CN106120158A - 复合擦拭材料生产装置及其工艺 - Google Patents
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Abstract
本发明公开了一种复合擦拭材料生产装置及其工艺，属于非织造材料制备领域。该生产装置制作工艺将热粘合性纤维经疏理机或气流成型装置处理后形成热粘合性纤维层，经加热系统对热粘合性纤维层进行热粘合加固，然后在加固后的热粘合性纤维层上方同步叠加覆盖湿法成型得到的湿纤维层，从而形成复合纤维层；再通过水刺作用和真空抽吸将复合纤维层中的湿纤维层中的纤维植入加固后的热粘合性纤维层中间，最后经过脱水得到复合擦拭材料。本发明使得两种不同性质的纤维原料及成网工艺，在同一生产线上连续完成，既解决了复合擦拭材料的品质问题，也解决了不能连续生产的浪费和效率问题，拓宽了产品的克重范围，为复合擦拭材料的应用及推广起到积极作用。
Description
技术领域
本发明属于非织造材料制备领域，尤其涉及一种复合擦拭材料生产装置及其工艺。
背景技术
现有的木浆复合擦拭材料装置及工艺技术，基本上采用以下两种技术：
第一种方法：疏理成网经水刺制成基材后再加木浆纸复合，经水刺设备将木浆纤维与基材纤维相互缠结，烘干后制成木浆复合擦拭材料。
优点：基材经水刺加固后直接与木浆纸复合，减少了基材烘干、成卷的工序，提高了生产效率，节约了能源；木浆纸是生产好的，符合产品生产要求的，在生产过程中，只要改变基材的定量和宽度，生产出来的产品即可符合产品要求，生产过程控制方便。
缺点：由于基材是疏理纤维层经水刺加固后成为基材，其克重不能太小，一般要求大于25g/m2，加上纤维层纵、横拉力比较差，伸大率大，最终产品的克重不能小于40g/m2，而且松厚度比较差，影响成品的使用效果。
第二种方法：将制成的基材卷材，经放卷装置，放入贴合设备与经湿法成网形成的木浆纤维贴合，再经水刺设备，将木浆纤维与基材纤维相互缠结，经烘干后制成木浆复合擦拭材料。
优点：基材是经加工后制成的卷筒，特别是用热粘合加工后的基材，其重量可以低于25g/m2，纵横向强力和伸长率都大大优于第一种方法中的基材；加上木浆纸改为用湿法成型的方法直接制成湿纤维层通过水刺与基材复合，克服了成品拉力差，伸长率大的缺点，提高了产品使用性能。
缺点：基材是成卷后放入复合机与湿纤维层复合，卷与卷之间需要转换，连续性生产比较麻烦，而且切换过程造成的原料浪费比较大。另外，由于基材是先做的，基本克重已经确定，在生产中产品的比例在最终克重确定的时候，其比例就无法随机即时调整，给产品的变化及工艺的优化带来困难。而且由于卷材要为了保持其强度性能，因此其克重不能过低，至少要达到18g/m2，无法满足低克重擦拭材料的要求。
发明内容
本发明的目的在于解决现有技术中生产的复合擦拭材料松厚度差，克重偏高，纵横向拉力差大，伸长率大等问题的问题，并提供一种复合擦拭材料生产装置，以实现二种不同的纤维在线制备纤维层，可以随时调整二种纤维的配比，提高成品品质。
本发明具体是通过以下技术方案实现的：
复合擦拭材料生产装置，包括纤维输送网、热粘合输送网、湿法输送网和水刺复合网；所述的纤维输送网、热粘合输送网和水刺复合网依次相接，实现连续输送；所述的纤维输送网用于输送干法成网设备输出的热粘合性纤维层；所述的湿法输送网用于输送湿法成型得到的湿纤维层；所述的热粘合输送网的承载面前段设有用于对热粘合性纤维层进行热粘合加固的加热系统，承载面后段上方与湿法输送网的一段并行相对设置；热粘合输送网的承载面后段上还设有用于将湿纤维层转移至热粘合性纤维层的上面的纤维转移装置；所述的水刺复合网的承载面前段设置水刺装置和真空吸水箱，水刺复合网的承载面后段下方设有脱水机构。
