薄型聚酯纺粘非织造工艺与性能的研究
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摘要
本论文研究的是薄型聚酯(PET)纺粘非织造宽幅式整体狭缝气流正压拉伸工艺对非织造布性能的影响，并首次提出了对超薄型聚酯纺粘非织造工艺的研究。本课题采用熔融纺丝(纺粘法)工艺，是将高分子聚合物加热熔融，经挤出机后，熔体从纺丝孔挤出进入空气中，熔体细流在空气中冷却的同时，以一定速度拉伸变细变长(气流或机械作用)，在该阶段高分子熔体细化同时凝固，而形成纤维后成网。
本课题实验用的原料为聚酯，是熔融纺丝工艺常用的一种聚合物，其主要性能参数有特性粘度、端羧基含量、二氧化钛含量、水分和灰分等，在熔融纺丝工艺中，要求聚酯中水分的含量的在一定范围内才能顺利纺丝，因此，聚酯在纺丝之前要先经过干燥工序。
熔融纺丝(纺粘法)工艺采用的是高速气流拉伸，其拉伸丝条的介质是高速气流。本课题选用的宽幅式整体狭缝气流正压拉伸工艺，其拉伸原理：气流拉伸丝条的介质是采用高压压缩的空气，利用气体质量小易于扩散的特性。拉伸气流本身对长丝没有直接的握持作用，通过高压气流对长丝产生的粘性摩擦力和在狭逢下方区域由于气流作用丝条强烈波动或摆动而产生的压推力，这两个力的共同作用使长丝得到有效的拉伸。拉伸装置可以上下移动，其移动距离对拉伸装置下方丝条的摆动幅度有很大的影响，对成网的均匀度影响很大。
在薄型聚酯纺粘非织造宽幅式整体狭缝气流正压拉伸工艺中，主要的工艺参数有：干燥温度、计量泵转速、纺丝温度、冷却风温度和风速、纺丝速度、ACD高度(拉伸装置底端到成网帘的距离)、成网速度、热轧辊压力和温度等，这些参数决定了聚酯纺粘非织造布的性能，主要包括：长丝线密度、结晶度；纺粘非织造布的纵横向断裂强力、断裂伸长率、厚度和成网均匀度等指标。比较不同工艺参数与测试不同聚酯纺粘非织造布的性能参数，得出其不同的工艺对纺粘非织造布的性能的影响，同时并分析原因。
The research on the light PET spunbonded nonwoven wide-range integral slit positive air stretching process to the effect of nonwoven performance, The study of super-light PET spunbonded nonwoven process is concemed firstly. The melt spinning process is adopted in the paper, that is, polymer is heated at first, and then transferred to the spinning packs including spinneret with a lot of holes by extruder, producing high number of filaments cooled off by cooling air coming from quench box, the filaments are transferred to the air stretching system that operated by compressed air at a certain pressure and are solidified at the same time, then deposited on the forming belt with high uniformity.
Polyester is used in the paper, it is used frequently by the melt spinning process, the performance: intrinsic viscosity、COOH groups、TiO_2 content、Ash content, Water content and so on. During the melt spinning process, water content is defined at a certain range, therefore, Polyester should be dried before spinning.
High-speed air stretching is adopted in the melt spinning process, the medium is high-speed air. The wide-range integral slit positive air stretching process is used, its principle: the filaments are stretched by compressed air with small quantity and easy to diffuse. The filaments have not seized directly by stretching air ,they are drawn adhesive frictional force produced by high pressure air to filaments and push force occurred by fluctuation and swing of filaments under stretching equipment, the two forces together are to make the filaments stretch. Stretching equipment can be moved up and down, the distance being moved affects the swing of filaments and web uniformity under it.
During the light PET spunbonded nonwoven wide-range integral slit positive air stretching process, the process parameter: drying temperature、revolution of metering pump、spinning temperature、cooling air temperature and speed、spinning speed、ACD height (the distance from the bottom of stretching equipment to the surface of the forming table)、the forming speed、the calendar pressure and temperature and so on. The parameter affected PET spunbonded nonwoven performances including: filament size、crystallization、tensile strength and elongation MD and CD、thickness、web university and so on. Comparing to different process parameters to the effect of spunbonded nonwovens and analyze.
