CN102619095B - Manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather - Google Patents
Manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather Download PDFInfo
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Abstract
The invention relates to a manufacturing method of artificial leather and especially relates to a manufacturing method of environmentally-friendly flame-retardant bunched sea-island chamois leather. The manufacturing method comprises that through a high-density needle-punching process on polyester sea-island fibers and high-shrinkage polyester fibers, a three-dimensional leather net structure is formed; through a special process of weaving a cloth by a needle-punching compound machine, a basic raw cloth having a stable size is obtained; through modified poly urethane (PU) impregnation, a leather structure is obtained; through a high-temperature high-pressure flash evaporation-based NaOH process, product ultrafining is realized; and through a process adopting a combined technology of an odorless flame-retardant technology, a polyvinyl acetate (PVA) ventilation technology, a high-shrinkage polyester density-increasing technology and a high-performance aging-resistant PU resin, a super leather performance reaching to or exceeding a leather performance of natural suede leather is obtained.
Description
Technical field
The present invention relates to a kind of manufacture method of dermatine, specifically the manufacture method of a kind of pencil island environmental protection flame retardant automobile chamois leather.
Background technology
Six great technological changes have been experienced in the evolution of dermatine.Be coated with Corvic from first generation woven fabric, second generation tWarp Knitted Fabrics is coated with polyurethane and is coated with polyurethane to third generation regular staple non-weaving cloth, is referred to as synthetic leather.
The 4th generation was to adopt indefinite island short fiber non-woven base fabric, and the leather of production is indefinite island microfiber leather.Indefinite island short fiber normally polyamide and polyethylene in the blend of 50:50 ratio reel off raw silk from cocoons make non-woven base fabric after, take out polyethylene with toluene again and open fibre, reached at the 0.001dtex that filament number is thin, more than thick reached at the 0.1dtex, for the production of the footwear leather, product applications is restricted mostly.Because world's Public environmental attitude grows to even greater heights, more and more strict to the control of Chemical Manufacture organic solvent pollution environment in the world, ISO has released the international standard of producing for the contaminative chemical solvent, some developed countries all transform original technology and equipment when formulation standard and market access principle, and this has caused China colleague's attention.
With the nonwoven fabric of island fiber with figured sea-island production be the leather of base belong to the 5th generation artificial leather, the leather of producing is deciding the island microfiber leather, its production technology is complicated, difficulty of processing is larger, so owing to having adopted the final Color of island fiber with figured sea-island product far above indefinite island product, owing to not adopting toluene in the technique, product does not have Residual Toluene in addition, but because self process characteristic determines that DIMENSIONAL STABILITY, physical index and pliability are relatively poor.
Island fiber with figured sea-island divides two kinds of light face and anti-suedes, state's anti-suede microfiber leather in island decided at the higher level but not officially announced is produced to some extent at present, but all be low-and-medium-grade products, owing to can not solve the technical problems such as fire-retardant, DIMENSIONAL STABILITY, gas permeability, the surface of product are ageing-resistant, smell, nuisance volatilization, so can't use at automotive material.
Because automotive trim requires must be mandatory fire-retardant, and commonsense method is made automotive leather and can't be reached fire-retardant requirement, face fabric for automobile seat requires that good DIMENSIONAL STABILITY must be arranged, the super fibre of present anti-suede can't reach this requirement, face fabric for automobile seat requires to reach surperficial ageing-resistant requirement,, the super fibre of present anti-suede can't reach this requirement.
In fact, present also useful anti-suede corium of automotive seat, reason is that anti-suede corium has good breathable moisture permeability, but because anti-suede corium deals with not environmental protection and expensive can't the use in batches, common leather can't reach such requirement, although fabric can reach ventilative, dimensionally stable requirement, because performance is low, nonelastic, toughness, general for low-grade economical-type automobile, can't satisfy the high-grade requirement of auto vendor's high-performance.
Therefore before the present invention occurred, the anti-suede superfine fiber leather of automobile domestic production research and development were still blank.
Summary of the invention
The objective of the invention is to be devoted to develop a kind of island environmental protection flame retardant automobile chamois leather that can be used in automotive seat and inner decoration facing; make it performance and meet and exceed anti-suede corium; and reduction automotive seat production cost; to watch for animals with ecological environment as purpose; realize low-carbon economy; reduce the animal animal and kill, namely reduced the carbon emission of animal in the cultivation.
