CN115198517A - 一种高硬度环保针刺地毯及其加工工艺 - Google Patents
一种高硬度环保针刺地毯及其加工工艺 Download PDFInfo
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Abstract
本发明公开了一种高硬度环保针刺地毯及其加工工艺,方案在制备时以40~60%的阻燃PES纤维和40~60%的低熔点4080阻燃纤维作为纤维原料,开松,循环,梳理,铺网形成均匀的纤网,并进行针刺固结,以形成面毯层,接着对面毯层进行热风定型,热风烘箱温度控制在190~220℃之间,保证低熔点4080阻燃纤维的最佳温度熔点,此时低熔点4080阻燃纤维在热风烘箱中融化并粘合阻燃PES纤维,实现产品的产品二次硬化和烫光,热定型后制备的地毯产品外观平整,地毯硬度和产品粘结强度都发生极大改变,浮毛问题也得到解决,兼具硬度强,粘合度高,表面平整无浮毛三大优势特点,效果较为优异。
Description
技术领域
本发明涉及针刺地毯技术领域,具体为一种高硬度环保针刺地毯及其加工工艺。
背景技术
针刺地毯是采用涤纶或丙纶短纤维,经过梳棉再铺排成网状,让不同的纤维相互交织在一起,相互缠结固着使织物规格化,再经过针刺等工艺针刺成型的坯布;现有技术通过纯热风棉工艺制作地毯,硬度不够,且产品粘结强度不高,产品二次加温压花,地毯厚薄不均。纯针刺棉工艺制作地毯,产品粘结强度高,但是硬度不够,且产品表面浮毛明显,影响美观。同时,随着地毯的应用越来越广泛,企业对于地毯表面的疏水性、耐磨性能要求也进一步提升。
基于该情况,本申请公开了一种高硬度环保针刺地毯及其加工工艺,以解决该技术问题。
发明内容
本发明的目的在于提供一种高硬度环保针刺地毯及其加工工艺,以解决上述背景技术中提出的问题。
为了解决上述技术问题,本发明提供如下技术方案:
一种高硬度环保针刺地毯及其加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;
(2)对面毯层进行热风定型,在190~220℃下热定型5~7min,得到针刺地毯。
较优化的方案,以重量百分比计,所述纤维原料包括为40~60%的阻燃PES纤维和40~60%的低熔点4080阻燃纤维。
较优化的方案,步骤(2)中,面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,85~90℃下浸渍1~2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,加入安息香二甲醚,紫外光辐照下固化20~30min,取出后洗涤,烘干。
较优化的方案,所述丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;
取丙烯酸酯单体,混合搅拌20~30min,加入乳化剂溶液,超声分散30~40min,加热升温至75~80℃,加入过硫酸钾溶液,保温反应2~2.5h,得到丙烯酸酯乳液;所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成。
较优化的方案,所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2;所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5;所述乳化剂用量为丙烯酸酯单体的2~4wt%;所述过硫酸钾用量为丙烯酸酯单体的0.5~1wt%。
较优化的方案,步骤(2)中,面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,85~90℃下浸渍1~2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,浸渍30~40min,取出后洗涤,烘干;
再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂,单面喷涂厚度为0.2~0.3mm,紫外光辐照下固化30~40min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛混合,超声分散20~30min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。
较优化的方案,所述疏水二氧化硅的制备步骤为:取无水乙醇和二氧化硅混合,超声分散,得到二氧化硅分散液;取乙烯基三甲氧基硅烷和无水乙醇混合,搅拌均匀,得到乙烯基三甲氧基硅烷溶液;将乙烯基三甲氧基硅烷溶液、二氧化硅分散液混合,氨水调节pH,40~45℃下搅拌反应2~2.5h,反应结束后离心,洗涤干燥,得到疏水二氧化硅;所述二氧化硅的粒径为1~2μm。
较优化的方案,所述巯基化二氧化钛的制备步骤为:取无水乙醇、去离子水混合,加入氨水调节pH,加入3-巯基丙基三甲氧基硅烷,65~70℃水浴下反应2~3h,反应后加入二氧化钛,氮气气氛下搅拌反应5~6h,离心收集产物,洗涤干燥,得到巯基化二氧化钛;所述二氧化钛的粒径为20~30nm。
