Environmental protection type nonwoven needle punched carpet and manufacture method thereof
Technical field
The present invention relates to a kind of nonwoven needle punched carpet, more specifically say, relate to a kind of manufacture method of nonwoven needle punched carpet and the nonwoven needle punched carpet of making by this method.
Background technology
Along with expanding economy, activities such as exhibition, fair are held frequently day by day.Now, various types of Venues generally use the comparatively cheap nonwoven needle punched carpet of price.In order to cooperate the different demands of every exhibition, employed carpet also will be changed thereupon, because it is pressed for time, every cost costlinesses such as storage, freight charges, these cheap nonwoven needle punched carpets all are usually after using once, transport to landfill and throw aside, even the carpet that these are disposable burns in some area, thereby cause huge waste and economic loss.
At present, in traditional nonwoven needle punched carpet was made, the technology of general using needle punched non-woven fabrics was made needle-punching substrate.Usually use terylene, polypropylene fibre or other fibrous raw material, its production specification is 240g/m
2To 300g/m
2Not etc., thickness is about 2.0mm, and wherein polyester fiber raw materials is relatively cheap on price, so most needle punched carpet all adopts it as raw material.In process of production, fibrous raw material is made the softer needle-punching substrate of quality with the method for nonwoven acupuncture, carry out the back processed then, promptly through foam gum and foam impregnation, enter again and carry out tentering, typing and oven dry in the bulky setting machine, cut edge after the last moulding, rolling.In this step of traditional handicraft, in order to make the needle-punching substrate typing, needle-punching substrate needs through foam gum and foam impregnation, enter again and carry out fixating shape step in the stentering forming dryer, therefore must add during this period such as butylbenzene glue or other chemical glue just to make it finalize the design fully, this just makes and has closed at least two kinds of materials (fibrous raw material and typing glue) in the product at least and mix, and can't realize that the recovery recirculation of putting product aside as useless produces, and is unfavorable for environmental protection.
As everyone knows, for material recovery, main is the material of heterogeneity in the discarded object to be put into different categories carry out processed afterwards, but just recirculation is used.Therefore; if the product of making according to the classical production process of nonwoven needle punched carpet; owing in the material that uses, sneaked into the chemical glue of certain component; in the reclaiming process; be difficult to chemical glue in the fibrous material and fibrous material be separated fully or dissolve, to reach the basic demand that environmental protection is reclaimed.Even of course, also need expensive cost to handle, the utmost point does not meet economic benefit.Therefore, the nonwoven needle punched carpet of throwing aside in a large number can't produce in reclaiming, unavoidably environment is polluted.
In addition, in traditional manufacture method, the employed make-up machine volume of industry is quite huge, not only occupy very big area, make the place use cost increase, and be fuel generally, air is caused certain pollution too with coal, heavy oil or diesel oil etc., along with the continuous rising of fuel price, the also corresponding increase of production cost.
The present invention is directed to above-mentioned problem, a kind of manufacture method of more environmental protection is provided, and can produce equal quality and nonwoven needle punched carpet with low cost with this method, be that nonwoven needle punched carpet of the present invention is the environmental protection type nonwoven needle punched carpet of recyclable regeneration more significantly.
Summary of the invention
To achieve these goals, task of the present invention is exactly to be configured in manufacturing technique and to retrofit at above-mentioned shortcoming, so that makes every effort to can both reach from raw material, feed consumption, production process so that finished product the environmental requirement of 3R, i.e. Reduce: cut down the consumption of energy; Reuse: use again and Recycle: reclaim once more.
Therefore, one object of the present invention is to provide a kind of environmental protection type nonwoven needle punched carpet made from adding the step of HEAT SETTING through the step of nonwoven acupuncture formation base cloth, and it is made of at least two kinds of fibrous raw materials of the same race with different melting points.According to the present invention, fibrous raw material can be selected from wherein a kind of in terylene, polypropylene fibre and other the fibrous raw material, preferably selects terylene for use.
In a preferred embodiment of the present invention, described fibrous raw material is selected polyster fibre for use.
