CN116656757A - 一种新型的细菌纤维素制作皮革方法 - Google Patents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
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- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
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Abstract
本发明涉及合成生物学技术领域,且公开了一种新型的细菌纤维素制作皮革方法,将醋酸杆菌菌种在无菌的环境下,置于恒温培养摇床上进行培养后,形成的细菌纤维素膜,细菌纤维素薄膜处理后制成皮革,实现了对环境友好、绿色、可持续和完全可降解,醋酸杆菌本就是传统食品行业中生产醋的有益菌种之一,对人体没有危害性,醋酸杆菌在发酵生产细菌纤维素的过程中,会产生醋酸作为副产物,而不会产生任何对环境有害的物质,醋酸杆菌自身也是自然界常见的菌种之一,不必担心菌种逃逸带来的对生态环境的影响,而醋酸杆菌生产的细菌纤维素,其化学本质和植物中的纤维素一致,能够在自然环境中被快速降解。
Description
技术领域
本发明涉及合成生物学技术领域,具体为一种新型的细菌纤维素制作皮革方法。
背景技术
环保理念与动物保护主义。随着经济的不断发展,越来越多的消费者认为动物皮革的生产过程对动物本身非常残忍,所以大家应该自觉自制动物类皮革。同时在国家动物保护法的规定下,一些珍贵的动物皮革资源越来越少。
动物类皮革的生产成本高昂,以山羊皮为例,一张好羊皮的价值占活羊总价值的45%-50%,而在山羊整个饲养周期中会消耗4000多公斤的饲料,3000多吨水。这种高成本长生产周期低通量的获取模式,使得动物皮革的价格居高不下,但是又满足不了消费者对皮革制品的大量需求。
动物皮革加工产生严重污染。动物皮革需要鞣制的工艺来使得皮革中的胶原结构和整个真皮结构稳定下来。在这个过程中,需要用到许多有毒的物质,如铬、镐、甲醛、氯化石蜡、二氧化硅、软化剂和铝,在浆料中的还原性三价铬会在加工的过程中被氧化成四价铬,而四价铬是在真皮产业中最让人担心的污染物,会引发人们的疾病。而生产过程中产生的油类物质也很难被降解,污染环境。
在目前人造革的生产中,基布、聚氨酯与聚氯乙烯是其最主要的两种原料,可制造出PVC、PU两大类人造革。而由于聚氯乙烯容易产生大量的环境污染,在我国“聚氯乙烯普通人造革生产线”被列限制类发展项目,因此PU(聚氨酯)革成为了目前人造革的主流方向。但PU革生产过程中大量使用的聚氨酯和DMF等溶剂会产生挥发性有机化合物(VOCs),对人体健康具有危害性。而目前环保PU革虽然使用了绿色环保且可以自然降解的水性聚氨酯或无溶剂聚氨酯,但其基布依旧使用以尼龙、涤纶、无纺布等不可降解材料为原料,使得目前的人造革废弃后依旧会对环境产生污染。
疫情期间无纺布用量增加,间接导致人造革制造成本上升,由于医用口罩与医用防护服等一次性用品的原料与人造革基布原料均为尼龙、涤纶与无纺布,疫情爆发以后尼龙、涤纶、无纺布等原材料需求大幅增长,导致行业面临的成本提高利润受到严重挤压。2020年我国人造革、合成革产业实现主营业务收入724.13亿元,同比下降17.02%。不受无纺布产量与成本限制且绿色环保可降解的基布材料亟待发展。
发明内容
针对现有技术的不足,本发明提供了一种新型的细菌纤维素制作皮革方法。
为实现上述目的,本发明提供如下技术方案:一种新型的细菌纤维素制作皮革方法,将醋酸杆菌菌种在无菌的环境下,恒温静置培养,置于恒温培养摇床上进行培养后,形成的细菌纤维素膜,细菌纤维素薄膜处理后制成皮革。
优选的,具体步骤为:
步骤1、培养基配置:利用乙醇、葡萄糖、蛋白胨、水、柠檬酸和磷酸氢二钠配置液体培养基;
