CN105365310A - 车用pe胶粉复合无纺布材料及其制备方法 - Google Patents
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Abstract
本发明公开了一种车用PE胶粉复合无纺布材料及其制备方法,属于无纺布加工技术领域。所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维60~65份,低熔点纤维28~32份,丙纶纤维8~15份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为30~80g。本发明还公开了该车用PE胶粉复合无纺布材料的制备方法,包括无纺布预热处理、上粉、热烘、复合、冷却和裁剪步骤。本发明的PE胶粉复合无纺布材料具有防止纤维的蜂窝结构和外观被破坏,提高生产效率、增强材料的吸音效果以及环保的优点。
Description
技术领域
本发明涉及无纺布加工技术领域,尤其涉及一种车用PE胶粉复合无纺布材料及其制备方法。
背景技术
PE胶粉复合无纺材料主要用于车的侧饰件、后备箱、车内地毯等场合,现有技术的工艺是用无纺针刺生产工艺将底布和面布复合,具有以下不足:1)无纺针刺复合会造成产品外观针孔增加,对外观和结构有破坏;2)针刺的断针在厚度为2mm以上产品中难以彻底发现、清除;3)针刺孔会造成材料吸音能力降低;4)生产效率低,大约5m/min。
另外,国家知识产权局于2012年12月19日公开了一件公告号为CN102825895A,名称为“一种汽车顶棚的一次干法成型的生产工艺”的发明专利,该专利公开的工艺通过采用无纺布PET、玻纤GF、PE胶粉或PP胶膜以及PU板材形成三明治结构的复合材料,叠加成的复合材料送入加热炉加热至270~350℃,使PE胶粉或PP胶膜融化并使各种组成材料软化,然后将材料送入水冷的温度为15~25℃的模具中,使用7~12MPa的压力,叠加的材料在模具中重新固化并成型,同时将面饰利用融化的PE胶粉或PP胶膜与材料粘结在一起,产品成型。该专利虽然采用的是无纺布复合技术,但其成分中的额玻纤GF在制备过程中,对操作人员的身体有害,且制的的产品,仍存在一定的安全隐患,另外,该专利的应用范围不够广,不能满足更多消费者的不同需求。
发明内容
本发明的旨在解决现有技术中汽车内装饰材料吸音效果不好、外观不够美观以及现有的工艺造成的断针以及效率低下的问题,提出一种车用PE胶粉复合无纺布材料,具有保护外观美观性,吸音性能强,生产效率高,产品等级高,环保的优点。
为了实现上述发明目的,本发明的技术方案如下:
车用PE胶粉复合无纺布材料,其特征在于:所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维60~65份,低熔点纤维28~32份,丙纶纤维8~15份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为30~80g。
为了更好地实现本发明,所述涤纶短纤维的规格为12d*64mm~4d*38mm。
所述低熔点纤维的熔点为140~150℃。
所述丙纶纤维的规格为7d*51mm~7d*75mm。
所述面层的涤纶纤维的规格为4d*51mm~13d*65mm。
本发明还提供了所述PE胶粉复合无纺布材料的制备方法,其特征在于:包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为100~110℃,烘房温度设为150~175℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量为30~80g/㎡;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为150~160℃,热烘时间为30~50s,使PE胶粉充分融化并保持不流动的状态;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为0.5~1.5MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
为了更好地实现本发明,所述PE胶粉的细度为40~200目。
步骤A中,热烘后的水分含量控制在0.03%内。
步骤A中,所述热烘的时间为8~12s。
步骤E中,所述复合后的无纺布材料的厚度为1~10mm。
步骤E中,冷却的方式为风冷,进风量为2100~4500m3/h,成本低,冷却效率高。
本发明的有益效果:
(1)本发明通过选用PE胶粉将无纺布材料进行复合,与现有技术中的材料相比,可防止纤维的蜂窝结构和外观被破坏,通过特定的无纺布原料配比设计,以及制备方法的配合改进,整体上将生产效率提高至8m/min,提高企业经济效益;本发明的制备方法与覆膜工艺相比,PE材料用量降低50~100g/㎡,同时可避免针刺复合工艺断针的问题。
另外,由于PE胶粉具有良好的热熔粘合、延展、柔软和无挥发物等特性,有效保持了无纺布材料自有的柔软、牵伸、耐折叠性能;与PE颗粒覆膜技术相比,PE胶粉的重量更轻,PE胶粉能更充分地填充在纤维间隙内,粘合效果更好同时增强复合材料的吸音效果,原料本身无毒,生产过程以及制得的产品安全、环保。
(2)本发明通过对制备无纺布的纤维规格的进行进一步优选,提高产品的可纺性,并优化底层无纺布纤维组成结构,提高产品的综合性能。
(3)本发明PE胶粉的细度为40~200目,该细度范围内的PE胶粉既可满足一定的细度,从而缩短融化时间,又不会导致制备PE胶粉的成本过高。
(4)本发明的步骤A热烘的作用是使无纺布材料收缩整形,并有效去除水分,热烘后的水分含量控制为0.03%以内,可进一步保证洒粉粘合效果和无纺布材料的收缩值的稳定。
说明书附图
图1为本发明实施例6的吸音检测结果图。
具体实施方式
实施例1
车用PE胶粉复合无纺布材料,所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维60份,低熔点纤维30份,丙纶纤维10份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为30。
实施例2
车用PE胶粉复合无纺布材料,所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维65份,低熔点纤维28份,丙纶纤维12份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为30g。
本实施例的车用PE胶粉复合无纺布材料的制备方法,包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为100℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量为30g/m2;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为150℃,热烘时间为50s;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为0.5MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
实施例3
车用PE胶粉复合无纺布材料,所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维62份,低熔点纤维32份,丙纶纤维8份;所述面层的无纺布由100%涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为80g。
