CN105835500B - 一种双层不织布吸音棉及其制备工艺 - Google Patents

一种双层不织布吸音棉及其制备工艺 Download PDF

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CN105835500B
CN105835500B CN201610160715.2A CN201610160715A CN105835500B CN 105835500 B CN105835500 B CN 105835500B CN 201610160715 A CN201610160715 A CN 201610160715A CN 105835500 B CN105835500 B CN 105835500B
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林云权
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Abstract

本发明公开了一种双层不织布吸音棉及其制备工艺，制备所述吸音棉的原料包括：无纺布，聚己二酸乙二醇酯，聚全氟乙丙烯，等规聚丙烯；制备工艺包括：对等规聚丙烯纤维进行熔喷成纤，冷却，制得等规聚丙烯纤维层；将所述的聚己二酸乙二醇酯和聚全氟乙丙烯混合后，进行熔喷成纤，冷却；将制备的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层与制备的等规聚丙烯纤维层进行热压，形成双层不织布；对得到双层不织布的正背两面分别层压复合上一层无纺布，得到所制的聚丙烯吸音棉。本发明制备得到的双层不织布吸音棉具有良好的耐低温性能，热稳定性和柔韧性，并且提高了等规聚丙烯的加工制造工艺的普遍适用性。

Description

一种双层不织布吸音棉及其制备工艺
技术领域
本发明涉及非织造布领域，具体涉及一种双层不织布吸音棉及其制备工艺。
背景技术
聚丙烯(PP)根据聚合物链段中甲基排布构型的不同而可以分为等规聚丙烯(iPP)、间规聚丙烯(sPP)和无规聚丙烯(aPP)三种构型聚合物。聚丙烯具有密度轻、耐热好、强度大、化学稳定等突出优点。并且通过技术手段调控，容易制备得到中空多孔结构，加大了对声音信号的吸收和阻隔，因此成为制备吸音棉材料的高分子备选原料之一。
聚己二酸乙二醇酯是一种由己二酸和过量乙二醇通过酯化反应在催化剂作用下形成的多元醇酯类聚合物。聚己二酸乙二醇酯由于具有良好的弹塑性能力，广泛应用在各种织造物、海绵、树脂纤维等各种弹性体中，能够很大程度上改善低温抗冲击能力，提高产品的弹性性能。
聚全氟乙丙烯(FEP)是四氟乙烯和六氟丙烯的嵌段共聚物，是一种综合性能极为优秀的氟聚合物。聚全氟乙丙烯具有极好的耐化学腐蚀性、热稳定性、耐低温性能、润滑性和优良的加工特性。聚全氟乙丙烯能够在-90℃～200℃温度范围内长期使用而不发生变化，对人体及环境不会造成污染。
在等规聚丙烯中添加聚己二酸乙二醇酯和聚全氟乙丙烯能够有效的改善聚丙烯低温时脆性大耐冲击差、抗老化性差、柔韧性弱等明显缺点，并且加入聚己二酸乙二醇酯和聚全氟乙丙烯能够提高等规聚丙烯对加工制造工艺的普遍适用性，更容易制备出性能优良的吸音棉材料。
中国专利CN201410182788.2公开了一种吸声材料及其制备方法，所述材料由三层组成，中心夹层为HXNBR/中空涤纶短纤复合材料，上下层为中空短纤非织造材料；其中，所述复合材料中HXNBR的质量百分比为50％～90％，中空涤纶短纤的质量百分比为10％～50％。制备方法包括：将HXNBR与中空涤纶短纤混炼，得到混合体；随后将混合体进行压制，得复合材料；最后放入两层中空短纤非织造材料中轻压，即得。但是该专利向HXNBR材料中添加大量中空涤纶短纤，极易在成纤制备过程中产生“飞花”现象，既造成了原料的浪费，还影响了成品的品质。
