RU2712318C1 - Method and system of tissue duplication - Google Patents

Abstract

FIELD: textile industry.

SUBSTANCE: invention relates to textile industry, particularly, to production of duplicated materials. Disclosed method of tissue duplication consists in the fact that rolls of connected materials prepared for continuous duplication are installed on automatic line and subjected to input quality control, depending on their type, specially selected adhesive is prepared, then material passes through system of tensioning devices and stretching of shafts, at that, there is continuous monitoring of mutual positioning of connected layers, adhesive unit consists of bath with glue, special design of the glue shaft and the crimping shaft operating in the pair with it, on the glue shaft in a special order a special relief is applied in a special way, which at the moment of glue application onto the fabric creates an air-glued cobweb, during lamination it fills the surface in the form of a micro-cobweb, while leaving sufficient space for steam removal, the fabric at the same time retains ductility and acquires shape stability, the weight increases insignificantly. Further, all is supplied to the lamination drum with the selected temperature and speed conditions, during the lamination, the crimping shafts are involved, if necessary, the adhesive layer is cooled and stabilized at the following process junctions, then the material is coiled. At the moment of production there is continuous monitoring of the main indicators on resistance to water column, weight, width of fabric, as well as breaking loads between layers. QC machines are sorted by presence of external defects and length. Note here that when glue is applied between fastened layers, it is not necessary to wait for complete polymerization thereof. Fabric is removed from line of duplication continuously after connection of layers. Final polymerization and set of strength occur already in finished rolls. And this does not affect performance. Rolls are immediately ready for quality control, length metering and sending to consumer. When using a water-repellent membrane, an adhesive compatible therewith in terms of chemical composition shows excellent adhesion to the layers being bonded. Used glue application method provides excellent air and vapor permeability, and in case of membrane, also water-repellent properties, while maintaining softness and elasticity, which is very important with further cutting of material and sewing therefrom the finished product. Disclosed tissue duplication system includes a measure-and-rejecting machine, a sewing machine (three-thread overlock), a single-trolley for rolls, system of shafts of automatic calendering duplicating machine-laminator, manual machine of chain stitch, glue shafts of automatic calendering duplicating machine-laminator, industrial mixer, automatic calendering duplicating machine-laminator, laminating drum automatic calendering duplicating machine-laminator, system of cooling and transporting shafts of automatic calendering duplicating machine-laminator, winding unit, electric disk knife, movable single-trolley for rolls, measure and rejecting machine, packing section table, polymer packing materials, scotch dispenser, hydraulic storage trolley, at that, initial stock is prepared by means of material rolls installation on the measure-and-rejecting machine and their unwinding at the measure-and-rejecting machine for appearance control, presence of defects, web width, further, the web rolls are joined to the continuous roller wound on the cardboard bobbin, the roller is moved from the table to the filling line into the laminator by means of the movable single-tier bogie for rolls, further preparation for start-up by means of pulling of filling material through working sections of laminator by means of system of shafts of automatic calendering duplicating machine-laminator for provision of uniform tension and symmetry of arrangement along width, further, connection of filling and laminating materials is performed by means of manual chain stitch machine to ensure uniform tension of material layers and non-fit seam, further preparation of the adhesive assembly by selecting and installing the shaft into the adhesive unit by means of glue shafts of the automatic calendering machine laminator for providing horizontal position in the fixing units, further preparing the adhesive composition and feeding it into the trough by means of an industrial mixer, checking the viscosity and homogeneity of the adhesive solution after preparation, checking and maintaining the constant level of the adhesive in the assembly, further, setting the rack, the glue shaft, the limiters of the assembly into the working position by means of the automatic calendering duplicating machine laminator for monitoring the linear parameters of the operating position, contacting the coil with an adhesive shaft, further installing a bobbin with a membrane on the shaft for coiling the film in the direction of movement of material, then, webs are laminated by membrane by means of joining and gluing layers of materials by means of laminating drum of automatic calendering duplicating laminator machine, further, finished fabric is cooled by means of system of cooling and conveying shafts of automatic calendering duplicating machine-laminator, note here that, if double duplication is required, the equipment is refilled once with duplicated material on one side and second duplication material (instead of membrane) on the other side and cycle is repeated.

