Method for making nonwoven needled felt

FIELD: textile, paper.

SUBSTANCE: invention refers to nonwoven material technology and can as a base of building, finishing and other similar materials. Method for making nonwoven needled felt involves pulverisation and emulsification of mixture, rest, hackle webbing, cure, dipping in binder, drying, and cooling. Thus rest is followed with straight and cross hackling packed within at least five web layers needle-punched over two stages. Besides before the second stage, reinforcing filament is added, while material is pull-up smoothed, glazed and dipped in binder, dried and processed in cold glazer.

EFFECT: higher efficiency of method for making nonwoven needled felt with improved application performance.

12 cl, 2 tbl

 

The invention relates to a process for the production of nonwovens and can serve as a basis for the production of construction, decoration and other similar materials.

It is known that the production of nonwovens, which are fabric and articles made from fibers, yarns or other materials without the use of spinning and weaving, in comparison with the traditional methods of production, for example, textile products, is simple technology, high performance equipment, numerous assortment of paintings. Non-woven materials with diverse properties, made in the conditions of automated manufacturing, possess a wide range of functional capabilities, which are provided as through the use of various materials and production methods of nonwoven materials. [Ozerov BV, V.E. Gusev Designing the production of nonwovens. M.: Izd-vo Light and food industries, 1984, 400 S.; Berchem E.N. and other technology for the production of nonwoven materials. M.: Izd-vo Light and food industries, 1982, 352 S.; Petrov, I.N., Andropov SCI Range, properties and applications of nonwovens. M: Legprombytizdat, 1991, 208 S.; Berchem E.N. and other Physico-chemical and combined methods of production of non-woven material is impressive. M: Legprombytizdat, 1993, 353 S.].

However, irrespective of the purpose of non-woven material is any material in its segment must have good complex physico-chemical properties, and a method of manufacturing is also a good technical and economic parameters.

To obtain the best set of physical-chemical and consumer properties of the nonwoven material in the corresponding segment you need to choose the structure of the material and methods of forming the desired structure.

The method typically includes, for example, actions such as the preparation and mixing of the fibers, brushing, oiling, the formation of the fibrous layer, hypoproteinemia, shrinking, and can be characterized by the efficiency of material opening, the effectiveness of scutching, the composition of the emulsion and a binder, the coefficient of uneven distribution of fibers, the speed of the webs, the linear speed of movement of the canvas, the temperature of heat treatment, etc.

A method of obtaining a non-woven material comprising a receiving fiber canvas, his igloprobivnye, timepressure hot calenders [see description to the patent of Russian Federation №2182613, MCL D04H 1/48, publ. 20.05.2002,]. Canvas get on a roller carding machine to obtain canvas using bicomponent fibers with a linear density of 0.64 Tex, the rate is the melting temperature of the core 110° With and shell 180°With heat treatment temperature of 90-110°C for 1-2 min, the density of perforations is 35-50 PR/cm2and the depth of 2 mm.

Thus obtained material has a surface density of 100-150 g/m2thickness of 0.29 to 0.56 mm, bulk density 0,205-0,424 g/cm3air permeability 67,359-133,164 DM3/cm2.c, dust capacity of 0.565-0,583.

However, the performance of the method is low, no more than 3-5 m/min

Also known is a method of obtaining a non-woven needle-punched material, including the formation of fibrous canvas, hypoproteinemia and heat rolling on the calender [see description to the patent of Russian Federation №2246565, MCL D04H 1/48, publ. 20.02.2005,]. During this thermal processing of punched material is carried out at a temperature of roll 130-220°C preferred rolling speed on the calender 3-5 m/min

As a result of implementation of the method are needle-punched nonwoven material made of fiber canvas, derived from polyester fibres and with a linear density of 0.17-2.0 Tex or blend bicomponent fibers, characterized by the density hypoproteinemia 50-250 PR/cm2and weighing 400 g/m2.

The proposed method allows to obtain the strength of the nonwoven material to 160-180 N in length and up to 53-65 H width at hardness of 6.0-6,7 SN is about the length and 3.3 to 3.8 SN width.

As in the previous case, the method has low productivity 3-5 m/min, which is determined by the speed of the rolling material on the calender.

