CN110241622B - 一种抗紫外线涤纶面料 - Google Patents
一种抗紫外线涤纶面料 Download PDFInfo
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- CN110241622B CN110241622B CN201910546130.8A CN201910546130A CN110241622B CN 110241622 B CN110241622 B CN 110241622B CN 201910546130 A CN201910546130 A CN 201910546130A CN 110241622 B CN110241622 B CN 110241622B
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- silk
- ultraviolet
- silk thread
- finished
- functional agent
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Abstract
本发明属于涤纶面料技术领域,具体的说是一种抗紫外线涤纶面料,涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,纺丝是将涤纶纺丝成丝线,该丝线的半径小于成品丝线的半径;扩丝是将上述丝线匀速穿过熔融态的功能剂中;酸洗和水洗处理是将上述成品丝线放入酸性溶液中进行酸洗;而后将酸洗后的成品丝线进行水洗;上浆工艺中,利用超声波震动配合丝线上浆。本发明通过在丝线表面设置气孔,气孔使得紫外线屏蔽剂更多的暴露在外界,从而使得紫外线屏蔽效果更好;并且由于气孔的形成,使得涤纶面料的透气性更好,克服了现有技术中抗紫外线和透气性效果不能兼顾的缺陷。
Description
技术领域
本发明属于涤纶面料技术领域,具体的说是一种抗紫外线涤纶面料。
背景技术
无机类紫外线屏蔽剂也称为紫外线反射剂,主要通过对紫外线的反射和折射而达到防紫外线的目的,阻止物质对紫外线的吸收。无机类紫外线屏蔽剂一般是陶瓷或金属氧化物等具有良好光反射或折射能力的材料,而且被加工成细粉或超细粉末与纤维织物相结合,增加织物表面对紫外线的反射和折射能力,防止紫外线透过织物损伤皮肤。这类粉末包括:高岭土、碳酸钙、滑石粉、氧化铁、氧化锌、氧化亚铅等。这些无机组分与有机紫外线吸收剂相比,在耐光性、防紫外线和耐热性方面都有一定的优越性。
紫外线吸收剂吸收紫外线的原理与染料吸收可见光的原理相似,都是由于分子内部的电子吸收光子而发生了能级的跃迁,电子在发生能级跃迁时,由于电子能级的量子化的原因,分子只能对特定的波长的光子进行吸收,于是就形成了分子的吸收光谱,如果这个光谱的波长正好处在紫外区域的话,那么这个物质就具有吸收紫外线的能力。
紫外线吸收剂的光吸收过程也就是其分子的电子从基态跃迁到较高能级的过程。当入射的光子能量正好等于吸收剂分子电子基态能级与某一激发态能级之差时,电子就从基态跃迁到这一激发态,同时吸收光子能量。分子这时就处于能量较高的激发态。由于分子中电子的能级是量子化的,所以电子并不能够吸收所有波长的光子,只能选择性的吸收特定波长的光子即能量等于该电子基态能级与某一激发态能级之差的光子。分子所吸收的光子的波长就组成了该紫外线吸收剂分子的吸收光谱。
紫外线吸收剂的作用原理是紫外线吸收剂吸收紫外线,在吸收紫外线后,紫外线吸收剂的分子结构发生异构变化,再以热能、磷光、荧光等形式释放能量。其本质是把紫外线转化为损伤能力较低的能量释放出来。
