WO2019148487A1 - 一种超细纤维面料及其制造工艺 - Google Patents

一种超细纤维面料及其制造工艺 Download PDF

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Publication number
WO2019148487A1
WO2019148487A1 PCT/CN2018/075239 CN2018075239W WO2019148487A1 WO 2019148487 A1 WO2019148487 A1 WO 2019148487A1 CN 2018075239 W CN2018075239 W CN 2018075239W WO 2019148487 A1 WO2019148487 A1 WO 2019148487A1
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WO
WIPO (PCT)
Prior art keywords
fabric
island
needle
impregnation
polyester
Prior art date
Application number
PCT/CN2018/075239
Other languages
English (en)
French (fr)
Inventor
钱国春
包旭旭
李梦娟
隋晓锋
Original Assignee
浙江梅盛新材料有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 浙江梅盛新材料有限公司 filed Critical 浙江梅盛新材料有限公司
Priority to EP18900566.3A priority Critical patent/EP3561164A4/en
Priority to PCT/CN2018/075239 priority patent/WO2019148487A1/zh
Priority to CN201880000055.9A priority patent/CN109154135B/zh
Publication of WO2019148487A1 publication Critical patent/WO2019148487A1/zh

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0013—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using multilayer webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C11/00—Teasing, napping or otherwise roughening or raising pile of textile fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
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    • D06C7/02—Setting
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0004—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using ultra-fine two-component fibres, e.g. island/sea, or ultra-fine one component fibres (< 1 denier)
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0034—Polyamide fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0036—Polyester fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/16—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using dispersed, e.g. acetate, dyestuffs
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
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    • D06P3/54—Polyesters using dispersed dyestuffs
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • D06P3/8214—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing ester and amide groups
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    • D06N2211/14—Furniture, upholstery
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    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/28—Artificial leather

Definitions

  • the invention relates to a superfine fiber fabric and a manufacturing process thereof, and belongs to the technical field of high-grade textile fabrics.
  • Microfiber is the abbreviation of microfiber PU synthetic leather.
  • the island-type microfiber is a kind of microfiber, which is divided into two types: island filament and island staple fiber (including fixed island type and indeterminate island type).
  • Island filaments are generally produced by weaving and knitting to produce suede fabrics for the production of clothing and apparel;
  • island staple fibers are usually produced by needle-punched nonwovens to produce thick faux leather fabrics, mainly used in shoes, sofas, and automotive interiors. , clothing, etc. All super-fiber fabrics generally have the highest purpose of achieving high-simulation leather.
  • the fixed-size super-fabric fabrics use alkali reduction to open the fiber, which is safer and more environmentally friendly than the indeterminate island-type microfiber fabric.
  • Ordinary microfiber needle-punched non-woven fabrics are usually made by ultra-short staple fibers through unpacking, mixing, carding, laying, acupuncture, etc., which are expensive to invest in equipment, high in production process conditions, and high in energy consumption.
  • the output is low, the average thickness of the fabric and the difficulty of the weight control are high, which brings difficulties to the subsequent resin impregnation and dyeing deep processing.
  • the thickness specifications of the produced fabrics are limited, and generally only 0.5-2.0mm medium thickness and no elastic specifications are produced. For the grey fabric, it is not possible to directly produce a grey fabric having a thickness of 0.5 mm or less and having an elastic type.
  • the applicant has conducted a special study to develop a microfiber fabric and a manufacturing process thereof, and the present invention is produced.
  • an object of the present invention is to provide a microfiber fabric having high strength and thin thickness and a manufacturing process thereof.
  • the technical solution adopted by the present invention is as follows:
  • the invention is for filling the specifications of the super-fiber fabric of 0.5 mm or less, adopting the ultra-fine fiber filament, and producing the elastic fabric with the thickness of 0.5 mm or less through the knitting, pulling and bristing process, and then impregnating and opening the fiber by the resin. Finishing after dyeing, sanding, etc., can be applied to automotive interiors, apparel and other fields.
  • a microfiber fabric comprising a base portion and a surface portion, the base portion being composed of island-type island filaments or/and ordinary filaments, the surface portion being composed of short fibers, the fabric being a base portion and a surface Partially entangled nonwoven structures.
  • the base portion further comprises a polyester high strength yarn having a fineness of 75-100D.
  • the island-type island filaments are polyester island filaments or/and nylon island filaments having a fineness of 75-150D
  • the ordinary filaments are polyester filaments or/and nylon filaments, and the fineness is 50D-200D
  • the short fibers are polyester island staple fibers or/and nylon island staple fibers.
  • the finished product of the microfiber fabric has a thickness of 0.5 mm or less.
  • a manufacturing process of a microfiber fabric wherein the island portion of the island-shaped island filament or/and the ordinary filament is passed through a weft-knitted, warp-knitted or woven process, and then a napped layer is formed on the surface by a napping process, in the napped layer
  • the short fiber is laid on the upper layer, and the non-woven structure of the short fiber and the surface of the substrate is formed by a non-woven complexing technique, and then subjected to impregnation, drying, fiber opening, dyeing and post-treatment to obtain a microfiber fabric, specifically including The following steps:
  • the height of the control coil is between 0.2 and 0.3 cm
  • the weight of the grey fabric is 200-300 g/m 2
  • the width of the door is 170-200 cm.
  • the fabric is pulled 4 times by a pulverizer, and the hair can be pulled out completely so that the length of the pile is 0.5-2.5 cm.
  • one to three layers of non-woven needle-punched fibers are evenly spread on the drawn product by the wire forming machine, and the weight per layer is 10-20 g, and the laying machine is out of the net.
  • the speed is 0.3-0.5 m/min.
