CN114960264A - 造纸毛毯及其制备方法 - Google Patents
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- Engineering & Computer Science (AREA)
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- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- Paper (AREA)
Abstract
本申请公开了一种造纸毛毯及其制备方法。所述造纸毛毯包括涂层、表层纤维层和复合纤维层,所述涂层铺设在所述表层纤维层上,所述表层纤维层铺设在所述复合纤维层上;所述表层纤维层的纤维材料之间具有缝隙,所述涂层填充至少部分所述缝隙以在所述涂层背离所述表面纤维层的一侧形成平面,所述涂层形成有气孔。本申请通过设置涂层填补了造纸毛毯在制备过程中产生的微小凹陷,可以提高造纸毛毯的平整度,进一步通过在涂层上设置气孔,使造纸毛毯的透气性适当降低。换言之通过设置涂层使造纸毛毯具有满足抄造纸页需求的起始性能,解决了造纸毛毯在前期使用时因表面不平整、透气性过大影响抄造纸页效率的问题。
Description
技术领域
本申请涉及造纸工业技术领域,特别是涉及一种造纸毛毯及其制备方法。
背景技术
造纸毛毯是造纸机压榨部必不可少的消耗品,可起到帮助纸页脱水,修饰纸面以及传递纸页的作用。造纸毛毯具有两个重要的性能参数,一个是平整度,另一个是透气性,平整度与透气性会影响造纸毛毯在使用过程中抄造纸页的质量与效率。
现有造纸毛毯主要是将化学短纤维网复合在基网上制成,在前期使用过程中,造纸毛毯的平整度难以达到标准。另外,造纸毛毯的透气性会随着使用逐渐降低,为了保证造纸毛毯的使用寿命,通常会选择透气性稍大的造纸毛毯,但这样会使造纸毛毯在前期使用时存在透气性过大,导致纸页水分难以脱离等问题。即现有的造纸毛毯的起始性能较差,抄造纸页时需要更多的时间才能使纸页达到理想的状态,影响效率。
发明内容
本申请主要解决的技术问题提供一种具有良好起始性能的造纸毛毯及其制备方法。
为解决上述技术问题,本申请采用的一个技术方案是:提供一种造纸毛毯,包括涂层、表层纤维层和复合纤维层,所述涂层铺设在所述表层纤维层上,所述表层纤维层铺设在所述复合纤维层上;所述表层纤维层的纤维材料之间具有缝隙,所述涂层填充至少部分所述缝隙以在所述涂层背离所述表面纤维层的一侧形成平面,其中,所述涂层形成有气孔。
其中,所述涂层与所述表层纤维层在垂直所述涂层表面的方向上部分重合。
其中,所述涂层为高分子发泡材料。
其中,所述高分子发泡材料为聚亚氨酯或聚氨酯中至少一种。
其中,所述复合纤维层包括依次堆叠设置的底层纤维层、基布层和内层纤维层。
其中,所述表层纤维层、所述内层纤维层基布层和所述复合纤维层的材料包括锦纶纤维,所述锦纶纤维的细度为3.3-66Dtex。
本申请采用的另一技术方案是:提供一种造纸毛毯的制备方法,包括:提供一造纸毛毯半成品,所述造纸毛毯半成品包括堆叠设置的所述复合纤维层和所述表层纤维层;
在所述表层纤维层上喷涂涂层液,制得带涂层的造纸毛毯半成品;
将所述涂层进行空刺处理,制得初级造纸毛毯。
其中,所述涂层液为高分子发泡浆液,所述高分子发泡浆液包含聚亚氨酯或聚氨酯中至少一种。
其中,所述提供造纸毛毯半成品的步骤进一步包括:
提供至少一个基网,以形成基布层;
提供纤维材料,将所述纤维经过梳理、针刺制得毛网;其中,所述毛网被配置为用于形成底层纤维层、内层纤维层以及表层纤维层;
将所述底层纤维层、所述基布层以及所述内层纤维层依次堆叠,并经过植绒针刺处理获得复合纤维层;
