CN106183265A - 一种轻质发泡聚丙烯复合隔热板材及其制备方法 - Google Patents

一种轻质发泡聚丙烯复合隔热板材及其制备方法 Download PDF

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CN106183265A
CN106183265A CN201610506865.4A CN201610506865A CN106183265A CN 106183265 A CN106183265 A CN 106183265A CN 201610506865 A CN201610506865 A CN 201610506865A CN 106183265 A CN106183265 A CN 106183265A
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周正清
朱金平
张耀文
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Jiangsu Dayi Material Technology Co.,Ltd.
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Abstract

本发明提供一种轻质发泡聚丙烯复合隔热板材包括从上到下的PET镀铝膜、中间复合层、PP发泡板；所述PET镀铝膜、中间复合层加工为复合镀铝膜，所述PP发泡板的加工原料包括固体颗粒状的聚丙烯‑K8003、聚丙烯‑T30S、茂金属PE‑1018LA、POE‑6202、钙母粒‑EG808，化妆品级白油以及粉末状的成核剂‑Sandostab 4030、发泡剂‑HYDROCEROL CF；本板材在制作过程中，使用三辊压光机中三辊之间转速差，使得复合PET镀铝膜上形成不规则的纹路，这样可以使得板材这层之间的结合更加牢固；也使得总板材具有优良的外观，也保持了PET镀铝膜的隔热性能。