The object of the present invention is achieved like this, and this manufacture method may further comprise the steps:
1., fiber opening mixes: (this fiber can be from domestic or Korea S for the 3.5D with 95% * 51mm terylene island fiber with figured sea-island, Japan buys) carry out shredding with 5% 5D * 51mm high-shrinkage polyester (this fiber can be bought from domestic or Korea S) by the nonwoven opener, shredding becomes two kinds of fibers to be transported to mixing bale opener behind the fritter and tentatively to mix, again fiber is delivered to pre-blowing machine by Fan pipeline and carry out further opener, fiber block is further reduced, then detected through metal detector by blower fan, get rid of the metal that the inside may be mingled with, at last inspection there is not the fiber conveying of metal to many storehouses mixing bunker, tiny fiber is fully mixed, carry out further opener through passing to fine opener by the blower fan suction through pipeline again after the mixing bunker mixing, make fiber be split into the tiny alabastrine fiber that is, send air pressure cotton box by blower fan to by the air channel again and make the fiber bat with certain volume density;
2., compound super fine nonwoven fabric is made: the bat that 1. above-mentioned steps makes makes the evenly mixed and disorderly carding machine of feeding of fiber by electronic-weighing; Fiber further mixes removal of impurities by carding machine again, fiber is thoroughly divided comb into single fiber, fibre web through mixed and disorderly combing changes to some extent to the brute force ratio in length and breadth, the fibre web of output is held lapping machine through double fastener again and is carried out lapping, by being folded transversally into the fibre web of certain thickness and width, with becoming lace curtaining to deliver into pre-needling;
A, pre-needling:
Adopt the elliptical orbit needing machine to become lace curtaining to carry to come high fluffy and carry out pre-needling without the fibre web of brute force, then delivering to main acupuncture carries out main acupuncture, and wherein the pre-needling needling density is 88 thorn/cm2, and depth of needling is 8 millimeters;
B, main acupuncture
The crosspointer plate Double felting needle felting machine that the good fibre web that some strength is arranged of pre-needling is transported to high-frequency computer control carries out acupuncture, requiring set needing machine is just to sting and two of anti-thorns, make the fiber obvolvent of fully tangling by acupuncture up and down, increase hyper-base cloth brute force and density, form the 3-D solid structure fibre web, enter woven fabric compound, wherein First needing machine needling density is 260 thorn/cm2, depth of needling is 5 millimeters, and second needing machine needling density is 400 thorn/cm2, and depth of needling is 8 millimeters;
C, woven fabric are compound
Ready 40g/m2 polyamide fibre woven fabric is put into below the 3-D solid structure fibre web of the 3rd main needing machine, the high frequency needle punching machine that enters simultaneously from top to bottom acupuncture carries out acupuncture, and then enter the 4th from bottom to top the high frequency needle punching machine of acupuncture carry out reverse side acupuncture, make the fiber obvolvent of fully tangling by acupuncture up and down, and woven fabric firmly is compound to the 3-D solid structure fibre web, form super fine compound nonwoven cloth, wherein the needling density of the 3rd main needing machine is 550 thorn/cm2, depth of needling is 6 millimeters, wherein the needling density of the 4th main needing machine is 480 thorn/cm2, and depth of needling is 10 millimeters;
D, thorn is had a shave
With in the C step compound good super fine compound nonwoven cloth deliver to the thorn machine had a shave, the needing machine needling density of wherein having a shave is 800 thorn/cm2, depth of needling is 3 millimeters, the every Gram Mass of super fine compound nonwoven cloth that stings is 400g/m2, thickness is 1.8mm;
3., compound super fine nonwoven fabric plates: above-mentioned compound super fine nonwoven fabric 2. need plate, heating to eliminate contraction through 120 ℃ of hot-rollings eliminates stress, again with can setting the pressure roller in 1.2mm gap, be processed into the walking speed of 10m/min have certain thickness, density and powerful compound super fine nonwoven fabric;
4., the PVA impregnation is processed:
The PVA(polyvinyl alcohol of the compound super fine nonwoven fabric after plating through 90 ℃ of impregnator thorough impregnations) in the solution, wherein the PVA solution concentration is 5%, the degree of crystallinity of PVA is 99%, then by the unnecessary PVA of roll pressed, the roll seam reaches pick-up 80%, carry out prebake through 110 ℃ of far-infrared baking ovens again, make just one-step film forming of PVA, avoid migration, and then dry by tensionless dryer, oven temperature is set as 110-130 ℃, because PVA oven dry heating effect shrinks high-shrinkage polyester fully, further improve compound super fine nonwoven fabric density, thickness is 1.8-1.9mm after the PVA drying and shaping;
5., wet method PU impregnation is processed:
The compound super fine nonwoven fabric of processing through PVA is delivered to wet production line carry out modification PU resin-dipping, wet method impregnation operation is that the compound super fine nonwoven fabric of upper operation is forced dipping in this operation with the wet polyurethane slurry, wherein PU resin modulus is 55, speed of production is 4-6m/min, then by the DMF(dimethyl formamide of finite concentration and concentration gradient is housed) solidify in the coagulating basin of the aqueous solution, setting temperature is 25-30 ℃, moisturizing speed is 1000k g/h, and then wash by multiple roll pressure rolling rinsing bowl, at last by PVA and the clean DMF of 90-100 ℃ of high-temperature water washing trough flush away except the inside, be that 115-130 ℃ of drying room formula tentering baking oven carries out dryness finalization by bake out temperature again, product P U content after the typing is 35-40%, thickness is 1.7-1.8mm, becomes the semi-finished product of automobile chamois leather, i.e. bass;
6., bass carries out the alkali decrement treatment: this operation is the bass behind the wet method impregnation PU to be carried out the alkali decrement extract out, bass contained to be immersed in 8% the NaOH solution flood, pick-up is 100%, then enter in 100 ℃ the steam box and carry out chemical reaction, making the sea part in NaOH and the islands-in-sea type fibre is COPET(alkali solubility terylene) carry out the complete hydrolysis reaction, and make COPET thoroughly resolve into little molecule, make composite fibre be pencil fine structure, then the alkaline terylene reaction residues that the COPET reaction residues that centrifugal extraction is hydrolyzed through the high pressure sucktion fan and ultrasonic wave water washing effect make decomposition is cleaned out, again through the rinsing bowl washing, thoroughly wash reaction residues off, regulate the pH value at rinsing bowl at last, make bass reach neutral requirement, then send again lower pre-grinding skin operation to carry out the processing of pre-grinding skin after sending down the drying line oven dry, wherein alkali decrement speed of production is 8m/min, steam box storage cloth amount 150m, thickness requirement 1.4mm after the decrement oven dry;
7., pre-grinding skin after the decrement:
Adopting the belt decorticating mill to carry out the pre-grinding skin according to product requirement to the surface of the bass after the decrement oven dry processes, reach surperficial velvet and the specific thickness requirement of automobile fabric, product behind the mill skin is delivered to dyeing process dyeing, wherein belt machine grinds shelling skin speed 5-6m/min, belt sand paper order several 240,320 and 400, positive mill skin amounts to 3 times, and reverse side need not be processed, bass thickness 1.2mm behind the pre-grinding skin;
8., the pre-grinding skin is processed bass dyeing:
This operation is that the bass behind the pre-grinding skin dyes, dyeing is to dye different colors according to the product colour needs, this patent uses the disperse dyes of conventional super fine dyeing to use the overflow dyeing method to reach product colouring requirement, and the product after dying is delivered to the oven dry upper wick and oiled and flame treatment;
9., dyeing product oils fire-retardant:
Oiling process is after passing through the tentering drying machine drying through hyperchromatic bass, again in the solution tank that contains the environmental protection fire retarding agent that is soaked with 10-15%, carrying out two rolls two and soaks, shut out redundant solution with roll at last, pick-up 80%, then dry with the tentering dryness finalization, bake out temperature is 110-130 ℃, offers the final sanding of next procedure after the oven dry and processes;
10., product sanding: adopt 400-500 order roll-type decorticating mill effects on surface to carry out sanding according to product requirement and process, rod formula mill skin speed 4-5m/min, reach the surperficial chamois leather velvet requirement of automobile fabric, the product behind the mill skin is this patent product island environmental protection flame retardant automobile chamois leather.