Another object of the present invention is to provide a kind of manufacture method of environmental protection type nonwoven needle punched carpet, wherein said method comprises the following steps:
One, the manufacturing step of needle-punching substrate, wherein:
-will beat pine in wherein a kind of ratio input opener on request of versicolor fibrous raw material of the same race such as terylene, polypropylene fibre and other fibrous raw material etc. and fibrous raw material;
-fibrous raw material versicolor of the same race of shredding sent into blend the different colors that require in the blending box;
-fibrous raw material after the colour mixture is transported in the carding machine, flat the delivering to again afterwards in the auxilliary net machine of comb makes it be netted plane;
-fibrous raw material after will handling through above-mentioned steps enter that make-up machine successively stings in advance, main hangnail, just sting, and become nonwoven needle-punching substrate (non-weaving cloth), directly enter back processing then or it is batched.
Two, the fixating shape step of needle-punching substrate, wherein:
-make the nonwoven needle-punching substrate carry out ultrared The pre-heat treatment, to improve the density of base cloth through the infra red treatment machine;
-carry out hot-pressing processing through embossing machine immediately then.
Specifically, in the fixating shape step of needle-punching substrate, described infra red treatment machine is with needle-punching substrate preheating and softening, make its contraction and improve its density, this moment, base cloth was in soft condition, still had certain temperature, then base cloth was passed through immediately the line that is hot pressed into of embossing machine, the density of base cloth is strengthened once more, and its effect is equal to or more is far more than the conventional method of handling with the oven dry of foam gum and foam impregnation stentering forming.
In order to increase the appearance effect of nonwoven needle punched carpet, embossing machine of the present invention also is provided with a special dandy roll, this dandy roll can be carved with diamond texture or other decorative pattern, not only increase aesthetic appearance, the more important thing is that order can be distributed in each part equably through the density of the base cloth of dandy roll processing, thereby make the also corresponding raising of hardness, abrasion resistance of base cloth.
In traditional handicraft, employed setting machine is except that bulky, owing to can't be complementary with the speed of production of making the needle-punching substrate step, thereby can not be in conjunction with installation.Yet, infra red treatment machine of the present invention can be according to the speed of different production demands and base cloth acupuncture aftershaping with embossing machine, adjust the processing speed of infra red treatment machine and embossing machine, both can be directly with the step of making needle-punching substrate in make-up machine combine installation, also can split installation, make production process more smooth, enhance productivity whereby.Because embossing machine volume of the present invention is little, floor space has only 1/10th of setting machine volume in the traditional handicraft, thereby has saved working space widely.In addition, it is power that infra red treatment machine of the present invention and embossing machine mainly adopt power supply, has both reduced a large amount of energy resource consumptions, need not to rely on petroleum by-product again, for example diesel oil, heavy oil and coal gas or coal etc. avoid causing the pollution of environment and air, have also reduced production cost simultaneously.
Innovation part of the present invention has been carried out breakthrough improvement just on this production link, under the principle that guarantees the original product quality and reduce cost, the present invention has given up original large-scale setting machine and has carried out typing to needle-punching substrate, but the step of selecting for use infra red treatment machine and embossing machine to finalize the design, foam gum and foam impregnation have promptly been saved in the traditional handicraft to the nonwoven needle-punching substrate, make the nonwoven needle punched carpet materials have only fibrous material to constitute from the beginning to the end, keeping its unicity, for material recovery in the future provides sufficient assurance.Owing to need not to use butylbenzene glue or other chemical addition agents such as chemical glue, thereby reduced production cost, also saved Water Energy simultaneously in large quantities.In this step, described infra red treatment machine and embossing machine all use power supply, make manufacturing process also accomplish environmental protection.
Owing in the whole production manufacture process, use single raw material, there is not any chemical addition agent, thereby make the final step of manufacturing, the feed consumption that is produced after promptly cutting edge, because nonwoven needle punched carpet only keeps a kind of production material to constitute in whole process of production all the time, make it produce feed consumption and have monistic structure equally.Therefore, the feed consumption part can reclaim equally, is reprocessed into to be the plastic raw materials grain, is used as further to recycle, thereby can realizes higher economic benefit.