将所述复合纤维层和所述表层纤维层堆叠,并进行植绒针刺处理以得到造纸毛毯半成品;
清洗烘干所述造纸毛毯半成品。
其中,所述造纸毛毯的制备方法还包括:将所述初级造纸毛毯加热定型制得所述造纸毛毯。
本申请的有益效果是:通过设置涂层以填补表层纤维层的纤维材料之间的缝隙,即通过设置涂层填补造纸毛毯在制备过程中产生的微小凹陷,可以提高造纸毛毯的平整度,同时也使造纸毛毯的透气性适当降低,保证抄造纸页的效率。换言之,通过设置涂层使造纸毛毯具有满足抄造纸页需求的起始性能,解决了造纸毛毯在前期使用时因表面不平整、透气性过大影响抄造纸页效率的问题。进一步通过在涂层上设置气孔,以满足造纸毛毯的透气需求。
附图说明
为了更清楚地说明本申请实施例中的技术方案,下面将对实施例描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本申请的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1是本申请一实施例提供的造纸毛毯的剖切结构示意图。
图2是本申请一实施例提供的造纸毛毯的立体结构示意图。
图3是本申请一实施例提供的造纸毛毯制备方法的流程示意图。
图4是本申请另一实施例提供的造纸毛毯制备方法的流程示意图。
具体实施方式
为使本申请的目的、技术方案和优点更加清楚,下面将结合本申请附图和实施例,对本申请实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅是本申请的一部分实施例,而不是全的实施例。基于本申请的实施例,本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例,都属于本申请保护范围。在不冲突的情况下,下述实施例及实施例中的特征可以相互组合。
需要说明,若本申请实施中有涉及“第一”、“第二”等的描述,则该“第一”、“第二”等描述仅用于描述目的,而不能理解为指示或暗示其对相对重要性和隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外,各个实施例之间的技术方案可以相互组合,但必须是本领域普通技术人员能够实现为基础,当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在,也不在本申请要求的保护范围之内。
请参阅图1和图2,图1是本申请提供的造纸毛毯100的剖切结构示意图,图2是图1实施例中造纸毛毯100的立体结构示意图。本申请提供一种造纸毛毯100,包括层叠设置的涂层12、表层纤维层14以及复合纤维层16。具体而言,涂层12铺设在表层纤维层14上,表层纤维层14铺设在复合纤维层16上,即复合纤维层16、表层纤维层14以及涂层12沿图1所示的竖直方向依次层叠设置。其中,表层纤维层14的纤维材料之间具有缝隙,涂层12填充至少部分缝隙以在涂层12背离表层纤维层14的一侧形成平面。可以理解的,在利用造纸毛毯进行造纸过程中,造纸毛毯在造纸机的压榨部的作用下帮助纸页脱水,并可对纸面进行修饰以及帮助纸页传递。在一般造纸机技术领域中,造纸毛毯与纸面直接接触,以实现上述功能效果。而基于造纸毛毯本身结构限制,在前期使用过程中,造纸毛毯的平整度难以达到标准。另外,造纸毛毯的透气性会随着使用逐渐降低,为了保证造纸毛毯的使用寿命,通常会选择透气性稍大的造纸毛毯,但这样会使造纸毛毯在前期使用时存在透气性过大,导致纸页水分难以脱离等问题。本申请实施例提供的造纸毛毯,通过设置涂层以填补表层纤维层的纤维材料之间的缝隙,即涂层在造纸过程中与纸面直接接触,以提高造纸毛毯与纸面接触的面的平整度。同时,基于造纸毛毯使用初期缝隙较大而使得透气性过大的技术问题,通过设置涂层可以降低造纸毛毯使用初期的透气性。