Advantage of the present invention and good effect:
Technically how to substitute the key that natural skin is this product, because structurally, the present invention is imitation natural leather 3-D solid structure and chemical composition, develops pencil island environmental protection flame retardant automobile chamois leather.
The basic technique principle of " pencil island environmental protection flame retardant automobile chamois leather ": by to natural leather in pencil collagen fiber structure (fineness 3-4um) the super fibre similar with performance make (skeleton material); Employing has the nonwoven process of three-dimensional net structure; The PU resin finishing that recharges excellent performance and have an open type microcellular structure high tenacity is processed and to be formed (imitative characteristic amino acid), reaches this three and requires to reach characteristics above corium
Air-moisture-permeable, toughness and DIMENSIONAL STABILITY requirement for automobile skin needs, the highly dense needling process technology that the composite fibre that my company adopts mixes is domestic initiation, it also is a unique company with this technology, guarantee the innovation performance of product island environmental protection flame retardant automobile chamois leather, thereby be that gas permeability, DIMENSIONAL STABILITY are solved.We adopt the fire-retardant method of impregnation to reach the requirement of automotive seat producer for flame-retarded technology.Because above factor island environmental protection flame retardant automobile chamois leather technology has the characteristics such as environmental protection, super corium be strong.
1, this project mainly is the fiber that mixes by a certain percentage by to terylene island fiber with figured sea-island and high-shrinkage polyester, by the combing lapping, and then carry out the composite acupuncture PROCESS FOR TREATMENT with woven fabric, form the network structure of three-dimensional structure, contain soaking technology by PVA more afterwards base material is carried out impregnation, product density is further increased, the base cloth that impregnation is good forms the cortex structure of porous by modification PU impregnation after coagulation, flush away PVA makes material have stable ventilating porous structure in water-washing process again, and then process by the NaOH friendly process and to make the product fine, at last by dyeing, special process such as mill skin etc. is processed, thereby adopts the tasteless technology such as fire-retardant to reach super corium performance above natural leather.
2, the invention solves technical problems such as gas permeability, DIMENSIONAL STABILITY, smell and gas permeability on the automotive leather; adopt unique green technology; realize low-carbon economy; it is shown one's talent from low and middle-grade microfiber leathers; make product be applied in batches the automotive trim field, enhance product performance and reduce simultaneously the automobile production cost, automobile lightweight and environmental protection developing goal; greatly solve the in short supply and quality of the current medium-to-high grade car interior trim leather problem that do not pass a test, market prospects are quite wide.
3, product environmental protection flame retardant automobile chamois leather of the present invention belongs to the hitech materials of a kind of new development in the artificial synthetic leather, is not natural skin.Because it has the advantages such as fire-retardant, wear-resisting, cold-resistant, ventilative, ageing-resistant, that quality is soft and outward appearance is beautiful, become the ideal chose that replaces anti-suede natural leather.
4, natural leather is to be formed by the collagenous fibres " braiding " that many thicknesses do not wait, and minute grain layer and lamina reticularis are two-layer, and grain layer is knitted by superfine collagenous fibres and formed, and netted the braiding by thicker collagenous fibres forms.Because the collagen bundle of ox-hide mutually interts in corium and interweaves with closely becoming net, and the superfine fibre skin base cloth of this product is to adopt the woven fabric of three-dimensional structure PROCESS FOR TREATMENT and the technique of the non-woven fabric compounded production of needle point method, be mainly up and down vertical acupuncture, making tangles between vertical and the horizontal direction fiber mutually is woven into network, environmental protection flame retardant automobile chamois leather of the present invention is to adopt the modified polyamine ester layer close with natural leather grain layer structure to form, casing play is to be composited with woven acupuncture after adopting island, Dinghai fiber and high-shrinkage polyester mixing acupuncture again, the lamina reticularis of its structure and natural leather is extremely similar, thereby super corium has extremely similar structure and performance to anti-suede natural leather.
Compare with natural leather, environmental protection flame retardant automobile chamois leather mainly contains following characteristics:
(1), stable, the employing of percentage elongation moderate size and the similar group molecular composition of natural leather (skin sense, toughness, elastic recovery are good).
(2), permeability is very good, can reach more than the corium twice.
(3), tearing strength and peel strength higher (ABRASION RESISTANCE, tear edge, tension intensity are high).
(4), folding fastness can compare favourably with natural leather.
(5), the product weather resisteant can be superior, the normal temperature bending reaches flawless 250,000 times, crooked 80,000 flawlesses of low temperature (20 ℃) (temperature tolerance, mechanicalness good).
