Manufacturing method of low-carbon environment-friendly recyclable space synthetic leather
Technical Field
The invention relates to the technical field of synthetic leather, in particular to a manufacturing method of low-carbon environment-friendly recoverable space synthetic leather.
Background
The existing synthetic leather manufacturing process is complex, and usually needs multiple procedures (such as base cloth impregnation, flocculation, padding, ironing, coating of aqueous polyurethane foaming material, predrying, flocculation, washing, drying, back coating and the like) to finish, so that a large amount of energy is consumed. In addition, organic solvents such as DMFA are often used in these processes, which have adverse environmental and operator health effects.
Disclosure of Invention
(One) solving the technical problems
Aiming at the defects of the prior art, the invention provides a manufacturing method of low-carbon environment-friendly recyclable space synthetic leather.
(II) technical scheme
In order to achieve the above purpose, the present invention provides the following technical solutions: a manufacturing method of low-carbon environment-friendly recoverable space synthetic leather comprises the following steps:
Step 1, recycling leftover materials: the synthetic leather leftover materials and waste synthetic leather materials generated in the production process are intensively recycled;
step 2, cleaning and granulating the recovered material: thoroughly cleaning the recovered leftover materials and waste materials, removing dirt and impurities on the surface, and then sending the mixture into a granulator for granulation treatment to form uniform and fine regenerated particles;
step 3, dissolving reclaimed materials: feeding the granulated regenerated particles into a double-screw extruder, heating and dissolving the regenerated particles through a temperature control system, and plasticizing the regenerated particles to form continuous and stable fluid;
step 4, manufacturing non-woven fabric base cloth: the melted material is cooled by an extrusion molding process to form non-woven fabric base cloth with certain strength and elasticity;
Step 5, treating the impregnating solution: preparing environment-friendly impregnating solution, feeding the obtained non-woven fabric base cloth into an impregnating tank, fully absorbing the impregnating solution in the non-woven fabric through multiple times of impregnation, and extruding the impregnated base cloth through a roller;
Step 6, solidification treatment: feeding the impregnated non-woven fabric base cloth into a solidification tank, and uniformly solidifying the impregnating solution in the base cloth by controlling parameters such as temperature, flow rate and the like to form a firm solidification layer;
Step 7, washing and drying: washing the solidified non-woven fabric base cloth for multiple times to ensure that excessive coagulating liquid and residual organic components are thoroughly removed, and drying the non-woven fabric base cloth by an advanced drying device after washing to ensure that the water content of the material is controlled within a specified range;
step 8, the thickness of the product is between 1.4mm and 1.55 mm;
step 9, treating the surface of the synthetic leather, such as embossing, hot pressing, waterproof coating and the like;
and 10, rolling and packaging qualified materials, and cutting according to requirements.
Preferably, in the step 2, ultrasonic cleaning is adopted, and the cleaned material is subjected to granulation treatment after air drying or drying.
Preferably, in the step 3, an antioxidant and an ultraviolet absorber may be added before the extrusion of the material to enhance the durability of the material in subsequent use.
Preferably, in the step 5, the impregnating solution comprises aqueous polyurethane, nano filler and plasticizer.
Preferably, in the step 5, the liquid carrying rate is controlled to be between 70 and 80 percent.
Preferably, in the step 7, the drying treatment includes infrared drying and hot air drying.
Preferably, in the step 8, the laser thickness gauge is used for monitoring and feeding back and adjusting the production parameters in real time, so as to ensure the thickness of the product.
Preferably, in the step 9, the surface of the synthetic leather is subjected to a specific functional coating treatment according to the requirement.
(III) beneficial effects
Compared with the prior art, the invention provides a manufacturing method of the low-carbon environment-friendly recyclable space synthetic leather, which has the following beneficial effects:
The manufacturing method of the low-carbon environment-friendly recyclable space synthetic leather effectively simplifies the manufacturing process, reduces the production steps and improves the production efficiency;
The energy consumption link in the manufacturing process is optimized, the whole energy consumption is reduced, and the resources are saved;
recycling and reutilization of production leftover materials and waste materials are realized;
the manufactured space synthetic leather has excellent physical properties and aesthetic properties, and can meet various application requirements;
The DMFA is cleaned by water washing, so that the pollution influence on operators and subsequent use of products is reduced.
