CN116096959A - 利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法以及阻燃人造丝短纤维层压体 - Google Patents

利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法以及阻燃人造丝短纤维层压体 Download PDF

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CN116096959A
CN116096959A CN202180062288.3A CN202180062288A CN116096959A CN 116096959 A CN116096959 A CN 116096959A CN 202180062288 A CN202180062288 A CN 202180062288A CN 116096959 A CN116096959 A CN 116096959A
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weight
parts
laminate
flame
staple fiber
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朴润泰
许宁
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Meng Shangyong
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Meng Shangyong
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
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Abstract

本发明涉及一种阻燃人造丝短纤维的制造方法以及利用所述短纤维的阻燃人造丝短纤维层压体，其特征在于，通过在将利用短纤维制成的网状物含浸到对淀粉以及无机粉末进行混合的阻燃液中之后进行干燥，可以使得无机粉末借助于淀粉吸附到短纤维中而无法脱落，从而增强其阻燃效率，而且通过利用所述短纤维形成层压体，可以借助于淀粉提升强度并借此提升加工性以及成形性。

Description

利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法以及阻燃人造丝短纤维层压体
技术领域
本发明涉及一种利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法以及阻燃人造丝短纤维层压体，尤其涉及一种通过在将利用短纤维制成的网状物含浸到对利用淀粉的糊(以下称之为“淀粉糊”)以及二氧化硅水分散溶液进行混合的阻燃液中之后进行干燥，可以使得二氧化硅粉末借助于淀粉吸附到短纤维中而无法脱落，从而增强其阻燃效率，而且通过利用所述短纤维形成层压体，可以借助于淀粉糊提升强度并借此提升加工性以及成形性的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法以及阻燃人造丝短纤维层压体。
背景技术
在建筑材料以及产业用材料等方面，主要使用由岩棉、石膏板、玻璃纤维、发泡胶等隔热材料和压缩木材以及粘接剂构成的硬质板材等，但是目前已经得知如上所述的板材会释放出对人体有害的物质，而且因为无法进行再利用而具有如引起环境公害等问题。