There is also known a method of production of nonwoven fabric weighing 100 g/m2and a width of 2 m, in which the fabric is produced by extrusion of polymer yarns in the thickness of 7 dtex. The resulting polymer fabric, reinforced with glass fibers, is subjected to igloprobivnye, creating 50 PR/cm2at a depth of 12 mm After igloprobivnye cloth handle on the calender on the S-shaped path at a temperature of 235°C and pressure of 25 daN/cm with a speed of 13 m/min, which provides contact between the two rollers in 15 seconds [see description for U.S. patent No. 5118550, MCL B05D 1/14, from 02.06.1992,].

The result is a needle-punched nonwoven material with a surface density of 107 g/m2with a tensile strength of 18.0 daN and elongation of 2.2% at 20°and accordingly 5,2 daN and 2.2% at 180°C.

The method provides the performance of 13 m/min, however, it is technologically very difficult, as it involves the continuous threads of the canvas directly from the polymer melt.

Closest to the claimed solution of the assignment, technical essence and the achieved result when use is a method of obtaining a non-woven material, VK is uchumi loosening, emulsione mixture, seasoning, formation of the canvas on the carding machines, impregnation of the canvas binder, drying, heat treatment and cooling [see description to the patent of Russian Federation №2057217, M CL D04H 1/64, publ. 27.03.1996,]. The method involves mixing the fibers and the processing of the canvas aqueous solution composition containing a nonionic surfactant, a silicon-organic compound or a mixture and tanning substance. The processing of the specified composition or combined with emulsionen, or is carried out after formation of the canvas.

The proposed method allows to obtain the strength of the nonwoven material to 160-180 N in length and up to 53-65 N width at hardness of 6.0-6,7 SN in length and 3.3 to 3.8 SN width.

However, the method does not provide the required performance, as it includes treatment with an aqueous solution containing about 6.0 wt.% the dissolved components and taken in an amount up to 15 wt.% from the mass of fibers.

Therefore, the aim of the proposed technical solution is to increase the productivity of the method of obtaining the nonwoven needle-punched material while maintaining high consumer properties of the material.

This objective is achieved in that in the known method of obtaining a non-woven material including loosening, emulsione mixture, seasoning, formation of canvas on the carding machine is, impregnation of the canvas binder, drying, heat setting and cooling, according to the invention after curing form the longitudinal and transverse Procesi, stack them in no less than five layers, treated with igloprobivnye in two stages, with the second stage of igloprobivnye add reinforcing threads, then align the material by tension, calendarbut with subsequent impregnation of the binder, after which the material is dried and processed on a cold calender.

According to the invention, emulsione carry out the composition of liminal in the amount of 0.15-16 wt.% by weight of the fibers by spraying.

According to the invention loosening spend to obtain raw materials with bulk density 15-18 kg/m3

According to the invention the seasoning is carried out for 4-5 hours.

According to the invention canvas form a 5-7 procesov.

According to the invention igloprobivnye carry not less than two stages - preliminary and main.

According to the invention as reinforcing fibers use the glass.

According to the invention the adhesive connection of the fibers is carried out by calendering at a temperature of 212-220°C, the speed of movement of the canvas of 12.6-12.9 m/min, contact time is 12-16 C.

According to the invention, the alignment is carried out at the tension 900-1100 N/m

According to the invention the heat setting carry PR the temperature 218-230° C for 16-18 C.

According to the invention as a binder used styrolacrylonitrile latex.

According to the invention the final drying is performed at a temperature 140-180-210°With over 70-80 C.

As can be seen from the statement of the essence of the proposed solutions, it differs from the prototype and, therefore, is new.

The decision also involves an inventive step. The basis of the invention is the task of improving the method of producing a nonwoven material. Due to the formation after curing longitudinal and transverse procesov, laying them in no less than five layers, processing igloprobivnye in two stages, add this before the second stage of the reinforcing fibers, the alignment material by tension, calendering, followed by impregnation of the binder before heat setting, drying and processing on a cold calender, provide a new technical result, which is that formed a reliable adhesive and mechanical bond all layers of material providing high thermo-mechanical characteristics. Due to this, there is a possibility to increase the performance of the method.

