A flake processing device, a processing method and the processed flake

Abstract

The present invention discloses a flake processing device, which comprises an electrostatic field unit, a cotton laying unit, an internal environment regulation unit and an infusion unit. The processing device combines electrospinning, electrostatic spraying and vacuum liquid absorption, uses the charge repulsion to fluff the fibers, the binder is evenly dispersed during the processing, the static electricity is easily conducted and released, the processing raw materials can be flexibly selected, and the processed flake is fluffy and has no static electricity accumulation. The present invention also discloses a flake processing method, which can be flexibly operated according to the properties of the raw materials, is applicable to natural cotton, chemical fiber and modified cotton, and the processed flakes all have good fluffiness and a wider range of uses. In addition, the present invention also discloses a flake processed by using the above device and method, and the raw materials used in the flake can be flexibly selected and proportioned as required, and the fluffiness is good.

Description

Technical Field

[0001] The present invention relates to a flake processing device and a processing method, and also relates to a flake processed by using the device and the method. Background Art

[0002] First of all, during the drying and shaping process of traditional polyester spray-bonded wadding, it has to go through dozens of metal rollers and rub closely against rubber continuously. Coupled with the fact that the fabric has a low moisture content and poor conductivity at high temperatures, and the charge is difficult to leak, this causes the continuous accumulation of static electricity. When the static voltage is too high at the operating position, the operators often get a strong electric shock. In addition, the repulsion and attraction caused by static electricity will also cause difficulties in folding the fabric, affecting the processing process and product quality. At present, in the processing operation of spray-bonded wadding carding, the lubrication is generally carried out by spraying to avoid static electricity and dust generated by friction. However, this operation method not only has low efficiency and the effect of eliminating static electricity is not obvious, but also the equipment will rust due to being wetted with water, affecting the service life. Chinese Patent CN203128714U also discloses a device for eliminating static electricity through high-voltage corona discharge.

[0003] Secondly, in the existing electrospinning process, through a stable and continuous directional electric field, the fluid solvent can be quickly volatilized, and finer filaments are formed through the "Taylor cone", but excessive volatilization of the solvent during the flake processing process will directly cause the film-forming aids or adhesives to lose fluidity and adhere to the surface layer of the flake; and the tip of the spinneret is easily blocked by the solution, which is not conducive to continuous processing.

[0004] Thirdly, in the prior art, the MaxChargeTM nozzle is an air-assisted electrostatic nozzle, which uses the principle of electrostatic adsorption and realizes spraying liquid on the surface of crop leaves through air-assisted diversion, and well solves the problems of droplet drift and spray distribution uniformity, but this technology can only spray liquid on the surface of an object.

[0005] The above-mentioned electrospinning and electrostatic spraying operations in the prior art can be carried out in an open environment.

[0006] Finally, when processing flakes by using the equipment and methods in the prior art, in order to achieve the effects of good warmth retention, good fluffiness and soft hand feeling of the flakes, it is necessary to screen the fineness, length, crimpness, cross-sectional shape and surface treatment state of the fibers, etc., so the selection of raw materials is restricted. Summary of the Invention

[0007] Object of the Invention: The object of the present invention is to provide a flake processing device and a processing method that can flexibly select raw materials and can achieve fluffy and static-free flakes. Another object of the present invention is to provide a flake processed by using the device and the method.

[0008] Technical solution: The flake processing equipment of the present invention includes an electrostatic field unit, a cotton laying unit, an internal environment control unit, and an infusion unit. The electrostatic field unit includes a high-voltage generator, an electrode, and an insulating box body. The high-voltage generator is provided with a high-voltage generator output terminal. The electrode is located inside the insulating box body and is connected to the high-voltage generator output terminal. The cotton laying unit includes a conductive metal mesh, which is located inside the insulating box body and is grounded or connected to a micro voltage. The internal environment control unit of the equipment includes an air inlet, an air extraction port, and an air extraction device. The air inlet is located on the insulating box body, on the same side as the electrode, and both are on the side where the conductive metal mesh contacts the flake. The air extraction port is located in the space of the insulating box body on the side where the conductive metal mesh does not contact the flake, and the air extraction port, the insulating box body, and the air extraction device are sequentially connected through pipelines. The infusion unit includes an extrusion device, a liquid storage chamber, and a liquid outlet device, and the liquid outlet device is connected to the electrode.

[0009] Preferably, the electrostatic field unit further includes an electrode slide rail, which is located inside the insulating box body and is used for the electrode to move.