In sum, the present invention no matter from raw material, feed consumption to finished product, its each link of manufacturing process is all considered environmental protection requirement fully.
Description of drawings
In order to understand purpose of the present invention, feature and effect fully, be described further below with reference to the technique effect of accompanying drawing to design of the present invention, concrete steps and generation.That should be appreciated that the following stated only is the typical embodiment of the present invention, so do not think limiting the scope of the invention, and wherein:
Fig. 1 is the flow chart of the manufacture method of environmental protection type nonwoven needle punched carpet of the present invention.
The specific embodiment
With reference to Fig. 1,, at first versicolor fibrous raw material of the same race is dropped into opener, with its dozen pine according to the manufacture method of environmental protection type nonwoven needle punched carpet of the present invention; Then the fibrous raw material versicolor of the same race of shredding is put into blending box and blend the different colors that require; Fibrous raw material comb by carding machine colour mixture is flat again; Then entering auxilliary net machine makes fibrous raw material be netted plane; And then by make-up machine fibrous raw material is stung in advance, main hangnail, just stings, form needle-punching substrate and it is batched.Above step is finished the making of nonwoven needle-punching substrate.Next enter the fixating shape step of needle-punching substrate, just make the nonwoven needle-punching substrate carry out ultrared The pre-heat treatment, to improve the density of base cloth through the infra red treatment machine; Carry out hot-pressing processing through embossing machine immediately at last, make nonwoven needle-punching substrate typing becoming nonwoven needle punched carpet.
The present invention's one preferred embodiment is raw material with the polyster fibre.Polyster fibre, polyester fiber just, it is for being the polyester resin that base stock makes with terephthalic acid (TPA) (TPA) and ethylene glycol (EG), through melt spinning with after be processed into.Therefore performances such as intensity height, good springiness, wrinkle resistance are big because it has, dimensionally stable, ABRASION RESISTANCE are good, chemical stabilization, quick-drying washable, heat resistance and weatherability are good are all used extensively at each industrial circle, are the raw materials that generally uses in the industry.
In this specific embodiment, depend on the difference of density, feel and the thickness of product, generally use the short polyster fibre of fineness degree as 8D~12D, its length is that 64mm is the most moderate.As shown in Figure 1, in the manufacturing step of needle-punching substrate, select the polyster fibre of different colours for use, general grammes per square metre is 350g/m
2, thickness is 2.5mm~3.0mm, length is that 64mm is the most moderate.According to required different colours, at first versicolor polyster fibre is dropped into opener respectively and make its dozen pine.For guarantee after the fixating shape step process of needle-punching substrate in keep the stability of needle-punching substrate, should select at least two kinds of polyster fibres for use with different melting points, for example wherein a kind of fusing point of selecting for use is 130 ℃ a polyster fibre, and it accounts for 10% to 25% of raw materials for production sum, is preferably 15%; All the other then available normal polyester fibers.
Then, again the fibrous raw material versicolor of the same race of shredding is sent into the colors that blend different requirements in the blending box.Then, the polyster fibre after the colour mixture is transported in the carding machine, flat the delivering to again afterwards in the auxilliary net machine of comb makes it be netted plane.
At this moment, raw materials for production are got ready substantially, prepare to enter that make-up machine successively stings in advance, main hangnail, the step of just stinging.According to embodiment, stinging the degree of depth in advance is 1.5mm to 2.0mm, and the main thorn degree of depth is 2.0mm to 3.0mm, and the acupuncture linear speed is 2 meters, and density is 700 pin/rice
2, the production temperature is 180 ℃ to 220 ℃.Polyester fiber raw materials after the acupuncture is molded to be the nonwoven needle-punching substrate, then that its rolling is standby.