EFFECT: technical result consists in increase in productivity due to increased speed of finished products output, in reduction of electric power consumption, reduction of the process chain due to reduced number of used equipment and elimination of the need to use energy-intensive heaters, wider range of consumer properties of the product.

2 cl, 1 tbl

Description

The invention relates to the textile industry, in particular to a technology for producing duplicate materials.

Often, the raw materials offered by manufacturers of materials do not have all the properties that are needed in a particular area. Manufacturers of raw materials do not create materials that combine the characteristics necessary for the end consumer. Often this happens due to the narrow specialization of manufacturers and the economic unprofitability of additional operations in mass production. A way to solve this problem is to combine the necessary materials by duplication.

Duplication of fabrics is the process of doubling and bonding materials using thread stitches and glue, or under pressure after fusion of the joined surface of one of the materials. The most common is the bonding of two fabrics (synthetic and wool, metallized and cotton, etc.) or the melting of one of the surfaces of foam rubber (polyurethane foam) and its connection under pressure with a fabric or knitwear. Duplication of textile materials is used to give textile materials new properties (water, radiation resistance, crease resistance, etc.).

Duplication materials:

Two-layer lining material

- Jersey duplicated with foam

- Non-woven fabric, duplicated with polyethylene foam or foam

- Loop fabric duplicated with foam For insoles and insulation inserts

- Cardboard duplicated with different density polyethylene foam

- Felt or non-woven fabric duplicated with faux fur

- Polyethylene foam dubbed with non-woven polyester needle-punched fabric

- Non-woven needle-punched fabric with hydro-impervious reflective film

For upper shoes

- Fabric duplicated with faux or genuine leather

- Fabric duplicated with polypropylene for thermoforming the bottom of the shoe

- Leather duplicated with faux fur

Also, depending on the problem being solved, other combinations are possible.

Using the thermal method of duplication of materials is the most economical way. However, it is not suitable for all materials, but only for those that are affected by temperature. For example, it is impossible to duplicate radiation-crosslinked polyethylene foil with a foil if the foil is not coated with a special thermal varnish or other thermoactive layer. Duplication by thermal bonding does not require high costs and sophisticated equipment.

Duplication of materials using adhesive systems is a more complex process. It consists in applying glue to one (or both) of the fastened surfaces and further combining duplicated materials using mechanical forces (rolling between shafts). When duplicating this method, you can fasten two, three or more materials. Depending on the specified characteristics of the final product, various adhesives can also be used. Duplication does not impose restrictions on stitched materials. For example, it is possible to duplicate such roll materials as polyethylene foams of various grades, films (PP, PPE, PVC, PE, Poly), foil, fabrics, non-woven materials, fiberglass, foam rubber in various combinations.

Duplication with glue requires more sophisticated equipment. In addition, it is necessary to know not only the characteristics of the materials, but also the adhesive systems used, which complicates the process several times in comparison with the method of thermal bonding.

With the right choice of glue, the result of duplication of roll materials is a quality product that combines the properties of both materials. Consequently, the range of applications of the resulting product is expanding.

So, for example, the adhesive method consists in connecting two layers of materials between which the adhesive is uniformly placed in the form of a continuous layer, strips or powder. Duplication is carried out on a calender under pressure and at high temperature. Under these conditions, the joined layers are firmly glued together, forming a single whole. For the top, dense and wear-resistant fabrics and knitted fabrics, faux fur, leather and suede are used. As a lining, dense massive massive woolen checkered multi-colored fabrics, knitted and non-woven fabrics with fleece, faux fur with polyacrylonitrile pile, fabrics with long fleece pile are used. Complex materials made of faux suede, duplicated with faux fur or fabric with a thick long fleece pile, imitate a fur sheepskin.

The layers given as an example give complex fabrics the necessary properties: water resistance, lightness, elasticity, wind resistance, crease resistance, softness, additional volume, rather high decorative, water and heat-protective properties. But they are also characterized by increased rigidity, poor drape, as well as low breathability.

The fire method is used to duplicate textile materials with foam rubber. The surface of the rolled polyurethane foam is melted, and then combined with a textile material under pressure and cooled.

