CN111593459A - 一种阻燃抗撕裂面料的生产方法 - Google Patents

一种阻燃抗撕裂面料的生产方法 Download PDF

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CN111593459A
CN111593459A CN201910126600.5A CN201910126600A CN111593459A CN 111593459 A CN111593459 A CN 111593459A CN 201910126600 A CN201910126600 A CN 201910126600A CN 111593459 A CN111593459 A CN 111593459A
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fabric
flame
retardant
yarn
weaving
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CN111593459B (zh
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程德亮
李双燕
崔振华
程曼丽
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Jiangsu Tangwear Industry Co ltd
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Abstract

本发明公开了一种阻燃抗撕裂面料的生产方法，包括：整经：将占总经根数80％‑95％的棉纱卷绕到第一织轴上，将占总经根数5％‑20％的复合增强纱卷绕到第二织轴上；浆纱：采用双浸单压上浆工艺对棉纱进行上浆,以贴伏棉纱毛羽，改善棉纱的集束性，增加棉纱表面光滑性，增强棉纱断裂强力保证织造的顺利进行；穿综和穿筘：对棉纱和复合增强纱进行穿综和扒筘；织造：利用第一织轴和第二织轴进行双轴织造得到面料；烧毛：对面料进行烧毛；预处理：对面料进行酶浆冷堆预处理；煮练漂：按煮练漂一步法对面料进行处理；丝光：在直辊丝光机上对面料进行丝光；染色：对面料进行染色；阻燃：对面料浸轧阻燃整理液；烘干、预缩和成品：对面料依次烘干、预缩和成品。本发明有效提高阻燃面料撕破强力。

Description

一种阻燃抗撕裂面料的生产方法
技术领域
本发明涉及安全防护用面料制备领域。
背景技术
棉纤维作为天然纤维之首，具有优良的柔软性、亲肤性及吸湿性，其制品深受人们的喜爱，被广泛用于休闲、体育、劳动防护等领域。众所周知，衣物在使用过程中，局部因长期受到集中负荷的作用，织物中的纱线会逐渐变细，从而使其达到强力极限而被撕破成裂缝，织物受到破坏。一旦破坏的地方被勾住或受到外力后，织物就会被撕成两半。撕破强力作为衡量服装坚牢度的重要指标，其优劣严重影响了服装的耐用性能。撕破强力越低，耐用性能越差。全棉阻燃防护服因其优良的吸湿性、阻燃性、较高的性价比被广泛用于煤矿、电力、钢铁等行业。但因天然纤维单纱强力不如合成纤维，再加上染色后整理工艺造成的损伤，故纯棉阻燃防护服的撕破强力不高。以市面上常见规格58”/20s*16s/128*60的全棉阻燃面料为例，其纬向撕破强力为33.9N，比国标GB 8965.1-2009《防护服装阻燃防护第1部分：阻燃服》中要求的25N仅高出一点。低的撕破强力导致其耐用性能差。