  • the needle-punched needle is punctured 4 times or more, and the composite base fabric is obtained by entanglement of the non-woven needle-punched fiber.
  • the needle-punching pressure parameter of the non-woven fabric is 6 kg, and the frequency of the needle punching machine is controlled at 500-900 thorns/min, needle board cloth needle density is 7500 needles/m 2 , producing a composite base fabric with a thickness of 0.45-1.0 mm, a gram weight of 250-350 g/m 2 and a door width of 170-200 cm.
  • the composite base fabric is pre-shrinked in the cylinder, and the pre-shrinking temperature is 130° C.-180° C., and the time used is 30-60 min.
  • the pre-shrinking can further increase the fabric density and reduce the use of the water-based polyurethane. Improve resilience and improve hand feeling.
  • the step (6) is the first drying and the first shaping: the composite base cloth is placed on the shaping machine movement to dry and trim the control door width, the drying temperature is 110-130 ° C, and the drying density is according to the density of the fabric. It is suitable to adjust the temperature and the speed of the car, and to dry and bake outside the slab.
  • the weight gain of the polyurethane is 8% ⁇ 2%.
  • alkali reduction amount of opening alkali concentration is 5%, temperature is 5 ° C / min, high temperature zone temperature is 96-110 ° C, the time used is 45-60 min, the fiber opening rate is 18% - 35%
  • the citric acid is used, and the pH is adjusted to 6-7, and the continuous cylinder is washed with a countercurrent flow.
  • the step (9) is followed by the second drying and the second setting: drying and setting after impregnation and alkali reduction, to facilitate sanding.
  • the step (10) is first sanding, and the surface of the composite base fabric is uneven after the fiber is opened, and the composite base cloth can be uniformly colored after being ground.
  • the dyeing in the step (11) after the joint of the composite base cloth, the dyeing, reduction washing, dehydration and shaping of the cylinder are controlled, and the initial dyeing temperature of the disperse dye is controlled at room temperature to 60 ° C at the initial dyeing, and gradually increases to 130 ° C after 1 h. , keep warm for 1 ⁇ 2h, then wash thoroughly, and carry out reduction and cleaning when dyed dark.
  • the disperse dye is prepared by a high-temperature leveling agent, a diffusing agent and an acetic acid having a concentration by weight of 98%.
  • the amount of the high-temperature leveling agent is 0.2-1.2 g/L and the amount of the diffusing agent is 0.5-liter per liter of the dye. 1g / L, the amount of acetic acid is 0.5 ⁇ 1.5g / L.
  • the amount of caustic soda is 6ml/L
  • the amount of insurance powder is 2.5g/L
  • the amount of dispersing agent is 0.1-0.5g/L.
  • the step (12) is the third drying and the third shaping: drying and setting again after the reduction cleaning, and controlling the temperature of the base cloth to be 100° C.-170° C., and the vehicle speed is adjusted to 5-30 m/min. , the speed is 30-60 m / min;
  • the step (13) is second grinding: the conventional product makes the length of the cloth surface uniform and the pile is not qualified. If the customer has a "writing effect" on the cloth surface, the length of the pile can be retained.
  • the step (14) is the fourth drying and the fourth setting: finally finalizing according to the product requirements;
  • the step (15) checks, rolls, and stores.
  • the invention fills in the blank specification blank of the normal production of the needle-punched nonwoven fabric (not adding the mechanical sheet process), and can produce the finished product having a thickness of 0.5 mm or less;
  • the fabric produced by the present invention can be selected from fibers having different properties from the grey cloth when laying the net, such as polyester filament yarn (whether polyester high-strength yarn or nylon filament, please confirm) when knitting, and nylon when laying the net.
  • the staple fiber makes the laid fiber and the grey fabric fiber entangled, and since the dye can be dispersed only when dyeing, the disperse dye does not color the nylon staple fiber, and a white color with an arbitrary color is formed on the surface of the fabric. Enriching the apparent color of the fabric, the process of the invention can realize the two-color effect of the finished fabric, and adopting the above-mentioned white dyeing process to have a very good two-color effect, high-grade appearance;
  • the fabric fabric structure of the invention has good resilience, the conventional water-based resin and the water-based polyurethane are added in an amount of 50%, which has both skin feeling and realistic elastic elongation of 10-30%, which is more common.
  • the chemical fiber fabric is more emulsive and more resilient than natural leather, thus expanding the application range of the fabric. It can be applied to high-end fabrics such as automotive interiors and women's spring and autumn fashions that require elastic extensibility to improve product market competitiveness. ;
  • the fabric produced by the process of the invention retains the drape of the knitted fabric, and after adding the ultrafine staple fiber by acupuncture, the moisture permeability thereof is increased, which can meet various needs of the apparel field; Net encryption, the sound insulation of the fabric is greatly improved, and the sound insulation function of the decorative materials of the automobile and the home interior can be enhanced;
  • the production process of the invention saves 3/5, the production capacity is increased by 2 times and the energy consumption is basically flat, the raw material cost is reduced by 1/5, the CV value is controlled easily, and the height can be realized. High-quality and high-volume production, and the raw materials used in the process are in line with environmental requirements.
  • the raw material of the microfiber fabric is one of the following raw material combinations:
  • Base part 75D polyester island filament and 75D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 75D nylon island filament and 75D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 75D polyester island filament, 50D polyester filament and 75D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 75D polyester island filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 75D nylon island filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 75D polyester island filament, 50D nylon filament and 75D polyester high-strength yarn; surface part of nylon island staple fiber; or,
  • Base part 75D polyester island filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 75D nylon island filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 75D polyester island filament, 75D nylon island filament and 75D polyester high-strength yarn; surface part of nylon island staple fiber and polyester island staple fiber; or,
  • Base part 50D polyester filament and 75D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 50D nylon filament and 75D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 50D polyester filament, 50D nylon filament and 75D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 50D polyester filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 50D nylon filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 50D polyester filament, 75D nylon island filament and 75D polyester high-strength yarn; surface part of nylon island staple fiber; or,
  • Base part 50D polyester filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 50D nylon filament and 75D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 50D nylon filament, 75D nylon island filament and 75D polyester high-strength yarn; surface part of nylon island staple fiber and polyester island staple fiber.