[0010] Preferably, the cotton laying unit further includes a metal mesh slide rail, which is located inside the insulating box body and is used for the conductive metal mesh to move.

[0011] Preferably, the internal environment control unit of the equipment further includes a heating device, which is located at the air inlet and forms a hot air cycle with the air extraction device.

[0012] Preferably, the air extraction port, the insulating box body, the air extraction device, and the air inlet in the internal environment control unit of the equipment are sequentially connected through pipelines to form a cycle.

[0013] Preferably, the internal environment control unit of the equipment further includes an air outlet and an air valve. The air outlet is located between the connecting pipelines of the air inlet and the air extraction device and is communicated with the external environment. The air valve is located in the pipeline where the air inlet, the air extraction device, and the air outlet are communicated.

[0014] The flake processing method of the present invention includes the following steps:

[0015] 1) Place the composite fiber group on the conductive metal mesh grounded or connected to a micro voltage. The adhesive is sprayed out by the liquid outlet device, and is charged by the electrode connected to the high-voltage generator output terminal, and is evenly sprayed on the surface of the composite fiber group.

[0016] 2) Use the air extraction device to perform negative pressure air extraction on the composite fiber flake obtained in step 1), then turn over the composite fiber flake, and repeat steps 1) to 2) once or multiple times.

[0017] 3) Perform pressing, ironing, and curing operations on each side of the bonded and formed composite fiber flake obtained in step 2) to obtain a finished flake.

[0018] Preferably, the voltage applied by the high-voltage generator in step 1) is -15 kV to 15 kV, the binder is an acrylate with a viscosity of 10 cP to 200 cP, and it can be further diluted.

[0019] Preferably, the air pressure of the negative-pressure air extraction in step 2) is 0.5 Pa - 1.5 Pa, and the operating temperature is from room temperature to 140 °C.

[0020] For the floc formed by using the above-mentioned floc processing equipment and method of the present invention, the mass ratio of cotton fiber to polyester fiber is 0 - 1:0 - 4 under absolute dry conditions, and the dry basis content of the binder in the finished product is 10% - 20%.

[0021] First, all the prior arts are various methods and equipment for eliminating fiber static electricity, while the floc processing equipment and processing method of the present invention actively charge the fibers and utilize the charge repulsion to fluff the fibers. Second, although the floc processing equipment and processing method of the present invention utilize a directional electric field, at the same time, it avoids excessive volatilization of the solvent, and uses vacuum liquid absorption to ensure a certain moisture content of the floc, so that the charge can be transferred to the lower-layer fibers and the metal mesh to achieve dynamic balance. Third, the floc is not only a surface structure, but also the internal penetration of film-forming aids or binders is required to achieve the bonding between fibers. Using only the nozzles in the prior art cannot meet the processing requirements of the floc. Although the floc processing equipment and processing method of the present invention utilize air flow, the main function of the air flow is to assist the penetration of the liquid droplets on the floc, rather than the guiding effect on the ejected liquid droplets. Finally, the floc processing equipment and processing method of the present invention are flexible in raw material selection, and the types and ratios of raw materials can be selected according to the conductivity of the raw materials, as long as the raw materials reach a suitable conductivity.

[0022] Beneficial effects: Compared with the prior art, the present invention has the following remarkable advantages:

[0023] (1) The floc of the present invention has good fluffiness.

[0024] (2) The processing equipment of the present invention can make the static electricity of the floc easy to transfer and release, avoiding static electricity accumulation.

[0025] (3) The processing equipment of the present invention can make the spraying of the film-forming agent or binder solution more uniform.

[0026] (4) The processing method of the present invention is flexible in the selection of raw material fibers and has few restrictions. Description of the Drawings

[0027] Figure 1 It is a schematic structural diagram of the equipment of the present invention. Detailed Embodiments

[0028] The technical solutions of the present invention will be further described below in conjunction with the embodiments.