For the upper layer, dense one-colored kapron fabrics, staple variegated fabrics, coat wool blend fabrics, various knitted fabrics of chemical fibers and faux fur are used. For the lining layer in three-layer materials, dense thin smooth polyamide fabrics and knitted fabrics are used.

The materials duplicated by foam rubber by the fire method are characterized by lightness, elasticity, crush resistance, good heat-shielding properties, but have low air permeability and are poorly draped. The thickness of the foam layer is 0.5-1.5 cm, the surface density of materials up to 500 g / m ² . Use such materials for the manufacture of outerwear, textile shoes, upholstered furniture.

With the piercing method of manufacturing complex materials, two or three textile materials are joined with synthetic threads on multi-needle quilting and stitching machines with thread seams of a chain or shuttle stitch.

Three-layer quilted materials for outerwear are made using dense cotton, synthetic or mixed fabrics, including with film coatings and various water-repellent impregnations, as a lining, thin smooth sliding synthetic fabrics and knitted fabrics. Between the front and lining layers there is a warming pad - polyacrylonitrile fleece, nonwoven heat-insulating materials of needle-punched or knitting-piercing method of manufacturing, non-woven glued volumetric heaters. In some cases, natural fluff is used as insulation.

For firmware use domestic and imported fully automated machines with electronic programming of work. The materials are connected with the lines of a chain or shuttle stitch, the firmware speed is 40-80 m / h. The use of synthetic threads for piercing stitches increases the wear resistance of the products and the resistance of the seams to abrasion, compression, and tension. Patterns created by firmware stitches are very diverse in shape and size: large and small stripes, squares, rhombuses, circles, rings, wavy lines, complex curly closed contours, asymmetric patterns, continuous embroidery patterns and so on.

The disadvantages of the method include the extremely low production rate and low water resistance of the obtained material due to the numerous punctures of the joined layers.

In the manufacture of complex materials, sometimes metallized materials, in particular foil, are also used. Their use significantly improves the heat-shielding properties of clothes, but worsens their hygienic and performance characteristics.

The prior art method for the production of duplicated fibrous nonwoven material (see patent RU 2418115 C1, published. 05/10/2011), however, the above method has several disadvantages. According to the specified method, the bonding of the components occurs due to the melting of the bicomponent fibers, which gives rigidity to the final product. Bicomponent fibers of different chemical composition (polyester and polypropylene) are contained not only in the second bonding layer, but also in the first and third, where they are also fused for better bonding. Production is energy-consuming, since thermal bonding requires a high (up to 250 ° C) temperature, and the use of powerful electric heaters makes it fire hazardous. What is a disadvantage. During the production process, it is possible to use only a carefully selected mixture of fibers that form the layers. In addition to surface density and chemical composition, the fiber length is also regulated, since if it is insufficient, the connection will be fragile. The more strictly regulated components, the more complicated and expensive production becomes. There is a need to form each of the layers separately, and, having only fulfilled all the conditions, then to combine them.

The cycle for preparing fiber for production includes:

- mashing the mixture

- combing fiber mixture

- canvas formation

- subsequent needle breaking.

Therefore, in addition to the line of duplication for the preparation of a uniform mixture with predetermined ratios of components, scutching, carding, canvas forming equipment, as well as needle-punched line are required. And in a number of cases, to give a hairiness, a structural needle-piercing machine may also be required. The number of necessary equipment is increasing. The next step is to assemble the package of three layers. From two fastened and one bonding layer on the equipment for collecting the package collect flooring. Then it is fed into the coander and oven. In a particular case - the installation of blowing with hot air. To feed the flooring, an unwinding device is additionally required. As can be seen from the description, the production preparation cycle includes a large number of units of equipment, which occupies production areas, consumes electricity, lengthens the process chain, and consequently, financial costs and cycle time. During the production process, when melting bicomponent fibers, an airtight crust is formed. Breathability suffers, stiffness increases. In addition, the process of melting bicomponent components is also strictly technologically regulated, both in temperature and in the time the temperature is exposed to the fiber. Otherwise, the fiber may not melt or melt into a continuous mass. So change the speed of release, and therefore productivity, is impossible. Heat treatment during bonding of the layers is carried out in a furnace by passing a packet of layers through a calender at a speed of 1.5-6.0 m / min. This indicator is key in determining the effectiveness of the entire production. The claimed method of duplication provides a speed of release up to 30 m / min, which is significantly higher than considered.

