CN108893866A - 一种无毒无味、减震环保复合棉及其制备工艺 - Google Patents
一种无毒无味、减震环保复合棉及其制备工艺 Download PDFInfo
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Abstract
本发明公开了一种无毒无味、减震环保复合棉及其制备工艺,由包括下述重量百分比的原料:PET中空绦纶短纤维30‑50%、低熔点热熔纤维35‑60%、ES纤维15‑35%、PVC增塑剂5‑10%、助剂1‑3%;本发明采用环保、无味性材料制成,常态下不融化、不分解、无有毒气体、无有毒物质产生、材料可回收再生,在制备与成型过程中无排放有害气体,可有效降解材料气味性和VOC散发,易加工成型,属于绿色材料,满足汽车行业的VOC及环保要求。
Description
技术领域
本发明属于吸音棉技术领域,具体涉及一种无毒无味、减震环保复合棉及其制备工艺。
背景技术
吸音减震材料是生产汽车内饰件不可或缺的组成成分,例如地毯隔音垫、前围隔音垫、顶棚隔音垫、减震缓冲垫、行李箱隔音垫、门板隔音垫、轮罩隔音垫、风道隔音垫、衣帽架隔音垫等附件的制造都离属于吸音减震材料的应用范围。然而,近年来,新车驾驶舱内空气质量已引起各行各业的高度重视,很多新车主反馈新车购买后一段时间里车内都有刺鼻的气味,如舱内停留时间过长后还容易引起头痛、恶心、呕吐、乏力等不良症状。严重时会出现抽搐、昏迷,并会伤害到人的肝脏、肾脏、大脑和神经***,造成记忆力减退等严重后果。归根源头便是一些不良汽车厂商通过降低所配套内饰件产品材料成本而使用劣质原料或生产工艺。随之带来的是车内气味性超标和VOC的增加。驾驶舱内环保型材料已成为各大车企重点关注对象。在现代汽车工业越来越追求高性能、优质量、低价格、安全环保的时代,对各零部件配套企业也提出了挑战性的要求,以达到主机厂对性能、质量、成本的要求。
发明内容
根据以上现有技术的不足,本发明所要解决的技术问题是提出一种无毒无味、减震环保复合棉及其制备工艺,从原料的选择和工艺的改进及设备3个方面出发,得到三维立体多孔网状结构,性能高、质量优、安全环保。
为了解决上述技术问题,本发明采用的技术方案为:
一种无毒无味、减震环保复合棉,由包括下述重量百分比的原料:PET中空绦纶短纤维30-50%、低熔点热熔纤维35-60%、ES纤维15-35%、PVC增塑剂5-10%、助剂1-3%。
优选的,所述的低熔点热熔纤维的熔点为110-150℃,所述的助剂为EVA乳液和PE蜡按熔融后体积比1-3:2-3的混合物;所述的ES纤维由皮-聚乙烯和芯-聚丙烯构成的皮芯结构的双组份纤维,熔点为130-140℃,成型时采用热风粘合式处理即得蓬松性ES纤维,采用热轧粘合式处理即得高强度ES纤维。
一种无毒无味、减震环保复合棉的制备工艺,包括以下步骤:
(1)将PET中空绦纶短纤维、低熔点热熔纤维投入称重开包机,经预开松到大仓混棉,在输棉风机风力的吸引下拉松成絮状,从而混合开松均匀,贮料混棉;
(2)通过输棉风机到振动辊棉机给棉,经过五组双锡林梳理、双道夫凝聚设备开毛梳理至罗拉剥棉,梳理成双层纤维;
(3)在铺网机加入ES纤维和双层纤维,均匀地铺叠成多层纤维网,PVC增塑剂和助剂经熔融、过滤随熔体细流均匀喷洒于多层纤维网上下表面,通过输送帘输送;
(4)在无纺针刺机中预针刺,再烘干定型冷却后,经裁切、检验、加热模压、冲切成型得复合吸音棉。
优选的,步骤(2)所述的双层纤维将低熔点热熔纤维作为皮层,将PET中空绦纶短纤维作为芯层,复合而成,其皮层可以在比芯层更低的温度下熔融,通过粘合即得双层纤维。
优选的,步骤(3)所述的铺网机底帘速度为2.33-2.85m/min,多层纤维的厚度为0.4-4mm,熔融温度为130-220℃,过滤的精度为200-250目。
优选的,步骤(4)所述的预针刺频率为1100-1300次/min,烘干的温度为160-230℃,烘干时间为8-12h,裁切时用纵切刀裁边,横电热丝切片,所述的加热模压分两个加热区,一级加热区的温度为250-300℃,加热时间为50-90s,二级加热区的温度为280-380℃,加热时间为60-120s。