步骤2、活化:融化的菌液均匀的涂抹在琼脂糖培养基斜面上;
步骤3、扩大:将菌体接种到液体培养基中;
步骤4、接种:将醋酸杆菌菌液接种到液体培养基中,在液体培养基的表层形成一定厚度的细菌纤维素膜;
步骤5、收膜:将细菌纤维素膜收获;
步骤6、干燥:对湿润的细菌纤维素薄膜进行压制处理,将水分压出并晾干为细菌纤维素干燥薄膜;
步骤7、涂饰:利用精密涂布机涂至作为基布的细菌纤维素上,烘至半干;
步骤8、压花:将烘干至半干的细菌纤维素皮革放置于压花机中进行压花,压花后进行彻底烘干,完成细菌纤维素皮革的制作。
优选的,所述步骤1中的液体培养基的配比为:1%乙醇、2%葡萄糖、1%蛋白胨、0.27%磷酸氢二钠、0.15%柠檬酸,余量为水,通过柠檬酸将液体培养基调节为pH6,培养基配置完成后,需经过121度,20分钟的高温高压灭菌过程以确保培养基完全无菌。
优选的,所述步骤2中的具体步骤为:将冷冻保存的醋酸杆菌菌种在冰上融化,融化的菌液均匀的涂抹在琼脂糖培养基斜面上,30度静置培养1-2天,待菌膜刚刚好覆盖整块琼脂糖斜面。
优选的,所述步骤3中具体步骤为:在琼脂糖斜面上取一块标准大小的覆盖有醋酸杆菌菌膜的固体培养基,将菌体接种到液体培养基中,并以30度,180转每分钟的摇床速度震荡培养醋酸杆菌过夜。
优选的,所述步骤4中的步骤中还包括有发酵,醋酸杆菌菌液接种到液体培养基中,并在发酵室合适的发酵条件下,温度30度,静置发酵2-3d。
优选的,所述步骤5中的具体步骤为:收获细菌纤维素膜后,通过碳酸氢钠煮沸去除细菌纤维素内的乙酸,同时加强细菌纤维素的整体机械性能。
优选的,所述步骤7中的具体步骤为将环保水性聚氨酯与助剂与色料充分混匀并且进行消泡处理后,利用精密涂布机涂至作为基布的细菌纤维素上,烘至半干。
优选的,所述步骤7和步骤8中的烘干温度依次为60-80℃热风烘干0.2-0.5h,烘至半干;烘干炉中在100-200℃的温度下历经0.5-1小时进行再次烘干,彻底烘干。
与现有技术相比,本发明提供了一种新型的细菌纤维素制作皮革方法,具备以下有益效果:
1、该新型的细菌纤维素制作皮革方法,实现了对环境友好、绿色、可持续和完全可降解,醋酸杆菌本就是传统食品行业中生产醋的有益菌种之一,对人体没有危害性,醋酸杆菌在发酵生产细菌纤维素的过程中,会产生醋酸作为副产物,而不会产生任何对环境有害的物质,醋酸杆菌自身也是自然界常见的菌种之一,不必担心菌种逃逸带来的对生态环境的影响,而醋酸杆菌生产的细菌纤维素,其化学本质和植物中的纤维素一致,能够在自然环境中被快速降解。
2、该新型的细菌纤维素制作皮革方法,增加了皮革的整体强度,醋酸杆菌生成的细菌纤维素是纳米级别的纤维素网络分子,纤维素链与纤维素链通过氢键相互作用紧密结合在一起,为整个材料提供了非常强的拉伸强度。
3、该新型的细菌纤维素制作皮革方法,用微生物代替植物和动物,使用生物高效生产真正廉价的纤维素,相比于动物皮革,醋酸杆菌生产同样面积和厚度的细菌纤维素只需要七天时间,并且消耗的材料只有少量的水、碳源(如葡萄糖)、氮源(如椰子水、蛋白胨、玉米粉等)以及一些无机盐离子,相比于人造革,细菌纤维素的生产过程中,没有使用任何的石油基材料,减少污染。
具体实施方式
下面将结合本发明实施例,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。
实施例一
一种新型的细菌纤维素制作皮革方法,将醋酸杆菌菌种在无菌的环境下,恒温静置培养,置于恒温培养摇床上进行培养后,形成的细菌纤维素膜,细菌纤维素薄膜处理后制成皮革。
具体步骤为:
步骤1、培养基配置:利用乙醇、葡萄糖、蛋白胨、水、柠檬酸和磷酸氢二钠配置液体培养基,液体培养基的配比为:1%乙醇、2%葡萄糖、1%蛋白胨、0.27%磷酸氢二钠、0.15%柠檬酸,余量为水,通过柠檬酸将液体培养基调节为pH6,培养基配置完成后,需经过121度,20分钟的高温高压灭菌过程以确保培养基完全无菌;