目前已经提出了利用废旧化学纤维制造板材的方法。例如，在韩国公开专利公报公告第87-5764号中，提出了一种将纤维状的聚丙烯细切粉碎并将如腈纶、涤纶以及尼龙等化学纤维裁切成10mm以上，并将其投入到梳棉机中而制成网状物(web)，接下来在加热室中对其进行一定时间的加热之后再进行切割而制成的挤压板形态的化学纤维板材。但是，所述方法将化学纤维物质切割成10mm左右的短纤维，从而因为短纤维之间的缠结较少而具有易于破碎的问题。此外，如上所述的板材会在发生火灾时因为生成烟气以及有害气体而不适合于作为建筑内饰材料使用。
此外，在韩国专利公报公告第95-6863号中，提出了一种在将废旧化学纤维切割成50～100mm左右的长纤维之后在轧棉机中进行轧棉而制作成棉花状态，然后再将其制作成一定厚度的垫子形态，接下来在将其层压成适当厚度的层之后利用高热以及高压对其进行加热加压，从而使得纤维之间彼此形成为一体的化学纤维板材的制造方法。但是，因为通过如上所述的方法制造出的化学纤维板材是在高温以及高压下成型，因此会导致纤维构成物质即聚合物物质的分解，而且还具有纤维的固有特性丧失的问题。
为了解决如上所述的问题，开发出了通过对利用普通涤纶纤维以及低熔点涤纶纤维制成的网状物进行融合而制造除聚酯纤维板材的方法。但是，虽然如上所述的聚酯纤维板材在保温性、隔热性、冲击吸收性、弹性以及外观等方面非常适合于作为建筑内饰材料使用，但是在发生火灾时在阻燃性方面存在问题。
此外，因为如上所述的现有的方法使用化学纤维，因此还具有作业环境差以及生成环境公害物质等问题。此外，如上所述的板材会在发生火灾时因为生成烟气以及有害气体而不适合于作为建筑内饰材料使用。
为了解决如上所述的现有问题，采用在含浸到对人造丝纤维以及无机粉末进行混合的阻燃液中并进行干燥之后使用的方式，但是如上所述的现有的利用阻燃人造丝短纤维的层压体会因为残留在短纤维表面的无机粉末脱落而导致粉末粉体飞散的问题，而且即使是抖落残留在短纤维表面的无机粉末的情况下，因为渗入到纤维内部的无机粉末并没有被固定，因此在经过一定时间之后会渗出到外部并导致阻燃性下降的问题，而且现有的通过对人造丝短纤维进行层压而形成的层压体的强度显著较低，因此会导致成形性以及加工性下降的问题。
为了解决如上所述的现有问题，采用通过将短纤维层压成较厚的厚度而增强其强度并通过以高密度进行挤压成型而确保其强度的方式，但是在以高密度进行挤压时虽然可以增强其强度，但是同时会导致吸音性下降的问题，而且因为使用大量的短纤维而在对所述短纤维层压体进行废弃时会导致产生大量短纤维的环境污染问题。
发明内容
本发明旨在解决如上所述的现有问题而提供一种通过在将利用短纤维制成的网状物含浸到对利用淀粉的糊以及二氧化硅水分散溶液进行混合的阻燃液中之后进行干燥，可以使得二氧化硅粉末吸收淀粉并使得二氧化硅粉末借助于淀粉糊吸附到短纤维中而无法脱落，从而增强其阻燃效率，而且可以借助于淀粉糊提升强度并借此提升加工性以及成形性的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法以及阻燃人造丝短纤维层压体。
为了解决如上所述的课题，本发明的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于，包括：梳棉工程S 100，利用开棉装置将短纤维开棉成原纱，并利用一定厚度以及宽度的梳棉装置将所开棉的纤维制作成网状物；网状物层压工程S200，通过对利用所述开棉装置形成的网状物进行多次层压而形成网状物层压物；针刺工程S300，在将所述网状物层压至一定的厚度之后，通过对所层压的网状物进行针刺而使其具有可彼此缠结不散开并维持所层压的形态的结合力；含浸工程S400，执行通过对25至30重量份的二氧化硅粉末、65至72重量份的蒸馏水以及3至5重量份的醋酸进行混合而制造出二氧化硅水分散溶液的第一工程和在向55至60重量份的通过所述第一工程制造出的二氧化硅水分散溶液混合34至41重量份的烷氧基硅烷以及4至6重量份的光催化材料之后利用混合器执行聚合反应的第二工程之后，通过向25至35重量份的通过所述第二工程制造出