The objective of the claimed technical solution is to eliminate the disadvantages of the prior art, as well as providing the possibility of using universal adhesive compositions that can combine any chemical composition of fabric materials that do not have a rigid binding to the parameters of the fiber.

The technical result consists in increasing productivity by increasing the speed of production of finished products, in reducing energy costs, in reducing the technological chain by reducing the number of equipment used and eliminating the need for energy-intensive heaters, in expanding the range of consumer qualities of products.

The claimed method of duplicating fabrics consists in setting up rolls of materials to be prepared that are prepared for continuous duplication, which have passed the incoming quality control, depending on their type, prepare glue specially selected in composition, then the material passes through a system of tensioners and expansion shafts, this is a continuous monitoring of the mutual positioning of the joined layers, the adhesive unit consists of a bath with glue, a special design of the adhesive shaft and working in paired with it, the crimping shaft, the original relief is specially applied in a special way on the glue shaft, which at the time of applying glue to the fabric creates an air-glue web, during lamination it fills the surface in the form of a micro-web, while leaving sufficient space for steam removal, the fabric at the same time, it retains plasticity and acquires shape stability, the weight increases slightly.

Then everything goes to the lamination drum with the selected temperature and speed conditions, crimp shafts are involved in the lamination process, if necessary, the adhesive layers are cooled and stabilized during the next technological transitions, then the material is rolled up.

At the time of production, there is a continuous monitoring of the main indicators of resistance to water column, weight, fabric width, as well as tensile loads between layers. OTK machines are sorted by the presence of external defects and length.

Moreover, when applying glue between the fastened layers there is no need to wait for its full polymerization. The fabric is removed from the duplication line continuously after the layers are joined. The final polymerization and curing take place already in the finished rolls. And this does not affect performance. Rolls are immediately ready for quality control, meter measurement and dispatch to the consumer. When using a water-repellent membrane, an adhesive compatible with it in chemical composition shows excellent adhesion to the layers to be bonded. The applied method of applying glue provides excellent indicators of air and vapor permeability, and in the case of a membrane, also water-repellent properties, while maintaining softness and elasticity, which is very important for further cutting of material and tailoring of the finished product from it.

The claimed fabric duplication system includes a measuring and rejecting machine, a sewing machine (overlock three-thread), a single-tier movable trolley for rolls, a system of rolls of an automatic calender backup laminating machine, a manual chain stitch machine, adhesive rolls of an automatic calender duplicating laminating machine, an industrial mixer, an automatic mixer calendaring duplicating laminating machine, laminating drum of an automatic calendaring duplicating laminating machine, a system of cooling and transporting all of the automatic calender duplicating laminating machine, winding unit, electric disk knife, single-tier movable trolley for rolls, measuring and rejecting machine, packing section table, polymer packaging materials, adhesive tape dispenser, hydraulic storage trolley, while the raw materials are prepared by installation rolls of material on a measuring and rejecting machine and unwinding them on a measuring and rejecting machine to control the appearance, presence of defects, web width, then the rolls of the web are connected to a continuous roller wound on a cardboard spool, the roller is moved from the table to the dressing line into the laminator by means of a single-tier movable roll carriage for rolls, then they are prepared for launch by pulling the filling material through the working sections of the laminator by means of the shaft system of the automatic calender duplicating machine - laminator to ensure uniform tension and symmetry of the location across the width, then make the connection of the refueling and laminar materials using a manual chain stitch machine to ensure uniform tension of the layers of materials and a non-stop seam, then prepare the adhesive unit by selecting and installing the shaft in the adhesive unit using the adhesive shafts of the automatic calender backup laminating machine to ensure a horizontal position in the fixing units, then prepare the adhesive the composition and feed it into the cuvette using an industrial mixer, check the viscosity and uniformity of the adhesive solution after preparation, checking and maintaining a constant level of glue in the assembly, then establish the squeegee, glue shaft, limiters of the assembly in the working position by means of an automatic calender backup laminating machine to control the linear parameters of the working position, contact the squeegee with the adhesive shaft, then install spools with membrane on the shaft for winding the film in the direction of movement of the material, then laminating the paintings with a membrane by connecting and gluing the layers of material rials by means of a laminating drum of an automatic calender duplicating machine-laminator, then the finished web is cooled by means of a system of cooling and conveying shafts of an automatic calender duplicating machine-laminator, while in case of double duplication, equipment is refilled with once duplicated material on one side and a second duplication material (instead of the membrane), on the other, and repeat the cycle.