市面上常规的抗撕裂面料，一般都以平纹为地组织，并每隔一定数量的地组织循环数在经、纬向以加强经、加强纬相互交织的方式形成加强格子，以提高其撕破强力(其中，将两根或两根以上的经纱同时穿在同一片综框内形成加强经纱，两根或两根以上的纬纱同时打纬形成加强纬纱。)如申请号为CN 103764886A的所述的抗撕裂织物就是以这样的方法实现抗撕裂的目的。但该方法存在以下不足：1、织物风格单一，无法满足人们对织物风格多样化的要求。2、平纹组织中，相邻的经纬纱交织次数最多，浮长线短，纱线滑移相对困难，受力三角小，受力三角中的纱线根数就少，从而不利于提高织物的撕破强力。3、织造过程中，起加强作用的经纱易出现松弛现象，使停经片下垂，造成无故停车，从而生产效率低下。
发明内容
本发明的目的在于提供阻燃抗撕裂面料的生产方法，有效提高阻燃面料撕破强力。
实现上述目的的技术方案是：
一种阻燃抗撕裂面料的生产方法，包括：
整经：将占总经根数80％-95％的棉纱卷绕到第一织轴上，将占总经根数5％-20％的复合增强纱卷绕到第二织轴上；
浆纱：采用双浸单压上浆工艺对棉纱进行上浆；
穿综和扒筘：对棉纱和复合增强纱进行穿综和扒筘；
织造：利用第一织轴和第二织轴进行双轴织造得到面料；
烧毛：对面料进行烧毛；
预处理：对面料进行酶浆冷堆预处理；
煮练漂：按煮练漂一步法对面料进行处理；
丝光：在直辊丝光机上对面料进行丝光；
染色：对面料进行染色；
阻燃：对面料浸轧阻燃整理液；
烘干、预缩和成品：对面料依次烘干、预缩和成品。
优选的，所述的棉纱选用10s-60s的单纱或股线；
所述复合增强纱为高强尼龙长丝、高强涤纶长丝、超高分子量聚乙烯纤维、芳纶1313、芳纶1414、PBO(聚对苯撑苯并二噁唑)纤维、聚苯硫醚、芳砜纶、聚亚酰胺纤维中的至少一种与棉纱并捻而成。
优选的，所述复合增强纱的纤度为200D-600D之间，与棉纱并捻捻度为40-200捻/10cm。
优选的，所述穿综和扒筘步骤中，采用顺穿法穿综，选用七片综框，边纱穿在第7片综框上，复合增强纱穿在第1、2两片综框上，地纱穿在第3、4、5、6片综框上；选用61号筘，每筘2入。
优选的，所述面料的基础组织为3/1左斜纹，经向棉纱与复合增强纱的比例为16:1，纬向棉纱与增强复合纱的比例为：19:1。
优选的，所述浆纱步骤中，双浸单压上浆工艺所用的粘着剂配比如下：变性淀粉43％，聚乙烯醇52％，羧甲基纤维素3％，渗透剂2％。
优选的，所述织造步骤中，第一织轴的张力为180kg，第二织轴的张力比第一织轴大10％；织机车速：550r/min，综平时间305°；
所述烧毛步骤中，将面料在气体烧毛机上烧毛，火焰温度为900℃，火焰口离布面的距离为1.5-2.0cm，采用两正一反烧毛工艺，车速为90-100m/min。
优选的，所述预处理步骤中，酶浆配比：复合酶15-20g/L，渗透剂：3g/L，PH值:7-10，对面料使用酶浆二浸二轧，轧余率100-110％，将轧浆处理后的面料打卷到转动轴上，并在布卷外包裹一层聚乙烯薄膜，转动轴以20-30°/s的速度做匀速圆周运动，室温堆放24h，接着先热水洗两遍，再冷水洗一遍；
所述煮练漂步骤中，对面料使用工作液二浸二轧，轧余率100％，然后在80℃的条件下汽蒸60min，最后充分水洗，工作液配比：复合酶制剂：6-8g/L，阴离子表面活性剂2-4g/L，过硫酸铵：4-8g/L，精炼剂：3-4g/L，过氧化氢：10-12g/L，活化剂：0.01g/L，氧漂稳定剂：0.5-1g/L，水玻璃：20-25g/L，PH：10-11。
优选的，所述丝光步骤中，氢氧化钠浓度为260-280g/L，车速为55-60m/min，PH：13-14；
所述染色步骤中，采用平缸染色，染色剂配方：KN型活性染料，六偏磷酸钠：3-5g/L，防染盐S：6-10g/L，匀染剂：10-15g/L，纯碱：10-20g/L，磷酸三钠5-10g/L，浴比为1:20-1:30；染色时，染液温度由室温以1.5-3.0℃/min的速度升至65℃，然后固色60min，接着进行水洗和皂洗，去除浮色。