中国专利CN201510632732.7公开了一种双层非织造吸声材料及其制备方法，非织造吸声材料为层状结构，由外而内分别为活性炭纤维毡和天然纤维吸声毡。其中，活性炭纤维毡由含碳纤维毡经预处理、预氧化、碳化、活化后制得，天然纤维吸声毡由废旧天然纤维和低熔点纤维形成的多层网体，与活性炭纤维毡粘合后通过热压成型技术制得双层非织造吸声材料。但是该专利活性炭纤维毡和天然纤维吸声毡的处理过程中会产生大量废水废气，对环境污染很大，难以治理。
因此需要提高聚丙烯吸音棉的耐低温性能，热稳定性和柔韧性，提高等规聚丙烯对加工制造工艺的普遍适用性，制备出性能更优良的不织布吸音棉材料。
发明内容
本发明针对上述问题，提供一种双层不织布吸音棉及其制备工艺，使得制备得到的双层不织布吸音棉具有良好的耐低温性能，热稳定性和柔韧性，并且提高等规聚丙烯的加工制造工艺的普遍适用性。
本发明解决上述问题所采用的技术方案是：
一种双层不织布吸音棉，制备所述吸音棉的原料及其重量份包括：无纺布1600份～3000份，聚己二酸乙二醇酯400份～700份，聚全氟乙丙烯300份～700份，等规聚丙烯1000份～1500份。
进一步地，无纺布的参数具体为：单位面积质量为400g/m2～500g/m2，堆积密度为0.45g/m3～0.60g/m3。
进一步地，聚己二酸乙二醇酯的相对分子质量为3500～5000。
进一步地，聚全氟乙丙烯的参数为：密度为2.15g/cm3～5.00g/cm3，相对分子质量为5000～8000。
进一步地，等规聚丙烯的参数为：相对分子质量为120000～130000，MFR为250g/10min～450g/10min。
根据本发明另一发明目的，在于提供一种上述吸音棉的制备工艺，包括以下步骤：
步骤S01，等规聚丙烯纤维层的制备：对所述等规聚丙烯纤维进行熔喷成纤，以10℃/min～20℃/min的降温速率进行冷却，制得厚度为10mm～15mm的等规聚丙烯纤维层；
步骤S02，聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的制备：将所述的聚己二酸乙二醇酯和聚全氟乙丙烯混合后，进行熔喷成纤，以10℃/min～20℃/min的降温速率进行冷却，得到聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层；
步骤S03，双层不织布的制备：将步骤S02制备的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层与步骤S01制备的等规聚丙烯纤维层进行热压，形成双层不织布；
步骤S04，层压复合：对步骤S03得到双层不织布的正背两面分别层压复合上一层无纺布，得到所制的聚丙烯吸音棉。
进一步地，步骤S01中，熔喷成纤时的喷头温度为160℃～195℃。
进一步地，步骤S02中，熔喷成纤时的喷头温度为260℃～280℃。
进一步地，步骤S02中，聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的厚度为：2.5mm～3.5mm。
进一步地，步骤S04中，层压复合具体为：层压温度为90℃～100℃，层压压力为15MPa～25MPa。
本发明的优点是：
1.本发明采用聚己二酸乙二醇酯作为吸音棉材料的原料之一，能够有效提高吸音棉的低温抗冲击能力和弹性性能；由于聚己二酸乙二醇酯是一种由己二酸和过量乙二醇通过酯化反应在催化剂作用下形成的多元醇酯类聚合物，具有良好的弹塑性能力，广泛应用在各种织造物、海绵、树脂纤维等各种弹性体中，能够很大程度上改善低温抗冲击能力，提高产品的弹性性能；
2.本发明采用聚全氟乙丙烯(FEP)作为吸音棉材料的原料之一，能够提高吸音棉的耐化学腐蚀性、热稳定性、耐低温性能、润滑性和优良的加工特性；由于聚全氟乙丙烯是四氟乙烯和六氟丙烯的嵌段共聚物，是一种综合性能极为优秀的氟聚合物，具有极好的耐化学腐蚀性、热稳定性、耐低温性能、润滑性和优良的加工特性，能够在-90℃～200℃温度范围内长期使用而不发生变化，对人体及环境不会造成污染；
3.本发明采用双层不织布制备吸音棉，既利用了聚丙烯材料的密度轻、耐热好、强度大、化学稳定等突出优点，还利用了聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层来改善聚丙烯低温时脆性大耐冲击差、抗老化性差、柔韧性弱等明显缺点，提高等规聚丙烯对加工制造工艺的普遍适用性，制备出性能更优的吸音棉材料。