  • the above fabric can pass through the manufacturing process of the following microfiber fabric, and specifically includes the following steps:
  • the fabric is drawn 4 times by a 24-roll strong plucking machine, and the grammage is 200-300 g/m 2 .
  • step (3) a layer of non-woven needle-punched fibers is evenly spread on the drawn product by the wire forming machine, and the speed of the netting machine is 0.3 m/min.
  • the composite base fabric is obtained by needle punching 4 times or more, the needle punching pressure parameter when non-woven is 6 kg, the frequency of the needle punching machine is 500 thorn/min, and the needle board cloth needle density At 7500 needles/m 2 , a composite base fabric having a thickness of 0.6 mm and a basis weight of 250 g/m 2 was produced.
  • the pre-shrinking temperature was 130 ° C, and the time used was 30 min.
  • the step (7) includes a first impregnation and a second impregnation, the first impregnation: an aqueous resin having a immersion concentration of 10%, a vehicle speed of 5 m/min, a liquid volume of 120%, and a pressure roller pressure. It is 0.5 MPa; the second impregnation: an aqueous polyurethane having a immersion liquid concentration of 12%, a vehicle speed of 7 m/min, a liquid volume of 120%-, and a pressure roller pressure of 0.5 MPa.
  • the dyeing in the step (11) after the seam of the grey cloth, the dyeing, reduction, washing, dehydration and shaping of the cylinder, the initial dyeing temperature is 50 ° C at the initial dyeing, the temperature is gradually raised to 130 ° C after 1 h, the heat is kept for 1 h, and then fully washed and dyed. Reductive cleaning in dark colors.
  • the finished product has a weight of 280-290 g/m 2 and a thickness of 0.50 mm.
  • the raw material of the microfiber fabric is one of the following raw material combinations:
  • Base part 110D polyester island filament and 85D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 110D nylon island filament and 85D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 110D polyester island filament, 125D polyester filament and 85D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 110D polyester island filament and 85D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 110D nylon island filament and 85D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 110D polyester island filament, 125D nylon filament and 85D polyester high-strength yarn; surface part of nylon island staple fiber; or,
  • Base part 110D polyester island filament and 85D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 110D nylon island filament and 85D polyester high-strength yarn
  • surface part nylon island staple fiber and polyester island staple fiber
  • Base part 110D polyester island filament, 110D nylon island filament and 85D polyester high-strength yarn; surface part of nylon island staple fiber and polyester island staple fiber; or,
  • Base part 125D polyester filament and 85D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 125D nylon filament and 85D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 125D polyester filament, 125D nylon filament and 85D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 125D polyester filament and 85D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 125D nylon filament and 85D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 125D polyester filament, 110D nylon island filament and 85D polyester high-strength yarn; surface part of nylon island staple fiber; or,
  • Base part 125D polyester filament and 85D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 125D nylon filament and 85D polyester high-strength yarn
  • surface part nylon island staple fiber and polyester island staple fiber
  • Base part 125D nylon filament, 110D nylon island filament and 85D polyester high-strength yarn; surface part of nylon island staple fiber and polyester island staple fiber;
  • the manufacturing process of the above microfiber fabric specifically includes the following steps:
  • the fabric is drawn 4 times by a 24-roll strong plucking machine, and the grammage is 200-300 g/m 2 .
  • step (3) two layers of non-woven needle-punched fibers are uniformly spread on the drawn product by the wire forming machine, and the speed of the netting machine is 0.4 m/min.
  • the composite base fabric is obtained by needle punching 4 times or more, the needle punching pressure parameter when non-woven is 6 kg, the frequency of the needle punching machine is 700 thorn/min, and the needle board cloth needle density At 7500 needles/m 2 , a composite base fabric having a thickness of 0.8 mm and a basis weight of 300 g/m 2 was produced.
  • the pre-shrinking temperature was 150 ° C, and the time used was 45 min.
  • the step (7) includes a first impregnation and a second impregnation, the first impregnation: an aqueous resin having a immersion concentration of 13%, a vehicle speed of 6 m/min, a liquid volume of 125%, and a pressure roller pressure. It is 0.5 MPa; the second impregnation: an aqueous polyurethane having a immersion liquid concentration of 16%, a vehicle speed of 7.5 m/min, a liquid volume of 125%, and a pressure roller pressure of 0.5 MPa.
  • the dyeing in the step (11) after the seam of the grey cloth, the dyeing, reduction, washing, dehydration and shaping of the cylinder, the initial dyeing temperature is 55 ° C at the initial dyeing, the temperature is gradually raised to 130 ° C after 1 h, the heat is maintained for 4.5 h, and then fully washed. Reduce and clean when dyed dark.
  • the finished product has a weight of 350-360 g/m 2 and a thickness of 0.48 mm.