的缩合反应溶液混合55至70重量份的硅酸盐以及5至10重量份的丙烯的方式形成混合液，接下来通过向所述混合液以9:1～8:2重量％混合利用淀粉的糊的方式形成阻燃液，最后通过将所述经过针刺的网状物层压物含浸到填充有所述阻燃液的灌中而使得短纤维具有阻燃效果；水分去除工程S500，为了去除所述经过含浸的网状物中的水分而使其通过成对构成的滚筒；表面整理工程S600，为了去除附着在所述去除水分之后的网状物表面的无机粉末而在从上部喷射空气的同时从下部吸入空气；以及，干燥工程S700，对执行所述表面整理工程之后的具有可湿性的网状物层压物进行干燥。
本发明的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：在所述含浸工程中，在执行通过将网状物层压物浸渍到混合有二氧化硅粉末的混合液中而使其吸收混合液的第一次含浸之后再进行干燥，接下来执行将网状物层压物浸渍到通过向所述混合液混合淀粉糊而形成的阻燃液中的第二次含浸。
本发明的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：所述混合液，是执行通过对25至30重量份的二氧化硅粉末、65至72重量份的蒸馏水以及3至5重量份的醋酸进行混合而制造出二氧化硅水分散溶液的第一工程和在向55至60重量份的通过所述第一工程制造出的二氧化硅水分散溶液混合34至41重量份的烷氧基硅烷以及4至6重量份的光催化材料之后利用混合器执行聚合反应的第二工程之后，向25至35重量份的通过所述第二工程制造出的缩合反应溶液混合55至70重量份的硅酸盐以及5至10重量份的丙烯的方式形成。
本发明的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：所述聚合反应，是在生成65～75℃的反应热的条件下执行8小时以上的反应。
通过如上所述的本发明的制造方法制造出的短纤维层压体，作为一种阻燃人造丝短纤维层压体，通过在将利用短纤维制成的网状物含浸到对利用淀粉的糊以及二氧化硅水分散溶液进行混合的阻燃液中之后进行干燥，可以使得二氧化硅粉末借助于淀粉糊吸附到短纤维中而无法脱落，从而增强其阻燃效率，而且可以通过利用如上所述的网状物形成层压体而提升强度并借此提升加工性以及成形性。
此外，本发明的阻燃人造丝短纤维层压体，其特征在于：在所述人造丝短纤维的内侧吸附有二氧化硅粉末，在外侧吸附有对淀粉糊进行吸附的二氧化硅粉末以及淀粉糊。
如上所述的本发明，本发明因为在短纤维表面没有无机粉末(阻燃材料)残留而不会发生粉末粉尘飞散的问题，而且即使是在经过一定的时间之后也不会导致渗入到纤维内部的无机粉末渗出到外部的问题，因此通过如上所述的本发明的阻燃人造丝短纤维制造方法制造出的阻燃人造丝短纤维具有优秀的品质，而且即使是在经过一定的时间之后也可以确保无机粉末固定附着在纤维内部并借此防止阻燃性下降的问题，此外在对大量的短纤维层压至较厚的厚度且为了形成一定的强度而已高密度进行挤压的制造方法中，即使是使用较少量的短纤维也可以提升其强度，因此可以提升成形性和加工性以及吸引性，还可以在对短纤维层压体进行废弃时只生成较少量的短纤维，是一种非常有用的发明。
附图说明
图1是对本发明的阻燃人造丝短纤维的制造方法进行图示的例示图。
图2是对本发明的另一实施例进行图示的制造工程图。
图3是对本发明的技术要旨即含浸工程的一实例进行图示的例示图。
图4a是对在将人造丝纤维含浸到在本发明中使用的混合液之后的短纤维的截面进行例示的示意图。
图4b是对在将人造丝纤维含浸到在本发明中使用的阻燃液之后的短纤维的截面进行例示的示意图。
图4c是对在将人造丝纤维第一次含浸到在本发明中使用的混合液并进行干燥之后再第二次含浸到阻燃液之后的短纤维的截面进行例示的示意图。
具体实施方式
接下来，参阅附图对本发明的较佳实施例进行详细的说明如下。