在一实施方式中,如图1所示,涂层12形成有气孔120,气孔120均匀分布在涂层12,气孔120可以贯穿涂层12。由于涂层12十分纤薄,且针刺痕迹的深度极小,因此气孔120在涂层12表面形成的凹陷可以忽略不计。同时,通过在涂层12上设置气孔120,可以满足造纸毛毯100的透气需求。需要说明的是,表层纤维层14的纤维材料的缝隙一般相对较大,进而使得造纸毛毯的透气性过大不利于初期使用。本申请通过设置涂层填充至少部分上述缝隙以减小造纸毛毯初期使用的透气性。进一步地,为避免涂层在涂覆过程中可能存在涂覆不均或者其他现象而使得造纸毛毯透气性能过小或者不均而不满足使用需求,本申请通过在涂层上设置气孔以满足造纸毛毯初期使用需求。
在一实施方式中,涂层12与表层纤维层14在垂直涂层12表面的方向上可以部分重合。例如,涂层12可以仅填充于表层纤维层14的材料缝隙中,或者,涂层12填充于表层纤维层14的部分材料缝隙中。又如,涂层12可以涂覆于表层纤维层14背离复合纤维层16的一侧,即在造纸毛毯100的层叠方向上,涂层12完全覆盖于表层纤维层14背离复合纤维层16的一侧表面。可以理解的,当涂层12位于表层纤维层14的材料缝隙中时,涂层12可以完全填充于该缝隙,或者涂层12可以填充缝隙的部分空间,以减小造纸毛毯100的表层透气性。
其中,涂层12通过喷涂的方式铺设在表层纤维层14上,涂层12的材料为高分子发泡材料,高分子发泡材料为聚亚氨酯或聚氨酯中的至少一种。例如,高分子发泡材料为聚亚氨酯、聚氨酯、聚亚氨酯和聚氨酯的混合物等。通过将高分子发泡材料喷涂到表层纤维层14上以形成涂层12,这一过程中高分子发泡材料会部分渗透到表层纤维层14中,并填充了至少部分表层纤维层14的纤维材料之间的空隙,从而使涂层12与表层纤维层14在垂直涂层12表面的方向上部分重合。
造纸毛毯100在喷涂涂层12前需要对表层纤维层14和复合纤维层16进行针刺处理,其中针刺的深度一般大于表层纤维层14的厚度,进而表层纤维层14和复合纤维层16之间的纤维缠绕在一起,使表层纤维层14与复合纤维层16之间紧密连接,同时,针刺会使表层纤维层14的表面上会形成微小的凹陷,涂层12的设置可以填充与遮盖这些微小的凹陷,使带涂层造纸毛毯100具有更好的平整度。
进一步地,基于实际生产需求,造纸毛毯在前期使用阶段的透气性通常会大于实际需求的透气性,目的是为了防止随着造纸毛毯的使用时间变长透气性降低,导致毛毯跳动、真空系统负荷过大等问题,但这会导致前期使用时造纸毛毯的透气性较大,影响纸页脱水。涂层12的设置可以使造纸毛毯100在前期使用时的透气性降低,在涂层12上进行针刺以形成气孔120,气孔120贯穿涂层12,可以在涂层12形成一些微小通孔,使造纸毛毯100的透气性到达理想的状态,满足纸页脱水的需求,进而保证了抄造纸页的效率。其中,气孔120可以均匀分布于涂层12上。当然,气孔120还可以呈其他不均匀分布形态。
值得说明的是,造纸毛毯100在抄造过程中会经过高压水水洗、与辊筒摩擦以及吸水箱抽吸等流程,这些流程在一定程度上会使涂层12被冲洗去除。此时带涂层造纸毛毯100的涂层12的部分被去除,使其透气性增大;与此同时,造纸毛毯100在使用过程中由于加热定型以及造纸纤维残留等问题又会使其透气性降低,两种影响造纸毛毯100透气性的因素会相互抵消,使造纸毛毯中后期仍具有良好的透气性以满足抄造纸页的需求。即涂层12的设置使造纸毛毯100具有一个良好的起始性能,同时也不影响中后期的使用。
在一实施例中,复合纤维层16和表层纤维层14的材料包含锦纶纤维。表层纤维层14采用3.3Dtex-15Dtex的锦纶纤维制成,例如采用细度为3.3Dtex、6.5Dtex、8Dtex、12.3Dtex或15Dtex等的锦纶纤维制成。