[0029] As Figure 1 shown, the extrusion device 1 is connected to the liquid storage chamber 2, the liquid storage chamber 2 is connected to a liquid discharging device 14, and the liquid discharging device 14 is connected to the electrode 3. The electrode 3, the electrode slide rail 4, the conductive metal mesh 5, and the metal mesh slide rail 6 are located inside an insulating box body. The electrode 3 is connected to the electrode slide rail 4, the conductive metal mesh 5 is connected to the metal mesh slide rail 6, and a floc is laid on one side of the conductive metal mesh 5 on the same side as the electrode 3. An air inlet 7 is located on the insulating box body, and the air inlet 7 is on the same side as the electrode 3. An air extraction port 8 is located in the space of the insulating box body on the side where the conductive metal mesh 5 does not contact the floc. The air extraction port 8, the insulating box body, and the air extraction device 10 are sequentially connected through pipelines. A heating device may also be provided at the air inlet 7, and it forms a hot air cycle with the air extraction device 10. The air extraction port 8, the insulating box body, the air extraction device 10, and the air inlet 7 may also be sequentially connected through pipelines to form a cycle. In this embodiment, the device may also include an air outlet 12 and an air valve 11. The air outlet 12 is located between the connecting pipelines of the air inlet 7 and the air extraction device 10 and communicates with the external environment. The air valve 11 is located in the pipeline where the air inlet 7, the air extraction device 10, and the air outlet 12 communicate with each other. The high-voltage generator 9 is provided with a high-voltage generator output terminal 13, and the high-voltage generator output terminal 13 is connected to the electrode 3.

[0030] The adhesive is stored in the liquid storage chamber 2 and is extruded from the liquid storage chamber 2 at a certain speed by the extrusion device 1, and is transported to the electrode 3 by the liquid outlet device 14 and sprayed out. The electrode 3 is connected to the output end 13 of the high-voltage generator through a wire, so that the sprayed liquid droplets are charged. Due to the charge repulsion, the liquid droplets are dispersed into fine droplets. Then, mainly under the action of the electric field force, blowing can be assisted to make the liquid droplets move in the direction of the conductive metal mesh 5. During the process, partial evaporation of the solution is allowed. The fine droplets transfer the charge to the floc, and the fibers of the floc are repelled by the charge and repel each other, becoming fluffy. The alternating blowing and suction through hot air circulation method can also be adopted. The wind speed can be intermittently controlled and coordinated with the liquid infusion unit, so that the cotton will not be overdried and caked due to the wind force. The main purpose of the air extraction is to help the liquid droplets penetrate into the inner layer of the floc, preliminarily dry, and have a certain guiding effect on the fine droplets. The electrode slide rail 4 is for the electrode 3 to move, and the metal mesh slide rail 6 is for the conductive metal mesh 5 to move. With the assistance of mechanical and electrical control, the adhesive is evenly spread on the floc. The conductive metal mesh 5 is grounded or connected to a micro voltage, and the high-voltage generator 9 can be grounded. When the air inlet 7 forms a cycle with the air extraction device 10, the air extraction port 8, and the insulating box through a pipeline, the air valve 11 controls the system pressure, and the air extraction device 10 controls the wind direction and wind speed in the system, and the air outlet 12 ensures the air exchange between the system and the outside. The air inlet 7 is provided with heating devices such as resistance wires and bathroom heaters to control the temperature inside the insulating box and on the surface of the floc. Two or more sets of pipelines can be set up for alternating cold and hot air circulation to meet different process requirements. The size and shape of the insulating box can be adjusted, aiming to maintain the temperature of the internal environment of the equipment, form a stable air flow during air extraction, avoid the charged liquid droplets being attracted by other grounded components, and reduce the influence of the external environment of the equipment. The air pressure and time of negative pressure air extraction depend on the temperature, the thickness of the floc, and the viscosity of the adhesive.

[0031] A large voltage difference needs to be formed between the voltage connected to the electrode 3 and the conductive metal mesh 5 to make the adhesive liquid droplets move along the direction of the voltage difference. The electrode 3 can be connected to a high voltage of -15 kV to 15 kV, and the connected voltage needs to be adjusted comprehensively according to factors such as the viscosity of the selected adhesive, the liquid outlet speed, and the system temperature. Connecting the electrode 3 to the same numerical negative high voltage and positive high voltage has a similar dispersion effect on the liquid droplets, only the spraying form is different. If a negative high voltage is applied, the fine droplets are not easily scattered outside the metal mesh with a slightly positive pressure.

[0032] The conductive metal mesh 5 can be grounded or connected to a micro voltage, and the connected micro voltage is -70 V to 70 V. If the conductivity of the processed floc is small, such as pure polyester, the conductive metal mesh 5 can be connected to a slightly negative voltage or grounded; while for natural fibers such as pure cotton with a large conductivity, to achieve the same fluffy effect, the conductive metal mesh 5 can be connected to a slightly positive voltage.