图1是对本发明的阻燃人造丝短纤维的制造方法进行图示的例示图，本发明执行利用开棉装置将短纤维开棉成类似于羽毛的原纱，并利用一定厚度以及宽度的梳棉装置将所开棉的纤维制作成网状物的梳棉工程S 100。此时所使用的的短纤维，是一种可以吸收后续说明的阻燃液的纤维类型，即如天然纤维、人造丝或对人造丝以及LM纱进行混合的纤维。
接下来，执行将利用所述开棉装置形成的网状物均匀地铺设到移送带上且为了形成一定的厚度而利用网状物层压装置对网状物进行多次层压并借此形成网状物层压物的网状物层压工程S200。
在通过所述网状物层压工程S200制造出短纤维层压体之后，执行通过对所层压的网状物进行针刺而使其具有可彼此缠结不散开并维持所层压的形态的结合力的针刺工程S300。
此外，如图2所示，也可以在网状物层压工程S200与针刺工程S300之间，执行在将通过所述网状物层压装置层压至一定高度的网状物层压物移送至移送带的同时在经由加热/挤压装置时对网状物层压物进行加热以及挤压并借此将层压至一定厚度如300mm的网状物层压物调节至50mm厚度的厚度调节工程S800，从而形成短纤维层压体。
在通过所述厚度调节工程S800制造出短纤维层压体之后，执行通过对所层压的网状物进行针刺而使其具有可彼此缠结不散开并维持所层压的形态的结合力的针刺工程S300。
此外，如图1至图2所示，执行通过对25至30重量份的二氧化硅粉末、65至72重量份的蒸馏水以及3至5重量份的醋酸进行混合而制造出二氧化硅水分散溶液的第一工程和在向55至60重量份的通过所述第一工程制造出的二氧化硅水分散溶液混合34至41重量份的烷氧基硅烷以及4至6重量份的光催化材料之后利用混合器执行聚合反应的第二工程之后，执行通过向25至35重量份的通过所述第二工程制造出的缩合反应溶液混合55至70重量份的硅酸盐以及5至10重量份的丙烯的方式形成混合液，接下来通过向所述混合液以9:1～8:2重量％混合利用淀粉的糊的方式形成阻燃液，最后通过将所述经过针刺的网状物层压物含浸到填充有所述阻燃液的灌中而使得短纤维具有阻燃效果的含浸工程S400。
在所述阻燃液的制造工程中，在采用重量份的下限值时虽然硬度会有所下降但粘附性优秀，而在采用上限值时虽然其表面硬度优秀但具有粘附性有所下降的问题。此外，可以向所述无机粉末混合氟碳树脂粉末使用。
此外，所述二氧化硅粉末以及氟碳树脂粉末使用100～200目的粒度大小，这是因为在粒度大小为100目以下的情况下，可能会导致在干燥之后轻易地从人造丝纤维脱离的问题，而在粒度大小为200目以上的情况下，可能会因为难以含浸到人造丝纤维而导致只残留在表面的问题。
所述二氧化硅粉末具有阻燃效果，而氟碳树脂粉末具有延迟起火的效果，在起火时氟碳树脂粉末将发生熔融并向下流动，从而抑制火灾的蔓延。
此外，无机粉末即二氧化硅粉末可以在发生火灾时抑制人造丝纤维起火，而且即使是在起火的情况下也可以在灭火时吸收自身体积的2～3倍的水分，从而在平时处于吸收水分的状态并在起火时通过排出水分而起到抑制起火的效果。
如图4a所示，在所述含浸工程S400中，在将人造丝纤维含浸到不包含淀粉的混合液中并进行干燥的情况下，对其截面构成进行观察可以发现，在吸附混合液的人造丝纤维的内侧只有无机粉末即二氧化硅粉末存在，因此在执行后续说明的水分去除工程S500、表面整理工程S600以及干燥工程S700时，接近人造丝纤维表面的部分的二氧化硅粉末将发生脱落。
但是如图4b所示，在将人造丝纤维含浸到阻燃液中的情况下，淀粉被吸附到人造丝纤维的表面且吸附有淀粉的二氧化硅粉末被吸附到人造丝纤维，从而在执行后续说明的水分去除工程S500、表面整理工程S600以及干燥工程S700时，吸附到人造丝纤维的淀粉以及吸附有淀粉的二氧化硅粉末将不会发生脱落。但是，因为淀粉糊的吸水量较少的性质，二氧化硅粉末的吸附量也将变少。