优选的，所述阻燃步骤中，对面料使用阻燃整理液二浸二轧，轧余率70％～75％，然后100℃～120℃条件下预烘，接着在条件：液氨2kg/100m织物，80℃～100℃，90s下连续式氨熏，然后利用双氧水50g/L氧，接着水洗，阻燃整理液的配方：尿素初缩体：200g/L；柔软剂：20g/L；渗透剂JFC(脂肪醇聚氧乙烯醚)：1g/L；
所述烘干、预缩和成品步骤中，在130℃～140℃条件下烘干；预缩时，超喂20％-30％，橡胶毯压力1-1.5kg，温度：100-110℃，车速25-35m/min。
本发明的有益效果是：本发明通过纱线选择、织物结构设计及染色后整理工艺优化等手段达到提高撕破强力的目的。尤其是利用了纱线、织物结构与后整理工艺的协同作用共同提高面料的撕破强力，即同时提高纱线强力、增大撕裂时受力三角、后整理时不损伤面料强力以提高面料的撕裂强力，使得改进后阻燃面料的经、纬向撕破强力均大于60N，延长使用寿命。同时，能够丰富织物风格。
附图说明
图1是本发明的阻燃抗撕裂面料的生产方法的流程图。
具体实施方式
下面将结合附图对本发明作进一步说明。
由于起增强作用的长丝由多根复丝组成，织造时静电作用会使复丝蓬松起来并相互缠绕，从而造成开口不清，不利于生产的顺利进行。另外，因上述长丝的缩率与棉纱不同，将他们直接作为增强经纱或纬纱织成面料，经染色或后整理后，增强长丝在织物表面会扭结成圈，不仅影响产品外观，而且增加了次品率。为解决上述问题，我们一方面将棉纱与增强长丝并捻形成复合纱，通过增加捻度的形式增加各复丝之间的抱合力，从而减少织口开口不清，另一方面增强纱可作为骨架，在染色后整理时支撑棉纱，以降低棉纱与增强纱的缩率差，从而使织物表面无加强纱扭结成圈的现象，提高了产品的正品率。
请参阅图1，本发明的阻燃抗撕裂面料的生产方法，包括下列步骤：
步骤S1，整经：将占总经根数80％-95％的棉纱卷绕到第一织轴上，将占总经根数5％-20％的复合增强纱卷绕到第二织轴上，避免了单一织轴生产时增强部分因停经片下沉，生产效率低下的问题。其中，棉纱选用10s-60s的单纱或股线。复合增强纱为高强尼龙长丝、高强涤纶长丝、超高分子量聚乙烯纤维、芳纶1313、芳纶1414、PBO纤维、聚苯硫醚、芳砜纶、聚亚酰胺纤维中的至少一种与棉纱并捻而成。复合增强纱的纤度为200D-600D之间，与棉纱并捻捻度为40-200捻/10cm。
本实施例中，选用32s棉纱、300D高强涤纶长丝作为原材料。在倍捻机上将32s棉纱与300D高强涤纶长丝加捻成复合增强纱备用，使用前该复合纱至少在织造车间放置24h。复合纱捻度为:40捻/10cm，捻向：Z捻。
设定总经根数为6590根，其中复合增强纱382根，织物经密为405根/10cm，纬密为268根/10cm。将6208根32s棉纱卷绕到第一织轴上，382根复合增强纱卷绕到第二织轴上。
步骤S2，浆纱：以披覆为主，增强保伸为原则，采用双浸单压上浆工艺。以变性淀粉为主粘着剂，具体配比如下：变性淀粉43％，聚乙烯醇52％，羧甲基纤维素3％，渗透剂2％。
步骤S3，穿综和扒筘：对棉纱和复合增强纱进行穿综和扒筘，其采用顺穿法穿综，选用七片综框，边纱穿在第7片综框上，复合增强纱穿在第1、2两片综框上，地纱穿在第3、4、5、6片综框上；选用61号筘，每筘2入。
步骤S4，织造：利用第一织轴和第二织轴进行双轴织造得到面料；第一织轴的张力为180kg，第二织轴的张力比第一织轴大10％；织机车速：550r/min，综平时间305°，适当增加后梁高度；通过织物结构设计，使其提高撕裂强力作用的经纬纱基本处于面料反面，从而有利于织物风格的多样性。该面料的基础组织为3/1左斜纹，经向棉纱与复合增强纱的比例为16:1，纬向经纱与复合增强纱的比例为：18:1，此方法仅在面料背面隐约形成6mm的方格，但对正面的外观无影响。