优选的,步骤(4)所述的复合吸音棉为亲水性复合棉或疏水性复合棉,若加入蓬松性ES纤维得亲水性复合棉,若加入高强度ES纤维得疏水性复合棉,厚度均为5-40mm,宽度均为1550-1650mm,克重均为750-850g/m2。
本发明有益效果是:
1.本发明的复合棉是一种慢回弹材料属于慢弹棉,当受力压缩后反馈比较棉软。靠纤维和胶衔接定型作用惰性减震缓冲、主要用来消除或缓冲微震动等不良效果。在汽车行业一般应用于四个车门、后备箱、车地板、行李仓及车顶进行二级降震降噪。同时质量轻,在同等厚度及压缩回弹率要求条件下,较同类型纺毡/再生材料/PU发泡类材料质量轻约30%,材料特性保持不变。得到的材料质量轻、环保、不易燃、导热系数小、吸音、隔音、减震、耐水、维护方便、可二次回收、生产质量稳定,是汽车内饰件最理想的辅助隔音降噪环保材料。
2.本发明投料时采用三组份开包投料、双梳理机梳理成纤维网后经过铺网工艺复合定型完成,由原单锡林工艺设备改进后为双锡林梳理、同步采用双道夫集成网、使单纤维网出网克重更轻、铺网层数更密、其内部纤维交织在一起,形成具有一定强度和韧性的三维立体多孔网状结构。复合结构材料中有许多贯通的微小间隙,当声波入射到多孔材料表面时,可以进入细孔中去,从而延长了音波穿透材料的时间,引起空隙内的空气和材料本身振动,空气的摩擦和粘滞作用使振动能(声能)不断转化为热能,从而使声波衰减,实现降噪目的。
3.本发明从工艺上将材料通过多道纤维开松工艺由双梳理机成单纤维网后经过特殊铺网工艺复合定型完成,并运用专用的烘干成型创新技术,形成具有一定强度和韧性的三维立体多孔网状结构,其主体纤维网排列方式是上下方向竖直排列制成也即倒“S”型,经10道工序精心加工而成。相对于平铺纤维而言抗拉强度大,蓬松度好;从材料上采用PET纤维棉,在成型性和环保性能方面均有很大程度提升;采用低熔点热熔纤维,当加热到一定温度后会软化熔融变成具有一定流动性的粘流体,冷却后又重新固化变成固体,易于和其他纤维混合,粘合涤纶长丝,具有低熔点、弹力好、热塑性柔软性好;加入不同的ES纤维得到亲水或疏水的复合棉,同一种工艺两种复合棉;加入PVC,具有耐火、抗静电、易成型的性能,且低投入高产量;得到的复合棉具有抗老化性能、耐高低温性能、耐阻燃性能、耐霉变性能、安全环保性能优于普通非化纤制品,在成型性和环保性能方面均有很大程度提升。
4.本发明的复合棉含有PE胶膜,高温加热后溶化与热熔毡直接粘合在一起,避免后期溶剂胶的使用,减少了车间环境污染,也保证产品没有挥发性有害物质,采用环保、无味性材料制成,常态下不融化,不分解,无有毒气体、无有毒物质产生、无毒无味、材料可回收再生,在制备与成型过程中无排放有害气体,可有效降材料气味性和VOC散发,同时生产成型无化学反应,易加工成型,属于绿色材料,满足汽车行业的VOC及环保要求。
附图说明
下面对本说明书附图所表达的内容及图中的标记作简要说明:
图1是本发明实施例1无毒无味、减震环保复合棉燃烧测试图。
图2是无毒无味、减震环保复合棉及制备工艺流程图。
具体实施方式
下面通过对实施例的描述,作进一步详细的说明,以帮助本领域技术人员对本发明的发明构思、技术方案有更完整、准确和深入的理解。
实施例1
原料:PET中空绦纶短纤维30%、低熔点热熔纤维408035%(熔点为150℃)、蓬松性ES纤维25%(熔点为135℃)、PVC增塑剂8%、助剂2%,其中助剂为EVA乳液和PE蜡按熔融后体积比1:2的混合物。
(1)将PET中空绦纶短纤维、低熔点热熔纤维投入称重开包机,经预开松到大仓混棉,在输棉风机风力的吸引下拉松成絮状,从而混合开松均匀,贮料混棉;
(2)通过输棉风机到振动辊棉机给棉,经过五组双锡林梳理、双道夫凝聚设备开毛梳理至罗拉剥棉,将低熔点热熔纤维作为皮层,将PET中空绦纶短纤维作为芯层,复合而成,其皮层可以在比芯层更低的温度下熔融,通过粘合即得双层纤维。