利用如上所述的性质，如图3所示，在将含浸工程S400分成在第一次含浸到混合液之后再第二次含浸到阻燃液中的方式执行的情况下，如图4c所示，在人造丝纤维的内侧吸附有没有吸附淀粉的二氧化硅粉末，而在外部表面一侧有吸附有淀粉的二氧化硅粉末以及淀粉残留，因此没有吸附淀粉的二氧化硅粉末将被人造丝纤维内侧的淀粉包围阻挡，从而无法渗出到外部。
此外，因为在执行所述含浸工程S400的过程中，会有阻燃液被吸入到网状物层压物中，因此为了挤出阻燃液，将执行使其通过成对构成的滚筒的水分去除工程S500。在所述水分去除工程S500中，采用以网状形态形成且由具有一对滚筒的压辊构成的挤压机为宜。这是因为可以在挤压时轻易地对水分进行排出。
如上所述，在完成水分去除工程S500之后，为了去除粘附在已去除水分的网状物表面的无机粉末，执行在从上部喷射空气的同时从下部吸入空气的表面整理工程S600。层压物伴随着移送带进行移动并从所移动的层压物的上部通过喷嘴将空气喷射到层压物的上部，此时作为移送带使用在移送带上形成有多个通孔或网状形态的移送带，从而可以对空气进行吸入的结构的移送带。
之所以在所述表面整理工程S600中使用空气，是因为可以在通过短纤维与短纤维之间的空隙的过程中抖落附着在短纤维表面的无机粉末并对短纤维的表面进行干燥，而如果只是从上部喷射空气，可能会导致空气无法通过层压物的问题发生，因此必须同时进行吸入。
此外，在执行所述表面整理工程之后，执行对具有可湿性的网状物层压物进行干燥的干燥工程S700，在所述干燥工程S700中，使用干燥机或烘箱且加热温度为60～90℃。所述温度范围是为了防止人造丝纤维发生变形。
通过如下所述的试验，对按照如上所述的方式制造出的本发明的短纤维层压体丝绵以及现有的短纤维层压体丝绵的最大热释放率、收缩率以及弹性力进行了调查。
试验方法：KS F 2271
试验方法：KS F ISO 5660-1(燃烧性能试验)
试验条件：
【比较例1】
将利用由100％人造丝构成的5.6旦尼尔且长度为64mm的纤维制造出的重量为780g/m2且厚度为8mm的经过针刺的短纤维层压体含浸到陶瓷阻燃液(由(株)LCOCITY销售的单液型常温固化环保水溶性无机质陶瓷树脂)之后进行干燥。
【试验例1】
将利用由100％人造丝构成的5.6旦尼尔且长度为64mm的纤维制造出的重量为780g/m2且厚度为8mm的经过针刺的短纤维层压体含浸到阻燃液之后进行干燥。
【试验例2】
将利用由100％人造丝构成的5.6旦尼尔且长度为64mm的纤维制造出的重量为780g/m2且厚度为8mm的经过针刺的短纤维层压体含浸到混合液之后进行干燥，接下来在再次含浸到阻燃液之后进行干燥。
【表1】
Figure BDA0004119188390000111
通过所述表1可以确认，在对网状物进行层压时，通过将所层压的网状物含浸到阻燃剂中且在含浸到混合液中之后再含浸到阻燃剂中，可以使得阻燃材料渗透到短纤维层压体的表面乃至于内部，从而不仅可以提升阻燃性，还可以为阻燃剂赋予粘附性，从而使得短纤维的强度***并降低其弹性力。
如上所述的本发明，本发明因为在短纤维表面没有无机粉末(阻燃材料)残留而不会发生粉末粉尘飞散的问题，而且即使是在经过一定的时间之后也不会导致渗入到纤维内部的无机粉末渗出到外部的问题，因此通过如上所述的本发明的阻燃人造丝短纤维制造方法制造出的阻燃人造丝短纤维具有优秀的品质，而且即使是在经过一定的时间之后也可以确保无机粉末固定附着在纤维内部并借此防止阻燃性下降的问题，此外在对大量的短纤维层压至较厚的厚度且为了形成一定的强度而已高密度进行挤压的制造方法中，即使是使用较少量的短纤维也可以提升其强度，因此可以提升成形性和加工性以及吸引性，还可以在对短纤维层压体进行废弃时只生成较少量的短纤维，是一种非常有用的发明。
【符号说明】
S 100：梳棉工程
S200：网状物层压工程
S300：针刺工程
S400：含浸工程