(6), do not have any pollution from producing to use, adopt green process technology, do not contain harmful material, environmental-protecting performance is superior.
5, product environmental protection flame retardant automobile chamois leather of the present invention can substitute all anti-suede corium products; can effectively reduce animal kills; keep ecosystem balance; protection of the environment; reduce the carbon emission of animal-breeding ight soil, exhaust, product can be widely used in the fields such as automobile both domestic and external, steamer, aircraft interior trim and environmental purification.
This formula for a product is reasonable, the advanced feasible environmental protection of technique, steady quality, is applicable to substituting the natural leather product.
(1) because the textile fabric work in-process is restive, non-weaving cloth Cheng Buqian particularly, fiber is that its uniformity is the difficult point of production control always take single as the unit free state.But adopt high-precision CV1 drawing-off control device for layering to make fibre web uniformity generation fundamental turn for the better, products C V value will be dropped to below 1.5% by 3%;
(2) produce the superfine high-density non-weaving cloth, of crucial importance through the application of broadwise brute force comparison product, therefore must make the powerful ratio of product near 1, this project adopts high accuracy two pass husband pair mixed and disorderly carding machines can guarantee that this index is stable;
(3) production island environmental protection flame retardant automobile chamois leather all has harsh requirement to indexs such as product fabric quality and inherent matter density, the domestic production line is difficult to solve at present, this project adopts needle plate form and the mixed and disorderly cloth pin of computer and the needing machine of having a shave of the Special Elliptic type track of German Di Luo company development, not only solves the problem of product thickness, matter density, flatness but also solve drawing-off and fault that needle tracking causes.
(4) compound front employing low-density composite acupuncture technology well is bonded together woven fabric with eedle-punched non-wovens, guarantees that product peels off index, and the highly dense technology of compound rear employing makes the product density increasing, uses simultaneously the preliminary draft device, and product can smoothly be integrated.By the special process parameter adjustment, reach optimum efficiency again, guarantee that final products surpass natural leather DIMENSIONAL STABILITY and pliability requirement.
The woven fabric of A, employing requires as follows:
A, specification are 40g/m2,
B, Density are: 12 * 12/cm2,
C, elongation: 30-80%,
D, chemical composition terylene.
E, intensity: 240N/5mm.
B, composite demand: peel strength is greater than 70N.
(6), needling process: when we adopt the terylene islands-in-sea type fibre, increase a small amount of high-shrinkage polyster, because follow-up raising volume density needs are satisfied in the follow-up contraction that is subjected to temperatures involved of high-shrinkage polyester; The three-dimensional structure of non-weaving cloth is more even, and company has adopted unique highly dense needling process simultaneously, and the volume density of product is greatly improved, and reaches the peculiar density requirements and the rebound performance that surmount corium, saves PU; The acupuncture combination process adopts woven nonwoven combination process, improves product size stability.
(7), the preliminary treatment of PVA impregnation process using far infrared, free shrink setting process, and make between rear PU and fiber and form diaphragm, water-wash away at last and make the flexible, porous moisture-penetrable ventilated purpose of product, be that product density further increases simultaneously; The above high temperature of 90 degree of PVA operation thoroughly shrinks the high-shrinkage polyester in the fiber, further raising product volume density.
(8), the PU wet processing adopts special impregnation product processing technique to make its product reach the specific (special) requirements of artificial leather.
(9), for to adopting multiple combination technique in the post processing of product, make properties of product unique by product being carried out the special technique such as fire-retardant, different style satisfies the requirement of automotive leather purposes.
(10), DMF all adopts recovery tower to carry out whole recyclings according to water and DMF boiling point different principle among the present invention.
Description of drawings
Fig. 1 is the island fiber with figured sea-island fibre section Electronic Speculum figure on raw materials used 37 islands in the fiber opening blend step of the present invention.
Fig. 2 is Electronic Speculum figure behind the bass behind the compound nonwoven cloth impregnation PU in the wet method PU impregnation treatment step of the present invention.
Fig. 3 is that bass of the present invention carries out in the alkali decrement treatment step bass and processes through NaOH and extract product cross section Electronic Speculum figure behind the sea component out.
Fig. 4 is to be this patent product pencil island environmental protection flame retardant automobile chamois leather Electronic Speculum figure in the product sanding step of the present invention.
Fig. 5 is natural leather Electronic Speculum figure.
The specific embodiment
Manufacture method of the present invention comprises following processing step:
This manufacture method may further comprise the steps:
1., fiber opening mixes: the 3.5D with 95% * 51mm terylene island fiber with figured sea-island (all can by 37 islands or 51 islands, sea component is COPET, the island component is PET)) with 5% 5D * the 51mm high-shrinkage polyester is main production raw material, wherein terylene island fiber with figured sea-island Electronic Speculum figure sees accompanying drawing 1, the Electronic Speculum figure that amplifies 4500 times by accompanying drawing 4 finds out, 37 island components are surrounded by sea component.Mixed fiber carries out shredding by the nonwoven opener, make the monoblock fiber be become fritter by mechanical shredding, then by a convoying curtain two kinds of fibers being transported to mixing bale opener tentatively mixes, produce static for reducing fibre frictoin, add the requirement that softens smoothly and good saturability is arranged to reach, the antistatic finish of terylene of mixed cotton opener after-applied 0.3% need to opened, again fiber is delivered to pre-blowing machine by Fan pipeline and carry out further opener, fiber block is further reduced, and then by the detection of blower fan process metal detector, get rid of the metal that the inside may be mingled with, then inspection there is not the fiber conveying of metal to many storehouses mixing bunker, tiny fiber is fully mixed, carry out further opener through passing to fine opener by the blower fan suction by pipeline again after the mixing bunker mixing, make fiber be split into the tiny alabastrine fiber that is, send air pressure cotton box by blower fan to by the air channel again and make the fiber bat with certain volume density.