本实施例的车用PE胶粉复合无纺布材料的制备方法,包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为110℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量80g/m2;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为160℃,热烘时间为30s;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为1MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
本实施例中,PE胶粉的细度为200目。
本实施例的涤纶短纤维的规格为12d*64mm~4d*38mm;所述低熔点纤维的熔点为150℃;所述丙纶纤维的规格为7d*51mm~7d*75mm;所述面层的涤纶纤维的规格为4d*51mm~13d*65mm。
实施例4
车用PE胶粉复合无纺布材料,所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维60份,低熔点纤维28份,丙纶纤维15份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为50g。
本实施例的车用PE胶粉复合无纺布材料的制备方法,包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为108℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量50g/m2;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为156℃,热烘时间为40s;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为1.5MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
本实施例中,PE胶粉的细度为100目;步骤A中,热烘在天然气烘房中进行,热烘的时间为50s,热烘后的水分含量控制在0.03%内。
本实施例的涤纶短纤维的规格为12d*64mm;所述低熔点纤维的熔点为140℃;所述丙纶纤维的规格为7d*75mm;所述面层的涤纶纤维的规格为13d*65mm。
实施例5
车用PE胶粉复合无纺布材料,所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维63份,低熔点纤维29份,丙纶纤维8份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为60g。
本实施例的车用PE胶粉复合无纺布材料的制备方法,包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为105℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量60g/m2;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为156℃,热烘时间为45s;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为0.8MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
本实施例的涤纶短纤维的规格为10d*50mm;所述低熔点纤维的熔点为145℃;所述丙纶纤维的规格为7d*54mm;所述面层的涤纶纤维的规格为8d*55mm。
本实施例中,PE胶粉的细度为40目;步骤A中,热烘在烘房中进行,热烘的时间为12s,热烘后的水分含量控制在0.03%内;步骤E中,冷却的方式为风冷,进风量为2100m3/h。
实施例6
车用PE胶粉复合无纺布材料,所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维63份,低熔点纤维30份,丙纶纤维12份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为70g。
本实施例的车用PE胶粉复合无纺布材料的制备方法,包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为110℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量70g/m2;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为155℃,热烘时间为45s;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为1.2MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
本实施例的涤纶短纤维的规格为4d*38mm;所述低熔点纤维的熔点为148℃;所述丙纶纤维的规格为7d*51mm;所述面层的涤纶纤维的规格为4d*51mm。
本实施例中,PE胶粉的细度为80目;步骤A中,热烘在烘房中进行,热烘的时间为10s,热烘后的水分含量控制在0.03%内;步骤E中,冷却的方式为风冷,进风量为2100~4500m3/h。
本实施例制得的无纺布用于车内地毯,厚度为5mm,对其吸音性能进行了检测,其中横坐标为频率,纵坐标为吸声系数,测试值和标准值的线型图如图1所示。
以上所述,仅是本发明的较佳实施例,并非对本发明做任何形式上的限制,凡是依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化,均落入本发明的保护范围之内。
Claims (10)
1.车用PE胶粉复合无纺布材料,其特征在于:所述无纺布包括底层和面层,所述底层的无纺布包括以下按重量份计的原料:涤纶短纤维60~65份,低熔点纤维28~32份,丙纶纤维8~15份;所述面层的无纺布由涤纶纤维制成;每㎡所述底层无纺布使用的PE胶粉的量为30~80g。
2.如权利要求1所述的车用PE胶粉复合无纺布材料,其特征在于:所述涤纶短纤维的规格为12d*64mm~4d*38mm;所述面层的涤纶纤维的规格为4d*51mm~13d*65mm。
3.如权利要求1所述的车用PE胶粉复合无纺布材料,其特征在于:所述低熔点纤维的熔点为140~150℃。
4.如权利要求1所述的车用PE胶粉复合无纺布材料,其特征在于:所述丙纶纤维的规格为7d*51mm~7d*75mm。
5.如权利要求1~4任一项所述的车用PE胶粉复合无纺布材料的制备方法,其特征在于:包括以下步骤:
A.无纺布预热处理
将放卷的底层无纺布置于烘房中进行热烘,热烘温度为100~110℃;
B.上粉
向步骤A预热处理好的底层无纺布洒上PE胶粉,洒粉量为30~80g/m2;
C.热烘
将洒有PE胶粉的底层无纺布送至烘房进行热烘,热烘温度为150~160℃,热烘时间为30~50s;
D.复合
将面层无纺布与紧靠烘房出口热烘后的底层无纺布进行复合,复合方式为压辊紧压,压辊的压力为0.5~1.5MPa;
E.冷却、裁剪
将复合后的无纺布材料进行冷却至常温,进行裁剪即可。
6.如权利要求5所述的车用PE胶粉复合无纺布材料的制备方法,其特征在于:所述PE胶粉的细度为40~200目。
7.如权利要求5所述的车用PE胶粉复合无纺布材料的制备方法,其特征在于:步骤A中,热烘后的水分含量控制在0.03%内。
8.如权利要求5或7所述的车用PE胶粉复合无纺布材料的制备方法,其特征在于:步骤A中,所述热烘的时间为8~12s。
9.如权利要求5所述的车用PE胶粉复合无纺布材料的制备方法,其特征在于:步骤E中,所述复合后的无纺布材料的厚度为1~10mm。
10.如权利要求5所述的车用PE胶粉复合无纺布材料的制备方法,其特征在于:步骤E中,冷却的方式为风冷,进风量为2100~4500m3/h。
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