紫外线吸收剂可以使紫外线的能量转化为光、热等形式释放出来,在一定程度上是稳定的,但长时间、大剂量的紫外线照射会引起其分子的分解。因此,为提高整理效果的耐久性,可采用微胶囊技术,并将紫外线吸收剂装入微胶囊中,对织物进行后整理。
目前,国际上尚无统一的纺织品防紫外线性能检测标准。在现有标准中,防紫外线的检测方法大致可分为直接测试法和仪器测试法。直接测试法包括人体测试法和变色褪色法,具有简便快捷等特点,但是人体测试法因人体间皮肤差异而存在较大的***偏差,重现性差,且测试过程中对人体有害。仪器测试法包括紫外线轻度累积法、紫外线法和分光光度计法。欧盟标准、澳大利亚/新西兰标准、英国标准、美国AATCC标准和中国标准均采用分光光度计法。该法主要是通过稳定的UV光源产生波长为290-400nm紫外射线,通过单色器照射试样,收集总的光谱投射射线,测定出总的光谱投射比,计算试样的紫外线透射率和防护系数UPF值。
UPF值指的是“皮肤无防护时计算出的紫外线辐射平均效应与皮肤有织物防护时计算出的紫外线辐射平均效应的比值”。
UPF值越高,就说明紫外线的防护效果越好。但国家标准中纺织品的UPF值最高的标识是50+,也就是UPF>50。因为UPF大于50以后,对人体的影响完全可以忽略不计。
国家质检总局颁布的《纺织品防紫外线性能的评定》标准中规定:
A.只有当样品的UPF值大于40,并且UVA的透过率小于5%时,才能称之为“防紫外线产品”,这两个条件缺一不可。这是衡量一种产品是不是“防紫外线产品”的指标。
B.防紫外线产品应该在标签上标有三个方面的内容:
1、国家标准的编号:GB/T 18830-2009
2、UPF值:
3、40+,或者50+
备注:
如果UPF的测定值:40<UPF≤50时,并且UVA的透过率小于5%,标识为:UPF40+
如果UPF的测定值大于50,并且UVA的透过率小于5%,标识为:UPF50+
长期使用以及在拉伸或者潮湿的情况下,该产品所提供的防护性能可能减少。
聚酯纤维(POLYESTERFIBERS),俗称“涤纶”,熔点255~260℃,在205℃时开始粘结。是由有机二元酸和二元醇缩聚而成的聚酯经纺丝所得的合成纤维,简称PET纤维,属于高分子化合物。聚酯纤维最大的优点是抗皱性和保形性很好,具有较高的强度与弹性恢复能力。其具有坚牢耐用、抗皱免烫、不粘毛等特点。
涤纶的用途很广,大量用于制造衣着和工业中制品。阻燃涤纶因具有永久阻燃性,应用范围很广,除了产业用纺织品、建筑内装饰、交通工具内装饰等发挥无可替代的作用外,还在防护服领域内发挥着不少的作用。
涤纶制作成衣物时具有较好的强度、滑爽挺括、易洗快干等特点,但是涤纶的吸湿性较差,穿着有闷热感,大大降低了穿着的舒适性。而且,现有的具有抗紫外线的涤纶面料大多是以涂层的形式设置在涤纶面料表面的,涤纶面料虽然具有抗紫外线的能力,但是进一步降低了涤纶面料的透气性,使得涤纶面料的使用受到一定的限制。
发明内容
针对现有技术的不足,本发明提供了一种涤纶面料,其保证了涤纶面料具有较好的抗紫外线的能力的同时,还具有较好的透气性能。
本发明为解决上述技术问题所采用的技术方案为:一种抗紫外线涤纶面料,所述涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,
所述纺丝是将涤纶纺丝成丝线,该丝线的半径小于成品丝线的半径;该处所指的纺丝是指熔融纺丝,该处所指的丝线为全拉伸丝(FDY),可以用于织布;该处所指的成品丝线的半径是指即将进行上浆处理的丝线的半径。
在纺制长丝时,凝固成形的丝条经给湿上油后,即以3500米/分左右的速度卷绕在筒管上得到预取向丝(POY)。POY无法直接用于织布,POY经过拉伸定型、加弹或者加捻得到拉伸丝(DT)、拉伸变形丝(DTY)或加捻丝,可直接用于织造或经变形加工而成变形丝。丝条凝固后经过上油直接进行拉伸以4500-5000m/min进行卷绕即得到全拉伸丝(FDY),可以用于织布。