  • the raw material of the microfiber fabric is one of the following raw material combinations:
  • Base part 150D polyester island filament and 100D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 150D nylon island filament and 100D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 150D polyester island filament, 200D polyester filament and 100D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 150D polyester island filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 150D nylon island filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 150D polyester island filament, 200D nylon filament and 100D polyester high-strength yarn; surface part of nylon island staple fiber; or,
  • Base part 150D polyester island filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 150D nylon island filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 150D polyester island filament, 150D nylon island filament and 100D polyester high-strength yarn; surface part nylon island staple fiber and polyester island staple fiber; or,
  • Base part 200D polyester filament and 100D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 200D nylon filament and 100D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 200D polyester filament, 200D nylon filament and 100D polyester high-strength yarn; surface part: polyester island staple fiber; or,
  • Base part 200D polyester filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 200D nylon filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber; or,
  • Base part 200D polyester filament, 150D nylon island filament and 100D polyester high-strength yarn; surface part of nylon island staple fiber; or,
  • Base part 200D polyester filament and 100D polyester high-strength yarn; surface part: nylon island staple fiber and polyester island staple fiber; or,
  • Base part 200D nylon filament and 100D polyester high-strength yarn
  • surface part nylon island staple fiber and polyester island staple fiber
  • Base part 200D nylon filament, 150D nylon island filament and 100D polyester high-strength yarn; surface part of nylon island staple fiber and polyester island staple fiber;
  • the manufacturing process of the above microfiber fabric specifically includes the following steps:
  • the fabric is drawn 4 times by a 24-roll strong plucking machine, and the grammage is 200-300 g/m 2 .
  • step (3) three layers of non-woven needle-punched fibers are evenly spread on the drawn product by the wire forming machine, and the speed of the netting machine is 0.5 m/min.
  • the composite base fabric is obtained by needle punching 4 times or more, the needle punching pressure parameter in the non-woven state is 6 kg, the frequency of the needle punching machine is 900 thorns/min, and the needle board cloth needle density At 7500 needles/m 2 , a composite base fabric having a thickness of 1.0 mm and a basis weight of 350 g/m 2 was produced.
  • the pre-shrinking temperature is 180 ° C, and the time used is 60 min.
  • the step (7) includes a first impregnation and a second impregnation, the first impregnation: an aqueous resin having a immersion liquid concentration of 17%, a vehicle speed of 7 m/min, a liquid volume of 130%, and a pressure roller pressure. It is 0.5 MPa; the second impregnation: an aqueous polyurethane having a immersion liquid concentration of 20%, a vehicle speed of 8 m/min, a liquid amount of 130%, and a pressure roller pressure of 0.5 MPa.
  • the step (11) dyeing after the seam of the grey cloth, the dyeing, reduction, washing, dehydration and shaping of the cylinder, the initial dyeing temperature is 60 ° C at the initial dyeing, the temperature is gradually raised to 130 ° C after 1 h, the heat is kept for 2 h, and then fully washed and dyed. Reductive cleaning in dark colors.
  • the finished product has a weight of 420-430 g/m 2 and a thickness of 0.50 mm.
  • the invention tests the finished product of the above embodiment, and the test method and test result are as follows:
  • Air permeability measurement The air permeability is measured by the ISO 9237 Feresze method, and the measured air pressure is 125 Pa.
  • Test method for tear test GB/T3917 tongue tear (falling speed: 500mm/min rising speed: 500mm/min; initial length: 100mm; ambient temperature: 25°C; ambient humidity: 65%, predetermined elongation: 70mm , peak amplitude 5N; warp tear 68.1N, latitudinal tear 53.8N)
  • test results of color fastness test According to GB3920-97, rubbing fastness, dry friction level 4, wet friction level 4.
  • PH value neutral the surface of the sample with hydrolysis resistance is free of cracks, the tensile/latitude tensile load exceeds 400 N/cm; the warp/weft tear load exceeds 60 N/cm; dry rubbing color fastness, wet rubbing color Fastness, washing rubbing fastness and light fastness of 3-4 grades.
  • the cleaning process replaces the existing chemical reagent reaction process. Even if the chemical process is used, the green cleaning of the whole process is considered as much as possible. Basically, no by-products that have an impact on the environment are produced, the scrap fabric is recycled, and the residual wool is reused. The three wastes are small and can reach the standard discharge.
  • the finished product has the advantages of less than 0.5 mm in thickness, and has the advantages of large gram, high density, high simulated skin, no odor, and the like, and therefore the invention can be applied to the fields of automobile interior, high-grade clothing, furniture decoration and the like.

