CN106120359B - 一种抗渗水涂层布的制造方法 - Google Patents

一种抗渗水涂层布的制造方法 Download PDF

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CN106120359B
CN106120359B CN201610712896.5A CN201610712896A CN106120359B CN 106120359 B CN106120359 B CN 106120359B CN 201610712896 A CN201610712896 A CN 201610712896A CN 106120359 B CN106120359 B CN 106120359B
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叶华亦
董佳杰
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Zhejiang Jinda Membrane Technology Co Ltd
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Abstract

本发明涉及一种抗渗水涂层布的制造方法,其包括基布织造、涂层剂制备、一次涂层、二次涂层、塑化成型或塑化成型和表面处理。选用高强聚酯纤维为原料,纤度为1000~1500D,按巴拿马织法织造成密度为每英寸(14‑20)×(14‑20),克重为244~540g/m2的涤纶基布;正面涂层的涂覆量为480~700g/m2,反面涂层的涂覆量为220~380g/m2。制成的产品厚度远远大于常规产品,却仍然能够保证各项物理机械性能,表面致密平整瑕疵少,且具有抗渗水、防霉抑菌、环保、耐老化、抗剥离等特点,其档次高于普通的蓬盖用防水布;可应用在饮水容器、小型泳池、隧道、堤坝、屋面等防水工程中,因此具有强大的市场和生命力。