本发明装置的主要设计要点是将干法成网设备与湿法成型设备进行有机组合，通过纤维输送网将干法成网设备输出的热粘合性纤维层直接输送至热粘合输送网，进行热粘合加固后与湿法成型器输出的湿纤维层直接叠加复合，进行水刺、脱水作用，形成最终成品。该设备在生产过程中，能够便捷地对复合纤维层中两层纤维进行调整，快速优化、调整两者的最佳工艺参数。而且由于热粘合性纤维层无需先制成卷材，因此热粘合性纤维层的克重可以做到15g/m2，最大程度的增加克重调整范围。相对于背景技术中所述的两种方法，能够大大降低最终成品的克重，同时提高生产效率，减少浪费。
作为优选，所述的干法成网设备为疏理机或气流成型装置，成网方式可以是直铺、交铺、气流等。
本发明中，输送网、热粘合输送网、湿法输送网和水刺复合网具体材质、型号可以根据其需要输送的材料及所处的工况环境进行选择，比如：纤维输送网可以用输送皮帘，也可以用40—100目尼龙网。热粘合输送网，由于要经过加热系统，因此需要由耐高温材料织成的网，可以用聚四氟网，钢丝、铜丝织成的网。湿法输送网可以是60—120目的尼龙网，也可以是70—120目的铜、钢丝网；水刺复合网可以选用40～120目的尼龙网，或选用60～100目的钢丝、铜丝网。
作为优选，所述的加热系统为单层烘房、多层烘房、单筒式烘房或多筒式烘房。
作为优选，所述的湿法输送网前端与外部湿法成型器的湿纤维层输出端相连。
作为优选，所述的纤维转移装置为压缩空气喷嘴、高压水针或真空吸移装置，可设置一种或多种。
作为优选，所述的水刺装置采用1-10道水刺；真空吸水箱采用1-15道单缝或多缝吸水箱。
本发明的另一目的在于提供一种复合擦拭材料生产工艺，所采用的具体技术方案为：将热粘合性纤维经疏理机或气流成型装置等干法成网设备处理后形成热粘合性纤维层，经加热系统对热粘合性纤维层进行热粘合加固，然后在加固后的热粘合性纤维层上方同步叠加覆盖湿法成型得到的湿纤维层，从而形成复合纤维层；再通过水刺作用和真空抽吸将复合纤维层中的湿纤维层中的纤维植入加固后的热粘合性纤维层中间，最后经过脱水得到复合擦拭材料。该方法可基于前述任一方式下的复合擦拭材料生产装置实现，也可以另行设计其他装置。
作为优选，所述的热粘合性纤维为长度20～50mm，细度1～5dtex的可疏理纤维，优选为ES、PP、PLA纤维。
作为优选，所述的湿纤维层的制造方法为：用水将2-5mm的天然植物纤维或3～10mm化学纤维中的一种或多种混合稀释成浓度为0.03～0.1％的水溶液，经湿法成型器成型脱水后，形成10～100g/m2的湿纤维层。
作为优选，水刺作用采用1-10道压力为1-10Mpa的高压水针。
本发明将热粘合纤维层和湿法成型纤维层的制作结合起来，使得两种不同性质的纤维原料及成网工艺，在同一生产线上连续完成，既解决了复合擦拭材料的品质提高问题，也解决了以前不能连续生产的浪费和效率问题，拓宽了产品的克重范围，提高了产品的强度以及其他方面的质量，降低了生产成本，为复合擦拭材料的应用及推广起到积极作用。
附图说明
图1为复合擦拭材料的生产装置结构示意图；
图2为图1中Ι部位放大图。
图中：热粘合性纤维层1、纤维输送网2、热粘合输送网3、加热系统4、加固后的热粘合性纤维层5、湿纤维层6、纤维转移装置7、湿法输送网8、复合纤维层9、水刺装置10、真空吸水箱11、水刺复合网12、脱水机构13、复合擦拭材料14。
具体实施方式
下面结合附图和实施例对本发明做进一步阐述，以便本领域技术人员更好地理解本发明的实质。各技术特征在没有冲突的情况下,均可进行相互组合。