2., compound super fine nonwoven fabric is made: 1. above-mentioned steps has certain volume density by the fiber that air pressure cotton box quantitatively feeds, because pressure evenly makes fibre density uniform and stable " bat ", such bat is by the electronic belt of the import automatic Weighing of weighing, make the evenly mixed and disorderly carding machine of feeding of fiber, guarantee the uniform and stable property of finished product grammes per square metre with this; Bat can make fiber further mix removal of impurities by carding machine by high property more in a jumble, and fiber is thoroughly divided comb into single fiber, change to some extent to the brute force ratio in length and breadth through the fibre web that makes with the mixed and disorderly effect of mixed and disorderly roller carding machine, but the fibre web of carding machine output is held lapping machine through the import Ao Tefa double fastener of stage Compensation Regulation again and is carried out lapping, by being folded transversally into the fibre web of certain thickness and width, with becoming lace curtaining to deliver into pre-needling.
A, pre-needling:
We adopt elliptical orbit needing machine that German Di Luo company produces that lapping machine is carried come high fluffy and carry out pre-needling without the fibre web of brute force, its first tool brute force and thickness are greatly reduced, and guarantee minimum drawing-off amount and do not have obvious needle tracking, then deliver to main acupuncture and carry out acupuncture, wherein the pre-needling needling density is 88 thorn/cm2, and depth of needling is 8 millimeters.。
Acupuncture Principles is that the needle plate at needing machine is implanted with up to ten thousand pieces of triangle prickers, hook thorn towards the needle point direction is arranged on the corner angle of each pricker, reciprocating motion by needle plate, pricker passes the stripping web plate and enters fiber web, passes trawl board again, passes in the process of fibre web at pricker, because oriented needle point direction hook thorn on the pricker, fiber is brought into fibre web inside from the surface, just as the nail of pin one by one is on fiber web, web thickness is greatly reduced and intensity is strengthened.
B, main acupuncture
The crosspointer plate Double felting needle felting machine that the good fibre web that some strength is arranged of pre-needling is transported to high-frequency computer control carries out acupuncture, requiring set needing machine is just to sting and two of anti-thorns, make the fiber obvolvent of fully tangling by acupuncture up and down, increase hyper-base cloth brute force and density, form the 3-D solid structure fibre web, enter woven fabric compound, wherein First needing machine needling density is 260 thorn/cm2, depth of needling is 5 millimeters, and second needing machine needling density is 400 thorn/cm2, and depth of needling is 8 millimeters.
C, woven fabric are compound
Ready 40g/m2 polyamide fibre woven fabric is put into below the 3-D solid structure fibre web of the 3rd main needing machine, the high frequency needle punching machine that enters simultaneously from top to bottom acupuncture carries out acupuncture, and then enter the 4th from bottom to top the high frequency needle punching machine of acupuncture carry out reverse side acupuncture, make the fiber obvolvent of fully tangling by acupuncture up and down, and woven fabric firmly is compound to the 3-D solid structure fibre web, form super fine compound nonwoven cloth, wherein the needling density of the 3rd main needing machine is 550 thorn/cm2, depth of needling is 6 millimeters, wherein the needling density of the 4th main needing machine is 480 thorn/cm2, and depth of needling is 10 millimeters.Wherein the lower thorn density degree of depth significantly reduces, and avoids stabbing woven fabric, and can make woven fabric and nonwoven fabric strong bonded, when increasing micro fiber leather base cloth brute force density is increased, and size is stablized.
D, thorn is had a shave
With in the C step compound good super fine compound nonwoven cloth deliver to the thorn machine had a shave,, guarantee that compound base fabric density improves to make simultaneously the compound base fabric surfacing bright and clean.The needing machine needling density of wherein having a shave is 800 thorn/cm2, and depth of needling is 3 millimeters, and the every Gram Mass of super fine compound nonwoven cloth that stings is 400g/m2, and thickness is 1.8mm.
3., compound super fine nonwoven fabric plates: above-mentioned compound super fine nonwoven fabric 2. need plate, heat to eliminate contraction through 120 ℃ of hot-rollings and eliminate internal stress, again with can setting the pressure roller in 1.2mm gap, be processed into the walking speed of 10m/min have certain thickness, density and powerful compound super fine nonwoven fabric.
4., the PVA impregnation is processed:
The PVA(polyvinyl alcohol of the compound super fine nonwoven fabric after plating through 90 ℃ of impregnator thorough impregnations) in the solution; wherein the PVA solution concentration is 5%; the degree of crystallinity of PVA is 99%; then by the unnecessary PVA of roll pressed; the roll seam reaches pick-up 80%; carry out prebake through 110 ℃ of far-infrared baking ovens again; make just one-step film forming of PVA; avoid migration, and then dry by tensionless dryer, oven temperature is set as 110-130 ℃; make PVA and wrap the fiber surface that is attached to compound nonwoven cloth fully; form diaphragm, go out in order to next procedure impregnation PU after washing, make between fiber and PU and form the space; be convenient to the breathable moisture permeability needs; because PVA oven dry heating effect shrinks high-shrinkage polyester fully, further improves compound super fine nonwoven fabric density, thickness is 1.8-1.9mm after the PVA drying and shaping.
5., wet method PU impregnation is processed:
The compound super fine nonwoven fabric of processing through PVA is delivered to wet production line carry out modification PU resin-dipping, wet method impregnation operation is that the compound super fine nonwoven fabric of upper operation is forced dipping in this operation with the wet polyurethane slurry, the impregnating groove that DMF solution is housed has three, the DMF concentration of first groove is 28%, the DMF concentration of second groove is 15%, the DMF concentration of second groove is 10%, owing in DMF solution solidifies groove, adopting different DMF Pressure, Concentration, Temperature condition control, make and get the distinctive porous ductile structure of leather that the PU generation has minute aperture on the impregnation compound nonwoven cloth, see accompanying drawing 2, the Electronic Speculum figure that amplifies 500 times by accompanying drawing 2 finds out, PU after solidifying is coated on around the fiber of compound nonwoven cloth, and forms a lot of apertures.