[0033] The mass ratio of the flake raw materials mainly considers the conductivity of the raw material fibers under the conditions of binder wetting and drying to achieve the dynamic balance of charge transfer. The selection of raw material fibers is flexible and can be mixed in the required proportions to achieve the appropriate conductivity. Since the cotton fat covering the degreased cotton and modified cotton has been removed, their conductivity is lower than that of natural raw cotton. The expected conductivity can be achieved by blending natural raw cotton and polyester. The lower the conductivity, the less charge needs to be transferred by the droplets to achieve the dynamic balance of charge and the fluffy effect.

[0034] In the flake processing method of the present invention, steps 1) to 2) can be alternately repeated in consideration of the actual binder concentration, which is similar to 3D printing. That is, after laying one or several layers of fibers, the binder is sprayed, and after high-temperature negative-pressure air extraction for fluffing and drying, one or several layers of fibers are laid again to repeat the above operations until the target flake thickness is reached. The air pressure and time of negative-pressure air extraction depend on the temperature, flake thickness, and binder viscosity. Considering the conductivity requirements, cotton and chemical fibers such as polyester can be alternately laminated without pre-mixing in proportion, and steps 1) to 2) are carried out. The binder in the flake processing method of the present invention can be further diluted on the basis of the binder viscosity of the existing technology, but factors such as flake thickness, flake conductivity, and system temperature need to be considered.

[0035] Example 1

[0036] The raw material used is modified cotton, the dry basis content of the binder in the finished product is 18%, the binder viscosity is 153.3 cP, the voltage applied by the high-voltage generator is 13 kV, the conductive metal mesh is connected to a voltage of 70 V, the air pressure of negative-pressure air extraction is 1.2 Pa, and the method of alternately laying flakes and applying the binder is adopted. The air extraction time is 10 s to 30 s, and it increases step by step with the flake thickness and the number of layers laid. For subsequent testing, the unit mass of the prepared flake is 167.4 g / m 2 。

[0037] The measured compression ratio is 46.6% and the recovery rate is 73.0%, meeting the national standard first-class product standard.

[0038] Example 2

[0039] For the mass ratio of the sprayed cotton raw materials, under absolute dry conditions, natural cotton fiber: polyester fiber = 1:0.3, the dry basis content of the binder in the finished product is 14.8%, the binder viscosity is 134.3 cP, the voltage applied by the high-voltage generator is -10 kV, the conductive metal mesh is grounded, the air pressure of negative-pressure air extraction is 1.5 Pa, and the method of first laying flakes to the target thickness and then applying the binder for drying is adopted. The air extraction time is 180 s. For subsequent testing, the unit mass of the prepared flake is 160.2 g / m 2 。

[0040] The measured compression ratio is 41.7% and the recovery rate is 76.8%, meeting the national standard first-class product standard.

[0041] Example 3

[0042] For the mass ratio of raw materials of sprayed cotton, under absolutely dry conditions, natural cotton fiber: polyester fiber = 1:4, the dry basis content of the binder in the finished product is 10.9%, the viscosity of the binder is 90.4 cP, the voltage applied by the high-voltage generator is 9 kV, the conductive metal mesh is connected to a slightly negative pressure, the wind pressure of negative pressure exhaust is 1.0 Pa. The method of alternating laying sheets and applying the binder is adopted, the exhaust time is 10 s - 20 s, and then electrostatic elimination is carried out by piercing with a soft grounded metal wire. For subsequent detection, the unit mass of the prepared flake is 150.3 g / m 2 。

[0043] The measured compression ratio is 40.5% and the recovery rate is 78.8%, meeting the national standard first-class product standard.

[0044] Example 4

[0045] For the mass ratio of raw materials of sprayed cotton, under absolutely dry conditions, natural cotton fiber: polyester fiber = 1:2, the dry basis content of the binder in the finished product is 10.9%, the viscosity of the binder is 90.4 cP, the voltage applied by the high-voltage generator is 9 kV, the conductive metal mesh is connected to a slightly negative pressure, the wind pressure of negative pressure exhaust is 1.0 Pa. Natural cotton fiber and chemical fiber are not premixed. Another layer of polyester is added between every two layers of cotton fiber for lamination, and then the binder is applied. The exhaust time is 10 s - 20 s, and then electrostatic elimination is carried out by piercing with a soft grounded metal wire. For subsequent detection, the unit mass of the prepared flake is 157.0 g / m 2 。

[0046] The measured compression ratio is 40.3% and the recovery rate is 75.3%, meeting the national standard first-class product standard.