所述扩丝是将上述丝线匀速穿过熔融态的功能剂中,使得上述丝线表面均匀粘附功能剂,形成成品丝线;所述功能剂中包括重量份的涤纶35-55份、碳酸盐5-25份和紫外线屏蔽剂8-15份;该工艺步骤是将纺丝时直径不满足要求的丝线加工成直径满足要求的丝线。
酸洗和水洗处理是将上述成品丝线放入酸性溶液中进行酸洗;而后将酸洗后的成品丝线进行水洗。该工艺步骤是通过酸性溶液使得碳酸盐分解,产生二氧化碳,在丝线表面形成气孔,以增加丝线表面的粗糙度,当将丝线编制成布料时,丝线之间的空隙增大,从而增加布料的透气性;丝线上形成的气孔使得布料的表面粗糙,从而有利于紫外线屏蔽剂对紫外线的散射,进而提高对紫外线的屏蔽。
所述上浆工艺中,利用超声波震动配合丝线上浆,使得浆液充满所述气孔。超声波震动频率介于1.5MHz至2.5MHz之间。
作为本发明的一种优先方式,纺丝形成的丝线的半径介于成品丝线半径的三分之二和成品丝线半径的四分之三之间。
作为本发明的一种优先方式,所述碳酸盐为碳酸氢钠、碳酸钠、碳酸钙、碳酸钡、碳酸钾中至少一种。
碳酸氢钠,化学式NaHCO3,俗称小苏打。白色细小晶体,在水中的溶解度小于碳酸钠。它也是一种工业用化学品,固体50℃以上开始逐渐分解生成碳酸钠、二氧化碳和水,270℃时完全分解。碳酸氢钠是强碱与弱酸中和后生成的酸式盐,溶于水时呈现弱碱性。碳酸氢钠与酸性溶液反应生成二氧化碳。
碳酸钠[497-19-8](Na2CO3),分子量105.99。化学品的纯度多在99.5%以上(质量分数),又叫纯碱,但分类属于盐,不属于碱。国际贸易中又名苏打或碱灰。它是一种重要的有机化工原料,主要用于平板玻璃、玻璃制品和陶瓷釉的生产。还广泛用于生活洗涤、酸类中和以及食品加工等。碳酸钠与酸性溶液反应生成二氧化碳。
碳酸钙(CaCO3)是一种无机化合物,俗称:灰石、石灰石、石粉、大理石等。碳酸钙呈中性,基本上不溶于水,溶于盐酸。白色固体状,无味、无臭。有无定型和结晶型两种形态。结晶型中又可分为斜方晶系和六方晶系,呈柱状或菱形。相对密度2.71。825~896.6℃分解,在约825℃时分解为氧化钙和二氧化碳。熔点1339℃,10.7MPa下熔点为1289℃。难溶于水和醇。与稀酸反应,同时放出二氧化碳,呈放热反应。也溶于氯化铵溶液。
碳酸钡,化学式BaCO3,分子量197.35。六角形微细晶体或白色粉末。难溶于水,密度4.43克/厘米2,熔点为1740℃(8820千帕-90大气压)1450℃分解,放出二氧化碳。微溶于含有二氧化碳的水,也溶于氯化铵或硝酸铵溶液生成络合物,溶于盐酸、硝酸放出二氧化碳。有毒。
碳酸钾,白色结晶粉末。密度2.428g/cm3。熔点891℃,沸点时分解,相对分子量138.21。溶于水,水溶液呈碱性,不溶于乙醇、丙酮和***。吸湿性强,暴露在空气中能吸收二氧化碳和水分,转变为碳酸氢钾,应密封包装。水合物有一水物、二水物、三水物。碳酸钾水溶液呈碱性。不溶于乙醇及醚。碳酸钾与酸性溶液反应生成二氧化碳。
作为本发明的一种优先方式,所述紫外线屏蔽剂包括重量份的纳米二氧化钛8-15份、纳米氧化锌2-4份、高岭土3-4份和滑石粉5-8份。
纳米二氧化钛直径在100纳米以下,产品外观为白色疏松粉末,屏蔽紫外线作用强,有良好的分散性和耐候性。可用于化妆品、功能纤维、塑料、涂料、油漆等领域,作为紫外线屏蔽剂,防止紫外线的侵害。
纳米氧化锌(ZnO)粒径介于1-100nm之间,是一种高端的高功能精细无机产品,表现出许多特殊的性质,如非迁移性、荧光性、压电性、吸收和散射紫外线能力等,对紫外线具有较好的散射作用。