Wherein P U resin modulus is 55, speed of production is 4-6m/min, then by solidifying in the coagulating basin that certain density DMF solution is housed, setting temperature is 25-30 ℃, moisturizing speed is 1000k g/h, and then wash by multiple roll pressure rolling rinsing bowl, at last by PVA and the clean DMF of 90-100 ℃ of high-temperature water washing trough flush away except the inside, be that 115-130 ℃ of drying room formula tentering baking oven carries out dryness finalization by bake out temperature again, product P U content after the typing is 35-40%, and thickness is 1.7-1.8mm.Become the semi-finished product of automobile chamois leather, i.e. bass.
The PU slurry of this operation needs need to be used chemical reaction kettle in addition, first in proportion the PU resin is extracted into reactor, then throw DMF into and carry out stirring and dissolving, prescription adds other auxiliary agent by a certain percentage afterwards, and fully stirred about 2 hours, then be put into and deliver to the wet method line in the carrying ladle, be extracted in the impregnating groove stand-by with air pump.
Wet polyurethane slurry PU raw material composition and formulation weight portion rate are as follows:
DMF:65-69 part
Modified polyurethane resin: 20-24 part
Foam stabilizer AR600:0.4-0.6 part
Accelerant A R120:1-2 part
Blowing agent AR100:3-4 part
Abscess mediator agent S-25:0.6-0.8 part
Mill base: 3-5 part
All there is production above resin, domestic each the large leather resin of auxiliary agent, auxiliary reagent factory.
Wet-process modified polyurethane slurry P U slurry collocation method is as follows, first 220 kilograms of weighted modified polyurethane resins is thrown into 3 tons reactor with air pump, and then throws 660 kilograms of DMF solution into air pump, and turn on agitator fully stirred 30 minutes; Again AR600 is weighed up 5 kilograms, AR120 weighs up 2 kilograms, and AR100 weighs up 4 kilograms, and S-25 weighs up 7 kilograms, pours into successively in the reactor, and the limit bevelling stirs, and stirs 30 minutes again; As required mill base is weighed up 4 kilograms at last and also drop into and fully stirred in the reactor 60 minutes, the outlet valve of opening again below the reactor is emitted the PU slurry for preparing, and delivers to production line with turnover barrel stand-by.
6., bass carries out the alkali decrement treatment: this operation is the bass behind the wet method impregnation PU to be carried out the alkali decrement extract out, bass contained to be immersed in 8% the NaOH solution flood, pick-up is 100%, then enter in 100 ℃ the steam box and carry out chemical reaction, making the sea part in NaOH and the islands-in-sea type fibre is COPET(alkalescence terylene) carry out the complete hydrolysis reaction, and make COPET thoroughly resolve into little molecule, make composite fibre be pencil fine structure, then the alkaline terylene reaction residues that the COPET reaction residues that centrifugal extraction is hydrolyzed through the high pressure sucktion fan and ultrasonic wave water washing effect make decomposition is cleaned out, again through the rinsing bowl washing, thoroughly wash reaction residues off, regulate the pH value at rinsing bowl at last, make bass reach neutral requirement, then send down and send again lower pre-grinding skin operation to carry out the pre-grinding skin after the drying line oven dry to process.Wherein alkali decrement speed of production is 8m/min, steam box storage cloth amount 150m, thickness requirement 1.4mm after the decrement oven dry.
The Electronic Speculum figure that wet method bass process NaOH processes behind the extraction sea component sees accompanying drawing 3, the Electronic Speculum figure that amplifies 4000 times by accompanying drawing 3 finds out, an islands-in-sea type fibre 37 tiny fibers that thoroughly minute shed after by decrement treatment, the fineness of this fiber has reached 3.4um, near corium fabric 4um fineness requirement.
7., pre-grinding skin after the decrement:
Adopt the belt decorticating mill to carry out the pre-grinding skin according to product requirement to the surface of the bass after the decrement oven dry and process, reach surperficial velvet and the specific thickness requirement of automobile fabric, the product behind the mill skin is delivered to dyeing process dyeing.Belt machine mill shelling skin speed 5-6m/min wherein, belt sand paper order is several 240,320 and 400, and positive mill skin amounts to 3 times, and reverse side need not be processed, bass thickness 1.2mm behind the pre-grinding skin
8., the pre-grinding skin is processed bass dyeing:
This operation is that the bass behind the pre-grinding skin dyes, dyeing is to dye different colors according to the product colour needs, this patent uses the disperse dyes of conventional super fine dyeing to use the overflow dyeing method to reach product colouring requirement, and the product after dying is delivered to the oven dry upper wick and oiled and flame treatment.
9., dyeing product oils fire-retardant:
Oiling process is after passing through the tentering drying machine drying through hyperchromatic bass, again in the solution tank that contains the environmental protection fire retarding agent that is soaked with 10-15%, carrying out two rolls two and soaks, shut out redundant solution with roll at last, pick-up 80%, then dry with the tentering dryness finalization, bake out temperature is 110-130 ℃, offers the final sanding of next procedure after the oven dry and processes.
This operation is with a certain proportion of import environmental protection fire retarding agent base cloth to be processed, thereby improves flexibility and the physical property of superfiber leather product.Treated base cloth meets the fire-retardant requirement of product.
