CN106183153B - 一种天然纤维毡布及其生产方法 - Google Patents
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Abstract
本发明涉及一种天然纤维毡布及其生产方法,它是天然纤维网用泡沫粘合剂粘结、挤压、烘干定型而成的膜,在膜表面还涂覆有防水层。由变性淀粉做粘合剂,尿素做起泡剂和水组成泡沫粘合剂,用拒水剂果蜡乳化液形成防水层。采用梳理机一次梳理形成天然纤维网,采用喷涂泡沫粘合剂粘结天然纤维网成膜,其烘干定型所消耗能源大大的降低;采用天然纤维、变性淀粉和果蜡乳化液作为生产原辅料,生产的产品可完全降解,防止土壤板结,整个生产过程环保,无污染;产品具有超薄、强度大的特点,有良好的保温、保湿、防水透气性能,一定程度防治病虫害。可广泛应用于农业、经济作物生产,花草树木遮阳、保湿,包装材料等领域,具有可观的经济和社会效益。
Description
技术领域
本发明涉及一种天然纤维毡布及其生产方法。
背景技术
中国作为农业大国,农作物产量随着农业科技的发展与推广正不断提高,地膜具有保温、保湿、促进农作物生长发育和增加产量的功效,所以地膜的应用作为一种现代农业技术对农作物增产、农民增收,促进农业生产的发展作用巨大。但由于现在普遍使用成本低廉的塑料地膜,而塑料地膜不可降解,带来了“白色污染”和使土壤板结,通透性变差,地力下降等问题。为此,市场开发了可部分或完全降解的多种地膜,如淀粉添加型可降解农用地膜、光降解农用地膜、植物纤维地膜等。而目前开发的淀粉添加型可降解地膜中,淀粉的质量分数只有20%~30%左右,其降解至多是其中淀粉成分的降解,而大部分残留的聚烯烃膜仍以一种多孔的结构形态存在,均不能完全消除农田中的“土壤板结、地力下降”问题。植物纤维地膜主要是纸地膜,虽然纸地膜在土壤中可被完全分解、无污染,是环保型地膜。但其强度低、抗风雨能力差、易破损,铺膜时容易被扯破,不适宜机械铺膜。因此,在实际使用中,铺膜难度大,费时费工,成本较高。发明名称为“植物纤维无纺布及生产方法”的专利(201010262355.x)公开了一种麻地膜及生产方法,其方法是将麻纤维经梳理机成网,再用气流成网机成网;麻纤维网用化学粘合剂浸渍进行化学粘合;用含氟拒水剂进行防水处理;一次性烘燥固结成膜,最后经冷轧机进行轧光整理、成卷。由于纤维气流成网速度较低,只有20~25米/分,在规模化生产过程,影响生产效率,推高成本;同时,化学粘合剂PVA是不能完全降解的,长期和反复使用,在土壤中逐步淤积,对土壤仍然会造成很大的破坏;采用浸渍粘合工艺,在浸渍过程中,麻纤维网含水量较大。烘燥固结需要消耗更多能源,严重影响生产效率和生产成本。因此,其工艺复杂、工序多、设备投资大(台数多)、生产成本高。同时,还不能做到完全降解,达到无污染。
发明内容
本发明的第一个目的是:提供一种天然纤维毡布,该产品采用天然纤维、变性淀粉和果蜡乳化液作为生产原辅料,产品可完全降解,无污染,有利于保护生态环境,防止土壤板结,产品具有超薄、强度大的特点,并有良好的保温、保湿、防水透气性能。
实现本发明第一个目的的技术方案是:一种天然纤维毡布,它是天然纤维网用粘合剂粘结、挤压、烘干定型而成的膜,在膜表面还涂覆有防水层,其特征在于,
所述天然纤维网是用梳理机对天然纤维进行一次梳理成型的纤维网,其天然纤维是亚麻纤维、苎麻纤维、棉花纤维中的一种或几种的组合;
所述粘合剂为泡沫粘合剂,它是由粘合剂、起泡剂和水组成的混合物,在每100重量份的泡沫粘合剂中,粘合剂为8~10重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉,起泡剂为尿素;
所述防水层是用拒水剂果蜡乳化液在天然纤维网用粘合剂粘结、挤压、烘干定型而成的膜表面上喷涂形成的,该果蜡乳化液为CFW型果蜡乳化液;