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Abstract

一种超细纤维面料，包括基体部分和表面部分，所述基体部分由定岛型海岛长丝或/和普通长丝构成，所述表面部分由短纤维构成，所述面料为基体部分和表面部分相互络合的无纺结构。一种超细纤维面料的制造工艺，其基体部分的定岛型海岛长丝或/和普通长丝通过纬编、经编或梭织工艺，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料。本超细纤维面料填补了针刺无纺布的厚度在0.5mm以下的成品规格空白，且具有非常好的双色效果，高档美观。

Description

一种超细纤维面料及其制造工艺 技术领域
本发明涉及一种超细纤维面料及其制造工艺，属于高档纺织面料技术领域。
背景技术
超纤是超细纤维PU合成革的简称，海岛型超细纤维是超细纤维的一个种类，分海岛长丝和海岛短纤(包括定岛型和不定岛型)两大类。海岛长丝一般通过机织和针织生产麂皮绒面料，用于服装、服饰的制作；海岛短纤通常通过针刺非织造生产厚型仿皮面料，主要用于制鞋、沙发、汽车内饰、服饰等。所有超纤面料一般都以实现高仿真皮为最高目的，定岛型超面料采用碱减量开纤，相对于不定岛型超纤面料采用甲苯开纤比较安全和环保。
普通的超细纤维针刺无纺布，通常做法是使超细短纤经过开包、混仓、梳理、铺网、针刺等工序，其设备投资昂贵，生产工艺条件高，能耗大，产量低，面料的平均厚度、克重控制难度高，给后续树脂含浸、染色深加工带来难度，生产的面料的厚度规格局限性较大，一般只能生产0.5-2.0mm中等厚度且无弹性规格坯布，不能直接生产0.5mm以下厚度且有弹型规格的坯布。也有厂家为追求0.5mm以下规格坯布，采用先生产1.2mm以上厚度，再采用面料横向厚度剖切片皮工艺，但这种做法的缺陷是：原先缠结一起的纤维被切开后，导致面料强度下降明显，影响后续应用。
有鉴于此，本申请人对此进行专门研究，开发出一种超细纤维面料及其制造工艺，本案由此产生。
发明内容
为了解决现有技术中存在的上述缺陷，本发明的目的是提供一种强度高、厚度薄的超细纤维面料及其制造工艺，为了实现上述目的，本发明采取的技术方案如下：
本发明为填补0.5mm以下超纤面料的规格，采用超细纤维长丝，通过针织，拉毛，刺毛工艺，生产出厚度在0.5mm以下且有弹性的坯布，再经树脂含浸、开纤、染色、磨毛等后整理，可应用到汽车内饰、服饰等领域。
一种超细纤维面料，包括基体部分和表面部分，所述基体部分由定岛型海岛长丝或/和普通长丝构成，所述表面部分由短纤维构成，所述面料为基体部分和表面部分相互络合的无纺结构。
作为优选，所述基体部分还包括涤纶高强丝，纤度为75-100D。
作为优选，所述定岛型海岛长丝为聚酯海岛长丝或/和锦纶海岛长丝，纤度为75-150D，所述普通长丝为聚酯长丝或/和锦纶长丝，纤度为50D-200D，所述短纤维为聚酯海岛短纤或/和锦纶海岛短纤。
所述超细纤维面料的成品厚度在0.5mm以下。
一种超细纤维面料的制造工艺，基体部分的定岛型海岛长丝或/和普通长丝通过纬编、经编或梭织工艺，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料，具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入75-100D涤纶高强丝，毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3) 铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(1)中，控制线圈高度在0.2-0.3cm之间，坯布重量克重200-300g/m 2，门幅为170-200cm。
所述步骤(2)中，所述坯布经拉毛机拉毛4次，能将毛彻底拉出来，使绒毛长度在0.5-2.5cm。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上一至三层无纺针刺纤维(即短纤)，每层克重为10-20g，铺网机出网的速度为0.3-0.5m/min。
所述步骤(4)中，经针刺机针刺4次以上，经无纺针刺纤维缠结得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率控制在500-900刺/min，针板布针密度为7500针/米 2，生产出厚度在0.45-1.0mm、克重为250-350g/m 2，门幅为170-200cm的复合基布。
所述步骤(5)中，将复合基布进行机缸预缩，预缩时温度为130℃-180℃，所用时间为30-60min，预缩可进一步提高面料密度，减少水性聚氨酯的使用量，提高回弹性，改善手感。
所述步骤(6)第一次烘干和第一次定型：将复合基布放到定型机机芯烘干切边控制门幅，烘干温度在110-130℃，烘干时根据坯布密度，调节温度和车速，以坯布里外烘干烘透为合适。
所述步骤(7)树脂含浸：在树脂与水性聚氨酯的混合液中对复合基布分别进行含浸处理，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓 度在10％-17％的水性树脂，车速5-7m/min，以带液量120％-130％，调节压力辊压力为0.5MPa，使复合基布的水性树脂的增重量为10％±2％；所述第二次含浸：浸液浓度在12％-20％的水性聚氨酯，车速7-8m/min，以带液量120％-130％调节压力辊压力为0.5MPa，使复合基布的水性聚氨酯的增重量为8％±2％。
所述步骤(8)碱减量开纤：碱液浓度为5％，升温为5℃/min，高温区温度为96-110℃，所用时间为45-60min，开纤率18％-35％；进行中和处理时，采用柠檬酸进行，并将pH值调节到6-7，出缸后采用连续化逆流式水洗。
所述步骤(9)第二次烘干和第二次定型：含浸和碱减量开纤后进行烘干和定型，以便于磨毛。
所述步骤(10)第一次磨毛，因开纤后复合基布表面凹凸不平，经磨毛后可使复合基布均匀着色。
所述步骤(11)染色：复合基布缝头后，进缸染色、还原清洗、脱水、定型，初染色时将分散染料的始染温度控制在室温～60℃，1h后逐渐升温至130℃，保温1～2h，然后充分水洗，染深色时进行还原清洗。
分散染料由高温匀染剂、扩散剂和重量百分比浓度为98％的醋酸配置而成，按照每升染料计算，所述高温匀染剂用量为0.2～1.2g/L，扩散剂用量为0.5～1g/L，醋酸用量为0.5～1.5g/L。还原清洗时，按照每升染料计算，烧碱用量为6ml/L，保险粉用量为2.5g/L，分散剂用量为0.1～0.5g/L。
所述步骤(12)第三次烘干和第三次定型：还原清洗后再次进行烘干、定型，定型时控制上述基布温度为100℃-170℃，车速调至5-30米/分，车速为30-60米/分；
所述步骤(13)第二次磨毛：常规产品使布面绒毛长短一致无绒疵为合格，如客户对布面有“书写效果”需求，可以通过保留绒毛的长度以实现。
所述步骤(14)第四次烘干和第四次定型：最后根据产品需求进行定型；
所述步骤(15)检验、打卷、入库。
本发明能实现如下技术效果：
(1)本发明填补了针刺无纺布的正常生产(非增加机械片皮工序)厚度规格空白，能生产出厚度为0.5mm以下的成品；
(2)本发明生产出的面料由于在铺网时，可以选择与坯布不同性质纤维，如针织时采用涤纶长丝纤维(是涤纶高强丝还是锦纶长丝，请确认)，铺网时采用锦纶短纤，使铺网纤维和坯布纤维充分缠结，又由于在染色时可以只投分散染料，分散染料对锦纶短纤不上色，在面料表面就形成了白色加任意色的双色效果，也丰富了面料的表观颜色，因此本发明工艺可以实现成品面料的双色效果，采用上述留白染色的工艺使其具有非常好的双色效果，高档美观；
(3)采用75-100D涤纶高强丝和75-250D定岛型海岛长丝和10D锦纶短纤，并采用上述技术方案，使面料物性指标明显高于同厚度的针刺无纺布；
(4)因本发明的面料坯布组织有较好的回弹性，加入常规的水性树脂及水性聚氨酯50％的用量，既有皮感，同时可现实10-30％的弹性伸长率，比普通化纤面料更具仿真性，比天然皮革更具回弹性，从而扩大了面料的应用范围，可应用于对弹性伸长性需求的汽车内饰、女士春秋时装等高端面料领域，提高产品市场竞争力；