具体实施方式
以下对本发明的实施例进行详细说明，但是本发明可以由权利要求限定和覆盖的多种不同方式实施。
实施例1
一种双层不织布吸音棉
制备吸音棉的原料及其重量份包括：
无纺布，单位面积质量为400g/m2，堆积密度为0.45g/m3，1600份；
聚己二酸乙二醇酯，相对分子质量为3500，400份；
聚全氟乙丙烯，密度为2.15g/cm3，相对分子质量为5000，300份；
等规聚丙烯，相对分子质量为120000，MFR为250g/10min，1000份。
实施例2
一种双层不织布吸音棉
制备吸音棉的原料及其重量份包括：
无纺布，单位面积质量为500g/m2，堆积密度为0.60g/m3，3000份；
聚己二酸乙二醇酯，相对分子质量为5000，700份；
聚全氟乙丙烯，密度为5.00g/cm3，相对分子质量为8000，700份；
等规聚丙烯，相对分子质量为130000，MFR为450g/10min，1500份。
实施例3
一种双层不织布吸音棉
制备吸音棉的原料及其重量份包括：
无纺布，单位面积质量为450g/m2，堆积密度为0.53g/m3，2300份；
聚己二酸乙二醇酯，相对分子质量为4250，550份；
聚全氟乙丙烯，密度为3.58g/cm3，相对分子质量为6500，500份；
等规聚丙烯，相对分子质量为125000，MFR为350g/10min，1250份。
实施例4
一种双层不织布吸音棉的制备工艺
包括以下步骤：
步骤S01，等规聚丙烯纤维层的制备：在喷头温度为160℃的条件下对所述等规聚丙烯纤维进行熔喷成纤，以10℃/min的降温速率进行冷却，制得厚度为10mm的等规聚丙烯纤维层。
步骤S02，聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的制备：在喷头温度为260℃的条件下，将所述的聚己二酸乙二醇酯和聚全氟乙丙烯混合后，进行熔喷成纤，以10℃/min的降温速率进行冷却，得到厚度为2.5mm的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层。
步骤S03，双层不织布的制备：将步骤S02制备的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层与步骤S01制备的等规聚丙烯纤维层进行热压，形成双层不织布。
步骤S04，层压复合：在层压温度为90℃，层压压力为15MPa的条件下，对步骤S03得到双层不织布的正背两面分别层压复合上一层无纺布，得到所制的聚丙烯吸音棉。
实施例5
一种双层不织布吸音棉的制备工艺
包括以下步骤：
步骤S01，等规聚丙烯纤维层的制备：在喷头温度为195℃的条件下对所述等规聚丙烯纤维进行熔喷成纤，以20℃/min的降温速率进行冷却，制得厚度为15mm的等规聚丙烯纤维层。
步骤S02，聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的制备：在喷头温度为280℃的条件下，将所述的聚己二酸乙二醇酯和聚全氟乙丙烯混合后，进行熔喷成纤，以20℃/min的降温速率进行冷却，得到厚度为3.5mm的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层。
步骤S03，双层不织布的制备：将步骤S02制备的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层与步骤S01制备的等规聚丙烯纤维层进行热压，形成双层不织布。
步骤S04，层压复合：在层压温度为100℃，层压压力为25MPa的条件下，对步骤S03得到双层不织布的正背两面分别层压复合上一层无纺布，得到所制的聚丙烯吸音棉。
实施例6
一种双层不织布吸音棉的制备工艺
包括以下步骤：
步骤S01，等规聚丙烯纤维层的制备：在喷头温度为178℃的条件下对所述等规聚丙烯纤维进行熔喷成纤，以15℃/min的降温速率进行冷却，制得厚度为13mm的等规聚丙烯纤维层。