所述天然纤维毡布的技术特性如下:单位面积重量为30~50g/㎡,厚度为0.20~0.35㎜,抗拉强度为1400~1800N/m,撕破强度为50~90N,顶破强度为100~200N,垂直渗透系数为6.0×10-4~8.0×10-4㎝/s。
上述天然纤维毡布,其所述变性淀粉为氧化交联淀粉;所述CFW型果蜡乳化液是由10wt%~20wt%天然棕榈蜡、2.5wt%~3.0wt%吗啉脂肪酸盐,余量为水组成的。
上述天然纤维毡布,其所述天然纤维是90wt%的亚麻纤维与10 wt %的棉花纤维组合,其中,亚麻纤维细度为1.5~2.5 dtex,长度为17~25mm,棉花纤维细度为1.5dtex~3dtex,长度为15 mm~35mm,或者是20wt%的棉花纤维与80wt%的苎麻纤维组合,其中,棉花纤维细度为1.5dtex~2.5dtex,长度为16mm~35 mm,苎麻纤维细度为3dtex~6dtex,长度为 25 mm~45 mm,或者是100wt%的亚麻短纤维,其细度为0.15~0.25tex,长度为17~25mm。
本发明的第二个目的是:提供一种天然纤维毡布的生产方法,该方法简便,环保,成本低,产品质量稳定。
实现本发明第二个目的的技术方案是:一种上述的天然纤维毡布的生产方法,其特征在于,具体步骤和工艺如下:
①原料纤维的处理
将原料天然纤维开包、混合开松后,除尘、除杂 ,所用天然纤维是亚麻纤维、苎麻纤维、棉花纤维中的一种或几种的组合;
②成网
将步骤①所得天然纤维经梳理机一次梳理后得到成型的天然纤维网 ;
③粘合成膜
将步骤②所得天然纤维网的双面用泡沫粘合剂进行喷涂,喷涂后挤压成膜;
所用泡沫粘合剂是由粘合剂、起泡剂和水,搅拌25分钟~30分钟形成的混合物,在每100重量份的泡沫粘合剂中,粘合剂为8~10重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉,起泡剂为尿素;
④烘干定型
将步骤③所得膜,在烘干温度为145℃~160℃,烘干时间为0.5分钟~1分钟的条件下进行烘干,再在定型温度为150℃~165℃,定型时间为0.5分钟~1分钟的条件下进行定型;
⑤防水处理
在步骤④所得膜的双面用拒水剂果蜡乳化液进行喷涂;
⑥轧光整理、成卷入库
将步骤⑤所得的膜,用冷轧机进行轧光处理后,分切成卷入库即为天然纤维毡布。
上述天然纤维毡布的生产方法,其制得的天然纤维毡布的技术特性如下:单位面积重量为30~50g/㎡,厚度为0.20~0.35㎜,抗拉强度为1400~1800N/m,撕破强度为50~90N,顶破强度为100~200N,垂直渗透系数为6.0×10-4~8.0×10-4㎝/s。
上述天然纤维毡布的生产方法,其所述步骤③的变性淀粉为氧化交联淀粉;所述步骤⑤的果蜡乳化液为CFW型果蜡乳化液,它是由10wt%~20wt%天然棕榈蜡、2.5wt%~3.0wt%吗啉脂肪酸盐,余量为水组成的。
上述天然纤维毡布的生产方法,其所述步骤④的烘干温度为150±2℃,烘干时间为0.8±0.1分钟;定型温度为160±2℃,定型时间为0.7±0.1分钟。
上述天然纤维毡布的生产方法,其所述步骤①的天然纤维是90wt%的亚麻纤维与10wt%的棉花纤维组合,其中,亚麻纤维细度为1.5~2.5 dtex,长度为17~25mm,棉花纤维细度为1.5dtex~3dtex,长度为15 mm~35mm,或者是20wt%的棉花纤维与80wt%的苎麻纤维组合,其中,棉花纤维细度为1.5dtex~2.5dtex,长度为16mm~35 mm,苎麻纤维细度为3dtex~6dtex,长度为 25 mm~45 mm,或者是100wt%的亚麻短纤维,其细度为0.15~0.25tex,长度为17~25mm。