如图1所示，为一种复合擦拭材料生产装置。该装置的结构中，主线为纤维输送网2、热粘合输送网3、湿法输送网8和水刺复合网12。这四条网面均各自通过若干个辊轴形成循环的输送体系，其中纤维输送网2、热粘合输送网3和水刺复合网12的输送面依次相接，实现纤维层从输送网2前端到水刺复合网12末端的连续输送。而湿法输送网8则位于热粘合输送网3的承载面后段上方，其中一段行程通过两个辊轴的限位，保持与湿法输送网8相互平行前进，两者之间间隔较小。
纤维输送网2的前端可以连接现有的干法成网设备，如疏理机或气流成型装置，热粘合性纤维经干法成网设备开松→气流、疏理→成网后，形成热粘合性纤维层1，由纤维输送网2输送至热粘合输送网3。热粘合输送网3的承载面前段设有单层烘房、多层烘房、单筒式烘房或多筒式烘房作为加热系统4，热源可以用导热油、电热板、远红外等。加热系统4对热粘合性纤维层进行热粘合加固，得到加固后的热粘合性纤维层5。而湿法输送网8与外部斜网、长网、园网等湿法成型器的湿纤维层输出端相连，将湿纤维层6输送至加固后的热粘合性纤维层5上方，通过热粘合输送网3的承载面后段上设置还有纤维转移装置7，将湿纤维层6从湿法输送网8上剥离，叠合到加固后的热粘合性纤维层5上方，得到复合纤维层9。纤维转移装置7可以选用1～3Mpa高压水针，也可以选用0.3～0.8Mpa的高压气流，也可以选-0.1～-0.3Mpa的真空抽吸箱。而在水刺复合网12的承载面前段一定位置处，上方设置水刺装置10，下方设置真空吸水箱11，对复合纤维层9进行水刺复合。水刺装置10采用1-10道水刺，水刺可以选择φ0.08～0.14mm孔径的水刺针板；真空吸水箱11采用1-15道单缝或多缝吸水箱，缝宽可以选择6～12mm。水刺复合网12的承载面后段下方设有脱水机构13，经过脱水后最终得到复合擦拭材料14。
利用上述装置生产负荷擦拭材料的一种具体方法为：将纤维长度为20～50mm，细度为1～4dtex的ES、PP、PLA等具有热粘合性的纤维，经开松→气流、疏理→成网，制成一定克重的热粘合性纤维层1，该纤维层克重一般为15～60g/㎡，由纤维输送网2送到热粘合输送网3上面，由热粘合输送网3带着纤维层进入加热系统4，系统内温度控制在80—250℃，根据纤维的克重及生产车速决定温度的高低，加热系统4可以选用导热油、电热板、远红外等加热方式；经热粘合后的纤维层在出加热系统后，在其上面有一套湿法成型机构，将2～5mm的木浆、棉浆、竹浆、麻浆等天然植物纤维原料，或3～10mm的粘胶、丙纶、涤纶等化学纤维原料，用水稀释至0.03～0.1％的浓度，经湿法成型器成型，湿法成型网脱水后，形成湿纤维层6，其克重为10～60g/m2(烘干后重)，经湿法输送网8输送后，由纤维转移装置7将湿法输送网上的湿纤维层6转移到加固后的热粘合性纤维层5上面；湿纤维层6和加固后的热粘合性纤维层5叠合后，上层为湿纤维层6，克重为10～60g/m2，下层为加固后的热粘合性纤维层5，克重为15～60g/m2，叠合后克重为25～120g/m2，再转移至水刺复合网上，经1—10道压力为1～10Mpa水针作用，将上层的湿纤维短纤层中的纤维植入下层热粘合纤维层中，同时用真空度为-0.1～0.3Mpa的1—15道真空箱的抽吸，将二种纤维互相缠结在一起；再经过真空度为-0.1～-0.5Mpa的脱水箱脱水后，烘干、卷取、分切、打包，制成不同规格及用途的复合擦拭材料。
上述方法在整个过程中，可以根据最终得到的成品性状，实时改变两层纤维的各种工序参数和原料参数，对成品性状进行调整。而且，其能够大大降低成品可制备的最小克重，具有其他装置无法比拟的优势。下面给出几个基于前述装置和该方法的生产工艺具体实施例，以便更好地理解本发明的实质。