Description

一种抗渗水涂层布的制造方法
技术领域
本发明涉及PVC防水纺织品技术领域,尤其是涉及一种具有多层结构的PVC抗渗水涂层织物的制造方法。
背景技术
PVC防水织物在高分子防水材料中占有重要地位。其特点是:原材料丰富,产品既有很高的韧性,又有很高的强度,还有较好的抗氧化、抗紫外线、耐温性等,并且用途广泛,适用于水池、堤坝、隧道、种植、屋面等多种防水工程。
过去,大多PVC涂层织物多用于蓬盖,如制成膜结构材料。近年来,这类复合材料飞速发展,已逐渐地从建筑与蓬盖的应用领域向其他方向发展。本产品主要是用作储水材料,如储水槽、储水袋。但是目前已有产品:(1)防渗水能力达不到预期效果;(2)物理机械性能不能达到该类产品强度的使用标准;(3)环保要求不达标等。这些缺点直接导致了已有的同类产品不适合用在储水装置领域。
发明内容
本发明的目的是提供一种适合制作成储水容器的PVC复合材料。
本发明旨在解决现有产品防渗水能力不足、力学性能不达标、环保不达标等技术问题。
本发明解决技术问题所采取的技术方案是:一种抗渗水涂层布的制造方法,其包括下列步骤:
(1)基布织造:选用高强聚酯纤维为原料,纤度为1000~1500D,按巴拿马织法织造成密度为每英寸(14-20)×(14-20),克重为244~540g/m2的涤纶基布;
(2)涂层剂制备:
按下列各组分以质量份计,加入4%~8%的颜料,搅拌、混合、研磨并过滤制成涂层剂A和涂层剂B:
PVC糊树脂 100份,
增塑剂 50~100份,
稳定剂 1~5份,
填料 5~80份,
功能性助剂 1~5份;
其中涂层剂A采用100目滤网过滤,涂层剂B采用80目滤网过滤;控制涂层剂A粘度范围15000~35000CPS,控制涂层剂B粘度范围8000~18000CPS;
(3)一次涂层:取上述涂层剂B,以每100kg计加入1~5kg交联剂,充分混合均匀,制备交联涂层剂B;先利用浮刀将交联涂层剂B均匀涂覆于涤纶基布的正面并经立式烘箱烘干处理,涂覆量控制为200~240g/m2;再利用辊刀将交联涂层剂B涂覆于涤纶基布的反面,涂覆量控制为80~140 g/m2;然后利用辊刀在正面再涂覆一层涂层剂B并烘干处理,涂覆量控制为190~290 g/m2;车速控制为10-18m/min,烘干温度为160~180℃;
(4)二次涂层:先利用辊刀将涂层剂A涂覆于经一次涂层后的涤纶基布的正面和反面并经烘干处理,正面的涂覆量为90~170g/m2,反面的涂覆量为140~240g/m2;车速控制为5-14m/min,烘干温度为160~180℃;
(5)经二次涂层后烘干处理后进行塑化成型,塑化温度为160~210℃;或者,在二次涂层后烘干处理后进行塑化成型,塑化温度为160~210℃,然后进行表面处理。
作为优选,步骤1)所选用的高强聚酯纤维为高强低收缩涤纶纤维并具有抗芯吸性能。
作为优选,步骤2)所述的增塑剂为符合欧盟2005/84/EC标准的不含6P的环保增塑剂。
作为优选,所述表面处理采用的表面处理剂为PVDF表面处理剂或丙烯酸酯表面处理剂。
本发明采用的基布为:选用1000~1500D的高强低收缩涤纶长丝织为原料,采用巴拿马织法织造而成的双经双纬机织布,使产品在拉伸断裂强度、撕裂强度等物理性能方面优越,拓展了产品的应用领域。
涂层剂于基布正反面的涂覆量比例以7/3 为宜。正面比反面厚的涂覆比例设计,可以保证正面表面风格清晰,涂层质密,气密性好,对于耐老化等起到良好的作用;同时该比例也有利于生产加工,可以有效消除针孔气泡等不良影响。
所述的PVC糊树脂通常选用以下公司生产的一种或者同时选用其中的几种,但总重量不变。
沈阳化工股份有限公司的PSH-10、PSH-20、PSM-31;
天津渤天化工有限公司的P-440、P-450、R-1069;
上海氯碱化工股份有限公司62-GP、P-450、R-1069;
安徽天辰化工股份有限公司PB-1302、PB-1152、PB-1702;
德国瓦克公司C56V、C100V、C57M。
所述的增塑剂为符合欧盟2005/84/EC标准的不含6P的环保增塑剂,通常选用DOTP、氯代脂肪酸甲酯、ATBC或其他品种,可以使用其中的一种,或者同时使用其中的几种,但总重量不变。增塑剂的加入可以大大降低PVC分子链间的作用力,使物料的硬度、模量、软化温度和脆化温度下降,伸长率、曲绕性和柔韧性提高,从而获得良好的加工性能。
所述的稳定剂可以是液体钡锌稳定剂、液体钙锌稳定剂、有机锡稳定剂中的一种或者两种以上。稳定剂的加入有效的抑制了PVC的脱氯化氢反应降解,防止性能下降。
所述的填料可以是500目以上至10000目的碳酸钙,也可以是同样规格的氢氧化铝。填充剂的加入可以增加容量、降低成本、改善尺寸稳定性,同时提高制品的拉伸强度,改善了制品的抗冲击性能。
所述的功能性助剂为抗菌助剂和光稳定剂。抗菌助剂可以是:上海瑞华化工有限公司的RHA-M-2,广州申悦贸易有限公司的艾斯嘉S+系列抗菌剂,加拿大TRA的DW-30,美国奥麒的VANQUISH 100(V-100)等。光稳定剂可以是:二苯甲酮类如Cyasorb UV-531、CyasorbUV-9、苯并三唑类如Tinuvin-P等,可以使用其中的一种,或者同时使用其中的几种,但总重量不变。光稳定剂和抗菌剂的加入可以赋予产品优良的光稳定性和抗菌性能,延长使用寿命并防止细菌的滋生带来的危害。
所述的颜料可以是:钛白粉、炭黑、氧化铁红等,其他还有群青、钴蓝、钴绿、镉黄、镉红、钼橙或偶氮颜料等。颜料的加入可以使制品做成各种颜色,使产品花色和品种多姿多彩。