A known possibility of the formation of fleece with the longitudinal and transverse orientation of the fibers [see Berchem E.N. and other technology for the production of nonwoven materials. M: L is GCA and food industry, 1982, p.86]when the webs with longitudinal orientation of the fibers produced several carding machines, lay the webs with transverse orientation of fibers. It is noted that fibrous canvases with the longitudinal and transverse orientation of the fibers should be of high tensile strength in longitudinal and transverse directions, dimensional stability and elasticity. This indicates that for the manufacture of such canvases requires a complex arrangement of the equipment and there are certain difficulties in the service chain machines [ibid].

Also known for the production of needle-punched nonwoven material, comprising preparing a mixture of fibers, the formation of fibrous canvas, hypoproteinemia, impregnation binder, drying and heat treatment. It was also noted that sometimes to achieve the required strength of needle-punched material used frame material in the form of woven fabric, mesh, film, etc, which come under the fibrous canvas or in the middle of the canvas [see ibid SCR-271].

The proposed solution is fundamentally different from known methods that offers a new sequence of the known methods of obtaining non-woven material, supplemented by new operations, such as "...adding reinforcing threads...", "...the alignment material by netgen what I...", which, combined with "...the connection of the fibers by adhesion...", "...the heat setting..." and "...treatment for cold calender...", provides an accelerated rate of production while ensuring such properties of the finished product as increased strength and resistance to shrinkage at a relatively high speed of production of the product in contrast to the prototype.

The proposed method is industrially applicable, as used in production of non-woven material brand FLEECE RF. Automated production allows to maintain the pre-set parameters of the method at specified intervals, which ensures the stability properties of the obtained product.

A method of obtaining a non-woven material is as follows.

First mix of fibrous raw materials, if you intend to produce webs from a mixture of fibers. Mixing and dispersing is carried out on the picker for 2-3 hours until a homogeneous mass density 16-18 kg/m3. Then carry out emulsione mixture, pre-prepare a solution consisting of a mixture of antistatic 6-8% and the rest of the water, which is used as liminal in the amount of 0.15-16 wt.% by weight of the fiber. Mix for emulsione in the form of a spray is applied to the fiber in the pipeline. The resulting homogeneous mass vylizyvaut in b is xah for 4-5 hours at a temperature of 18-20° C. After addition of a mixture of fibers of the solution to emulsione exercise loosening until a homogeneous mass density 12-16 kg/m3. Thus treated raw material is a fibrous mass consisting of various sized pieces of fibers. Scraps of fibers of different types is not enough evenly distributed in the mixture, and the individual fibers are mixed with each other. For obtaining of the heterogeneous mass of high quality product in the form of fibrous webs, the fiber is treated at the carding machines for separation of tangled bits and bundles into individual fibers, the allocation of trash, partial straightening and the orientation of the fibers in one direction. The web is the initial structure for the formation of the canvas, removable with removable drum carding machines. His stack on each other with a given number of plies by mechanical conveyors converters procesov. Thus, the formation of the canvas from 5-7 procesov. Then the canvas condense on needle machines, creating a mechanical connection in the canvas. After the seal on the first needle machine to the canvas serves reinforcing fiberglass yarn brand IS 68 Z20 TS N8 S12 E4 and the canvas is fed to the second needle machine, which creates an additional mechanical connection to the to between the fibers of procesov, and between the fibers of procesov and fiberglass fibers. Formed canvas leveled by a tension load 900-1100 N/m and carry the adhesive connection of the fiber, which is treated by calendering at a temperature of 212-220°and the velocity of the canvas of 12.6-12.9 m/min At the time of contact of the fibers with the calender does not exceed 12-16 C. After processing calenders fiber thermofixing (in the camera thermobonded) using hot air at a temperature of 218-230°C for 16-18 C. After processing calenders perform impregnation of the canvas binder. As a binder used, for example, styrolacrylonitrile latex Acronal S 888 S in the number of 15-17 wt.%.