(3)在底帘速度为2.50m/min的铺网机中加入ES纤维和双层纤维,均匀地铺叠成厚度为2mm的多层纤维网,PVC增塑剂和助剂经180℃高温熔融、过200目筛后随熔体细流均匀喷洒于多层纤维网上下表面,通过输送帘输送;
(4)在无纺针刺机中预针刺,预针刺频率为1100次/min,经180℃烘干8h定型,冷却后,经裁切、检验、加热模压,加热模压分两个加热区,一级加热区的温度为250℃,加热时间为60s,二级加热区的温度为280℃,加热时间为80s,冲切成型得厚度为10mm,宽度均为1550mm复合吸音棉。
实施例2
原料:PET中空绦纶短纤维35%、低熔点热熔纤维408035%(熔点为150℃)、高强度ES纤维20%(熔点为135℃)、PVC增塑剂7%、助剂3%,其中助剂为EVA乳液和PE蜡按熔融后体积比1:3的混合物。
(1)将PET中空绦纶短纤维、低熔点热熔纤维投入称重开包机,经预开松到大仓混棉,在输棉风机风力的吸引下拉松成絮状,从而混合开松均匀,贮料混棉;
(2)通过输棉风机到振动辊棉机给棉,经过五组双锡林梳理、双道夫凝聚设备开毛梳理至罗拉剥棉,将低熔点热熔纤维作为皮层,将PET中空绦纶短纤维作为芯层,复合而成,其皮层可以在比芯层更低的温度下熔融,通过粘合即得双层纤维。
(3)在底帘速度为2.65m/min的铺网机加入ES纤维和双层纤维,均匀地铺叠成厚度为1mm的多层纤维网,PVC增塑剂和助剂经200℃高温熔融、过220目筛后随熔体细流均匀喷洒于多层纤维网上下表面,通过输送帘输送;
(4)在无纺针刺机中预针刺,预针刺频率为1200次/min,经200℃烘干10h定型,冷却后,经裁切、检验、加热模压、加热模压分两个加热区,一级加热区的温度为280℃,加热时间为80s,二级加热区的温度为330℃,加热时间为100s。冲切成型得厚度均为10mm,宽度均为1600mm的复合吸音棉。
实施例3
原料:PET中空绦纶短纤维30%、低熔点热熔纤维408035%(熔点为150℃)、高强度ES纤维25%(熔点为135℃)、PVC增塑剂7%、助剂3%,其中助剂为EVA乳液和PE蜡按熔融后体积比2:3的混合物。
(1)将PET中空绦纶短纤维、低熔点热熔纤维投入称重开包机,经预开松到大仓混棉,在输棉风机风力的吸引下拉松成絮状,从而混合开松均匀,贮料混棉;
(2)通过输棉风机到振动辊棉机给棉,经过五组双锡林梳理、双道夫凝聚设备开毛梳理至罗拉剥棉,将低熔点热熔纤维作为皮层,将PET中空绦纶短纤维作为芯层,复合而成,其皮层可以在比芯层更低的温度下熔融,通过粘合即得双层纤维。
(3)在底帘速度为2.85m/min的铺网机加入ES纤维和双层纤维,均匀地铺叠成厚度为3mm的多层纤维网,PVC增塑剂和助剂经220℃高温熔融、过250目筛后随熔体细流均匀喷洒于多层纤维网上下表面,通过输送帘输送;
(4)在无纺针刺机中预针刺,预针刺频率为1300次/min,经230℃烘干12h定型,冷却后,经裁切、检验、加热模压、加热模压分两个加热区,一级加热区的温度为300℃,加热时间为90s,二级加热区的温度为380℃,加热时间为120s,冲切成型得厚度均为8mm,宽度均为1650mm的复合吸音棉。
对实施例1-3的环保复合吸音棉进行常规性能测试。
1.面密度:分别取实施例1-3的试样,每个尺寸为250mm×250mm,称得的重量×16,其结果800g±50g/m2。
2.导热性:按照GB/T 3139进行试验,其结果≤0.050w/(m.K)
3.阻燃性:按照GB8410进行试验,其结果≤100mm/min
4.抗溶剂性:将样品浸如以下任一溶液中4小时(去离子水、发动机油、制动液、长效冷却液、3%的盐溶液、2.5%的硫酸)后观察有无出现出现溶解、粘合、脱层等现象,结果见表2。
5.VOC含量测试:将实施例3所得试样裁剪为尺寸100mm×100mm,用填充氮气的试样袋封装,于65℃下加热2h,后测试。采用TDS GC/MS测试苯、甲苯、乙苯、二甲苯、苯乙烯和TVOC,结果见表3;采用HPLC测试甲醛、乙醛、丙烯醛、丙酮、丙醛、丁烯醛、异丁烯醛、丁酮、丁醛、苯甲醛、戊醛、甲基苯甲醛、己醛,结果见表4。