高岭土,熔点:约1785℃,是一种非金属矿产,是以高岭石族粘土矿物为主的粘土和粘土岩。其质纯的高岭土呈洁白细腻、松软土状,具有良好的可塑性和耐火性等理化性质。其矿物成分主要由高岭石、埃洛石、水云母、伊利石、蒙脱石以及石英、长石等矿物组成。高岭土用途十分广泛,主要用于造纸、陶瓷和耐火材料,其次用于涂料、橡胶填料、搪瓷釉料和白水泥原料,少量用于塑料、油漆、颜料、砂轮、铅笔、日用化妆品、肥皂、农药、医药、纺织、石油、化工、建材、国防等工业部门。
滑石粉,研磨成粉状的滑石,滑石属于三八面体矿物,其结构式为(Mg6)[Si8]O20(OH)4。滑石一般呈块状、叶片状、纤维状或放射状,质地非常软,并且具有滑腻的手感。滑石的用途很多,如作耐火材料、造纸、橡胶的填料、绝缘材料、润滑剂、农药吸收剂、皮革涂料、化妆材料及雕刻用料等等。滑石粉是化妆品行业的优质填充剂,其特点为:含有大量的硅元素。它具有阻隔红外线的作用,因此增强了化妆品的防晒和抗红外线的性能。
作为本发明的一种优先方式,所述酸性溶液为硫酸氢钠、硫酸铜、氯化铁、氯化铝或者硫酸铝的水溶液或者稀盐酸溶液,溶液的物质的量浓度介于0.5-2mol/L之间。
作为本发明的一种优先方式,上述扩丝过程采用挂丝工艺完成。
作为本发明的一种优先方式,所述挂丝工艺包括以下步骤:
S1,将功能剂内各组分按照重量份充分混合,然后将功能剂加热至255~260℃,使功能剂处于熔融态;
S2,将丝线由下向上穿过漏斗状的挂丝容器,挂丝容器上端开口大于下端开口;
S3,使丝线匀速穿过挂丝容器,同时,向挂丝容器中添加熔融态的功能剂;挂丝容器对功能剂进行恒温加热,以保证功能剂始终处于熔融态。
S4,对挂丝后的丝线进行空冷,制成成品丝线。
作为本发明的一种优先方式,所述丝线与挂丝容器同轴布置,且挂丝容器的下端开口直径为所述丝线直径的1.1-1.3倍。
作为本发明的一种优先方式,所述丝线穿过挂丝容器的速度为0.8-1.2m/s。
有益效果:本发明通过将碳酸盐、紫外线屏蔽剂和涤纶进行充分混合,而后将混合物加热至熔融态,而后利用挂丝工艺将混合物粘附在丝线表面,然后再利用酸性溶液对丝线进行酸性,使得丝线表面的碳酸盐溶解并产生二氧化碳,在丝线表面留有气孔,气孔使得紫外线屏蔽剂更多的暴露在外界,从而使得紫外线屏蔽效果更好;并且由于气孔的形成,使得涤纶面料的透气性更好,克服了现有技术中抗紫外线和透气性效果不能兼顾的缺陷。
附图说明
图1至图3是本发明的成品纤维丝在光电显微镜下不同尺寸的微观视图;
图4为本发明挂丝容器的剖视图;
图中:壳体结构1、电加热片2、进料口3、出料口4和圆锥形通孔5。
具体实施方式
下面将结合具体实施例,对本发明的技术方案作详细说明,应理解这些实施例仅用于说明本发明而不用于限制本发明的范围,在阅读了本发明之后,本领域技术人员对本发明的各种等价形式的修改均落入本申请所附权利要求所限定的范围内。
本申请的图1至图3表示了本发明实施例1的成品纤维丝在光电显微镜下不同尺寸的微观视图,其中图3中的9.6nm和10.6nm均表示气孔的壁厚。
如图4所示,作为本发明的一种实施例,所述挂丝容器包括倒圆锥形的壳体结构1,壳体结构1内设有沿壳体结构1内部螺旋形布置的电加热片2,壳体结构1的下部和上部分别设有进料口3和出料口4,所述进料口3和出料口4分别通过一个真空柱塞泵与真空反应釜连接,两个真空柱塞泵均安装在真空反应釜内;所述壳体结构1中心设有上下贯通的圆锥形通孔5,圆锥形通孔5的母线与壳体结构1之间的夹角为ɑ,且满足2°≤ɑ≤4°。
优选的,电加热片2的温度恒定在257℃,与出料口4连接的真空柱塞泵的流量略小于与进料口3连接的真空柱塞泵的流量,两者的差值为功能剂的消耗量,即粘附在丝线上的功能剂的量。