In the fixating shape step of needle-punching substrate as shown in Figure 1, earlier standby nonwoven needle-punching substrate is sent into the infra red treatment machine and carry out ultrared The pre-heat treatment.In specific embodiment, using the general temperature of infra red treatment machine is 120 ℃ to 220 ℃, and the best is 160 ℃ to 180 ℃, and to advance highly be 3m, be the high-temperature process of 6m, standard line length per minute 2m to 5m back and forth.For instance, grammes per square metre and density be 320 grams/square metre base cloth, general comparatively stable adjustment is per minute 2m to 3m.At first, needle-punching substrate is carried out preheating, make needle-punching substrate that certain contraction be arranged, for example, shrinkage factor is about 15% to 20%, so that the density of base cloth improves 15% to 20%.In addition, through ultrared The pre-heat treatment, also can regulate speed of production, the step that enters next embossing typing for base cloth is got ready.
The step that the present invention is played the most critical effect is to use the distinctive embossing machine of the present invention.This embossing machine comprises that one has the dandy roll of different pattern (according to actual needs) and the elastic caoutchouc roller of a support dandy roll.According to specific embodiment, dandy roll can be carved with diamond texture or other decorative pattern, and its diameter is 210mm, larger diameter can be 500mm, and pressure is 60cm/kg, and the production temperature is 120 ℃ to 220 ℃, the best is 180 ℃ to 200 ℃, and rubber rollers typically have a diameter from 320mm.Needle-punching substrate is through after the ultrared The pre-heat treatment, send into embossing machine, hot pressing by dandy roll, various decorative patterns are hot-pressed onto on the base cloth of preheating, not only increase aesthetic appearance, and make the density of the base cloth of handling through dandy roll can be distributed in each part equably, thereby make the also corresponding raising of hardness, abrasion resistance of base cloth.According to specific embodiment, through the nonwoven needle punched carpet of hot pressing postforming, its thickness is 2.0mm to 2.2mm.
Can see, in the type-approval process of this base cloth, the present invention is the line that is hot pressed into by suitable adjustment, ultrared The pre-heat treatment and dandy roll, so that the typing of needle-punching substrate reaches required hardness and density, wherein there is not the material that adds any auxiliary typing, make the production process of whole nonwoven needle punched carpet remain this a kind of material of polyster fibre, in the future reclaiming manufacturing performs sufficient assurance.Should expect that the decorative pattern on the dandy roll can be carved according to different needs, the decorative pattern density of being carved is high more, and the pattern lines of hot-forming nonwoven needle punched carpet is close more, so that might reach level and smooth basically plane.
After the base cloth typing, need cut edge and rolling.Be to be understood that because the unicity of material, the feed consumption that is produced can reclaim equally, can be used as to be reprocessed into plastic raw materials, thereby reduces production costs indirectly, realizes higher economic benefit.
In above-mentioned step, it is standby that needle-punching substrate can rolling after moulding, more preferably, because infra red treatment machine of the present invention and embossing machine directly can combine installation with the make-up machine in the step of making needle-punching substrate, also can split installation.Like this, needle-punching substrate is after moulding, according to different production demands, can omit in the manufacturing step of needle-punching substrate and batch standby step, and directly send into next step, be i.e. infrared ray The pre-heat treatment and embossing machine thermocompression forming, can make production process more smooth, enhance productivity whereby.
In another embodiment of the present invention,, can be raw material with polypropylene fiber, though the cost of material of polypropylene fiber is than polyster fibre height according to special needs.Generally use grammes per square metre to be 280g/m
2, thickness is that 2.5mm~3.0mm, length are the polypropylene fiber of 64mm, its manufacture method and said method basically identical are no longer done at this and to be given unnecessary details.It should be noted, be in the production process of raw material with the polypropylene fiber, because the fusing point of polypropylene fiber is 130 ℃ or higher, so its production temperature should not be above 130 ℃.
In sum, compare material formation, production link, so that produce feed consumption and reclaim and all reach environmental protection requirement with traditional nonwoven needle punched carpet according to the environmental protection type nonwoven needle punched carpet that method of the present invention is made.
Description in this specification is a preferred embodiment of the present invention, and under the situation that does not break away from spirit of the present invention or essential characteristic, the present invention can implement with other particular form.Described embodiment only is used as in every respect and illustrates rather than limit.Therefore, protection scope of the present invention is represented with appending claims rather than is represented with above-mentioned explanation.All changes in the implication that is equal in claims and the scope of limit should be included among protection scope of the present invention.