(5)本发明工艺生产的面料，保留了针织面料的悬垂性，通过针刺加入 超细短纤后，增加了它的透湿度，可满足服饰领域的多种需求；还有通过针刺铺网加密，面料的隔音性有较大的提高，可增强汽车及家居内包的装饰材料的隔音功能；
(6)本发明生产工艺相比传统同规格的针刺无布，设备投入节约3/5，产能提高2倍且能耗基本持平，原料成本下降1/5，CV值控制简易，能实现高质高效量产，且所用原料合工艺均符合环保要求。
具体实施方式
为了使本发明的技术手段及其所能达到的技术效果，能够更清楚更完善的揭露，兹提供了若干个实施例详细说明，但本发明不受以下实施例的限定：
实施例1
本实施例的一种超细纤维面料，超细纤维面料的原料为以下原料组合的一种：
基体部分：75D聚酯海岛长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：75D锦纶海岛长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：75D聚酯海岛长丝、50D聚酯长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：75D聚酯海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：75D锦纶海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：75D聚酯海岛长丝、50D锦纶长丝和75D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：75D聚酯海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：75D锦纶海岛长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：75D聚酯海岛长丝、75D锦纶海岛长丝和75D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：50D聚酯长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：50D锦纶长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：50D聚酯长丝、50D锦纶长丝和75D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：50D聚酯长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：50D锦纶长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：50D聚酯长丝、75D锦纶海岛长丝和75D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：50D聚酯长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：50D锦纶长丝和75D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：50D锦纶长丝、75D锦纶海岛长丝和75D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤。
上述面料可以通过以下一种超细纤维面料的制造工艺，具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入75D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，克重为200-300g/m 2。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上1层无纺针刺纤维，铺网机出网的速度为0.3m/min。
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为500刺/min，针板布针密度为7500针/米 2，生产出厚度为0.6mm、克重为250g/m 2的复合基布。
所述步骤(5)中，预缩时温度为130℃，所用时间为30min。
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为10％的水性树脂，车速5m/min，带液量120％，压力辊压力为0.5MPa； 所述第二次含浸：浸液浓度为12％的水性聚氨酯，车速7m/min，带液量120％-，压力辊压力为0.5MPa。
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为50℃，1h后逐渐升温至130℃，保温1h，然后充分水洗，染深色时进行还原清洗。
本实施例成品米克重为：280-290g/m 2，厚度为0.50mm。
实施例2
本实施例的一种超细纤维面料，超细纤维面料的原料为以下原料组合中的一种：
基体部分：110D聚酯海岛长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：110D锦纶海岛长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：110D聚酯海岛长丝、125D聚酯长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：110D聚酯海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：110D锦纶海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：110D聚酯海岛长丝、125D锦纶长丝和85D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：110D聚酯海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛 短纤和聚酯海岛短纤；或，
基体部分：110D锦纶海岛长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：110D聚酯海岛长丝、110D锦纶海岛长丝和85D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：125D聚酯长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：125D锦纶长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：125D聚酯长丝、125D锦纶长丝和85D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：125D聚酯长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：125D锦纶长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：125D聚酯长丝、110D锦纶海岛长丝和85D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：125D聚酯长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：125D锦纶长丝和85D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：125D锦纶长丝、110D锦纶海岛长丝和85D涤纶高强丝；表 面部分锦纶海岛短纤和聚酯海岛短纤；
上述超细纤维面料的制造工艺具体包括如下步骤：