Written by Han Wensheng(Textile Engineering)
Supervised by Prof Jin Xiangyu
本课题实验用的原料为聚酯，是熔融纺丝工艺常用的一种聚合物，其主要性能参数有特性粘度、端羧基含量、二氧化钛含量、水分和灰分等，在熔融纺丝工艺中，要求聚酯中水分的含量的在一定范围内才能顺利纺丝，因此，聚酯在纺丝之前要先经过干燥工序。
熔融纺丝(纺粘法)工艺采用的是高速气流拉伸，其拉伸丝条的介质是高速气流。本课题选用的宽幅式整体狭缝气流正压拉伸工艺，其拉伸原理：气流拉伸丝条的介质是采用高压压缩的空气，利用气体质量小易于扩散的特性。拉伸气流本身对长丝没有直接的握持作用，通过高压气流对长丝产生的粘性摩擦力和在狭逢下方区域由于气流作用丝条强烈波动或摆动而产生的压推力，这两个力的共同作用使长丝得到有效的拉伸。拉伸装置可以上下移动，其移动距离对拉伸装置下方丝条的摆动幅度有很大的影响，对成网的均匀度影响很大。
在薄型聚酯纺粘非织造宽幅式整体狭缝气流正压拉伸工艺中，主要的工艺参数有：干燥温度、计量泵转速、纺丝温度、冷却风温度和风速、纺丝速度、ACD高度(拉伸装置底端到成网帘的距离)、成网速度、热轧辊压力和温度等，这些参数决定了聚酯纺粘非织造布的性能，主要包括：长丝线密度、结晶度；纺粘非织造布的纵横向断裂强力、断裂伸长率、厚度和成网均匀度等指标。比较不同工艺参数与测试不同聚酯纺粘非织造布的性能参数，得出其不同的工艺对纺粘非织造布的性能的影响，同时并分析原因。
The research on the light PET spunbonded nonwoven wide-range integral slit positive air stretching process to the effect of nonwoven performance, The study of super-light PET spunbonded nonwoven process is concemed firstly. The melt spinning process is adopted in the paper, that is, polymer is heated at first, and then transferred to the spinning packs including spinneret with a lot of holes by extruder, producing high number of filaments cooled off by cooling air coming from quench box, the filaments are transferred to the air stretching system that operated by compressed air at a certain pressure and are solidified at the same time, then deposited on the forming belt with high uniformity.
Polyester is used in the paper, it is used frequently by the melt spinning process, the performance: intrinsic viscosity、COOH groups、TiO_2 content、Ash content, Water content and so on. During the melt spinning process, water content is defined at a certain range, therefore, Polyester should be dried before spinning.
High-speed air stretching is adopted in the melt spinning process, the medium is high-speed air. The wide-range integral slit positive air stretching process is used, its principle: the filaments are stretched by compressed air with small quantity and easy to diffuse. The filaments have not seized directly by stretching air ,they are drawn adhesive frictional force produced by high pressure air to filaments and push force occurred by fluctuation and swing of filaments under stretching equipment, the two forces together are to make the filaments stretch. Stretching equipment can be moved up and down, the distance being moved affects the swing of filaments and web uniformity under it.
During the light PET spunbonded nonwoven wide-range integral slit positive air stretching process, the process parameter: drying temperature、revolution of metering pump、spinning temperature、cooling air temperature and speed、spinning speed、ACD height (the distance from the bottom of stretching equipment to the surface of the forming table)、the forming speed、the calendar pressure and temperature and so on. The parameter affected PET spunbonded nonwoven performances including: filament size、crystallization、tensile strength and elongation MD and CD、thickness、web university and so on. Comparing to different process parameters to the effect of spunbonded nonwovens and analyze.