较优化的方案,所述季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的0.5~1wt%。
较优化的方案,根据以上任一项所述的一种高硬度环保针刺地毯的加工工艺加工的针刺地毯。
与现有技术相比,本发明所达到的有益效果是:
本发明公开了一种高硬度环保针刺地毯及其加工工艺,方案在制备时以40~60%的阻燃PES纤维和40~60%的低熔点4080阻燃纤维作为纤维原料,开松,循环,梳理,铺网形成均匀的纤网,并进行针刺固结,以形成面毯层,此时针刺成型厚度为产品最终定型厚度的2倍;接着对面毯层进行热风定型,热风烘箱温度控制在190~220℃之间,保证低熔点4080阻燃纤维的最佳温度熔点,此时低熔点4080阻燃纤维在热风烘箱中融化并粘合阻燃PES纤维,实现产品的产品二次硬化和烫光,热定型后制备的地毯产品外观平整,地毯硬度和产品粘结强度都发生极大改变,浮毛问题也得到解决,兼具硬度强,粘合度高,表面平整无浮毛三大优势特点,效果较为优异。
在此方案基础上,本申请对面毯层进行一次整理,其具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,85~90℃下浸渍1~2h,在面毯层表面接枝有巯基,再将其置于丙烯酸酯乳液中浸渍,通过光引发剂在紫外光辐照下固化,此时面料表面的巯基能够与丙烯酸酯中的碳碳双键、炔基进行点击反应,使得丙烯酸酯乳液能够很好的结合在面毯层表面,以提高面毯层的表面整理效果。
本方案中利用丙烯酸酯单体共聚形成含氟丙烯酸酯乳液,该丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成;甲基丙烯酸十二氟庚酯的引入能够实现面毯层的表面疏水性,抗污效果更为优异;甲基丙烯酸丙炔酯的引入能够保证丙烯酸酯乳液浸渍面毯层时具有足够反应的炔基官能团,以保证巯基点击反应的顺利实现,从而保证面毯层与丙烯酸酯乳液之间的结合性能。
在此基础上,本申请进一步对方案进行改进,引入二次表面处理步骤,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,再浸泡至丙烯酸酯乳液中;该过程与前述步骤相比,并未引入光引发剂和紫外光辐照,而是单纯将面毯层浸渍于丙烯酸酯乳液中。
之后再进行二次表面处理,在面毯层两侧表面喷涂疏水整理剂,喷涂后紫外光辐照下固化;由于面毯层表面含有巯基,丙烯酸酯乳液中含有碳碳双键、炔基,而疏水整理剂中含有大量的巯基和供反应的碳碳双键,此时利用紫外光辐照,丙烯酸酯乳液可作为中间层,并分别与面毯层、疏水整理剂交联接枝,疏水整理剂、丙烯酸酯乳液能够更好的附着在面毯层表面,能够有效提高其表面附着效果,耐水洗性能大大提升。
需强调:若该过程中在一次整理后就引入光引发剂和紫外光辐照固化,丙烯酸酯中可反应的官能团会先与面毯层反应,因而在后续疏水整理剂附着时,其附着效果较差,多次水洗后疏水整理剂易脱落。
本方案中疏水整理剂由N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛混合制备,该疏水整理剂实现了以下几个效果:
(1)疏水二氧化硅引入了疏水基团乙烯基三甲氧基硅烷,且方案中限定了所述二氧化硅的粒径为1~2μm,所述二氧化钛的粒径为20~30nm,因而面毯层表面能够形成微纳结构,配合疏水基团的引入,以实现面毯层表面疏水。
(2)疏水二氧化硅表面采用乙烯基三甲氧基硅烷改性,能够引入乙烯基,而季戊四醇四-3-巯基丙酸酯、巯基二氧化钛能够引入巯基,在紫外光辐照时,季戊四醇四-3-巯基丙酸酯、巯基二氧化钛、疏水二氧化硅三者能够相互交联接枝,同时三者能够与丙烯酸酯中的反应基团进行接枝,以提高二氧化硅、二氧化钛在面毯层表面的附着,其不仅能够保证疏水性能的实现,还能够提高面毯层表面耐磨性能和耐水洗性能。
本发明公开了一种高硬度环保针刺地毯及其加工工艺,方案设计合理,各步骤改进适宜,制备得到的针刺地毯不仅具有优异的表面疏水性能,而且其表面硬度高,耐磨性能好,表面整理剂与面毯层之间的结合更为优异,耐水洗,具有较高的实用性。
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。
以下实施例中,所述阻燃PES纤维购买自中国石化仪征化纤有限责任公司,其规格为:ZK2936.67dtex×60mm,产品批号为YZ197109Z1。所述低熔点4080阻燃纤维购买自扬州富威尔复合材料有限公司,其产品代码为LCF110-03,规格为LMF4D×51mm。
所述疏水二氧化硅的制备步骤为:取无水乙醇和二氧化硅混合,超声分散30min,得到质量浓度为1%的二氧化硅分散液;取乙烯基三甲氧基硅烷和无水乙醇混合,搅拌40min,得到质量浓度为4%的乙烯基三甲氧基硅烷溶液;将乙烯基三甲氧基硅烷溶液、二氧化硅分散液混合,所述乙烯基三甲氧基硅烷、二氧化硅的质量比为10:1;氨水调节pH至10,40℃下搅拌反应2.5h,反应结束后离心,洗涤干燥,得到疏水二氧化硅;所述二氧化硅的粒径为2μm。