本发明的技术效果是:1、本发明技术方案的天然纤维毡布与现有同类产品相比,其区别在于:①用变性淀粉做粘合剂与起泡剂尿素及水组成的泡沫粘合剂替代了现在通用的合成的高分子粘合剂;②用果蜡乳化液替代通用的含氟拒水剂;③用天然纤维经梳理机一次梳理形成天然纤维网。这样,不仅产品具有超薄、强度大的特点,并有良好的保温、保湿、防水透气性能,还克服了现有塑料地膜以及可部分或完全降解的多种地膜存在的不宜降解,对环境和土壤造成破坏的缺点;克服了现有的纸地膜,强度低、抗风雨能力差、易破损,铺膜时容易被扯破,不适宜机械铺膜,铺膜难度大、费时费工、成本较高的缺点;2、本发明技术方案的天然纤维毡布的生产方法具有下述优点:①采用梳理机一次梳理成网不仅省去了气流成网的工序,减少了设备投资,更避免了由于天然纤维气流成网速度较低(只有20~25米/分),影响生产效率,推高成本的缺欠;②天然纤维网采用喷涂泡沫粘合剂粘结制得的膜,其含水量远低于采用浸渍粘合工艺得到的膜,因此,烘干、定型所消耗能量少,生产效率高,生产成本低;③用变性淀粉替代化学合成粘合剂,用果蜡乳化液替代含氟拒水剂,使得原辅料均可完全降解,更安全且符合现代环保要求;④各个工序及工艺条件易控制,可以确保制得的天然纤维毡布产品质量稳定。
具体实施方式
以下结合实施例对本发明做进一步描述,但不局限于此。
实施例所用原材料除另有说明外均为市售工业用品,可通过商业渠道购得。
实施例1
天然纤维毡布具体步骤和工艺如下:
①原料纤维的处理
将原料天然纤维开包、混合开松后除尘除杂 ,所用天然纤维是100wt%的亚麻短纤维,细度为1.5~2.5dtex左右,长度为17~25mm;
②成网
将步骤①所得天然纤维,经梳理机一次梳理后得到天然纤维网;
③粘合成膜
将步骤②所得天然纤维网在防粘托网托举下经过喷涂区,用均匀喷头将泡沫粘合剂喷涂在天然纤维网双面,然后用压辊挤压成膜;
所用泡沫粘合剂是由粘合剂、起泡剂和水,搅拌25分钟形成的混合物,在每100重量份的泡沫粘合剂中,粘合剂为9重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉氧化交联淀粉,起泡剂为尿素;
④烘干定型
将步骤③所得膜用托网托住,传输至烘干设备,在烘干温度为150℃,烘干时间为0.8 分钟的条件下进行烘干,再在定型温度为160℃,定型时间为0.6分钟的条件下进行定型;
⑤防水处理
在步骤④所得膜的双面用拒水剂果蜡乳化液进行喷涂,其果蜡乳化液为CFW型果蜡乳化液;
⑥轧光整理、成卷入库
将步骤⑤所得的膜,用冷轧机进行轧光处理后,分切成卷,入库即为天然纤维毡布,其幅宽 200 ㎝,每卷长度 100 米;
制得的天然纤维毡布的技术特性如下:单位面积重量为35g/㎡,厚度为0.28㎜,抗拉强度为1458N/m,撕破强度为72.8N,顶破强度为125.2N,垂直渗透系数为7.12×10-4㎝/s。
实施例2
天然纤维毡布具体步骤和工艺如下:
与实施例1基本相同,不同点如下:
步骤①所用植物纤维是90wt%的亚麻纤维与10wt%的棉花纤维组合,其中,亚麻纤维细度为1.5~2.5 dtex,长度为17~25mm,棉花纤维细度为1.5dtex~3dtex,长度为15 mm~35mm;
步骤③所用泡沫粘合剂,在每100重量份的泡沫粘合剂中,粘合剂为10重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉氧化交联淀粉,起泡剂为尿素;
步骤④是在烘干温度为150℃,烘干时间为0.8 分钟的条件下烘干,再在定型温度为160℃,定型时间为0.6 分钟的条件下进行定型;
制得的天然纤维毡布的技术特性如下:单位面积重量为40g/㎡,厚度为0.32㎜,抗拉强度为1358N/m,撕破强度为70.9N,顶破强度为115.3N,垂直渗透系数为6.80×10-4㎝/s。
实施例3
天然纤维毡布具体步骤和工艺如下:
与实施例1基本相同,不同点如下:
步骤①所用植物纤维是80wt%的苎麻纤维与20wt%的棉花纤维组合,其中,苎麻纤维细度为3~6 dtex,长度为25~45mm,棉花纤维细度为1.5dtex~2.5dtex,长度为16 mm~35mm;