实施例1
选用1.5D×38mm的ES纤维，经开松后输送到疏理机疏理成20g/m2的纤维层，经纤维输送网将纤维层送到钢丝热粘合输送网上，进入单层烘房，热源采用导热油加热，温度控制在180℃，速度为60m/min。制成粘合纤维层。
选用针叶木浆纤维，将纤维分散后，稀释成0.05％的水溶液，进入斜网成型器，经脱水成型的湿纤维层40g/m2，由湿法80目的尼龙成型网，速度为60m/min，带至40目钢丝粘合输送网上方，与粘合纤维层贴合，经由压缩空气为0.5Mpa的气流作用，将湿纤维层转移至粘合纤维层上方，形成复合纤维层，克重为60g/m2，再转移到100目的尼龙水刺复合网上，经二道压力为3Mpa，二道压力为4Mpa，三道压力为5Mpa的水针作用及真空度为-0.1Mpa的13道真空吸水箱后，使上层的短纤维层中的纤维植入下层的热粘合纤维层中，使得两种纤维相互缠结，形成具有一定强度、松厚度好的纤维层，再进一步用-0.3Mpa真空箱脱水、烘干、卷取后制成克重为56～58g/m2的复合擦拭材料。根据用户的要求分切成所需的规格尺寸，供应市场。
实施例2
选用2D×30mm的PLA纤维，经开松后输送到疏理机疏理成15g/m2的纤维层，经纤维输送网将纤维层送到60目四氟热粘合输送网上，进入二层烘房，热源采用导热油加热，温度控制在200℃，速度为80m/min。制成粘合纤维层。
选用3mm棉浆纤维，将纤维分散后，稀释成0.03％的水溶液，进入斜网成型器，经脱水成型的湿纤维层10g/m2，由湿法100目的铜丝长网成型网，速度为80m/min，带至60目四氟热粘合输送网上方，与粘合纤维层贴合，经由水刺压力为1Mpa的水力作用，将湿纤维层转移至粘合纤维层上方，形成复合纤维层，克重为25g/m2，再转移到120目的钢丝网上，经一道压力为2Mpa，二道压力为3Mpa，二道压力为4Mpa的水针作用及真空度为-0.2Mpa8道的真空吸水箱后，使上层的短纤维层中的纤维植入下层的热粘合纤维层中，使得两种纤维相互缠结，形成具有一定强度、松厚度好的纤维层，再进一步用-0.3Mpa真空箱脱水、烘干、卷取后制成克重为23～24g/m2的复合擦拭材料。根据用户的要求分切成所需的规格尺寸，供应市场。
实施例3
选用1D×28mm的PP纤维，经开松后输送到疏理机疏理成40g/m2的纤维层，经纤维输送网将纤维层送到热粘合输送网上，进入单层烘房，热源采用导热油加热，温度控制在240℃，速度为40m/min。制成粘合纤维层。
选用1.0D×5mm的粘胶纤维，将纤维分散后，稀释成0.1％的水溶液，进入圆网成型器，经脱水成型的湿纤维层40g/m2，由湿法80目的铜丝园网成型网，速度为30m/min，带至60目铜网粘合输送网上方，与粘合纤维层贴合，经由真空度为0.3Mpa的作用，将湿纤维层转移至粘合纤维层上方，形成复合纤维层，克重为80g/m2，再转移到80目的铜丝网上，经二道压力为3Mpa，二道压力为4Mpa，二道压力为5Mpa，二道压力为6Mpa的水针作用及10道真空度为-0.2Mpa的真空吸水箱后，使上层的短纤维层中的纤维植入下层的热粘合纤维层中，使得两种纤维相互缠结，形成具有一定强度、松厚度好的纤维层，再进一步用-0.5Mpa真空箱脱水、烘干、卷取后制成克重为75～78g/m2的复合擦拭材料。根据用户的要求分切成所需的规格尺寸，供应市场。
由此可见，本领域的普通技术人员，在不脱离本发明的精神和范围的情况下，还可以做出各种变化和变型。因此凡采取等同替换或等效变换的方式所获得的技术方案，均落在本发明的保护范围内。
