CN106012577A - 一种新型复合材料及其制备方法 - Google Patents

一种新型复合材料及其制备方法 Download PDF

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CN106012577A
CN106012577A CN201610607309.6A CN201610607309A CN106012577A CN 106012577 A CN106012577 A CN 106012577A CN 201610607309 A CN201610607309 A CN 201610607309A CN 106012577 A CN106012577 A CN 106012577A
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何建雄
王良
王一良
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Dongguan Xionglin New Materials Technology Co Ltd
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Abstract

本发明涉及一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径≤5μm。本发明通过选择特定组分和含量的聚氨酯原料组分，配合扩链、交联、中和步骤，得到聚氨酯材料，与由锦纶纤维和芳纶纤维，尤其是芳砜纶纤维，混合防止的基材层配合，得到软硬度适中，韧性高，透气性好的复合材料，能够用作合成革。

Description

一种新型复合材料及其制备方法
技术领域
本发明涉及材料领域，具体涉及一种新型复合材料及其制备方法，尤其涉及一种能够用于合成革的新型复合材料及其制备方法。
背景技术
合成革是一种模拟天然革的组成和结构，并可作为其代用材料的塑料制品，其广泛应用于制作鞋、靴、箱包和球类等制品。目前，市场上使用的合成革通常以经浸渍的无纺布为网状层，微孔聚氨酯层作为粒面层制得，并具有一定的透气性，但是这种合成革的疏水性较差，导致其防水效果不佳，也间接影响了合成革的透气性能。而且，超细纤维合成革类似于天然皮革的三维网络结构，使其具有很好的仿真皮效果，但与天然皮革相比超细纤维合成革的绒毛较短、较少，在绒感和书写效应方面与真皮有明显差距，因此，针对以上缺陷，还有待改进。
TPU压延环保合成革即通过压延生产工艺制得的皮革，攻克压延工艺对TPU材料的限制，可直接通过压延工艺生产100％环保皮革制品。然而并非所有的TPU弹性体都可应用于压延制程，且亦非所有TPU压延级产品都可生产皮革。
本领域需要开发一种能够采用压延技术的新型复合材料，可以用作合成革。
发明内容
本发明的目的之一在于提供一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；
所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径≤5μm。
本发明选用特定的基材层配合聚氨酯发泡层得到能够作为合成革使用的复合材料。
优选地，所述聚氨酯发泡层的制备原料按重量份数包括如下组分：
异佛二酮二异氰酸酯 30～70
三羟甲基丙烷 15～35
蓖麻油 15～35
聚醚二元醇 10～20
扩链剂 1～5
催化剂 0.05～0.1
中和剂 0.5～1
溶剂 5～10
增塑剂 3～5
4A沸石 5～8
水 40～80；
其中三羟甲基丙烷、蓖麻油和聚醚多元醇的质量比为2:1:1。
特定组分的聚氨酯原料能够获得软硬适中，透气性好，手感光滑的合成革，尤其是三羟甲基丙烷、蓖麻油和聚醚多元醇的特定质量比，使得聚氨酯的软段、硬段比例适中，最终在制得的合成革中获得良好的软硬度和机械加工性。
优选地，所述锦纶纤维的母粒材料为PA6。
优选地，芳纶纤维为芳砜纶纤维。
优选地，所述聚醚多元醇的分子量为1200～1500。
分子量为1200～1500聚醚多元醇使得聚氨酯的软硬度合适，配合基材层，获得良好的柔韧性。
优选地，所述扩链剂为小分子扩链剂,优选1,4-丁二醇。
优选地，所述催化剂为辛酸亚锡。
优选地，所述中和剂为三乙胺。
优选地，所述增塑剂为DEHP。
优选地，所述基材为混合纺丝的锦纶纤维和芳纶纤维得到的无纺布。
本发明目的之二是提供一种目的之一所述复合材料的制备方法，其特征在于，所述方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯、蓖麻油、聚醚二元醇、扩链剂、催化剂、溶剂和水混合，升温至60～70℃，进行反应0.5～1h，之后加入4A沸石和三羟甲基丙烷在70～75℃反应1～2h，之后加入增塑剂、中和剂中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
与现有技术相比，本发明具有以下有益效果：
本发明通过选择特定组分和含量的聚氨酯原料组分，配合扩链、交联、中和步骤，得到聚氨酯材料，与由锦纶纤维和芳纶纤维，尤其是芳砜纶纤维，混合防止的基材层配合，得到软硬度适中，韧性高，透气性好的复合材料，能够用作合成革。
具体实施方式
下面通过具体实施方式来进一步说明本发明的技术方案。
本领域技术人员应该明了，所述实施例仅仅是帮助理解本发明，不应视为对本发明的具体限制。
实施例1
一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径3～5μm；所述基材层的厚度为0.05mm左右，所述聚氨酯发泡层的厚度为3m左右；
制备方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯(70重量份)、蓖麻油(35重量份)、聚醚二元醇(分子量1500，20重量份)、1,4-丁二醇(5重量份)、辛酸亚锡(0.1重量份)、溶剂(10重量份)和水(80重量份)混合，升温至70℃，进行反应0.8h，之后加入4A沸石(8重量份)和三羟甲基丙烷(35重量份)在75℃反应1.5h，之后加入DEHP(5重量份)、三乙胺(1重量份)中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳砜纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
实施例2
一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径2～4μm；所述基材层的厚度为0.05mm左右，所述聚氨酯发泡层的厚度为3m左右；
制备方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯(50重量份)、蓖麻油(25重量份)、聚醚二元醇(分子量1200，20重量份)、1,4-丁二醇(3重量份)、辛酸亚锡(0.08重量份)、溶剂(8重量份)和水(60重量份)混合，升温至65℃，进行反应1h，之后加入4A沸石(7重量份)和三羟甲基丙烷(25重量份)在70℃反应2h，之后加入DEHP(4重量份)、三乙胺(0.7重量份)中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳砜纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
实施例3
一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径3～5μm；所述基材层的厚度为0.05mm左右，所述聚氨酯发泡层的厚度为3m左右；
制备方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯(30重量份)、蓖麻油(15重量份)、聚醚二元醇(分子量1300，10重量份)、1,4-丁二醇(1重量份)、辛酸亚锡(0.05重量份)、溶剂(5重量份)和水(40重量份)混合，升温至60℃，进行反应0.5h，之后加入4A沸石(8重量份)和三羟甲基丙烷(15重量份)在73℃反应1h，之后加入DEHP(5重量份)、三乙胺(1重量份)中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳砜纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
对比例1
一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径3～5μm；所述基材层的厚度为0.05mm左右，所述聚氨酯发泡层的厚度为3m左右；
制备方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯(70重量份)、蓖麻油(40重量份)、聚醚二元醇(分子量1500，25重量份)、1,4-丁二醇(5重量份)、辛酸亚锡(0.1重量份)、溶剂(10重量份)和水(80重量份)混合，升温至70℃，进行反应0.8h，之后加入4A沸石(8重量份)和三羟甲基丙烷(35重量份)在75℃反应1.5h，之后加入DEHP(5重量份)、三乙胺(1重量份)中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳砜纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
对比例2
一种复合材料，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径3～5μm；所述基材层的厚度为0.05mm左右，所述聚氨酯发泡层的厚度为3m左右；
制备方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯(70重量份)、蓖麻油(35重量份)、聚醚二元醇(分子量1500，20重量份)、1,4-丁二醇(5重量份)、辛酸亚锡(0.1重量份)、溶剂(10重量份)和水(80重量份)混合，升温至75℃，进行反应0.8h，之后加入4A沸石(8重量份)和三羟甲基丙烷(35重量份)在65℃反应1.5h，之后加入DEHP(5重量份)、三乙胺(1重量份)中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳砜纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
性能测试
对实施例和对比例得到的复合材料进行邵氏A硬度测试(GB/T531-1999)，拉伸强度测试(GB/T528-1998)，延伸率(断裂伸长率GB/T528-1998)测试，结果见表1：
表1实施例和对比例得到的复合材料的性能测试结果
邵氏A硬度 拉伸强度(MPa) 延伸率(％)
实施例1 75 18.0 510
实施例2 73 17.5 508
实施例3 74 17.3 518
对比例1 88 13.2 430
对比例2 50 11.5 402
本发明通过聚氨酯各个原料组分的协同增效，配合适当的制备方法，与基材层贴合后获得了硬度适中，拉伸强度和延伸率表现优异的复合材料。
申请人声明，本发明通过上述实施例来说明本发明的工艺方法，但本发明并不局限于上述工艺步骤，即不意味着本发明必须依赖上述工艺步骤才能实施。所属技术领域的技术人员应该明了，对本发明的任何改进，对本发明所选用原料的等效替换及辅助成分的添加、具体方式的选择等，均落在本发明的保护范围和公开范围之内。

