结束,间隔一定周期后继续上述程序,完成下道薄状线条熔融体3制备。
优选地,超声波焊头10的震动频率为2000-50000次/秒,超声波焊头10的发热温度为150-400度,刀棱s下压涤纶纤维纺织布的表面的时间为0.02-1秒。应当注意的是,刀棱s下压涤纶纤维纺织布的表面的时间和和压力需要被合理设置,从而避免涤纶纤维纺织布的发生熔断或者薄状线条熔融体3过厚导致不易撕裂的情形。
采用这种加工设备和加工方法,制备时不需要对金属刀模和超声波焊头进行预热,可以利用下压接触共振产生热量,离开共振消失热量减退,来实现线状高温带的形成和温控,因此可以实现连续操作,且实现每次刀头的温度基本一致,保证各薄状线条熔融体3的一致性。
以上对本发明所提供的可撕开成单片的涤纶纤维纺织布进行了详细介绍,本文中应用了具体个例对本发明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发明及核心思想。应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以对本发明进行若干改进和修饰,这些改进和修饰也落入本发明权利要求的保护范围内。
Claims (4)
1.可撕开成片的连续性涤纶纤维纺织布的加工方法:其特征在于:
连续性涤纶纤维纺织布经过加工设备;
所述涤纶纤维纺织布包括由纱线编织而成的基层及设置在基层两个侧面的毛圈层,所述毛圈层的每个毛圈编织单元与基层的环形单元或半环形单元交织,以使基层和毛圈层结合;
所述加工设备包括超声波焊头和受驱动机构驱动的金属刀模;
所述金属刀模包括一沿纺织布宽度方向延伸的刀棱,所述超声波焊头包括一搁置表面;
所述连续性涤纶纤维纺织布承载于所述搁置表面上,所述超声波焊头接收超声波而高频振动;
在驱动机构的作用下,所述刀棱下移接触涤纶纤维纺织布的表面,从而金属刀模与超声波焊头发生共振;
所述超声波焊头的头部产生线状高温带,所述线状高温带的宽度与刀棱的宽度一致;
所述金属刀模与超声波焊头挤压涤纶纤维纺织布并保持一定时间后回升;所述基层及两个毛圈层在线状高温带作用下熔融,并在刀棱和超声波焊头的挤压下形成薄状线条熔融体;
间隔一定周期后继续上述步骤,完成下道薄状线条熔融体的制备;
所述薄状线条熔融体横贯涤纶纤维纺织布的宽度,所述薄状线条熔融体的厚度为0.01-2毫米,宽度为1-5毫米;
所述薄状线条熔融体位于涤纶纤维纺织布的厚度的中线,所述薄状线条熔融体的厚度小于等于所述基层的厚度,并在涤纶纤维纺织布的两个表面形成内凹的线槽;
通过薄状线条熔融体可分离出独立单片的纺织布,所述薄状线条熔融体的一部分残留在剩余连续性涤纶纤维纺织布的外边缘,撕扯后残留在外边缘的薄状线条熔融体硬、薄且边缘毛糙。
2.根据权利要求1所述可撕开成片的连续性涤纶纤维纺织布的加工方法,其特征在于所述超声波焊头的震动频率为2000-50000次/秒,所述超声波焊头的发热温度为150-400度。
3.根据权利要求1所述可撕开成片的连续性涤纶纤维纺织布的加工方法,其特征在于所述刀棱与涤纶纤维纺织布的接触时间为0.02-1秒。
4.根据权利要求1所述可撕开成片的连续性涤纶纤维纺织布的加工方法,其特征在于所述驱动机构的运行和超声波焊头的超声发射受一控制信号控制,以实现联动。
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