所述巯基化二氧化钛的制备步骤为:取无水乙醇、去离子水混合,所述无水乙醇、去离子水体积比为6:1,加入氨水调节pH至8,加入3-巯基丙基三甲氧基硅烷,70℃水浴下反应2h,反应后加入二氧化钛,氮气气氛下搅拌反应6h,离心收集产物,依次用无水乙醇、去离子水洗涤,90℃下真空干燥,得到巯基化二氧化钛。
所述二氧化钛的粒径为30nm。所述3-巯基丙基三甲氧基硅烷、二氧化钛的质量比为1:2;所述二氧化钛、无水乙醇和去离子水总量的比值为1g:60mL。
实施例1:
一种高硬度环保针刺地毯的加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;以重量百分比计,所述纤维原料包括为40%的阻燃PES纤维和60%的低熔点4080阻燃纤维。
(2)对面毯层进行热风定型,在220℃下热定型5min,得到针刺地毯。
实施例2:
一种高硬度环保针刺地毯的加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;以重量百分比计,所述纤维原料包括为60%的阻燃PES纤维和40%的低熔点4080阻燃纤维。
(2)对面毯层进行热风定型,在190℃下热定型7min,得到针刺地毯。
检测试验1:
取实施例1~2制备的针刺地毯,面毯厚度为5mm,检测其极限氧指数和表面硬度,以仅使用阻燃PES纤维制备的面毯层作为常规产品,具体检测数据如下表所示:
项目 | 极限氧指数 | 表面硬度 |
实施例1 | 32 | 72 |
实施例2 | 32 | 73 |
常规产品 | 30 | 48 |
实施例3:在实施例1的基础上进一步改进方案,增加一次表面整理步骤。
一种高硬度环保针刺地毯的加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;以重量百分比计,所述纤维原料包括为40%的阻燃PES纤维和60%的低熔点4080阻燃纤维。
(2)对面毯层进行热风定型,在220℃下热定型5min。
(3)面毯层热定型后,进行一次表面整理,将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,85℃下浸渍1h,浸渍浴比为1:10;取出后依次用无水乙醇、去离子水洗涤,烘干;再浸泡至丙烯酸酯乳液中,浸渍浴比为1:10;加入安息香二甲醚,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化20min,取出后洗涤,烘干;所述安息香二甲醚用量为丙烯酸酯乳液的2wt%。
丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2,所述乳化剂、去离子水的质量比为1:45;所述过硫酸钾和去离子水的重量比为1:70。
取丙烯酸酯单体,混合搅拌20min,加入乳化剂溶液,超声分散30min,加热升温至75℃,加入过硫酸钾溶液,保温反应2h,得到丙烯酸酯乳液。
所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5。所述乳化剂用量为丙烯酸酯单体的3wt%;所述过硫酸钾用量为丙烯酸酯单体的1wt%。
实施例4:在实施例2的基础上进一步改进方案,增加一次表面整理步骤。
一种高硬度环保针刺地毯的加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;以重量百分比计,所述纤维原料包括为60%的阻燃PES纤维和40%的低熔点4080阻燃纤维。
(2)对面毯层进行热风定型,在190℃下热定型7min。
(3)面毯层热定型后,进行一次表面整理,将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,90℃下浸渍2h,浸渍浴比为1:10;取出后依次用无水乙醇、去离子水洗涤,烘干;再浸泡至丙烯酸酯乳液中,浸渍浴比为1:10;加入安息香二甲醚,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化30min,取出后洗涤,烘干。所述安息香二甲醚用量为丙烯酸酯乳液的2wt%。
丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2,所述乳化剂、去离子水的质量比为1:45;所述过硫酸钾和去离子水的重量比为1:70。
取丙烯酸酯单体,混合搅拌30min,加入乳化剂溶液,超声分散40min,加热升温至80℃,加入过硫酸钾溶液,保温反应2.5h,得到丙烯酸酯乳液。
所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5。所述乳化剂用量为丙烯酸酯单体的3wt%;所述过硫酸钾用量为丙烯酸酯单体的1wt%。
实施例5:在实施例1的基础上进一步改进方案,增加一次表面整理步骤和二次表面处理步骤。
一种高硬度环保针刺地毯的加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;以重量百分比计,所述纤维原料包括为40%的阻燃PES纤维和60%的低熔点4080阻燃纤维。
(2)对面毯层进行热风定型,在220℃下热定型5min。