For the product fire resistance is further improved, adopt environmental protection import fire retardant, from knowing of experiment, must carry out and combination matching by two kinds of fire retardants, just can reach the optimum resistance combustion effect, so this patent environmental protection fire retarding agent H Z R-3 formulation weight portion rate is as follows:
(1), fire retardant BC1226 3-7 part
(2), fire retardant PDP 4-8 part
(3), water H2O 80-90 part.
Above auxiliary agent fire retardant is produced by Japan, is domesticly act as sole agent by the Shanghai trading company that fills enamel, and can buy therefrom.
Environmental protection fire retarding agent HZR-3 fire retardant collocation method is as follows, by overanxious net 90 kilograms of soft water is thrown into surge-tank first, and then weighted fire retardant BC1226 white powder is amounted to 6 kilograms pours into into surge-tank, and turn on agitator fully stirred 30 minutes; Again fire retardant PDP solution is weighed up 7 kilograms and slowly pour in the surge-tank, the limit bevelling stirs, and stirs 30 minutes again, with air pump deployed retardant solution is delivered to production line with turnover barrel stand-by.
10., product sanding: adopt 400-500 order roll-type decorticating mill effects on surface to carry out sanding according to product requirement and process, rod formula mill skin speed 4-5m/min, reach the surperficial chamois leather velvet requirement of automobile fabric, product behind the mill skin is this patent product pencil island environmental protection flame retardant automobile chamois leather, see accompanying drawing 4, amplified natural leather Electronic Speculum figure that 850 times Electronic Speculum figure and accompanying drawing 5 amplify 1600 times contrasts and finds out the super long and slender dimension of leather, network structure, air hole structure and the cortex structure similar to corium by accompanying drawing 4.
Claims (4)
1. the manufacture method of a pencil island environmental protection flame retardant automobile chamois leather is characterized in that:
This manufacture method may further comprise the steps:
1., fiber opening mixes: the 3.5D with 95% * 51mm terylene island fiber with figured sea-island and 5% 5D * 51mm high-shrinkage polyester carries out shredding by the nonwoven opener, shredding becomes two kinds of fibers to be transported to mixing bale opener behind the fritter and tentatively to mix, again fiber is delivered to pre-blowing machine by Fan pipeline and carry out further opener, fiber block is further reduced, then detected through metal detector by blower fan, get rid of the metal that the inside may be mingled with, at last inspection there is not the fiber conveying of metal to many storehouses mixing bunker, tiny fiber is fully mixed, carry out further opener through passing to fine opener by the blower fan suction through pipeline again after the mixing bunker mixing, make fiber be split into the tiny alabastrine fiber that is, send air pressure cotton box by blower fan to by the air channel again and make the fiber bat with certain volume density;
2., compound super fine nonwoven fabric is made: the bat that 1. above-mentioned steps makes makes the evenly mixed and disorderly carding machine of feeding of fiber by electronic-weighing; Fiber further mixes removal of impurities by carding machine again, fiber is thoroughly divided comb into single fiber, fibre web through mixed and disorderly combing changes to some extent to the brute force ratio in length and breadth, the fibre web of output is held lapping machine through double fastener again and is carried out lapping, by being folded transversally into the fibre web of certain thickness and width, with becoming lace curtaining to deliver into pre-needling;
A, pre-needling:
Adopt the elliptical orbit needing machine to become lace curtaining to carry to come high fluffy and carry out pre-needling without the fibre web of brute force, then delivering to main acupuncture carries out main acupuncture, and wherein the pre-needling needling density is 88 thorn/cm2, and depth of needling is 8 millimeters;
B, main acupuncture
The crosspointer plate Double felting needle felting machine that the good fibre web that some strength is arranged of pre-needling is transported to high-frequency computer control carries out acupuncture, requiring set needing machine is just to sting and two of anti-thorns, make the fiber obvolvent of fully tangling by acupuncture up and down, increase hyper-base cloth brute force and density, form the 3-D solid structure fibre web, enter woven fabric compound, wherein First needing machine needling density is 260 thorn/cm2, depth of needling is 5 millimeters, and second needing machine needling density is 400 thorn/cm2, and depth of needling is 8 millimeters;
C, woven fabric are compound
Ready 40g/m2 polyamide fibre woven fabric is put into below the 3-D solid structure fibre web of the 3rd main needing machine, the high frequency needle punching machine that enters simultaneously from top to bottom acupuncture carries out acupuncture, and then enter the 4th from bottom to top the high frequency needle punching machine of acupuncture carry out reverse side acupuncture, make the fiber obvolvent of fully tangling by acupuncture up and down, and woven fabric firmly is compound to the 3-D solid structure fibre web, form super fine compound nonwoven cloth, wherein the needling density of the 3rd main needing machine is 550 thorn/cm2, depth of needling is 6 millimeters, wherein the needling density of the 4th main needing machine is 480 thorn/cm2, and depth of needling is 10 millimeters;
D, thorn is had a shave
With in the C step compound good super fine compound nonwoven cloth deliver to the thorn machine had a shave, the needing machine needling density of wherein having a shave is 800 thorn/cm2, depth of needling is 3 millimeters, the every Gram Mass of super fine compound nonwoven cloth that stings is 400g/m2, thickness is 1.8mm;
3., compound super fine nonwoven fabric plates: above-mentioned compound super fine nonwoven fabric 2. need plate, heating to eliminate contraction through 120 ℃ of hot-rollings eliminates stress, again with can setting the pressure roller in 1.2mm gap, be processed into the walking speed of 10m/min have certain thickness, density and powerful compound super fine nonwoven fabric;
4., the PVA impregnation is processed:
The compound super fine nonwoven fabric after plating in the PVA solution of 90 ℃ of impregnator thorough impregnations, wherein the PVA solution concentration is 5%, the degree of crystallinity of PVA is 99%, then by the unnecessary PVA of roll pressed, the roll seam reaches pick-up 80%, carry out prebake through 110 ℃ of far-infrared baking ovens again, make just one-step film forming of PVA, avoid migration, and then dry by tensionless dryer, oven temperature is set as 110-130 ℃, because PVA oven dry heating effect shrinks high-shrinkage polyester fully, further improve compound super fine nonwoven fabric density, thickness is 1.8-1.9mm after the PVA drying and shaping;
5., wet method PU impregnation is processed:
The compound super fine nonwoven fabric of processing through PVA is delivered to wet production line carry out modification PU resin slurry dipping, wet method impregnation operation is that the compound super fine nonwoven fabric of upper operation is forced dipping in this operation with the wet polyurethane slurry, wherein PU resin modulus is 55, speed of production is 4-6m/min, then by solidifying in the coagulating basin that certain density DMF solution is housed, setting temperature is 25-30 ℃, moisturizing speed is 1000kg/h, and then wash by multiple roll pressure rolling rinsing bowl, at last by PVA and the clean DMF of 90-100 ℃ of high-temperature water washing trough flush away except the inside, be that 115-130 ℃ of drying room formula tentering baking oven carries out dryness finalization by bake out temperature again, product P U content after the typing is 35-40%, thickness is 1.7-1.8mm, becomes the semi-finished product of automobile chamois leather, i.e. bass;
6., bass carries out the alkali decrement treatment: this operation is the bass behind the wet method impregnation PU to be carried out the alkali decrement extract out, bass contained to be immersed in 8% the NaoH solution flood, pick-up is 100%, then enter in 100 ℃ the steam box and carry out chemical reaction, making the sea part in NaOH and the islands-in-sea type fibre is that alkaline terylene carries out the complete hydrolysis reaction, and make alkaline terylene thoroughly resolve into little molecule, make composite fibre be pencil fine structure, then the alkaline terylene reaction residues that the alkaline terylene reaction residues that centrifugal extraction is hydrolyzed through the high pressure sucktion fan and ultrasonic wave water washing effect make decomposition is cleaned out, again through the rinsing bowl washing, thoroughly wash reaction residues off, regulate the pH value at rinsing bowl at last, make bass reach neutral requirement, then send again lower pre-grinding skin operation to carry out the processing of pre-grinding skin after sending down the drying line oven dry, wherein alkali decrement speed of production is 8m/min, steam box storage cloth amount 150m, thickness requirement 1.4mm after the decrement oven dry;
7., pre-grinding skin after the decrement:
Adopting the belt decorticating mill to carry out the pre-grinding skin according to product requirement to the surface of the bass after the decrement oven dry processes, reach surperficial velvet and the specific thickness requirement of automobile fabric, product behind the mill skin is delivered to dyeing process dyeing, wherein belt machine grinds shelling skin speed 5-6m/min, belt sand paper order several 240,320 and 400, positive mill skin amounts to 3 times, and reverse side need not be processed, bass thickness 1.2mm behind the pre-grinding skin;
8., the pre-grinding skin is processed bass dyeing:
This operation is that the bass behind the pre-grinding skin dyes, dyeing is to dye different colors according to the product colour needs, use the disperse dyes of conventional super fine dyeing to use the overflow dyeing method to reach product colouring requirement, the product after dying is delivered to the oven dry upper wick and is oiled and flame treatment;
9., dyeing product oils fire-retardant:
Oiling process is after passing through the tentering drying machine drying through hyperchromatic bass, again in the solution tank that contains the environmental protection fire retarding agent that is soaked with 10-15%, carrying out two rolls two and soaks, shut out redundant solution with roll at last, pick-up 80%, then dry with the tentering dryness finalization, bake out temperature is 110-130 ℃, offers the final sanding of next procedure after the oven dry and processes;
10., product sanding: adopt 400-500 order roll-type decorticating mill effects on surface to carry out sanding according to product requirement and process, rod formula mill skin speed 4-5m/min, reach the surperficial chamois leather velvet requirement of automobile fabric, the product behind the mill skin is island environmental protection flame retardant automobile chamois leather.
2. the manufacture method of a kind of pencil according to claim 1 island environmental protection flame retardant automobile chamois leather, it is characterized in that: the described wet method PU impregnation treatment process 5. middle DMF aqueous solution is solidified the different DMF Pressure, Concentration, Temperature condition control of employing, makes the PU on the impregnation compound nonwoven cloth produce the distinctive porous ductile structure of leather with minute aperture; Bass thickness requirement 1.7-1.8mm after the wet method drying and shaping, resin content 35% in the bass, and wet processing is determined speed of production 5.5m/min, gives water speed 1000kg/h, 25 ℃ of temperature, PU resin concentration 20%; DMF coagulating basin concentration ladder, first solidifies concentration 28%, the second setting temperature 15%, the three solidifies concentration 10%.
3. the manufacture method of a kind of pencil according to claim 1 island environmental protection flame retardant automobile chamois leather is characterized in that: the wet polyurethane slurry PU raw material of described wet method PU impregnation treatment process in 5. form and the amount portion rate as follows:
DMF:65-69 part
Modified polyurethane resin: 20-24 part
Foam stabilizer AR600:0.4-0.6 part
Accelerant A R120:1-2 part
Blowing agent AR100:3-4 part
Abscess mediator agent S-25:0.6-0.8 part
Mill base: 3-5 part.
4. the manufacture method of a kind of pencil according to claim 1 island environmental protection flame retardant automobile chamois leather is characterized in that: described dyeing product oil fire-retardant operation 9. in the environmental protection fire retarding agent ratio of weight and number as follows:
Fire retardant BC1226 3-7 part
Fire retardant PDP 4-8 part
Water H2O 80-90 part.
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