Written by Han Wensheng(Textile Engineering)
Supervised by Prof Jin Xiangyu
引文
[1] 柯勤飞，靳向煜．非织造学．上海：东华大学出版社．2004
[2] 王延熹．非织造布生产技术[M]．上海：中国纺织大学出版社．1998
[3] Nonwovens Report International. 1997. (319):14
[4] 纺粘非织造新闻．中国纺粘网．2005
[5] 郭合信．纺粘法非织造布．中国纺织出版社．56-60
[6] Internationl Fiber Journal. 1998. (3).49-52
[7] Nonwovens News. Nonwovens Industry.1997
[8] akajima Advance Fiber Spinning Technology Woodhead, Cambridge,1992
[9] 皱荣华，双组分复合纺粘法非织造布，上海合成纤维研究所
[10] 赵耀明等．非织造布在医疗领域中的应用和展望．合成纤维．1997．(6)：45
[11] 靳向煜．吴海波等非织造布在医疗卫生领域的应用和发展．纺织学报．1997
[12] Nonwoven laminate suitable for medical applications Medical Textiles 1997(4)6-7
[13] Ann-Catherine Ericson．保持卫生产品包覆层的再润湿性能．IFP-瑞士纤维及聚合物研究所
[14] 迟景魁．土工合成材料在西部开发中的作用及发展前景．中国土工合成材料工程协会．2001
[15] 李允成，徐心华等．涤纶长丝生产．中国纺织出版社．27-29
[16] 郭秉臣主编．非织造布学．中国纺织出版社．2002．90-95
[17] L．Gerking Nanoval Gmbh & Co．KG采用Nanoval工艺的纺粘非织造布．中国国际产业用纺织品及非织造布论坛．180～190
[18] 徐占祥．徐树刚．纺粘牵伸器牵伸机理研究(Ⅲ)．产业用纺织品．2002．(5)21-24
[19] Th．Gries．Lurgi Zimmer公司(德国)PET短纤和长丝：生产工艺的发展趋势．国际纺织导报．1999．(2)36-37
[20] Hermann Balk. Troidorf. Germany. Apparatus for Spinning Core Filaments. 2000
[21] Susanne Dahl Thomsen. Torben Laigaard Mikkelsen(DK). Polymer Fibres And Their Use In The Preparation Of Nonwovens With High Bulk And Resilience. 2005
[22] Spunbond Technology Today. Miller Freeman, Inc. 1992
[23] 卢福民．先进的薄型聚酯非织造布纺粘技术．产业用纺织品．(20)11-14
[24] 孟家明．任夕娟．成展．涤纶短纤维在纺程中的取向与性能研究．合成技术及应用．第14卷．14-15
[25] 姚穆等主编．纺织材料学．中国纺织出版社．2000
[26] 赵书经主编．纺织材料实验教程．中国纺织出版社．2000
[27] 日本纤维机械学会纤维工学出版委员会编．纤维的形成结构与性能．纺织工业出版社．1988
[28] 徐占祥．徐树刚．纺粘牵伸器牵伸机理研究(Ⅰ)．(Ⅱ)．产业用纺织品．2002．
[29] 栾宏志．王金坤．董卫．Zinser涤纶牵伸丝工艺探析．合成技术及应用1998．第2期45～46
[30] 张建鹏．耿伟．刘凯进．纺粘法气流牵伸原理分析。纺织学报．1997(18)10-12
[31] 刘玉田．防水透气织物水蒸气渗透性试验方法概览．世界橡胶工业．2002．40-46
[32] 王玉琦．陈庆军．浅谈骤冷风系统及其改进．非织造布．2001(9)48-49
[33] Gajanan S Bhat, Sanjiv R Malkan. Extruded Continuous Filament Nonwovens: Advances in Scientific Aspects. Journal of Applied Polymer Science, 2002, 83: 572-585
[34] 崔宁．原玲．对聚酯切片流变行为的研究．中国纺织科学研究院研发中心科研报告．2002
[35] 任夕娟．孟家明．聚酯(PET)纤维结品度测定的研究．合成技术及应用．(13卷)4-6
[36] Hindeleh, A.M. and Johnson, J. J. Phys(D),1971,4.259; ibkd, Polymer, 1978, 19, 27.
[37] Gagon D K, Denn M M. Computer simulation of steady polymer melt spinning. Polymer Engineering and Science, 1991, 42
[38] Mastui M. Air drag on a continuous filament in melt spinning. Transaction of the society of Rheology, 1976, 20(3)
[39] 王延伟．薄型聚酯非织造布热轧工艺的探讨．非织造布．2002．第4期．20～21
[40] Hajji N, Spruiell J E, Lu FM, et al. Modelingof the 'Reicofil' spunbonding process. INDA Journal of Nonwovens Research, 1992,
[41] Ingold, T.S. and Miller, K. S., "Drained Axisymmetric Loading of Reinforced City", 《Geotechnical Engineering》, Vol. 109, No. 7, 60～62, 1983.