(3)面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,浸渍浴比为1:10;85℃下浸渍1h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,浸渍浴比为1:10;浸渍30min,取出后洗涤,烘干。
丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2,所述乳化剂、去离子水的质量比为1:45;所述过硫酸钾和去离子水的重量比为1:70。
取丙烯酸酯单体,混合搅拌30min,加入乳化剂溶液,超声分散40min,加热升温至80℃,加入过硫酸钾溶液,保温反应2.5h,得到丙烯酸酯乳液。
所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成,所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5。所述乳化剂用量为丙烯酸酯单体的3wt%;所述过硫酸钾用量为丙烯酸酯单体的1wt%。
(4)再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂(先一侧喷涂,固化后喷涂另一侧),单面喷涂厚度为0.3mm,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化30min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛混合,超声分散20min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。所述季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的1wt%。
实施例6:在实施例2的基础上进一步改进方案,增加一次表面整理步骤和二次表面处理步骤。
一种高硬度环保针刺地毯的加工工艺,包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;以重量百分比计,所述纤维原料包括为60%的阻燃PES纤维和40%的低熔点4080阻燃纤维。
(2)对面毯层进行热风定型,在190℃下热定型7min。
(3)面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,浸渍浴比为1:10;90℃下浸渍2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,浸渍浴比为1:10;浸渍40min,取出后洗涤,烘干。
丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2,所述乳化剂、去离子水的质量比为1:45;所述过硫酸钾和去离子水的重量比为1:70。
取丙烯酸酯单体,混合搅拌30min,加入乳化剂溶液,超声分散40min,加热升温至80℃,加入过硫酸钾溶液,保温反应2.5h,得到丙烯酸酯乳液。
所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成,所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5。所述乳化剂用量为丙烯酸酯单体的3wt%;所述过硫酸钾用量为丙烯酸酯单体的1wt%。
(4)再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂(先一侧喷涂,固化后喷涂另一侧),单面喷涂厚度为0.3mm,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化40min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛混合,超声分散30min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。所述季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的1wt%。
对比例1:以实施例6为对照实验,进行参数变更,对比例1中仅加入普通二氧化硅。
具体变更步骤为:
(4)再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂(先一侧喷涂,固化后喷涂另一侧),单面喷涂厚度为0.3mm,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化40min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、二氧化硅、巯基化二氧化钛混合,超声分散30min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。所述季戊四醇四-3-巯基丙酸酯、二氧化硅、巯基化二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的1wt%。