所述的交联剂可以是中山市东菱化工有限公司生产的EP304或其他不含6P的交联剂 。交联剂是一种能在线型分子间起桥架作用,从而使多个线型分子相互键合交联成网状结构,促进或调节聚合物分子链间共价键或离子键形成的物质。交联剂中的异氰酸酯基团的质量含量为3~5%。
本发明的优点是:制成的产品厚度远远大于常规产品,却仍然能够保证各项物理机械性能,表面致密平整瑕疵少,且具有抗渗水、防霉抑菌、环保、耐老化、抗剥离等特点,其档次高于普通的蓬盖用防水布。可以应用在饮水容器、小型泳池、隧道、堤坝、屋面等防水工程中。因此具有强大的市场和生命力。
附图说明
图1为本发明一种抗渗水涂层布的结构示意图。
图中1-保护层A、2-内增强层、3-结合层A、4-基布、5-结合层B、6-保护层B。
下面结合具体实施例对本发明作进一步的说明。
具体实施方式
实施例1:一种抗渗水涂层布的制造方法。
该抗渗水涂层布如图1所示,其自上而下由保护层A1、内增强层2、结合层A3、基布4、结合层B5、保护层B6,其中保护层A1为涂层剂A、内增强层2为涂层剂B、结合层A3为交联涂层剂B、结合层B5为交联涂层剂B、保护层B6涂层剂A;其制造包括下列步骤:
(1)选用高强低收缩涤纶丝为原料,纤度为1000D,在高速剑杆织机上以巴拿马织法制造,织造成密度为15×15/英寸,克重为267g/m2的高强涤纶基布;
(2)涂层剂制备:
按下列各组分以质量份计,加入5%的颜料,搅拌、混合、研磨并过滤制成涂层剂A和涂层剂B:
涂层剂A:
P-440 80份,
C100V 20份,
DOTP 70份,
钡锌稳定剂 2.5份,
超细氢氧化铝 25份,
DW-30 1份,
Cyasorb UV-531 1.5份;
涂层剂B:
P-440 50份,
PSM-31 50份,
DOTP 66份,
钡锌稳定剂 2.5份,
3000目重钙 35份,
DW-30 1份;
其中涂层剂A采用100目尼龙滤网过滤,涂层剂B采用80目尼龙滤网过滤;控制涂层剂A粘度20000CPS,控制涂层剂B粘度15000CPS;
(3)一次涂层:取部分上述涂层剂B,以质量计加入3% EP-304交联剂,交联剂中异氰酸酯基团含量为3%,充分搅拌均匀,制备成交联涂层剂B;先利用浮刀将交联涂层剂B均匀涂覆于涤纶基布的正面并经立式烘箱烘干处理,涂覆量控制为230g/m2;再利用辊刀将交联涂层剂B涂覆于涤纶基布的反面,涂覆量控制为120 g/m2;然后利用辊刀在正面再涂覆一层涂层剂B并烘干处理,涂覆量控制为210 g/m2;车速控制为14m/min,烘干温度为180℃;
(4)二次涂层:利用辊刀分别将涂层剂A涂覆于经一次涂层后的涤纶基布的正面和反面并经烘干处理,正面涂覆量控制为170 g/m2,反面涂覆量控制为140g/m2;车速控制为10m/min,烘干温度为180℃;
(5)经二次涂层后烘干处理后进行塑化成型,塑化温度为205℃;
(6)塑化成型后进行表面处理,基布反面通过第一表处槽,用80目网纹辊进行一次表面涂覆并烘干,随后分别在基布的正面用60目和100目网纹辊进行两次表面涂覆,烘干温度为130℃;
(7)表面处理后打卷,包装,入库。
实施例2:一种抗渗水涂层布的制造方法。
该抗渗水涂层布如图1所示,其自上而下由保护层A1、内增强层2、结合层A3、基布4、结合层B5、保护层B6,其中保护层A1为涂层剂A、内增强层2为涂层剂B、结合层A3为交联涂层剂B、结合层B5为交联涂层剂B、保护层B6涂层剂A;其其制造包括下列步骤:
(1)选用高强低收缩涤纶丝为原料,纤度为1300D,在高速剑杆织机上以巴拿马织法制造,织造成密度为18×18/英寸,克重为404g/m2的高强涤纶基布;
(2)涂层剂制备:
按下列各组分以质量份计,加入6%的颜料,搅拌、混合、研磨并过滤制成涂层剂A和涂层剂B:
涂层剂A:
P-440 30份,
R-1069 60份,
C56V 10份,
DOTP 70份,
钙锌稳定剂 2.5份,
超细氢氧化铝 25份,
V-100 1.5份,
Tinuvin-P 2份;
涂层剂B:
PB-1302 60份,
PSM-31 40份,
DOTP 66份,
钙锌稳定剂 2.5份,
4500目重钙 35份,
DW-30 1份;
其中涂层剂A采用100目尼龙滤网过滤,涂层剂B采用80目尼龙滤网过滤;控制涂层剂A粘度15000CPS,控制涂层剂B粘度13000CPS;
(3)一次涂层:取部分上述涂层剂B,以质量计加入3.5% EP-304交联剂,交联剂中异氰酸酯基团含量为3%,充分搅拌均匀,制备成交联涂层剂B;先利用浮刀将交联涂层剂B均匀涂覆于涤纶基布的正面并经立式烘箱烘干处理,涂覆量控制为216g/m2;再利用辊刀将交联涂层剂B涂覆于涤纶基布的反面,涂覆量控制为120 g/m2;然后利用辊刀在正面再涂覆一层涂层剂B并烘干处理,涂覆量控制为210 g/m2;车速控制为15m/min,烘干温度为180℃;
(4)二次涂层:利用辊刀将涂层剂A涂覆于经一次涂层后的涤纶基布的正面和反面并经烘干处理,正面涂覆量控制为160 g/m2,反面涂覆量控制为150 g/m2;车速控制为8m/min,烘干温度为180℃;
(5)经二次涂层后烘干处理后进行塑化成型,塑化温度为200℃;
(6)塑化后打卷,包装,入库。
由上述方法制得的产品,经测试,达到如下质量指标:
①断裂强度:(经/纬)≥4000N/5cm(GB/T3923.1-1997);
②撕裂强度:(经/纬)≥500N/400N/5cm(GB/T3923.1-1997);
③剥离强度:≥100N/5cm(DIN53 359A);
④厚度:≥0.8mm(FZ-T01003-91);
⑤防霉抗菌等级:0级(ASTM G21);
⑥抗渗水:≥60kpa(FZ-T01004-2008);
⑦环保要求:欧盟6P(第2005/84/EC号)。