S500：水分去除工程
S600：表面处理工程
S700：干燥工程
S800：厚度调节工程

Claims (6)

1.一种利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于，包括：
梳棉工程(S100)，利用开棉装置将短纤维开棉成原纱，并利用一定厚度以及宽度的梳棉装置将所开棉的纤维制作成网状物；
网状物层压工程(S200)，通过对利用所述开棉装置形成的网状物进行多次层压而形成网状物层压物；
针刺工程(S300)，在将所述网状物层压至一定的厚度之后，通过对所层压的网状物进行针刺而使其具有可彼此缠结不散开并维持所层压的形态的结合力；
含浸工程(S400)，执行通过对25至30重量份的二氧化硅粉末、65至72重量份的蒸馏水以及3至5重量份的醋酸进行混合而制造出二氧化硅水分散溶液的第一工程和在向55至60重量份的通过所述第一工程制造出的二氧化硅水分散溶液混合34至41重量份的烷氧基硅烷以及4至6重量份的光催化材料之后利用混合器执行聚合反应的第二工程之后，通过向25至35重量份的通过所述第二工程制造出的缩合反应溶液混合55至70重量份的硅酸盐以及5至10重量份的丙烯的方式形成混合液，接下来通过向所述混合液以9:1～8:2重量％混合利用淀粉的糊的方式形成阻燃液，最后通过将所述经过针刺的网状物层压物含浸到填充有所述阻燃液的灌中而使得短纤维具有阻燃效果；
水分去除工程(S500)，为了去除所述经过含浸的网状物中的水分而使其通过成对构成的滚筒；
表面整理工程(S600)，为了去除附着在所述去除水分之后的网状物表面的无机粉末而在从上部喷射空气的同时从下部吸入空气；以及，
干燥工程(S700)，对执行所述表面整理工程之后的具有可湿性的网状物层压物进行干燥。
2.根据权利要求1所述的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：
在所述含浸工程中，在执行通过将网状物层压物浸渍到混合有无机粉末的混合液中而使其吸收混合液的第一次含浸之后再进行干燥，接下来执行将网状物层压物浸渍到通过向所述混合液混合淀粉糊而形成的阻燃液中的第二次含浸。
3.根据权利要求1所述的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：
所述混合液，是执行通过对25至30重量份的二氧化硅粉末、65至72重量份的蒸馏水以及3至5重量份的醋酸进行混合而制造出二氧化硅水分散溶液的第一工程和在向55至60重量份的通过所述第一工程制造出的二氧化硅水分散溶液混合34至41重量份的烷氧基硅烷以及4至6重量份的光催化材料之后利用混合器执行聚合反应的第二工程之后，向25至35重量份的通过所述第二工程制造出的缩合反应溶液混合55至70重量份的硅酸盐以及5至10重量份的丙烯的方式形成。
4.根据权利要求1所述的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：
向所述二氧化硅粉末混合氟碳树脂粉末。
5.根据权利要求1所述的利用人造丝短纤维的具有阻燃性的短纤维层压体的制造方法，其特征在于：
所述聚合反应，是在生成65～75℃的反应热的条件下执行8小时以上的反应。
6.一种阻燃人造丝短纤维层压体，其特征在于：
通过在将利用短纤维制成的网状物含浸到对利用淀粉的糊以及二氧化硅水分散溶液进行混合的阻燃液中之后进行干燥，可以使得二氧化硅粉末借助于淀粉糊吸附到短纤维中而无法脱落，从而增强其阻燃效率，而且可以通过利用如上所述的网状物形成层压体而提升强度并借此提升加工性以及成形性，在所述人造丝短纤维的内侧吸附有二氧化硅粉末，在外侧吸附有对淀粉糊进行吸附的二氧化硅粉末以及淀粉糊。
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