步骤③所用泡沫粘合剂,在每100重量份的泡沫粘合剂中,粘合剂为10重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉氧化交联淀粉,起泡剂为尿素;
步骤④是在烘干温度为150℃,烘干时间为1.0 分钟的条件下烘干,再在定型温度为160℃,定型时间为0.8 分钟的条件下进行定型;
制得的天然纤维毡布的技术特性如下:单位面积重量为40g/㎡,厚度为0.26㎜,抗拉强度为1539N/m,撕破强度为77.9N,顶破强度为138.6N,垂直渗透系数为6.86×10-4㎝/s。
Claims (5)
1.一种天然纤维毡布,它是天然纤维网用粘合剂粘结、挤压、烘干定型而成的膜,在膜表面还涂覆有防水层,其特征在于,
所述天然纤维网是用梳理机对天然纤维进行一次梳理成型的纤维网,其天然纤维是亚麻纤维、苎麻纤维、棉花纤维中的一种或几种的组合;所述粘合剂为泡沫粘合剂,它是由粘合剂、起泡剂和水组成的混合物,在每100重量份的泡沫粘合剂中,粘合剂为8~10重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉,起泡剂为尿素;所述防水层是用拒水剂果蜡乳化液在天然纤维网用粘合剂粘结、挤压、烘干定型而成的膜表面上喷涂形成的,该果蜡乳化液为CFW型果蜡乳化液;
所述天然纤维毡布的技术特性如下:单位面积重量为30~50g/㎡,厚度为0.20~0.35㎜,抗拉强度为1400~1800N/m,撕破强度为50~90N,顶破强度为100~200N,垂直渗透系数为6.0×10-4~8.0×10-4㎝/s。
2.根据权利要求1所述的天然纤维毡布,其特征在于,所述变性淀粉为氧化交联淀粉;所述CFW型果蜡乳化液是由10wt%~20wt%天然棕榈蜡、2.5wt%~3.0wt%吗啉脂肪酸盐,余量为水组成的。
3.根据权利要求1所述的天然纤维毡布,其特征在于,所述天然纤维是90wt%的亚麻纤维与10wt%的棉花纤维组合,其中,亚麻纤维细度为1.5~2.5dtex,长度为17~25mm,棉花纤维细度为1.5dtex~3dtex,长度为15mm~35mm,或者是20wt%的棉花纤维与80wt%的苎麻纤维组合,其中,棉花纤维细度为1.5dtex~2.5dtex,长度为16mm~35mm,苎麻纤维细度为3dtex~6dtex,长度为25mm~45mm,或者是100wt%的亚麻短纤维,其细度为0.15~0.25tex,长度为17~25mm。
4.一种权利要求1、2、3之一所述的天然纤维毡布的生产方法,其特征在于,具体步骤和工艺如下:
①原料纤维的处理
将原料天然纤维开包、混合开松后,除尘、除杂,所用天然纤维是亚麻纤维、苎麻纤维、棉花纤维中的一种或几种的组合;
②成网
将步骤①所得天然纤维经梳理机一次梳理后得到成型的天然纤维网;
③粘合成膜
将步骤②所得天然纤维网的双面用泡沫粘合剂进行喷涂,喷涂后挤压成膜;
所用泡沫粘合剂是由粘合剂、起泡剂和水,搅拌25分钟~30分钟形成的混合物,在每100重量份的泡沫粘合剂中,粘合剂为8~10重量份、起泡剂为1重量份、余量为水,其中的粘合剂为变性淀粉,起泡剂为尿素;
④烘干定型
将步骤③所得膜,在烘干温度为145℃~160℃,烘干时间为0.5分钟~1分钟的条件下进行烘干,再在定型温度为150℃~165℃,定型时间为0.5分钟~1分钟的条件下进行定型;
⑤防水处理
在步骤④所得膜的双面用拒水剂果蜡乳化液进行喷涂;
⑥轧光整理、成卷入库
将步骤⑤所得的膜,用冷轧机进行轧光处理后,分切成卷入库即为天然纤维毡布。
5.根据权利要求4所述的天然纤维毡布的生产方法,其特征在于,所述步骤④的烘干温度为150±2℃,烘干时间为0.8±0.1分钟;定型温度为160±2℃,定型时间为0.7±0.1分钟。
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