[0047] Example 5

[0048] Pure polyester is selected as the raw material, the dry basis content of the binder in the finished product is 18.7%, the viscosity of the binder is 90.4 cP, the voltage applied by the high-voltage generator is 5 kV, the conductive metal mesh is connected to a slightly negative pressure, the wind pressure of negative pressure exhaust is 1.0 Pa. The method of alternating laying one layer of fiber and applying one layer of binder is adopted. The exhaust time for each time is 10 s - 20 s, and then electrostatic elimination is carried out by piercing with a soft grounded metal wire. For subsequent detection, the unit mass of the prepared flake is 154.2 g / m 2 。

[0049] The measured compression ratio is 37.7% and the recovery rate is 82.3%, meeting the national standard qualified product standard.

Claims

1. A method for processing a fluffy flake, characterized in that, it includes the following steps: 1) Place the composite fiber group on a grounded or micro-voltage-connected conductive metal mesh (5). The adhesive is ejected through a liquid outlet device (14), and is charged by an electrode (3) connected to the output end (13) of a high-voltage generator, and is evenly sprayed onto the surface of the composite fiber group; 2) Use a ventilation device (10) to perform negative-pressure ventilation on the composite fiber flake obtained in step 1), then turn over the composite fiber flake, and repeat steps 1) to 2) once or multiple times; 3) Perform pressing, ironing and curing operations on each side of the bonded and formed composite fiber flake obtained in step 2) to obtain a finished flake; The processing equipment for processing the fluffy flake is provided with an electrostatic field unit, a cotton laying unit, an internal environment regulation unit and an infusion unit. Among them, the electrostatic field unit is provided with a high-voltage generator (9), an electrode (3) and an insulating box body. The high-voltage generator (9) is provided with a high-voltage generator output end (13). The electrode (3) is located inside the insulating box body and is connected to the high-voltage generator output end (13); among them, the cotton laying unit is provided with a conductive metal mesh (5), and the conductive metal mesh (5) is located inside the insulating box body and is grounded or connected to a micro-voltage; among them, the internal environment regulation unit of the equipment is provided with an air inlet (7), an air extraction port (8) and a ventilation device (10). The air inlet (7) is located on the insulating box body. The air inlet (7) is on the same side as the electrode (3), and both are on the side where the conductive metal mesh (5) contacts the flake. The air extraction port (8) is located in the space of the insulating box body on the side where the conductive metal mesh (5) does not contact the flake, and the air extraction port (8), the insulating box body and the ventilation device (10) are sequentially connected through pipelines; among them, the infusion unit is provided with an extrusion device (1), a liquid storage room (2) and a liquid outlet device (14), and the liquid outlet device (14) is connected to the electrode (3).

2. The method for processing a fluffy flake according to claim 1, characterized in that, the electrostatic field unit is further provided with an electrode slide rail (4), and the electrode slide rail (4) is located inside the insulating box body to supply the electrode (3) to move.

3. The method for processing a fluffy flake according to claim 1, characterized in that, the cotton laying unit is further provided with a metal mesh slide rail (6), and the metal mesh slide rail (6) is located inside the insulating box body to supply the conductive metal mesh (5) to move.

4. The method for processing a fluffy flake according to claim 1, characterized in that, the internal environment regulation unit of the equipment is further provided with a heating device, which is located at the air inlet (7) and forms a hot air cycle with the ventilation device (10).

5. The method for processing a fluffy flake according to claim 1, characterized in that, the air extraction port (8), the insulating box body, the ventilation device (10), and the air inlet (7) in the internal environment regulation unit of the equipment are sequentially connected through pipelines to form a cycle.

6. The method for processing a fluffy flake according to claim 5, characterized in that, The internal environment control unit of the device is also provided with an air outlet (12) and an air valve (11). The air outlet (12) is located between the connection pipeline of the air inlet (7) and the air extraction device (10) and communicates with the external environment. The air valve (11) is located in the pipeline where the air inlet (7), the air extraction device (10) and the air outlet (12) communicate with each other.

7. The method for processing the bulking floccules according to claim 1, characterized in that in step 1), the voltage applied by the high-voltage generator is -15 kV to 15 kV, and the adhesive is an acrylate with a viscosity of 10 cP to 200 cP.

8. The method for processing the bulking floccules according to claim 1, characterized in that in step 2), the air pressure of the negative-pressure air extraction is 0.5 Pa to 1.5 Pa, and the operating temperature is from normal temperature to 140 °C.

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