Claims (10)
1.一种复合擦拭材料生产装置，其特征在于，包括纤维输送网、热粘合输送网、湿法输送网和水刺复合网；所述的纤维输送网、热粘合输送网和水刺复合网依次相接，实现连续输送；所述的纤维输送网用于输送干法成网设备输出的热粘合性纤维层；所述的湿法输送网用于输送湿法成型得到的湿纤维层；所述的热粘合输送网的承载面前段设有用于对热粘合性纤维层进行热粘合加固的加热系统，承载面后段上方与湿法输送网的一段并行相对设置；热粘合输送网的承载面后段上还设有用于将湿纤维层转移至热粘合性纤维层的上面的纤维转移装置；所述的水刺复合网的承载面前段设置水刺装置和真空吸水箱，水刺复合网的承载面后段下方设有脱水机构。
2.如权利要求1所述的复合擦拭材料生产装置，其特征在于，所述的干法成网设备为疏理机或气流成型装置。
3.如权利要求1所述的复合擦拭材料生产装置，其特征在于，所述的加热系统为单层烘房、多层烘房、单筒式烘房或多筒式烘房。
4.如权利要求1所述的复合擦拭材料生产装置，其特征在于，所述的湿法输送网前端与外部湿法成型器的湿纤维层输出端相连。
5.如权利要求1所述的复合擦拭材料生产装置，其特征在于，所述的纤维转移装置为压缩空气喷嘴、高压水针或真空吸移装置。
6.如权利要求1所述的复合擦拭材料生产装置，其特征在于，所述的水刺装置采用1-10道水刺；真空吸水箱采用1-15道单缝或多缝吸水箱。
7.一种复合擦拭材料生产工艺，其特征在于，将热粘合性纤维经干法成网设备处理后形成热粘合性纤维层，经加热系统对热粘合性纤维层进行热粘合加固，然后在加固后的热粘合性纤维层上方同步叠加覆盖湿法成型得到的湿纤维层，从而形成复合纤维层；再通过水刺作用和真空抽吸将复合纤维层中的湿纤维层中的纤维植入加固后的热粘合性纤维层中间，最后经过脱水得到复合擦拭材料。
8.如权利要求7所述的复合擦拭材料生产工艺，其特征在于，所述的热粘合性纤维为长度20～50mm，细度1～5dtex的可疏理纤维，优选为ES、PP、PLA纤维。
9.如权利要求7所述的复合擦拭材料生产工艺，其特征在于，所述的湿纤维层的制造方法为：用水将2-5mm的天然植物纤维或3～10mm化学纤维中的一种或多种混合稀释成浓度为0.03～0.1％的水溶液，经湿法成型器成型脱水后，形成10～100g/m2的湿纤维层。
10.如权利要求7所述的复合擦拭材料生产工艺，其特征在于，水刺作用采用1-10道压力为1-10Mpa的高压水针。
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| CN205934323U (zh) * | 2016-08-18 | 2017-02-08 | 杭州湿法无纺布设备有限公司 | 一种复合擦拭材料生产装置 |
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| CN106906569A (zh) * | 2017-02-07 | 2017-06-30 | 常州维盛无纺科技有限公司 | 天然纤维与化学纤维多层梳理复合无纺布基材的制备方法 |
| CN108625041A (zh) * | 2018-06-08 | 2018-10-09 | 常熟市森拓非织造布有限公司 | 一种抗菌型水刺非织造材料 |
| CN110154491A (zh) * | 2019-06-04 | 2019-08-23 | 杭州千千达科技有限公司 | 一次性复合毛巾材料的生产装置及其工艺 |
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