对比例2:以实施例6为对照实验,进行参数变更,对比例2中限定疏水二氧化硅的粒径为30nm。
具体变更步骤为:
(4)再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂(先一侧喷涂,固化后喷涂另一侧),单面喷涂厚度为0.3mm,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化40min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛混合,超声分散30min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。所述季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的1wt%。
方案中采用的二氧化硅、二氧化钛的粒径均为30nm。
对比例3:以实施例6为对照实验,进行参数变更,对比例3中仅加入普通二氧化钛。
具体变更步骤为:
(4)再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂(先一侧喷涂,固化后喷涂另一侧),单面喷涂厚度为0.3mm,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化40min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、二氧化钛混合,超声分散30min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。所述季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的1wt%。
对比例4:以实施例6为对照实验,进行参数变更,对比例4丙烯酸酯乳液中并未引入甲基丙烯酸丙炔酯单体。
具体变更步骤为:
(3)面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,浸渍浴比为1:10;90℃下浸渍2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,浸渍浴比为1:10;浸渍40min,取出后洗涤,烘干。
丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2,所述乳化剂、去离子水的质量比为1:45;所述过硫酸钾和去离子水的重量比为1:70。
取丙烯酸酯单体,混合搅拌30min,加入乳化剂溶液,超声分散40min,加热升温至80℃,加入过硫酸钾溶液,保温反应2.5h,得到丙烯酸酯乳液。
所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯组成,所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯的质量比为8:2:4。所述乳化剂用量为丙烯酸酯单体的3wt%;所述过硫酸钾用量为丙烯酸酯单体的1wt%。
对比例5:以实施例6为对照实验,进行参数变更,对比例5中一次整理后引入光引发剂和紫外固化。
具体变更步骤为:
(3)面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,浸渍浴比为1:10;90℃下浸渍2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,浸渍浴比为1:10;加入安息香二甲醚,紫外光(波长为365nm,功率2.5mW/cm2)辐照下固化30min,取出后洗涤,烘干。所述安息香二甲醚用量为丙烯酸酯乳液的2wt%。
丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2,所述乳化剂、去离子水的质量比为1:45;所述过硫酸钾和去离子水的重量比为1:70。
取丙烯酸酯单体,混合搅拌30min,加入乳化剂溶液,超声分散40min,加热升温至80℃,加入过硫酸钾溶液,保温反应2.5h,得到丙烯酸酯乳液。
所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成,所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5。所述乳化剂用量为丙烯酸酯单体的3wt%;所述过硫酸钾用量为丙烯酸酯单体的1wt%。
检测试验2:
取实施例3~6、对比例1~5制备的地毯,面毯厚度为5mm,进行以下性能检测:
1、水接触角:采用接触角测量仪进行测试,水滴大小为5μL,每个测试样品分别在不同的位置测试五次,取平均值。
2、耐磨性:将地毯裁剪成直径为100cm的圆形样品,通过圆盘织物平磨实验仪进行磨擦实验,重锤质量为500g,测量摩擦600转,检测并记录样品质量损失率。
3、将样品按照GB/T8629-2001《纺织品试验用家庭洗涤和干燥程序》公开的5A程序水洗30次,检测其水接触角和耐磨性能。