优选的,挂丝容器内功能剂的最高液面始终高于出料口4的高度,避免空气进入真空反应罐中。
优选的,进行挂丝工艺前,向真空反应釜内通入脱水二氧化碳直至常压,实现对功能剂进行保护。
通过上述挂丝容器的设置,可以保证功能剂温度的恒定以及功能剂的循环式流动。
实施例1:
一种抗紫外线涤纶面料,所述涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,
纺丝:将涤纶通过熔融纺丝方法纺丝成全拉伸丝(FDY),全拉伸丝(FDY)的半径等于成品丝线半径的三分之二;将全拉伸丝(FDY)缠绕在卷筒上。
制备功能剂,取涤纶35份、硅酸盐6份和紫外线屏蔽剂14份,将涤纶切割成直径为0.1mm的涤纶切片,然后将涤纶切片和硅酸盐、紫外线屏蔽剂放入真空反应釜进行混合搅拌40分钟,搅拌温度为室温,而后将真空反应釜逐渐加热至257℃并保持,加热过程中真空反应釜不断搅拌。紫外线屏蔽剂包括重量份的纳米二氧化钛8份、纳米氧化锌3份、高岭土3份和滑石粉7份。
扩丝:将全拉伸丝(FDY)的一端穿过挂丝容器并通过牵引轮缠绕在卷筒上,牵引轮对全拉伸丝(FDY)以0.1m/s的速度进行牵引,然后将熔融态的功能剂加入挂丝容器内,然后以0.8-1.2m/s的风速对挂丝后的全拉伸丝(FDY)进行风冷形成成品丝线,成品丝线经牵引轮缠绕在卷筒上。
酸洗和水洗处理:将上述成品丝线连同卷筒一起放入0.8mol/L的硫酸铝溶液中浸泡2小时,然后将成品丝线的一端以1m/s的速度引出,并经过清水池进行清洗,而后缠绕在卷筒上。
上浆:利用超声波震动配合丝线上浆,使得浆液充满所述气孔,超声波震动频率为1.5MHz。
纺织:将上浆后的成品纤维丝纺织成涤纶布料。
所述碱减量处理(也称为仿真丝绸整理)是已知的,其是指在高温和较浓的烧碱液中处理涤纶面料的过程,涤纶表面被碱刻蚀后,其质量减轻,纤维直径变细,表面形成凹坑,纤维的剪切刚度下降,消除了涤纶丝的极光,并增加了织物交织点的空隙,使得织物手感柔软、光泽柔和,改善了吸湿排汗性。碱减量处理的后续处理工艺均为已知。
实施例2:
一种抗紫外线涤纶面料,所述涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,
纺丝:将涤纶通过熔融纺丝方法纺丝成全拉伸丝(FDY),全拉伸丝(FDY)的半径等于成品丝线半径的三分之二;将全拉伸丝(FDY)缠绕在卷筒上。
制备功能剂,取涤纶40份、硅酸盐15份和紫外线屏蔽剂9份,将涤纶切割成直径为0.1mm的涤纶切片,然后将涤纶切片和硅酸盐、紫外线屏蔽剂放入真空反应釜进行混合搅拌40分钟,搅拌温度为室温,而后将真空反应釜逐渐加热至257℃并保持,加热过程中真空反应釜不断搅拌。紫外线屏蔽剂包括重量份的纳米二氧化钛11份、纳米氧化锌2份、高岭土3份和滑石粉5份。
扩丝:将全拉伸丝(FDY)的一端穿过挂丝容器并通过牵引轮缠绕在卷筒上,牵引轮对全拉伸丝(FDY)以0.1m/s的速度进行牵引,然后将熔融态的功能剂加入挂丝容器内,然后以0.8-1.2m/s的风速对挂丝后的全拉伸丝(FDY)进行风冷形成成品丝线,成品丝线经牵引轮缠绕在卷筒上。
酸洗和水洗处理:将上述成品丝线连同卷筒一起放入1.2mol/L的硫酸铝溶液中浸泡2小时,然后将成品丝线的一端以1m/s的速度引出,并经过清水池进行清洗,而后缠绕在卷筒上。
上浆:利用超声波震动配合丝线上浆,使得浆液充满所述气孔,超声波震动频率为1.6MHz。
纺织:将上浆后的成品纤维丝纺织成涤纶布料。