步骤S5，烧毛：将面料缝头后在气体烧毛机上烧毛，火焰温度为900℃，火焰口离布面的距离为1.5-2.0cm，采用两正一反烧毛工艺，车速为90-100m/min。织物经烧毛后，轧酶浆灭火。
步骤S6，预处理：对面料进行酶浆冷堆预处理；酶浆配比：复合酶15-20g/L，渗透剂：3g/L，PH值:7-10，对面料使用酶浆二浸二轧，轧余率100-110％，将轧浆处理后的面料打卷到转动轴上，并在布卷外包裹一层聚乙烯薄膜，转动轴以20-30°/s的速度做匀速圆周运动，室温堆放24h，接着先热水洗两遍，再冷水洗一遍。
步骤S7，煮练漂：按煮练漂一步法对面料进行处理。对面料使用工作液二浸二轧，轧余率100％，然后在80℃的条件下汽蒸60min，最后充分水洗，工作液配比：复合酶制剂：6-8g/L，阴离子表面活性剂2-4g/L，过硫酸铵：4-8g/L，精炼剂：3-4g/L，过氧化氢：10-12g/L，活化剂：0.01g/L，氧漂稳定剂：0.5-1g/L，水玻璃：20-25g/L，PH：10-11。经上述方法进行前处理的面料，毛效达到11.5cm(30min)，白度为80，强力损损失8％。
步骤S8，丝光：在直辊丝光机上对面料进行丝光；氢氧化钠浓度为260-280g/L，车速为55-60m/min，PH：13-14。
步骤S9，染色：对面料采用平缸染色，染色剂配方：KN型活性染料，六偏磷酸钠：3-5g/L，防染盐S：6-10g/L，匀染剂：10-15g/L，纯碱：10-20g/L，磷酸三钠5-10g/L，浴比为1:20-1:30；染色时，染液温度由室温以1.5-3.0℃/min的速度升至65℃，然后固色60min，接着进行水洗和皂洗，去除浮色，保证面料的色牢度。
步骤S10，阻燃：对面料使用阻燃整理液二浸二轧，轧余率70％～75％，然后100℃～120℃条件下预烘，接着在条件：液氨2kg/100m织物，80℃～100℃，90s下连续式氨熏，然后利用双氧水50g/L氧，接着水洗，阻燃整理液的配方：尿素初缩体：200g/L；柔软剂：20g/L；渗透剂JFC：1g/L。
步骤S11，烘干、预缩和成品：对面料依次烘干、预缩和成品。其中，烘干温度130℃～140℃；预缩时，超喂20％-30％，橡胶毯压力1-1.5kg，温度：100-110℃，车速25-35m/min。
经上述方案生产的面料，撕裂时受力三角增大，从而提高了产品的撕裂强力。
以上实施例仅供说明本发明之用，而非对本发明的限制，有关技术领域的技术人员，在不脱离本发明的精神和范围的情况下，还可以作出各种变换或变型，因此所有等同的技术方案也应该属于本发明的范畴，应由各权利要求所限定。

Claims (10)

1.一种阻燃抗撕裂面料的生产方法，其特征在于，包括：
整经：将占总经根数80％-95％的棉纱卷绕到第一织轴上，将占总经根数5％-20％的复合增强纱卷绕到第二织轴上；
浆纱：采用双浸单压上浆工艺对棉纱进行上浆；
穿综和扒筘：对棉纱和复合增强纱进行穿综和扒筘；
织造：利用第一织轴和第二织轴进行双轴织造得到面料；
烧毛：对面料进行烧毛；
预处理：对面料进行酶浆冷堆预处理；
煮练漂：按煮练漂一步法对面料进行处理；
丝光：在直辊丝光机上对面料进行丝光；
染色：对面料进行染色；
阻燃：对面料浸轧阻燃整理液；
烘干、预缩和成品：对面料依次烘干、预缩和成品。
2.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述的棉纱选用10s-60s的单纱或股线；
所述复合增强纱为高强尼龙长丝、高强涤纶长丝、超高分子量聚乙烯纤维、芳纶1313、芳纶1414、PBO纤维、聚苯硫醚、芳砜纶、聚亚酰胺纤维中的至少一种与棉纱并捻而成。