步骤2、活化:融化的菌液均匀的涂抹在琼脂糖培养基斜面上,具体步骤为:将冷冻保存的醋酸杆菌菌种在冰上融化,融化的菌液均匀的涂抹在琼脂糖培养基斜面上,30度静置培养1-2天,待菌膜刚刚好覆盖整块琼脂糖斜面;
步骤3、扩大:将菌体接种到液体培养基中,具体步骤为:在琼脂糖斜面上取一块标准大小的覆盖有醋酸杆菌菌膜的固体培养基,将菌体接种到液体培养基中,并以30度,180转每分钟的摇床速度震荡培养醋酸杆菌过夜;
步骤4、接种:将醋酸杆菌菌液接种到液体培养基中,在液体培养基的表层形成一定厚度的细菌纤维素膜,步骤中还包括有发酵,醋酸杆菌菌液接种到液体培养基中,并在发酵室合适的发酵条件下,温度30度,静置发酵2-3d;
步骤5、收膜:将细菌纤维素膜收获,具体步骤为:收获细菌纤维素膜后,通过碳酸氢钠煮沸去除细菌纤维素内的乙酸,同时加强细菌纤维素的整体机械性能;
步骤6、干燥:对湿润的细菌纤维素薄膜进行压制处理,将水分压出并晾干为细菌纤维素干燥薄膜;
步骤7、涂饰:利用精密涂布机涂至作为基布的细菌纤维素上,烘至半干,具体步骤为:将环保水性聚氨酯与助剂与色料充分混匀并且进行消泡处理后,利用精密涂布机涂至作为基布的细菌纤维素上,烘至半干;
步骤8、压花:将烘干至半干的细菌纤维素皮革放置于压花机中进行压花,压花后进行彻底烘干,完成细菌纤维素皮革的制作。
所述步骤7和步骤8中的烘干温度依次为60-80℃热风烘干0.2-0.5h,烘至半干;烘干炉中在100-200℃的温度下历经0.5-1小时进行再次烘干,彻底烘干。
对比例一
真皮制作方法:方法步骤:
晾晒,把剥好的皮钉在墙上或放在洁净地面上晾干,但不能曝晒,鲜皮干燥的最适温度为20-30度,当生皮的水分含量降低到15%时,细菌就不易繁殖,达到防腐的目的。
浸泡,将皮革放入大缸内,加清水浸泡,夏季浸泡1天,冬季需浸泡2-3天。
去肉,将皮张里面朝上,用到刮除剥皮时带的残肉和油脂。
清洗,肉里刮完以后,用清水冲洗,然后加碱、肥皂等洗涤剂清洗毛皮,直到全部洗干净为止。
酸浸,酸浸液组成为5-6克/升;硫酸钠30-50克/升;氯化钠30-40克/升,温度36-38度,时间36-38小时,用水量每张皮14升左右,将食盐、硫酸溶解澄清倒入划槽,加水配成要求浓度的酸浸液,再加温到制定要求,转动滑板搅拌均匀,投入毛皮,继续划动1-2分钟,之后每天加温并划动一次,浸至36小时检查质量。
鞣制,鞣制液为碱式硫酸铬0.2克/升,明矾10克/升,氯化钠30克/升,硫酸钠30克/升,硫代硫酸钠2克/升,JFC湿润剂0.3克/升,碳酸氢钠适量,用水量每张皮10~12升,PH值下皮时1.2-2,出缸时4-4.5,温度40-45,时间72小时,将鞣制液倒入划槽,把浸酸的毛皮浸入,并划动1-2分钟,然后每隔1小时划动1次,每次1-2分钟,温度控制第一天40度,第2、3天45度,出缸前皮板收缩温度应达到70度以上,使鞣剂结合牢固。
水洗,将硝盐等杂志去除,换水次数不要太多。
甩干,使用离心机或者人工去除毛皮水份。
加脂,使皮板更加柔软,脂的配方使50度温水890克,加入软皮白油或合成加脂剂100克,湿润剂10克,将乳液刷涂在皮板上,要求温度40-50度。
干燥,烘干,抹匀石膏粉搓揉,第二次用刃刀铲,片除浮肉,再撒上石膏粉铲第3次,并注意将边缘铲开铲软,铲硬后用干布擦拭毛被直至干净,并晒干,干后堆放一夜再回铲一次即为成品。
对比例二
合成革工艺,配料主要配的是人造革的涂层剂(浆料),包括聚氨酯、聚氯乙烯、聚丙烯酸酯、聚醚等多个品种,根据具体的产品,用量和搭配也不同,其中聚氨酯涂层剂,就是常见的PU树脂,配料步骤主要包含称量树脂----加入溶剂搅拌均匀-----慢慢加入色料-----搅拌均匀----测黏度----复色调色----复测粘度----过滤----密封备用。
具体步骤为:
涂层工艺,主要是将浆料涂在基底上,一般有三涂、二涂加刮刀(二刀半)、二涂、一涂加刮刀(一刀半)、单涂等,采用何种涂层方式,主要根据产品的品种来决定,表面有特殊要求的变色产品(如镜面变色、耐刮变色)采用三涂工艺,龟裂变色、粗花纹套色、龟裂疯马等一般采用二刀半工艺,大多数鞋面革产品、粗花纹产品和一般镜面产品采用二涂工艺,纸纹套色产品、表面有爽滑要求的鞋里产品,一般会采用一刀半,普通的鞋里采用,一刀工艺法。
贴合工艺,贴合方式有湿贴或半干贴两种方式,基材为各种织物的一般用湿贴工艺,凝固涂层所产生的贝斯为基底的产品,一般均采用半干贴工艺。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (9)
1.一种新型的细菌纤维素制作皮革方法,其特征在于:将醋酸杆菌菌种在无菌的环境下,恒温静置培养,形成的细菌纤维素膜,细菌纤维素薄膜处理后制成皮革。
2.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:具体步骤为:
步骤1、培养基配置:利用乙醇、葡萄糖、蛋白胨、水、柠檬酸和磷酸氢二钠配置液体培养基;
步骤2、活化:融化的菌液均匀的涂抹在琼脂糖培养基斜面上;
步骤3、扩大:将菌体接种到液体培养基中;
步骤4、接种:将醋酸杆菌菌液接种到液体培养基中,在液体培养基的表层形成一定厚度的细菌纤维素膜;
步骤5、收膜:将细菌纤维素膜收获;
步骤6、干燥:对湿润的细菌纤维素薄膜进行压制处理,将水分压出并晾干为细菌纤维素干燥薄膜;
步骤7、涂饰:利用精密涂布机涂至作为基布的细菌纤维素上,烘至半干;
步骤8、压花:将烘干至半干的细菌纤维素皮革放置于压花机中进行压花,压花后进行彻底烘干,完成细菌纤维素皮革的制作。
3.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤1中的液体培养基的配比为:1%乙醇、2%葡萄糖、1%蛋白胨、0.27%磷酸氢二钠、0.15%柠檬酸,余量为水,通过柠檬酸将液体培养基调节为pH6,培养基配置完成后,需经过121度,20分钟的高温高压灭菌过程以确保培养基完全无菌。
4.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤2中的具体步骤为:将冷冻保存的醋酸杆菌菌种在冰上融化,融化的菌液均匀的涂抹在琼脂糖培养基斜面上,30度静置培养1-2天,待菌膜刚刚好覆盖整块琼脂糖斜面。
5.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤3中具体步骤为:在琼脂糖斜面上取一块标准大小的覆盖有醋酸杆菌菌膜的固体培养基,将菌体接种到液体培养基中,并以30度,180转每分钟的摇床速度震荡培养醋酸杆菌过夜。
6.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤4中的步骤中还包括有发酵,醋酸杆菌菌液接种到液体培养基中,并在发酵室合适的发酵条件下,温度30度,静置发酵2-3d。
7.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤5中的具体步骤为:收获细菌纤维素膜后,通过碳酸氢钠煮沸去除细菌纤维素内的乙酸,同时加强细菌纤维素的整体机械性能。
8.根据权利要求1所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤7中的具体步骤为:将环保水性聚氨酯与助剂与色料充分混匀并且进行消泡处理后,利用精密涂布机涂至作为基布的细菌纤维素上,烘至半干。
9.根据权利要求8所述的一种新型的细菌纤维素制作皮革方法,其特征在于:所述步骤7和步骤8中的烘干温度依次为60-80℃热风烘干0.2-0.5h,烘至半干;烘干炉中在100-200℃的温度下历经0.5-1小时进行再次烘干,彻底烘干。
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