Detailed Description
The technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
A manufacturing method of low-carbon environment-friendly recoverable space synthetic leather comprises the following steps:
Step 1, recycling leftover materials: and (3) intensively recycling the synthetic leather scraps and waste synthetic leather materials generated in the production process. The waste materials of an external mechanism can be accepted, so that the recovery range is enlarged, and the raw material source is increased;
Step 2, cleaning and granulating the recovered material: and thoroughly cleaning the recovered leftover materials and waste materials, and removing stains and impurities on the surface. The ultrasonic cleaning technology can be adopted, so that the cleaning effect is further improved, and no pollution is ensured in the granulating process. The cleaned material is subjected to air drying or drying treatment and then is sent into a granulator for granulation treatment, so that uniform and fine regenerated particles are formed;
step 3, dissolving reclaimed materials:
feeding the granulated regenerated particles into a double-screw extruder, heating and melting by an accurate temperature control system, plasticizing to form continuous and stable fluid, and optionally adding an antioxidant and an ultraviolet absorber to enhance the durability of the material in subsequent use;
Step 4, manufacturing non-woven fabric base cloth: and cooling the melted material through an extrusion molding process to form the non-woven fabric base cloth with certain strength and elasticity. The thickness and strength of the base cloth can be controlled by adjusting parameters of the extruder and the die head so as to meet the requirements of different purposes;
Step 5, treating the impregnating solution: the components of the prepared environment-friendly impregnating solution can comprise aqueous polyurethane, nano-filler and plasticizer, so that the performance of the base fabric is improved. The obtained nonwoven fabric base fabric was fed into an impregnation tank, and impregnated with the impregnating solution a plurality of times, whereby the inside of the nonwoven fabric was sufficiently impregnated with the impregnating solution. The soaked base cloth is extruded by a roller, and the liquid carrying rate is controlled to be 70-80%;
Step 6, solidification treatment: feeding the impregnated non-woven fabric base cloth into a solidification tank, and uniformly solidifying the impregnating solution in the base cloth by accurately controlling parameters such as temperature, flow rate and the like to form a firm solidification layer;
Step 7, washing and drying: and (3) washing the coagulated non-woven fabric base fabric for a plurality of times to ensure that excessive coagulating liquid and residual organic components are thoroughly removed, for example, DMFA is cleaned. The water washing equipment can be provided with a multi-stage filtration system, so that water resources are recycled, and the water consumption is further reduced. After washing, drying treatment is carried out by an advanced drying device, and an infrared drying or hot air drying mode can be adopted to ensure that the water content of the material is controlled within a specified range;
step 8, thickness control:
The thickness of the synthetic leather is strictly controlled in the production process, and the thickness of the product is ensured to be between 1.4mm and 1.55mm so as to meet the standards of different application scenes on the thickness of the material. Monitoring and feeding back and adjusting production parameters in real time by using a laser thickness gauge, so as to ensure the consistency and the precision of products;
step 9, surface treatment and post-treatment: the surface of the synthetic leather is treated, such as embossing, hot pressing, waterproof coating and the like, so that the beauty and the functionality of the product are improved. Specific functional coating treatment such as antibiosis, dust prevention, static prevention and the like can be carried out according to the requirements of customers;
Step 10, rolling and slitting: the synthetic leather after the treatment is rolled and packaged, and is accurately cut according to the requirements of customers, so that products with different sizes and shapes are provided, and the synthetic leather is suitable for various application scenes.
Example 1: in the implementation process, the recycled leftover materials are strictly cleaned and granulated, so that the uniformity of particles is ensured. The improved screw extruder is utilized to melt and granulate, the non-woven fabric base cloth is extruded and molded, the impregnating solution adopts a low-toxicity aqueous polyurethane formula, the liquid ratio of the base cloth is ensured to be about 75% through repeated soaking and extrusion, then the base cloth is solidified in a solidification tank by using green and environment-friendly solidification liquid, and the base cloth is thoroughly dried after washing by water, so that the thickness of the finished synthetic leather is ensured to be about 1.5mm, and the base cloth has good flexibility and waterproof performance.
Example 2: in the embodiment, the process is further optimized, and the cleaning efficiency is improved and the environment is protected by adding the biodegradable detergent in the cleaning process of recycling the leftover materials. In the granulating process, an antioxidant and a light stabilizer are added, so that the material is ensured to be stable in performance in long-term use. Nano particles are added into the impregnating solution, so that the strength and the wear resistance of the synthetic leather are further improved. In the water washing link, a multistage countercurrent washing technology is adopted, so that the washing effect is improved under the condition of reducing water consumption. The surface of the final synthetic leather is treated with the easy-cleaning coating, so that the synthetic leather not only has excellent mechanical properties, but also has the characteristics of antifouling property and easy cleaning.
In order to describe the possible application scenarios, technical principles, practical embodiments, and the like of the present application in detail, the following description is made with reference to the specific embodiments. The embodiments described herein are only for more clearly illustrating the technical aspects of the present application, and thus are only exemplary and not intended to limit the scope of the present application.
Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the application. The appearances of the phrase "in various places in the specification are not necessarily all referring to the same embodiment, nor are they particularly limited to independence or relevance from other embodiments. In principle, in the present application, as long as there is no technical contradiction or conflict, the technical features mentioned in each embodiment may be combined in any manner to form a corresponding implementable technical solution.
Unless defined otherwise, technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application pertains; the use of related terms herein is for the purpose of describing particular embodiments only and is not intended to limit the application.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.