A detailed description of the claimed method with a list of equipment used is given in table 1.

Depending on the materials used and their combinations, the water resistance can reach more than 20,000 mm of water. In the practical application of tissue lamination with a membrane, the water resistance indicators exceed those declared by the manufacturer. Improving performance is due to the reinforcement of the membrane with fabric, fleece, knitwear or lining mesh.

The production speed of 10000-20000 m per shift, the temperature range of lamination from 100 to 130 ° C.

Claims (2)

1. A method of duplication of fabrics, including the preparation of feedstock, which consists of installing rolls of material on a measuring and rejecting machine and unwinding them, then connect the rolls of fabric into a continuous roller wound on a cardboard spool, then move the roller from the table to the filling line in the laminator, prepare for launch and pull the filling material through the working sections of the laminator, connect the filling and laminated materials, prepare the adhesive unit, namely, make a choice and install new shaft into the glue assembly, prepare the glue composition and supply it to the cuvette, set the squeegee, glue shaft, stoppers of the assembly in the working position and install the spools with the membrane on the shaft, laminate the membranes with a membrane by joining and gluing layers of materials, cooling the finished fabric, and to obtain finished products, winding the finished web onto a cardboard spool, cutting the roller with the finished product, and then quality control of the finished product. 2. A fabric duplication system, including a measuring and rejection machine, a sewing machine (three-thread overlock), a single-tier movable trolley for rolls, an automatic calender duplicating laminating machine shaft system, a chain stitch manual machine, adhesive rolls of an automatic calendaring duplicating laminating machine, an industrial mixer , an automatic calender dubbing machine-laminator, a laminating drum of an automatic calender dubbing machine-laminator, a system of cooling and conveying shafts tomato calender duplicating machine-laminator, winding unit, electric disk knife, single-tier movable trolley for rolls, measuring and rejecting machine, packing section table, polymer packaging materials, adhesive tape dispenser, hydraulic storage trolley, while preparing raw materials by installing rolls material on the measuring and rejecting machine and unwinding them on the measuring and rejecting machine to control the appearance, presence of defects, web width, then producing t connecting the rolls of web into a continuous roller wound around a cardboard spool, transfer the roller from the table to the filling line into the laminator by means of a single-tier movable trolley for rolls, then prepare to start by pulling the filling material through the working sections of the laminator using the shaft system of the automatic calender duplicating machine - laminator to ensure uniform tension and symmetry of the location across the width, then make the connection of the filling and laminated materials by means of a manual chain stitch machine to ensure uniform tension of the layers of materials and a non-stop seam, then the adhesive unit is prepared by selecting and installing the shaft in the adhesive unit using the adhesive rolls of the automatic calender backup laminating machine to ensure a horizontal position in the fixing units, then the adhesive composition is prepared and feed it into the cuvette using an industrial mixer, check the viscosity and uniformity of the adhesive after preparing, checking and maintaining a constant level of glue in the assembly, then the rake, glue shaft, and limiters of the assembly are installed in the working position by means of an automatic calender backup laminating machine to control the linear parameters of the working position, the rake is in contact with the glue shaft, then spools with a membrane are installed on the shaft for winding the film in the direction of movement of the material, then laminating the paintings with a membrane by connecting and gluing layers of materials by means of a laminating drum of an automatic calender duplicating machine-laminator, then the finished web is cooled by means of a system of cooling and conveying shafts of an automatic calender duplicating machine-laminator, while in case of double duplication, equipment is refilled with once duplicated material on one side and a second duplication material ( instead of the membrane) on the other and repeat the cycle.