(1)以实施例2-1至2-18的任一组为主要原料，并加入75-100D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，克重为200-300g/m 2。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上2层无纺针刺纤维，铺网机出网的速度为0.4m/min。
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为700刺/min，针板布针密度为7500针/米 2，生产出厚度在0.8mm、克重为300g/m 2的复合基布。
所述步骤(5)中，预缩时温度为150℃，所用时间为45min。
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为13％的水性树脂，车速6m/min，带液量125％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为16％的水性聚氨酯，车速7.5m/min，带液量125％，压力辊压力为0.5MPa。
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为55℃，1h后逐渐升温至130℃，保温4.5h，然后充分水 洗，染深色时进行还原清洗。
本实施例成品米克重为：350-360g/m 2，厚度为0.48mm。
实施例3
本实施例的一种超细纤维面料，超细纤维面料的原料为以下原料组合中的一种：
基体部分：150D聚酯海岛长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：150D锦纶海岛长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：150D聚酯海岛长丝、200D聚酯长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：150D聚酯海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：150D锦纶海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：150D聚酯海岛长丝、200D锦纶长丝和100D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：150D聚酯海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：150D锦纶海岛长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：150D聚酯海岛长丝、150D锦纶海岛长丝和100D涤纶高强丝； 表面部分锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：200D聚酯长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：200D锦纶长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：200D聚酯长丝、200D锦纶长丝和100D涤纶高强丝；表面部分：聚酯海岛短纤；或，
基体部分：200D聚酯长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：200D锦纶长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤；或，
基体部分：200D聚酯长丝、150D锦纶海岛长丝和100D涤纶高强丝；表面部分锦纶海岛短纤；或，
基体部分：200D聚酯长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：200D锦纶长丝和100D涤纶高强丝；表面部分：锦纶海岛短纤和聚酯海岛短纤；或，
基体部分：200D锦纶长丝、150D锦纶海岛长丝和100D涤纶高强丝；表面部分锦纶海岛短纤和聚酯海岛短纤；
上述超细纤维面料的制造工艺具体包括如下步骤：
(1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入75-100D涤纶高强丝，经24针34寸毛圈机针织，通过纬编工艺织成坯布；(2)将坯布进 行拉毛；(3)铺网；(4)针刺；(5)机缸预缩；(6)第一次烘干和第一次定型；(7)含浸；(8)碱减量开纤；(9)第二次烘干和第二次定型；(10)第一次磨毛；(11)染色；(12)第三次烘干和第三次定型；(13)第二次磨毛；(14)第四次烘干和第四次定型；(15)检验、打卷、入库。
所述步骤(2)中，所述坯布经24辊强力拉毛机拉毛4次，克重为200-300g/m 2。
所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上3层无纺针刺纤维，铺网机出网的速度为0.5m/min。
所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为900刺/min，针板布针密度为7500针/米 2，生产出厚度在1.0mm、克重为350g/m 2的复合基布。
所述步骤(5)中，预缩时温度为180℃，所用时间为60min。
所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为17％的水性树脂，车速7m/min，带液量130％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为20％的水性聚氨酯，车速8m/min，带液量130％，压力辊压力为0.5MPa。
所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为60℃，1h后逐渐升温至130℃，保温2h，然后充分水洗，染深色时进行还原清洗。
本实施例成品米克重为：420-430g/m 2，厚度为0.50mm。
本发明对以上实施例的成品进行测试，测试方法和测试结果如下：
1、测试方法：
透气度测量通过ISO 9237的费雷泽方法测量透气度，测量气压为125Pa
撕裂测试的测试方法：GB/T3917舌形撕破(下降速度：500mm/min上升速度：500mm/min；初始长度：100mm；环境温度：25℃；环境湿度：65％，预定伸长：70mm，峰值幅度5N；经向撕裂68.1N，纬向撕裂53.8N)
2、测试结果
表1超细纤维面料成品测试结果表
Figure PCTCN2018075239-appb-000001
由上表可知：
拉伸强度≥600N；撕裂强度≥50N；符合《聚氨酯束状超细纤维合成革》的要求。
色牢度试验的测试结果：根据GB3920-97，摩擦牢度，干摩4级，湿摩4级。
耐洗检验GB/T3921.3-1997，符合要求。
PH值中性；耐水解性的试样表面无龟裂情形，经/纬向拉伸负荷超过400N/cm；经/纬向撕裂负荷超过60N/cm；干摩擦色牢度、湿摩擦色牢度、水 洗摩擦牢度、日晒色牢度达3-4级。
本发明生产过程和成品的环保性，单位产品耗能量的经济性，全过程采用无张力松弛工艺和低温开纤及染色工艺，较多应用环保型节能设备并进行工艺改进，较多采用机械物理等清洁工艺替代现有化学试剂反应工艺，即使使用化学工艺也尽量考虑到生产全过程的绿色清洁，基本没有生产对环境有影响的副产品，坯布边角料循环利用，磨余毛料实现再利用，产生的三废量小且均能达标排放。
本发明成品厚度在0.5mm以下，且具有克重大、密度高、仿真皮性高、无气味等优点，因此本发明可应用到汽车内饰、高档服饰、家具装饰等领域。
以上内容是结合本发明的优选实施方式对所提供技术方案所作的进一步详细说明，不能认定本发明具体实施只局限于上述这些说明，对于本发明所属技术领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干简单推演或替换，都应当视为属于本发明的保护范围。

Claims (10)