[42] 庄楚强．吴亚森编．应用数理统计基础．华南理工大学出版社．2002
[43] 郁崇文．汪军．工程参数的最优化设计．东华大学出版社．2003
[2] 王延熹．非织造布生产技术[M]．上海：中国纺织大学出版社．1998
[3] Nonwovens Report International. 1997. (319):14
[4] 纺粘非织造新闻．中国纺粘网．2005
[5] 郭合信．纺粘法非织造布．中国纺织出版社．56-60
[6] Internationl Fiber Journal. 1998. (3).49-52
[7] Nonwovens News. Nonwovens Industry.1997
[8] akajima Advance Fiber Spinning Technology Woodhead, Cambridge,1992
[9] 皱荣华，双组分复合纺粘法非织造布，上海合成纤维研究所
[10] 赵耀明等．非织造布在医疗领域中的应用和展望．合成纤维．1997．(6)：45
[11] 靳向煜．吴海波等非织造布在医疗卫生领域的应用和发展．纺织学报．1997
[12] Nonwoven laminate suitable for medical applications Medical Textiles 1997(4)6-7
[13] Ann-Catherine Ericson．保持卫生产品包覆层的再润湿性能．IFP-瑞士纤维及聚合物研究所
[14] 迟景魁．土工合成材料在西部开发中的作用及发展前景．中国土工合成材料工程协会．2001
[15] 李允成，徐心华等．涤纶长丝生产．中国纺织出版社．27-29
[16] 郭秉臣主编．非织造布学．中国纺织出版社．2002．90-95
[17] L．Gerking Nanoval Gmbh & Co．KG采用Nanoval工艺的纺粘非织造布．中国国际产业用纺织品及非织造布论坛．180～190
[18] 徐占祥．徐树刚．纺粘牵伸器牵伸机理研究(Ⅲ)．产业用纺织品．2002．(5)21-24
[19] Th．Gries．Lurgi Zimmer公司(德国)PET短纤和长丝：生产工艺的发展趋势．国际纺织导报．1999．(2)36-37
[20] Hermann Balk. Troidorf. Germany. Apparatus for Spinning Core Filaments. 2000
[21] Susanne Dahl Thomsen. Torben Laigaard Mikkelsen(DK). Polymer Fibres And Their Use In The Preparation Of Nonwovens With High Bulk And Resilience. 2005
[22] Spunbond Technology Today. Miller Freeman, Inc. 1992
[23] 卢福民．先进的薄型聚酯非织造布纺粘技术．产业用纺织品．(20)11-14
[24] 孟家明．任夕娟．成展．涤纶短纤维在纺程中的取向与性能研究．合成技术及应用．第14卷．14-15
[25] 姚穆等主编．纺织材料学．中国纺织出版社．2000
[26] 赵书经主编．纺织材料实验教程．中国纺织出版社．2000
[27] 日本纤维机械学会纤维工学出版委员会编．纤维的形成结构与性能．纺织工业出版社．1988
[28] 徐占祥．徐树刚．纺粘牵伸器牵伸机理研究(Ⅰ)．(Ⅱ)．产业用纺织品．2002．
[29] 栾宏志．王金坤．董卫．Zinser涤纶牵伸丝工艺探析．合成技术及应用1998．第2期45～46
[30] 张建鹏．耿伟．刘凯进．纺粘法气流牵伸原理分析。纺织学报．1997(18)10-12
[31] 刘玉田．防水透气织物水蒸气渗透性试验方法概览．世界橡胶工业．2002．40-46
[32] 王玉琦．陈庆军．浅谈骤冷风系统及其改进．非织造布．2001(9)48-49
[33] Gajanan S Bhat, Sanjiv R Malkan. Extruded Continuous Filament Nonwovens: Advances in Scientific Aspects. Journal of Applied Polymer Science, 2002, 83: 572-585
[34] 崔宁．原玲．对聚酯切片流变行为的研究．中国纺织科学研究院研发中心科研报告．2002
[35] 任夕娟．孟家明．聚酯(PET)纤维结品度测定的研究．合成技术及应用．(13卷)4-6
[36] Hindeleh, A.M. and Johnson, J. J. Phys(D),1971,4.259; ibkd, Polymer, 1978, 19, 27.
[37] Gagon D K, Denn M M. Computer simulation of steady polymer melt spinning. Polymer Engineering and Science, 1991, 42
[38] Mastui M. Air drag on a continuous filament in melt spinning. Transaction of the society of Rheology, 1976, 20(3)
[39] 王延伟．薄型聚酯非织造布热轧工艺的探讨．非织造布．2002．第4期．20～21
[40] Hajji N, Spruiell J E, Lu FM, et al. Modelingof the 'Reicofil' spunbonding process. INDA Journal of Nonwovens Research, 1992,
[41] Ingold, T.S. and Miller, K. S., "Drained Axisymmetric Loading of Reinforced City", 《Geotechnical Engineering》, Vol. 109, No. 7, 60～62, 1983.
[42] 庄楚强．吴亚森编．应用数理统计基础．华南理工大学出版社．2002
[43] 郁崇文．汪军．工程参数的最优化设计．东华大学出版社．2003