所述碱减量处理(也称为仿真丝绸整理)是已知的,其是指在高温和较浓的烧碱液中处理涤纶面料的过程,涤纶表面被碱刻蚀后,其质量减轻,纤维直径变细,表面形成凹坑,纤维的剪切刚度下降,消除了涤纶丝的极光,并增加了织物交织点的空隙,使得织物手感柔软、光泽柔和,改善了吸湿排汗性。碱减量处理的后续处理工艺均为已知。
实施例3:
一种抗紫外线涤纶面料,所述涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,
纺丝:将涤纶通过熔融纺丝方法纺丝成全拉伸丝(FDY),全拉伸丝(FDY)的半径等于成品丝线半径的三分之二;将全拉伸丝(FDY)缠绕在卷筒上。
制备功能剂,取涤纶35份、硅酸盐20份和紫外线屏蔽剂10份,将涤纶切割成直径为0.1mm的涤纶切片,然后将涤纶切片和硅酸盐、紫外线屏蔽剂放入真空反应釜进行混合搅拌40分钟,搅拌温度为室温,而后将真空反应釜逐渐加热至257℃并保持,加热过程中真空反应釜不断搅拌。紫外线屏蔽剂包括重量份的纳米二氧化钛15份、纳米氧化锌3份、高岭土4份和滑石粉5份。
扩丝:将全拉伸丝(FDY)的一端穿过挂丝容器并通过牵引轮缠绕在卷筒上,牵引轮对全拉伸丝(FDY)以0.1m/s的速度进行牵引,然后将熔融态的功能剂加入挂丝容器内,然后以0.8-1.2m/s的风速对挂丝后的全拉伸丝(FDY)进行风冷形成成品丝线,成品丝线经牵引轮缠绕在卷筒上。
酸洗和水洗处理:将上述成品丝线连同卷筒一起放入1.5mol/L的硫酸铝溶液中浸泡2小时,然后将成品丝线的一端以1m/s的速度引出,并经过清水池进行清洗,而后缠绕在卷筒上。
上浆:利用超声波震动配合丝线上浆,使得浆液充满所述气孔,超声波震动频率为1.6MHz。
纺织:将上浆后的成品纤维丝纺织成涤纶布料。
所述碱减量处理(也称为仿真丝绸整理)是已知的,其是指在高温和较浓的烧碱液中处理涤纶面料的过程,涤纶表面被碱刻蚀后,其质量减轻,纤维直径变细,表面形成凹坑,纤维的剪切刚度下降,消除了涤纶丝的极光,并增加了织物交织点的空隙,使得织物手感柔软、光泽柔和,改善了吸湿排汗性。碱减量处理的后续处理工艺均为已知。
实施例4:
一种抗紫外线涤纶面料,所述涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,
纺丝:将涤纶通过熔融纺丝方法纺丝成全拉伸丝(FDY),全拉伸丝(FDY)的半径等于成品丝线半径的三分之二;将全拉伸丝(FDY)缠绕在卷筒上。
制备功能剂,取涤纶55份、硅酸盐10份和紫外线屏蔽剂15份,将涤纶切割成直径为0.1mm的涤纶切片,然后将涤纶切片和硅酸盐、紫外线屏蔽剂放入真空反应釜进行混合搅拌40分钟,搅拌温度为室温,而后将真空反应釜逐渐加热至257℃并保持,加热过程中真空反应釜不断搅拌。紫外线屏蔽剂包括重量份的纳米二氧化钛9份、纳米氧化锌3份、高岭土3份和滑石粉6份。
扩丝:将全拉伸丝(FDY)的一端穿过挂丝容器并通过牵引轮缠绕在卷筒上,牵引轮对全拉伸丝(FDY)以0.1m/s的速度进行牵引,然后将熔融态的功能剂加入挂丝容器内,然后以0.8-1.2m/s的风速对挂丝后的全拉伸丝(FDY)进行风冷形成成品丝线,成品丝线经牵引轮缠绕在卷筒上。
酸洗和水洗处理:将上述成品丝线连同卷筒一起放入2mol/L的硫酸铝溶液中浸泡2小时,然后将成品丝线的一端以1m/s的速度引出,并经过清水池进行清洗,而后缠绕在卷筒上。
上浆:利用超声波震动配合丝线上浆,使得浆液充满所述气孔,超声波震动频率为2.5MHz。
纺织:将上浆后的成品纤维丝纺织成涤纶布料。
所述碱减量处理(也称为仿真丝绸整理)是已知的,其是指在高温和较浓的烧碱液中处理涤纶面料的过程,涤纶表面被碱刻蚀后,其质量减轻,纤维直径变细,表面形成凹坑,纤维的剪切刚度下降,消除了涤纶丝的极光,并增加了织物交织点的空隙,使得织物手感柔软、光泽柔和,改善了吸湿排汗性。碱减量处理的后续处理工艺均为已知。