  1. 一种超细纤维面料的制造工艺，基体部分的定岛型海岛长丝或/和涤纶高强长丝通过纬编、经编或梭织工艺，然后通过拉毛处理在其表面形成拉毛层，在拉毛层上铺短纤维，并利用无纺络合技术使短纤维和基体表面的拉毛层形成络合的无纺结构，再经含浸、干燥、开纤、染色以及后处理得到超细纤维面料，其特征在于，具体包括如下步骤：
    (1)以定岛型海岛长丝或/和普通长丝为主要原料，并加入涤纶高强丝，通过纬编工艺织成坯布；控制线圈高度在0.2-0.3cm之间，坯布重量克重200-300g/m 2，门幅为170-200cm。
    (2)将步骤(1)所得的坯布进行拉毛；所述坯布经拉毛机拉毛4次，将毛彻底拉出来，使绒毛长度在0.5-2.5cm；
    (3)铺网：经成网机在步骤(2)拉毛后的制品上均匀铺上一至三层无纺针刺纤维，每层克重为10-20g，铺网机出网的速度为0.3-0.5m/min；
    (4)络合：对步骤(3)铺网后的制品进行针刺，经针刺机针刺4次以上，经无纺针刺纤维缠结得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率控制在500-900刺/min，针板布针密度为7500针/米 2，生产出厚度在0.45-1.0mm、克重为250-350g/m 2，门幅为170-200cm的复合基布；
    (5)预缩：将步骤(4)所制得的复合基布进行机缸预缩，进一步提高面料密度，预缩时温度为130℃-180℃，所用时间为30-60min；
    (6)烘干定型：将步骤(5)制得的复合基布放到定型机机芯烘干切边控制门幅，烘干温度在110-130℃，烘干时根据坯布密度，调节温度和车速，以坯布里外烘干烘透为合适；
    (7)含浸：在树脂与水性聚氨酯的混合液中对步骤(6)制得的复合基 布分别进行含浸处理，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度在10％-17％的水性树脂，车速5-7m/min，以带液量120％-130％，调节压力辊压力为0.5MPa，使复合基布的水性树脂的增重量为10％±2％；所述第二次含浸：浸液浓度在12％-20％的水性聚氨酯，车速7-8m/min，以带液量120％-130％调节压力辊压力为0.5MPa，使复合基布的水性聚氨酯的增重量为8％±2％；
    (8)对步骤(7)含浸后的复合基布进行碱减量开纤，碱液浓度为5％，升温为5℃/min，高温区温度为96-110℃，所用时间为45-60min，开纤率18％-35％；进行中和处理时，采用柠檬酸进行，并将pH值调节到6-7，出缸后采用连续化逆流式水洗；
    (9)烘干定型：将步骤(8)碱减量开纤后的复合基布进行烘干和定型，以便于磨毛；
    (10)将步骤(9)烘干定型后的复合基布进行第一次磨毛；
    (11)染色：将步骤(10)制得的复合基布缝头后，进缸染色、还原清洗、脱水、定型，初染色时，将分散染料的始染温度控制在室温～60℃，1h后逐渐升温至130℃，保温1～2h，然后充分水洗，染深色时进行还原清洗；
    (12)将步骤(11)染色后的复合基布进行烘干定型，定型时控制上述基布温度为100℃-170℃，车速调至5-30米/分，车速为30-60米/分；
    (13)将步骤(12)制得的复合基布进行第二次磨毛；
    (14)将步骤(13)制得的复合基布进行烘干定型，根据产品需求进行定型；
    (15)检验、打卷、入库。
  2. 根据权利要求1所述的超细纤维面料的制造工艺，其特征在于，所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上1层无纺针刺纤维，铺网机出网的速度为0.3m/min；
    所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为500刺/min，针板布针密度为7500针/米 2，生产出厚度为0.6mm、克重为250g/m 2的复合基布；
    所述步骤(5)中，预缩时温度为130℃，所用时间为30min；
    所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为10％的水性树脂，车速5m/min，带液量120％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为12％的水性聚氨酯，车速7m/min，带液量120％-，压力辊压力为0.5MPa；
    所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为50℃，1h后逐渐升温至130℃，保温1h，然后充分水洗，染深色时进行还原清洗。
  3. 根据权利要求1所述的超细纤维面料的制造工艺，其特征在于，所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上2层无纺针刺纤维，铺网机出网的速度为0.4m/min；
    所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为700刺/min，针板布针密度为7500针/米 2，生产出厚度在0.8mm、克重为300g/m 2的复合基布；
    所述步骤(5)中，预缩时温度为150℃，所用时间为45min；
    所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸 液浓度为13％的水性树脂，车速6m/min，带液量125％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为16％的水性聚氨酯，车速7.5m/min，带液量125％，压力辊压力为0.5MPa；
    所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为55℃，1h后逐渐升温至130℃，保温4.5h，然后充分水洗，染深色时进行还原清洗。
  4. 根据权利要求1所述的超细纤维面料的制造工艺，其特征在于，所述步骤(3)中，经成网机在拉毛后的制品上均匀铺上3层无纺针刺纤维，铺网机出网的速度为0.5m/min；
    所述步骤(4)中，经针刺机针刺4次以上得到复合基布，无纺时的针刺压力参数为6公斤，针刺机的频率为900刺/min，针板布针密度为7500针/米 2，生产出厚度在1.0mm、克重为350g/m 2的复合基布；
    所述步骤(5)中，预缩时温度为180℃，所用时间为60min；
    所述步骤(7)中，包括第一次含浸和第二次含浸，所述第一次含浸：浸液浓度为17％的水性树脂，车速7m/min，带液量130％，压力辊压力为0.5MPa；所述第二次含浸：浸液浓度为20％的水性聚氨酯，车速8m/min，带液量130％，压力辊压力为0.5MPa；
    所述步骤(11)染色：坯布缝头后，进缸染色、还原清洗、脱水、定型，初染色时始染温度为60℃，1h后逐渐升温至130℃，保温2h，然后充分水洗，染深色时进行还原清洗。
  5. 一种采用权利要求1-4所述制造工艺所制得的超细纤维面料，其特征在于：包括基体部分和表面部分，所述基体部分包括定岛型海岛长丝或/和普 通长丝，所述表面部分由短纤维构成，所述面料为经过拉毛处理的基体部分和表面部分相互络合的无纺结构。
  6. 如权利要求5所述的超细纤维面料，其特征在于：所述基体部分还包括涤纶高强丝，其涤纶高强丝的纤度为75-100D。
  7. 如权利要求5所述的超细纤维面料，其特征在于：所述定岛型海岛长丝为聚酯海岛长丝或/和锦纶海岛长丝，纤度为75-150D。
  8. 如权利要求5所述的超细纤维面料，其特征在于：所述普通长丝为聚酯长丝或/和锦纶长丝，纤度为50D-200D。
  9. 如权利要求5所述的超细纤维面料，其特征在于：所述短纤维为聚酯海岛短纤或/和锦纶海岛短纤。
  10. 如权利要求5所述的超细纤维面料，其特征在于：所述超细纤维面料的成品厚度在0.5mm以下。
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