表1
表2抗溶剂性测试
表3 VOC含量测试
测试项目 | MDL | VOC含量 |
苯(g/m3) | 10 | 46 |
甲苯 | 10 | 57 |
乙苯 | 10 | 23 |
二甲苯 | 10 | 91 |
苯乙烯 | 10 | 34 |
TVOC | - | 3200 |
表4 VOC含量测试
测试项目 | MDL | VOC含量 |
甲醛 | 30 | ND |
乙醛 | 15 | ND |
丙烯醛 | 15 | ND |
丙酮 | 15 | ND |
丙醛 | 15 | ND |
丁烯醛 | 15 | ND |
异丁烯醛 | 15 | ND |
丁酮 | 15 | ND |
丁醛 | 15 | ND |
苯甲醛 | 15 | ND |
戊醛 | 15 | ND |
甲基苯甲醛 | 15 | ND |
己醛 | 15 | ND |
上面对本发明进行了示例性描述,显然本发明具体实现并不受上述方式的限制,只要采用了本发明的方法构思和技术方案进行的各种非实质性的改进,或未经改进将本发明的构思和技术方案直接应用于其它场合的,均在本发明的保护范围之内。本发明的保护范围应该以权利要求书所限定的保护范围为准。
Claims (7)
1.一种无毒无味、减震环保复合棉,其特征在于,由包括下述重量百分比的原料:PET中空绦纶短纤维30-50%、低熔点热熔纤维35-60%、ES纤维15-35%、PVC增塑剂5-10%、助剂1-3%。
2.根据权利要求1所述的一种无毒无味、减震环保复合棉,其特征在于,所述的低熔点热熔纤维的熔点为110-150℃,所述的助剂为EVA乳液和PE蜡按熔融后体积比1-3:2-3的混合物;所述的ES纤维由皮-聚乙烯和芯-聚丙烯构成的皮芯结构的双组份纤维,熔点为130-140℃,成型时采用热风粘合式处理即得蓬松性ES纤维,采用热轧粘合式处理即得高强度ES纤维。
3.一种无毒无味、减震环保复合棉的制备工艺,其特征在于,包括以下步骤:
(1)将PET中空绦纶短纤维、低熔点热熔纤维投入称重开包机,经预开松到大仓混棉,在输棉风机风力的吸引下拉松成絮状,从而混合开松均匀,贮料混棉;
(2)通过输棉风机到振动辊棉机给棉,经过五组双锡林梳理、双道夫凝聚设备开毛梳理至罗拉剥棉,梳理成双层纤维;
(3)在铺网机加入ES纤维和双层纤维,均匀地铺叠成多层纤维网,PVC增塑剂和助剂经熔融、过滤随熔体细流均匀喷洒于多层纤维网上下表面,通过输送帘输送;
(4)在无纺针刺机中预针刺,再烘干定型冷却后,经裁切、检验、加热模压、冲切成型得复合吸音棉。
4.根据权利要求3所述的一种无毒无味、减震环保复合棉的制备工艺,其特征在于,步骤(2)所述的双层纤维将低熔点热熔纤维作为皮层,将PET中空绦纶短纤维作为芯层,复合而成,其皮层可以在比芯层更低的温度下熔融,通过粘合即得双层纤维。
5.根据权利要求3所述的一种无毒无味、减震环保复合棉的制备工艺,其特征在于,步骤(3)所述的铺网机底帘速度为2.33-2.85m/min,多层纤维的厚度为0.4-4mm,熔融温度为130-220℃,过滤的精度为200-250目。
6.根据权利要求3所述的一种无毒无味、减震环保复合棉的制备工艺,其特征在于,步骤(4)所述的预针刺频率为1100-1300次/min,烘干的温度为160-230℃,烘干时间为8-12h,裁切时用纵切刀裁边,横电热丝切片,所述的加热模压分两个加热区,一级加热区的温度为250-300℃,加热时间为50-90s,二级加热区的温度为280-380℃,加热时间为60-120s。
7.根据权利要求3所述的一种无毒无味、减震环保复合棉的制备工艺,其特征在于,步骤(4)所述的复合吸音棉为亲水性复合棉或疏水性复合棉,若加入蓬松性ES纤维得亲水性复合棉,若加入高强度ES纤维得疏水性复合棉,厚度均为5-40mm,宽度均为1550-1650mm,克重均为750-850g/m2。
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