结论:本发明公开了一种高硬度环保针刺地毯及其加工工艺,方案设计合理,各步骤改进适宜,制备得到的针刺地毯不仅具有优异的表面疏水性能,而且其表面硬度高,耐磨性能好,表面整理剂与面毯层之间的结合更为优异,耐水洗,具有较高的实用性。
最后应说明的是:以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。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 (10)
1.一种高硬度环保针刺地毯及其加工工艺,其特征在于:包括以下步骤:
(1)将阻燃PES纤维、低熔点4080阻燃纤维按比例开松,循环,梳理,铺网形成均匀的纤网,再经过针刺固结形成面毯层;
(2)对面毯层进行热风定型,在190~220℃下热定型5~7min,得到针刺地毯。
2.根据权利要求1所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:以重量百分比计,所述纤维原料包括为40~60%的阻燃PES纤维和40~60%的低熔点4080阻燃纤维。
3.根据权利要求1所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:步骤(2)中,面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,85~90℃下浸渍1~2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,加入安息香二甲醚,紫外光辐照下固化20~30min,取出后洗涤,烘干。
4.根据权利要求3所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:所述丙烯酸酯乳液的制备步骤为:取乳化剂和去离子水,混合均匀,得到乳化剂溶液;取过硫酸钾和去离子水,混合均匀,得到过硫酸钾溶液;
取丙烯酸酯单体,混合搅拌20~30min,加入乳化剂溶液,超声分散30~40min,加热升温至75~80℃,加入过硫酸钾溶液,保温反应2~2.5h,得到丙烯酸酯乳液;所述丙烯酸酯单体由丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯组成。
5.根据权利要求4所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:所述乳化剂包括OP-10和SDS,所述OP-10和SDS的质量比为3:2;所述丙烯酸丁酯、甲基丙烯酸酯甲酯、甲基丙烯酸十二氟庚酯和甲基丙烯酸丙炔酯的质量比为8:2:4:5;所述乳化剂用量为丙烯酸酯单体的2~4wt%;所述过硫酸钾用量为丙烯酸酯单体的0.5~1wt%。
6.根据权利要求1所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:步骤(2)中,面毯层热定型后,进行一次表面整理,具体步骤为:将热定型后的面毯层置于3-巯基丙基三甲氧基硅烷、无水乙醇混合液中浸泡,85~90℃下浸渍1~2h,取出后洗涤,烘干,再浸泡至丙烯酸酯乳液中,浸渍30~40min,取出后洗涤,烘干;
再进行二次表面处理,具体步骤为:取浸渍丙烯酸酯乳液的面毯层,在面毯层两侧表面喷涂疏水整理剂,单面喷涂厚度为0.2~0.3mm,紫外光辐照下固化30~40min,得到成品;
所述疏水整理剂的制备步骤为:取N,N-二甲基甲酰胺、季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛混合,超声分散20~30min,加入安息香二甲醚,搅拌均匀,得到疏水整理剂。
7.根据权利要求6所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:所述疏水二氧化硅的制备步骤为:取无水乙醇和二氧化硅混合,超声分散,得到二氧化硅分散液;取乙烯基三甲氧基硅烷和无水乙醇混合,搅拌均匀,得到乙烯基三甲氧基硅烷溶液;将乙烯基三甲氧基硅烷溶液、二氧化硅分散液混合,氨水调节pH,40~45℃下搅拌反应2~2.5h,反应结束后离心,洗涤干燥,得到疏水二氧化硅;所述二氧化硅的粒径为1~2μm。
8.根据权利要求6所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:所述巯基化二氧化钛的制备步骤为:取无水乙醇、去离子水混合,加入氨水调节pH,加入3-巯基丙基三甲氧基硅烷,65~70℃水浴下反应2~3h,反应后加入二氧化钛,氮气气氛下搅拌反应5~6h,离心收集产物,洗涤干燥,得到巯基化二氧化钛;所述二氧化钛的粒径为20~30nm。
9.根据权利要求6所述的一种高硬度环保针刺地毯的加工工艺,其特征在于:所述季戊四醇四-3-巯基丙酸酯、疏水二氧化硅、巯基化二氧化钛的质量比为1:3:8;所述安息香二甲醚用量为疏水整理剂的0.5~1wt%。
10.根据权利要求1~9中任一项所述的一种高硬度环保针刺地毯的加工工艺加工的针刺地毯。
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