表层纤维层14选用细度较小的纤维可以使得表层纤维层表面更加平整,进而使用高分子发泡材料喷涂形成的涂层12的表面也相对平整,有利于纸页的抄造。
复合纤维层16可以包括依次堆叠的底层纤维层62、基布层64和内层纤维层66。
其中,底层纤维层62采用40Dtex-60Dtex的锦纶纤维制成,例如采用细度为40Dtex、50Dtex或60Dtex等的锦纶纤维制成。
底层纤维层62不与纸面接触,细度较大的纤维保证了造纸毛毯100的机械强度,使造纸毛毯100具有较长的使用寿命。
基布层64由至少一个基网制成,基布层64可以是由单层、双层或多层基网层叠设置形成,具体根据需要进行定制,在此不做限定。在一实施方式中,如图2所示,基布层64可由双层基网层叠形成,即基布层64可以包括层叠设置的第一基网641和第二基网642。
具体而言,如图2所示,第一基网641由第一经线6411和第一纬线6412编织而成。第二基网642由第二经线6421和第二纬线6422编织而成。第一经线6411、第一纬线6412、第二经线6421以及第二纬线6422可以由至少一股股丝加捻而成,每股股丝由至少一根单丝加捻而成。其中单丝的材料可以包括锦纶纤维。
进一步地,第一基网641和第二基网642的编织结构可以是1/5、1/3或2/3破斜纹结构。例如,第一基网641和第二基网642的编织结构均为1/3破斜纹结构;第一基网641的编织结构为1/5破斜纹结构,第二基网642的编织结构为1/3破斜纹结构;或者第一基网641的编织结构为1/3破斜纹结构,第二基网642的编织结构为2/3破斜纹结构等。
具有破斜纹结构的第一基网641和第二基网642在保证强度的同时具有一定的柔软度,且两者间具有一定空隙,使基布层64具有优越的空间结构,进而使造纸毛毯100具有良好的压缩回弹性能,不易出现压实、板结等现象。
内层纤维层66采用30Dtex-60Dtex的锦纶纤维制成,例如内层纤维层66采用细度为30Dtex、45Dtex、50Dtex或60Dtex等的锦纶纤维制成。
值得说明的是,表层纤维层14、内层纤维层66、底层纤维层62均可以采用多个毛层铺叠制成,通过植绒针刺的方式在各毛层间形成纤维与纤维之间的连接,增加了各纤维层之间的抱合力,提升了造纸毛毯100的稳定性。
请参阅图3,图3是本申请一实施例中带涂层造纸毛毯制备方法的流程示意图。需要注意的是,若有实质相同的效果,本实施方式并不以图3所示的流程顺序为限。如图3所示,制备方法包括:
S301:提供一造纸毛毯半成品。
其中,造纸毛毯半成品可以包括表层纤维层和复合纤维层,所述表层纤维层和复合纤维层如上述实施例描述,在此不做赘述。
S302:在造纸毛毯半成品的表层纤维层上喷涂涂层液,制得带涂层的造纸毛毯半成品。
其中,涂层液为高分子发泡浆液,高分子发泡浆液中高分子发泡材料的质量份数为25-35份,例如高分子发泡材料的质量份数为25份、28份、30份、32份、33.6份或35份等。高分子发泡材料中包含聚亚氨酯、或聚氨酯中的至少一种,例如,高分子发泡浆液中包含聚亚氨酯、聚氨酯或聚亚氨酯和聚氨酯的混合物等。
S303:对涂层进行空刺处理,制得初级造纸毛毯。
其中,空刺的深度可以与涂层12的厚度相同,通过空刺在涂层12上形成气孔120,气孔120贯穿涂层12。通过对涂层12进行空刺的步骤可以使涂层12形成许多细微的通孔,使制得的造纸毛毯100的透气性达到理想的状态,即使造纸毛毯100具有较好的初始性能,保证了抄造纸页的效率。
请参阅图4,图4是本申请另一实施例中带涂层造纸毛毯制备方法的流程示意图。制备方法包括:
S401:将纤维加捻成经线和纬线,再将经线和纬线通过重型环织机织造成基网,将至少一个所述基网制成基布层。
其中,将纤维加捻成单丝,将至少一条单丝加捻成股丝并制成经线和纬线。再将经线和纬线通过重型环织机织造成基网。具体而言,第一基网641由第一经线6411和第一纬线6412编织而成。第二基网642由第二经线6421和第二纬线6422编织而成。第一经线6411、第一纬线6412、第二经线6421和第二纬线6422的具体结构如上述实施例描述,在此不做赘述。将制得的第一基网641和第二基网642堆叠设置并通过热定型处理,得到基布层64,热定型处理的温度为120℃-150℃,例如热定型处理的温度为120℃、130℃、140℃或150℃等。
第一基网641和第二基网642之间存在一定空隙,使制得的基布层64具有良好的回弹性和滤水性。另外,热定型处理可以消除拉伸过程中产生的内应力,使基布层64的形状结构稳定,抱合力增强,避免在后续使用中出现形态或尺寸的改变。
S402:将纤维用梳理机梳理成网,再由预刺机针刺成一定宽度、长度、定量的毛网,将至少一个毛网进行针刺处理制得底层纤维层、内层纤维层以及表层纤维层。
其中,当毛网的层数多于一层时,将毛网堆叠设置,并且每增加一层毛网可以进行一次针刺处理。不同纤维层使用的纤维细度不同,在一实施方式中,所述底层纤维层62、内层纤维层66以及表层纤维层14的具体结构参数参见上述实施方式,在此不做赘述。
S403:将底层纤维层、基布层以及内层纤维层依次堆叠,并经过植绒针刺处理获得复合纤维层,再将复合纤维层和表层纤维层堆叠,进行植绒针刺处理并清洗烘干得到造纸毛毯半成品。
其中,植绒针刺可以采用单面针刺或双面针刺的方式进行,具体根据各纤维层的厚度与所选用纤维的细度来决定,在此不做限定。在一实施方式中,植绒针刺处理后还可以进行空刺处理,以进一步增加初级毛毯的抱合力。
多层纤维层的设置可以提高初级毛毯的吸水性能,植绒针刺处理将纤维与纤维之间产生连接,使各个纤维层之间产生抱合力,提高了初级毛毯的稳定性。空刺处理是为了增加纤维与纤维之间的连接,增加抱合力,使初级毛毯更加稳定。
清洗的具体方法为将初级毛毯在碱性溶液中浸泡不小于4小时,再用清水冲洗干净,碱性溶液可以为5%氢氧化钠溶液。在冲洗干净后使用吸水箱尽可能吸除初级毛毯上的水分并通过加热烘干的方式去除初级毛毯上的剩余水分。
需要说明的是,步骤S402和步骤S403在一些实施方式中可以进行结合,将制得的毛网逐层铺设并针刺处理,而不是先制得底层纤维层、内层纤维层以及表层纤维层后再进行堆叠和针刺处理。即以基布层为基础每铺设一层毛网进行至少一次针刺处理,其中制备毛网所使用的纤维的细度根据需求进行调整,以形成和底层纤维层、内层纤维层以及表层纤维层相似的结构。
S404:在造纸毛毯半成品的表层纤维层上喷涂涂层液,制得带涂层的造纸毛毯半成品。
其中,涂层液为高分子发泡浆液,高分子发泡浆液中高分子发泡材料的质量份数为25-35份,例如高分子发泡材料的质量份数为25份、28份、30份、32份、33.6份或35份等。高分子发泡浆液包含聚亚氨酯、或聚氨酯中的至少一种。例如高分子发泡浆液包含聚亚氨酯、聚氨酯、聚亚氨酯和聚氨酯的混合物等。
高分子发泡浆液在造纸毛毯半成品表面形成一个涂层12,并在垂直涂层12表面的方向上可以部分重合,具体结构关系可参见上述实施方式中的描述,不做赘述。
S405:对涂层进行空刺处理,制成初级造纸毛毯。
其中,空刺的深度与涂层12的厚度相同,空刺在涂层12形成气孔120,气孔120贯穿涂层12。通过对涂层12进行空刺的步骤可以使涂层12形成许多细微的通孔,制得的造纸毛毯100的透气性适当增大,以达到最理想的状态,使造纸毛毯100具有较好的初始性能,保证了抄造纸页的效率。