3.根据权利要求2所述的阻燃抗撕裂面料的生产方法，其特征在于，所述复合增强纱的纤度为200D-600D之间，与棉纱并捻捻度为40-200捻/10cm。
4.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述穿综和扒筘步骤中，采用顺穿法穿综，选用七片综框，边纱穿在第7片综框上，复合增强纱穿在第1、2两片综框上，地纱穿在第3、4、5、6片综框上；选用61号筘，每筘2入。
5.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述面料的基础组织为3/1斜纹、3/1破斜纹或2/2方平组织，经向棉纱与复合增强纱的比例为16:1，纬向棉纱与增强复合纱的比例为：19:1；增强复合纱的组织为1/3或2/2加强斜纹。
6.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述浆纱步骤中，双浸单压上浆工艺所用的粘着剂配比如下：变性淀粉40-45％，聚乙烯醇50-55％，羧甲基纤维素3-5％，渗透剂1-5％。
7.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述织造步骤中，第一织轴的张力为180kg，第二织轴的张力比第一织轴大10％；织机车速：550r/min，综平时间305°；
所述烧毛步骤中，将面料在气体烧毛机上烧毛，火焰温度为900℃，火焰口离布面的距离为1.5-2.0cm，采用两正一反烧毛工艺，车速为90-100m/min。
8.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述预处理步骤中，酶浆配比：复合酶15-20g/L，渗透剂：3g/L，PH值:7-10，对面料使用酶浆二浸二轧，轧余率100-110％，将轧浆处理后的面料打卷到转动轴上，并在布卷外包裹一层聚乙烯薄膜，转动轴以20-30°/s的速度做匀速圆周运动，室温堆放24h，接着先热水洗两遍，再冷水洗一遍；
所述煮练漂步骤中，对面料使用工作液二浸二轧，轧余率100％，然后在80℃的条件下汽蒸60min，最后充分水洗，工作液配比：复合酶制剂：6-8g/L，阴离子表面活性剂2-4g/L，过硫酸铵：4-8g/L，精炼剂：3-4g/L，过氧化氢：10-12g/L，活化剂：0.01g/L，氧漂稳定剂：0.5-1g/L，水玻璃：20-25g/L，PH：10-11。
9.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述丝光步骤中，氢氧化钠浓度为260-280g/L，车速为55-60m/min，PH：13-14；
所述染色步骤中，采用平缸染色，染色剂配方：KN型活性染料，六偏磷酸钠：3-5g/L，防染盐S：6-10g/L，匀染剂：10-15g/L，纯碱：10-20g/L，磷酸三钠5-10g/L，浴比为1:20-1:30；染色时，染液温度由室温以1.5-3.0℃/min的速度升至65℃，然后固色60min，接着进行水洗和皂洗，去除浮色。
10.根据权利要求1所述的阻燃抗撕裂面料的生产方法，其特征在于，所述阻燃步骤中，对面料使用阻燃整理液二浸二轧，轧余率70％～75％，然后100℃～120℃条件下预烘，接着在条件：液氨2kg/100m织物，80℃～100℃，90s下连续式氨熏，然后利用双氧水50g/L氧，接着水洗，阻燃整理液的配方：尿素初缩体：200g/L；柔软剂：20g/L；渗透剂JFC：1g/L；
所述烘干、预缩和成品步骤中，在130℃～140℃条件下烘干；预缩时，超喂20％-30％，橡胶毯压力1-1.5kg，温度：100-110℃，车速25-35m/min。
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