Claims (8)

1.一种复合材料，其特征在于，所述复合材料包括依次贴合的基材层和聚氨酯发泡层；
所述基材层为锦纶超细纤维和芳纶纤维的混纺无纺布层；所述基材层的纤维直径≤5μm。
2.如权利要求1所述复合材料，其特征在于，所述聚氨酯发泡层的制备原料按重量份数包括如下组分：
异佛二酮二异氰酸酯 30～70
三羟甲基丙烷 15～35
蓖麻油 15～35
聚醚二元醇 10～20
扩链剂 1～5
催化剂 0.05～0.1
中和剂 0.5～1
溶剂 5～10
4A沸石 5～8
增塑剂 3～5
水 40～80；
其中三羟甲基丙烷、蓖麻油和聚醚多元醇的质量比为2:1:1。
3.如权利要求1或2所述复合材料，其特征在于，所述锦纶纤维的母粒材料为PA6；
优选地，芳纶纤维为芳砜纶纤维；
优选地，所述聚醚多元醇的分子量为1200～1500。
4.如权利要求1～3之一所述复合材料，其特征在于，所述扩链剂为小分子扩链剂,优选1,4-丁二醇；
优选地，所述催化剂为辛酸亚锡。
5.如权利要求1～4之一所述复合材料，其特征在于，所述中和剂为三乙胺。
6.如权利要求1～5之一所述复合材料，其特征在于，所述增塑剂为DEHP。
7.如权利要求1～6之一所述复合材料，其特征在于，所述基材为混合纺丝的锦纶纤维和芳纶纤维得到的无纺布。
8.一种如权利要求1～7之一所述复合材料的制备方法，其特征在于，所述方法包括如下步骤：
(1)将聚氨酯发泡层的原料中的异佛二酮二异氰酸酯、蓖麻油、聚醚二元醇、扩链剂、催化剂、溶剂和水混合，升温至60～70℃，进行反应0.5～1h，之后加入4A沸石和三羟甲基丙烷在70～75℃反应1～2h，之后加入增塑剂、中和剂中和至pH值为7；
(2)将锦纶纤维母粒注入纺丝机，将芳纶纤维母粒注入另一纺丝机，两者同时按照2:1的纺丝量进行纺丝，得到基材层；
(3)将步骤(1)得到的产物、增塑剂投入捏合机，之后经过密炼机和开炼机炼塑后，送至压延机与基材层贴合，得到所述复合材料。
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