Claims (2)

1.一种抗渗水涂层布的制造方法,其特征在于包括下列步骤:
(1)基布织造:选用高强聚酯纤维为原料,纤度为1000~1500D,按巴拿马织法织造成密度为每英寸(14-20)×(14-20),克重为244~540g/m2的涤纶基布;所选用的高强聚酯纤维为高强低收缩涤纶纤维并具有抗芯吸性能;
(2)涂层剂制备:
按下列方案一或方案二各组分以质量份计,加入4%~8%的颜料,搅拌、混合、研磨并过滤制成涂层剂A和涂层剂B:
方案一,涂层剂A:
P-440 80份,
C100V 20份,
DOTP 70份,
钡锌稳定剂 2.5份,
超细氢氧化铝 25份,
DW-30 1份,
Cyasorb UV-531 1.5份;
涂层剂B:
P-440 50份,
PSM-31 50份,
DOTP 66份,
钡锌稳定剂 2.5份,
3000目重钙 35份,
DW-30 1份;
方案二,涂层剂A:
P-440 30份,
R-1069 60份,
C56V 10份,
DOTP 70份,
钙锌稳定剂 2.5份,
超细氢氧化铝 25份,
V-100 1.5份,
Tinuvin-P 2份;
涂层剂B:
PB-1302 60份,
PSM-31 40份,
DOTP 66份,
钙锌稳定剂 2.5份,
4500目重钙 35份,
DW-30 1份;
其中涂层剂A采用100目滤网过滤,涂层剂B采用80目滤网过滤;控制涂层剂A粘度范围15000~35000CPS,控制涂层剂B粘度范围8000~18000CPS;
(3)一次涂层:取上述涂层剂B,以每100kg计加入1~5kg交联剂,充分混合均匀,制备交联涂层剂B;先利用浮刀将交联涂层剂B均匀涂覆于涤纶基布的正面并经立式烘箱烘干处理,涂覆量控制为200~240g/m2;再利用辊刀将交联涂层剂B涂覆于涤纶基布的反面,涂覆量控制为80~140 g/m2;然后利用辊刀在正面再涂覆一层涂层剂B并烘干处理,涂覆量控制为190~290 g/m2;车速控制为10-18m/min,烘干温度为160~180℃;
(4)二次涂层:先利用辊刀将涂层剂A涂覆于经一次涂层后的涤纶基布的正面和反面并经烘干处理,正面的涂覆量为90~170g/m2,反面的涂覆量为140~240g/m2;车速控制为5-14m/min,烘干温度为160~180℃;
(5)经二次涂层后烘干处理后进行塑化成型,塑化温度为160~210℃;或者,在二次涂层后烘干处理后进行塑化成型,塑化温度为160~210℃,然后进行表面处理。
2.如权利要求1所述的一种抗渗水涂层布的制造方法,其特征在于:所述表面处理采用的表面处理剂为PVDF表面处理剂或丙烯酸酯表面处理剂。
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