对实施例1至4所得面料进行抗紫外线、透气性检测和UPF检测,其中,抗紫外线性能测试面料对紫外线(尤其波长290-400nm的紫外线)的透过率,透气性测试面料对空气的透气率(透气性测试:采用GB/T5453-1997标准进行测试),同时,在面料被洗涤20次后再次测试面料的抗紫外线性能和透气性能,对照例为市售普通抗紫外线面料,测试结果如下表1:
表1:性能检测报告
由上表可见,实施例1至4所得的涤纶面料具有良好的透气性和抗紫外线性能,且洗涤20次后,其性能基本保持不变,符合国家质检总局颁布的《纺织品防紫外线性能的评定》标准的规定。
以上所述仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (4)
1.一种抗紫外线涤纶面料,其特征在于:所述涤纶面料通过如下工艺流程制得:纺丝→扩丝→酸洗和水洗处理→上浆→纺织→碱减量处理→染色→烘干→水洗→烘干,其中,
所述纺丝是将涤纶纺丝成丝线,该丝线的半径小于成品丝线的半径;
所述扩丝是将上述丝线匀速穿过熔融态的功能剂中,使得上述丝线表面均匀粘附功能剂,形成成品丝线;所述功能剂中包括重量份的涤纶35-55份、碳酸盐5-25份和紫外线屏蔽剂8-15份;
酸洗和水洗处理是将上述成品丝线放入酸性溶液中进行酸洗;而后将酸洗后的成品丝线进行水洗;
所述上浆工艺中,利用超声波震动配合丝线上浆;
所述紫外线屏蔽剂包括重量份的纳米二氧化钛8-15份、纳米氧化锌2-4份、高岭土3-4份和滑石粉5-8份;
所述酸性溶液为硫酸氢钠、硫酸铜、氯化铁、氯化铝或者硫酸铝的水溶液或者稀盐酸溶液,溶液的物质的量浓度介于0.5-2mol/L之间;
上述扩丝过程采用挂丝工艺完成;
所述挂丝工艺包括以下步骤:
S1,将功能剂内各组分按照重量份充分混合,然后将功能剂加热至255~260℃,使功能剂处于熔融态;
S2,将丝线由下向上穿过漏斗状的挂丝容器,挂丝容器上端开口大于下端开口;
S3,使丝线匀速穿过挂丝容器,同时,向挂丝容器中添加熔融态的功能剂;
S4,对挂丝后的丝线进行空冷,制成成品丝线;
所述挂丝容器包括倒圆锥形的壳体结构(1),壳体结构(1)内设有沿壳体结构(1)内部螺旋形布置的电加热片(2),壳体结构(1)的下部和上部分别设有进料口(3)和出料口(4),所述进料口(3)和出料口(4)分别通过一个真空柱塞泵与真空反应釜连接,两个真空柱塞泵均安装在真空反应釜内;所述壳体结构(1)中心设有上下贯通的圆锥形通孔(5),圆锥形通孔(5)的母线与壳体结构(1)之间的夹角为ɑ,且满足2°≤ɑ≤4°;
电加热片(2)的温度恒定在257℃,与出料口(4)连接的真空柱塞泵的流量略小于与进料口(3)连接的真空柱塞泵的流量,两者的差值为功能剂的消耗量,即粘附在丝线上的功能剂的量;
挂丝容器内功能剂的最高液面始终高于出料口(4)的高度,避免空气进入真空反应罐中;
进行挂丝工艺前,向真空反应釜内通入脱水二氧化碳直至常压,实现对功能剂进行保护;
所述丝线与挂丝容器同轴布置,且挂丝容器的下端开口直径为所述丝线直径的1.1-1.3倍。
2.根据权利要求1所述的一种抗紫外线涤纶面料,其特征在于:纺丝形成的丝线的半径介于成品丝线半径的三分之二和成品丝线半径的四分之三之间。
3.根据权利要求1所述的一种抗紫外线涤纶面料,其特征在于:所述碳酸盐为碳酸氢钠、碳酸钠、碳酸钙、碳酸钡、碳酸钾中至少一种。
4.根据权利要求1所述的一种抗紫外线涤纶面料,其特征在于:所述丝线穿过挂丝容器的速度为0.8-1.2m/s。
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