Finish the process of obtaining non-woven needle-punched material by drying at a temperature of 140-180-210°With over 70-80 C, the additional heat treatment and cooling. Cooling is carried out by passing the material between the hollow shafts of cold calender temperature which is in the range 8-20°S. This operation is performed to prevent sticking of the material when forming rolls of finished products. Examples of the method are given in table 1

Table 1
Example 1

140 g/m2
Note the R 2

170 g/m2
Mixing fibers of raw materials, h2,53
The density of the raw material after mixing, kg/m315-1815-18
The density of the raw material after emulsione before caracasana, kg/m31212
The density of perforations in the first stage, 1/cm250-5550-55
The density of perforations in the second stage, 1/cm250-5555-60
The load in tension, N/M800-900900-1100
The processing speed on the calender, m/min12,912,9
Temperature treatment on the calender, °210-215210-220
The time of contact of the canvas with calender, min0,18-0,200,20-0,22
The temperature of the heat-setting of the canvas, °218-230218-230
The duration of the heat-setting of the canvas, min0,260,27
Drying temperature after impregnation binder, °140-180-210140-180-210
Drying time, min1,151,18

The characteristics of the material is, obtained as described above are shown in table 2

Table 2
Example 1Example 2Example 3Example 4
Surface material density, g/cm2140150160170
The breaking load of length N490520560620
The breaking load of width N270280300330
Breaking elongation length ±10%21212222
Breaking elongation width ±10%28282929
Material thickness, mm, ±8%0,80,80,91,0

As can be seen from the description of the essence of the technical solutions and examples of its implementation, the method is not technologically complex operations, has a sufficiently high performance and provides needle-punched nonwoven material with good technical properties for a given segment, namely bituminous Stroitel the data finishing and other similar materials.

1. A method of manufacturing a non-woven needle-punched material including loosening, emulsione mixture, seasoning, formation of the canvas on the carding machines, heat setting, impregnation of the canvas binder, drying and cooling, characterized in that after curing form the longitudinal and transverse Procesi, which is placed in not less than five procesov, treated with igloprobivnye in two stages, with the second stage add reinforcing threads, then align the material by tension, calendarbut with subsequent impregnation of the binder, after which the material is dried and processed on a cold calender.

2. The method according to claim 1, characterized in that emulsione carry out the composition of liminal in the amount of 0.15-16 wt.% by weight of the fibers by spraying.

3. The method according to claim 1, characterized in that the loosening of the hold to obtain raw materials with bulk density 16-18 kg/m3.

4. The method according to claim 1, characterized in that the seasoning is carried out for 4-5 hours

5. The method according to claim 1, characterized in that canvas is formed from 5-7 procesov.

6. The method according to claim 1, characterized in that igloprobivnye carry not less than two stages - preliminary and main.

7. The method according to claim 1, characterized in that reinforcing fibers use the glass.

8. The method according to claim 1, great for the present, however, adhesive connection of the fibers is carried out on the calenders at a temperature 212-220°C, the speed of movement of the canvas of 12.6-12.9 m/min, contact time is 12-16 C.

9. The method according to claim 1, characterized in that the alignment is carried out at the tension 900-1100 N/M

10. The method according to claim 1, characterized in that the heat setting is carried out at a temperature 218-230°C for 16-18 C.

11. The method according to claim 1, characterized in that the binder used styrolacrylonitrile latex.

12. The method according to claim 1, wherein the final drying is performed at a temperature 140-180-210°With over 70-80 C.



 

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1 tbl, 1 ex

FIELD: textile, paper.

SUBSTANCE: invention refers to nonwoven material technology and can as a base of building, finishing and other similar materials. Method for making nonwoven needled felt involves pulverisation and emulsification of mixture, rest, hackle webbing, cure, dipping in binder, drying, and cooling. Thus rest is followed with straight and cross hackling packed within at least five web layers needle-punched over two stages. Besides before the second stage, reinforcing filament is added, while material is pull-up smoothed, glazed and dipped in binder, dried and processed in cold glazer.

EFFECT: higher efficiency of method for making nonwoven needled felt with improved application performance.

12 cl, 2 tbl

FIELD: engineering procedures.

SUBSTANCE: one version of the method consists that the cloth is placed on porous substrate movable on the straight or rotating about the axis. At least one side of the cloth is processed with some water jets rowed perpendicularly to cloth moving direction. Herewith a row is formed with one-section jets and at least other section jets different from the first one.

EFFECT: improved surface properties of the product.

33 cl, 17 dwg

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