步骤S02，聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的制备：在喷头温度为270℃的条件下，将所述的聚己二酸乙二醇酯和聚全氟乙丙烯混合后，进行熔喷成纤，以15℃/min的降温速率进行冷却，得到厚度为3.0mm的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层。
步骤S03，双层不织布的制备：将步骤S02制备的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层与步骤S01制备的等规聚丙烯纤维层进行热压，形成双层不织布。
步骤S04，层压复合：在层压温度为95℃，层压压力为20MPa的条件下，对步骤S03得到双层不织布的正背两面分别层压复合上一层无纺布，得到所制的聚丙烯吸音棉。
实验例1
对实施例1～6所制的双层不织布吸音棉与普通市售PP吸音棉的低温抗冲击能力、弹性模量、耐化学腐蚀性、热稳定性、耐低温性能和润滑性进行测试，测试结果如表1所示。
其中测试弹性模量的实验条件为：跨距为30mm，应力速率为30mm/min。
其中柔软性能通过测试双层不织布的表面摩擦性能来表征，采用表面性能测试仪，测量试样移动时的摩擦力和粗糙度的积分电压，得出试样的平均摩擦系数(MIU)。
其中热稳定性能指采用差热分析法，测试聚合物在210℃的高温氧气中加速老化的方法，以氧化诱导期(OIT)(min)为指标。
其中耐低温性能采用高分子材料脆化温度测试。
表1性能测试结果
以上仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (5)

1.一种双层不织布吸音棉的制备工艺，其特征在于，包括以下步骤：
步骤S01，等规聚丙烯纤维层的制备：按重量份称取相对分子质量为120000～130000，MFR为250g/10min～450g/10min的等规聚丙烯1000份～1500份，对所述等规聚丙烯纤维进行熔喷成纤，以10℃/min～20℃/min的降温速率进行冷却，制得厚度为10mm～15mm的等规聚丙烯纤维层；
步骤S02，聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的制备：按重量份称取相对分子质量为3500～5000的聚己二酸乙二醇酯400份～700份和密度为2.15g/cm3～5.00g/cm3、相对分子质量为5000～8000的聚全氟乙丙烯300份～700份，将所述的聚己二酸乙二醇酯和聚全氟乙丙烯混合后，进行熔喷成纤，以10℃/min～20℃/min的降温速率进行冷却，得到聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层；
步骤S03，双层不织布的制备：将步骤S02制备的聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层与步骤S01制备的等规聚丙烯纤维层进行热压，形成双层不织布；
步骤S04，层压复合：对步骤S03得到双层不织布的正背两面分别层压复合上一层单位面积质量为400g/m2～500g/m2，堆积密度为0.45g/m3～0.60g/m3的无纺布，得到所制的聚丙烯吸音棉，其中，无纺布的重量份数为1600份～3000份。
2.根据权利要求1所述的制备工艺，其特征在于，步骤S01中，所述熔喷成纤时的喷头温度为160℃～195℃。
3.根据权利要求1所述的制备工艺，其特征在于，步骤S02中，所述熔喷成纤时的喷头温度为260℃～280℃。
4.根据权利要求1所述的制备工艺，其特征在于，步骤S02中，所述聚己二酸乙二醇酯和聚全氟乙丙烯的共混纤维层的厚度为：2.5mm～3.5mm。
5.根据权利要求1所述的制备工艺，其特征在于，步骤S04中，所述层压复合具体为：层压温度为90℃～100℃，层压压力为15MPa～25MPa。
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