另外,涂层12在使用过程中经过高压水冲洗、与辊轮摩擦、吸水箱抽吸等步骤会被去除,造纸毛毯100的透气性会增大,而造纸毛毯100因为纸屑纤维的堵塞和辊轮的摩擦等透气性又会降低,两者的作用相抵消使造纸毛毯100在中后期使用时仍具有良好的透气性。
S406:将初级造纸毛毯加热定型制得造纸毛毯。
在一实施方式中,通过油热辊筒对造纸毛毯100进行加热定型。通过加热定型的方式可以使造纸毛毯100中的部分纤维软化,纤维与纤维之间连接更加紧密,增加了各纤维层之间的抱合力,使造纸毛毯100具有更好的稳定性。采用油热辊筒进行加热,使毛毯受热均匀,同时也使造纸毛毯100表面更加平整。
综上所述,本申请提供了一种造纸毛毯及制备方法,通过设置涂层填补了造纸毛毯在制备过程中由于植绒针刺产生的微小凹陷,提高了造纸毛毯的平整度,进一步对涂层进行空刺处理,以使造纸毛毯的透气性达到理想状态,保证造纸毛毯前期使用时抄造纸页的效率。即本申请通过设置涂层并对涂层进行空刺处理,使造纸毛毯具有满足造纸需求的起始性能,解决了其他造纸毛毯在前期使用时因表面不平整、透气性过大影响抄造纸页效率的问题。同时随着使用过程中高压水冲洗、压辊磨蹭、吸水强抽吸等步骤,造纸毛毯涂层会随着使用被去除,不影响造纸毛毯中后期的使用效果。
以上所述仅为本申请的实施方式,并非因此限制本申请的专利范围,凡是利用本申请说明书及附图内所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本申请的专利保护范围内。
Claims (10)
1.一种造纸毛毯,其特征在于,包括涂层、表层纤维层和复合纤维层;所述涂层铺设在所述表层纤维层上,所述表层纤维层铺设在所述复合纤维层上;所述表层纤维层的纤维材料之间具有缝隙,所述涂层填充至少部分所述缝隙以在所述涂层背离所述表层纤维层的一侧形成平面;
其中,所述涂层形成有气孔。
2.根据权利要求1所述的造纸毛毯,其特征在于,所述涂层与所述表层纤维层在垂直所述涂层表面的方向上部分重合。
3.根据权利要求2所述的造纸毛毯,其特征在于,所述涂层为高分子发泡材料。
4.根据权利要求3所述的造纸毛毯,其特征在于,所述高分子发泡材料为聚亚氨酯或聚氨酯中至少一种。
5.根据权利要求1所述的造纸毛毯,其特征在于,所述复合纤维层包括依次堆叠设置的底层纤维层、基布层和内层纤维层。
6.根据权利要求5所述的造纸毛毯,其特征在于,所述表层纤维层和所述复合纤维层的材料包括锦纶纤维,所述锦纶纤维的细度为3.3-66Dtex。
7.一种根据权利要求1-6任一项所述的造纸毛毯的制备方法,其特征在于,包括:
提供一造纸毛毯半成品,所述造纸毛毯半成品包括堆叠设置的所述复合纤维层和所述表层纤维层;
在所述表层纤维层上喷涂涂层液,制得带涂层的造纸毛毯半成品;
对所述涂层进行空刺处理,制得初级造纸毛毯。
8.根据权利要求7所述的制备方法,其特征在于,所述涂层液为高分子发泡浆液,所述高分子发泡浆液包含聚亚氨酯或聚氨酯中至少一种。
9.根据权利要求7所述的制备方法,其特征在于,所述提供造纸毛毯半成品的步骤进一步包括:
提供至少一个基网,以形成基布层;
提供纤维材料,将所述纤维材料经过梳理、针刺制得毛网;其中,所述毛网被配置为用于形成底层纤维层、内层纤维层以及表层纤维层;
将所述底层纤维层、所述基布层以及所述内层纤维层依次堆叠,并经过植绒针刺处理获得复合纤维层;
将所述复合纤维层和所述表层纤维层堆叠,并进行植绒针刺处理以得到造纸毛毯半成品;
清洗烘干所述造纸毛毯半成品。
10.根据权利要求7所述的制备方法,其特征在于,所述制备方法还包括:将所述初级造纸毛毯加热定型制得所述造纸毛毯。
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