Description

一种轻质发泡聚丙烯复合隔热板材及其制备方法
技术领域
本发明涉及隔热板材生产工艺技术领域，具体涉及一种轻质发泡聚丙烯复合隔热板材及其制备方法。
背景技术
在生产生活中，人们会使用到大量的隔热复合材料，在建筑装修、户外保暖、汽车内饰等各个方面。这些隔热复合材料通常使用化工材料加工而成，其中轻质聚丙烯发泡复合隔热板是一种优质的保温材料它具有质量轻，隔热性能好，易于回收利用，常用作汽车内饰材料，发泡聚丙烯的封闭式泡孔结构使其热导率不会因潮湿而受影响，因此可用作保温材料。现在很多的汽车隔热材料采用泡沫材料与镀铝膜或者铝箔材料通过胶粘复合在一起，形成基础隔热板材，此种板材有较大的气味挥发隐患，容易对使用者的健康造成伤害，而且这种板材的粘接层易随温度升高而脱落，其耐热性收到很大考验。
发明内容
针对以上问题，本发明提供一种轻质发泡聚丙烯复合隔热板材及其制备方法，该隔热板材结构稳定，具有较高的撕裂强度并不破坏镀铝膜层，可以很好保持隔热效果。
本发明解决其技术问题所采用的技术方案是：该一种轻质发泡聚丙烯复合隔热板材包括从上到下依次逐层贴合的PET镀铝膜、中间复合层、PP发泡板；所述PET镀铝膜、中间复合层加工为复合镀铝膜，所述PP发泡板的加工原料包括固体颗粒状的聚丙烯-K8003、聚丙烯-T30S、茂金属PE-1018LA、POE-6202、钙母粒-EG808，化妆品级白油以及粉末状的成核剂-Sandostab4030、发泡剂-HYDROCEROL CF；本发明提供的上述一种轻质发泡聚丙烯复合隔热板材的制备方法，其步骤如下：
一、配料：按照PP发泡板配方单要求称取各种原料；
二、混料：将步骤一中称取得的配料聚丙烯-K8003、聚丙烯-T30S、茂金属PE-1018LA、POE-6202加白油在高速混合机里面预混1min，然后投入成核剂-Sandostab 4030、发泡剂-HYDROCEROL CF混合1-3min；
三、上料：将步骤二中混合好的原料加入到挤出机料斗；
四、挤出发泡：在加热通道中对加入到挤出机中的物料进行加热融化，然后将熔融塑化后的熔融体混合料输送到挤出模具，挤出胚板料；
五、三辊压光：将从步骤四中挤出模具出来的胚板料引入三辊压光机，将三辊转速设定为上中棍转速同步，下棍转速比中棍快150-700RPM，三辊压光机温度控制如下：上棍80-90℃，中棍60-80℃，下棍50-70℃；
六、复合；将所述复合PET镀铝膜固定在步骤五中所述三辊压光机放卷架上调整好张力，经过三辊压光机下棍让PET镀铝膜面与下棍接触，复合层与挤出的胚板料热合，然后将热合后的板料通过三辊压光装置复合；
七、牵引定型：将从步骤六中输出的板材通过牵引机构从板材前部进行牵引拉动，在牵引过程中板材自然冷却至室温定型；
八、纵向裁切；通过刀具对步骤七中成型的板材两侧边沿进行切割；
九、记米横切：根据板材规格要求，步骤八中输出的板材进行横向切割，获取整片的板材；
十、检验：用肉眼查看外观，使用游标卡尺和卷尺检查步骤九中裁剪好的板材尺寸规格；
十一、包装入库：在步骤十中产品检验合格后对板材进行包装，将包装好的板材放入仓库。
作为优选，聚丙烯-K8003使用45kg，聚丙烯-T30S使用35kg，所述茂金属PE-1018LA使用12kg，所述POE-6202使用7kg，钙母粒-EG808使用2KG，化妆品级白油使用0.3KG，所述成核剂-Sandostab 4030使用0.4KG，所述发泡剂-HYDROCEROL CF使用0.3KG；所述中间复合层使用EPE泡棉材料，所述中间复合层的EPE泡棉厚度为2.0mm，所述中间复合层的EPE泡棉与PET镀铝膜之间采用热合方式粘结。
本发明的有益效果在于：本轻质发泡聚丙烯复合隔热板材在制作过程中，通过改性聚丙烯的复配来发泡，可得到密度0.35-0.7之间的PP发泡板材，通过复合PET镀铝膜增加材料的隔热性能，通过步骤五的三辊压光机中三辊之间转速差，使得复合PET镀铝膜上形成不规则的纹路，这样可以使得板材这层之间的结合更加牢固；也使得总板材具有优良的外观，也保持了PET镀铝膜的隔热性能。
具体实施方式
下面结合实施例对本发明进一步说明：
实施例一
一种轻质发泡聚丙烯复合汽车内饰用隔热板材的制备方法，包括以下步骤：
1)配料：
将复合PET镀铝膜固定在放卷架上调整好张力经过下棍让PET镀铝膜面与下棍接触，复合层与挤出胚板热合，通过三辊压光装置复合而成。复合镀铝膜为EPE复合PET镀铝膜，其为热合方式，EPE厚度为2.0MM。
2)混料：
1、将上述固体颗粒料加入混料机，倒入适量白油预混。
2、将剩余粉体料加入预混好的混料机中继续混合均匀。
3)上料：将上述混合好的物料加入到挤出机料斗。
4)挤出发泡：
2)挤出机温度(℃)：
2)挤出胚板：
经过熔融塑化后的熔融体混合料进入挤出模头，挤出胚板料，根据生产不同厚度的板材预调模唇间隙，并预先将模头模具温度调整至如下温度：
5)三辊压光：
1)从挤出模具出来的胚板料引入三辊压光机，中下棍间距为所需厚度板材N+0.03-N+0.08mm，中上棍间距为N-0.2mm，三辊转速为上中棍转速同步，下棍转速比中棍快150-700RPM。
三辊压光机温度控制如下：
上棍80-90℃ 中棍60-80℃ 下棍50-70℃
三辊之间的速度差，可以使得铝膜表面呈现不规则纹路，使得铝膜难以被撕开，而且铝膜的表面设计有可以有效的进行漫反光，保温性能更好，这样使用在建筑或者车体表面时，不会出周围造成较大影响，使用更加方面安全。
6)复合：将复合PET镀铝膜固定在放卷架上调整好张力经过下棍让PET镀铝膜面与下棍接触，复合层与挤出胚板热合，通过三辊压光装置复合而成。EPE镀铝膜中EPE厚度为1.0mm，EPE与PET镀铝膜粘接方式为淋膜。
7)牵引定型：从三辊出来的板材温度较高，通过牵引冷却至室温定型。
8)纵向裁切；根据板材规格要求，架好刀具纵向裁切板材。
9)记米横切：根据板材规格要求，预设记米器尺寸。板材进入剪板机后完成最后剪切工序。
10)检验：根据质量标准进行检验，肉眼查看外观，使用游标卡尺和卷尺检查尺寸规格是否符合要求。
11)包装入库：产品检验合格后按照客户要求，采用薄膜包装。
另外需要将边角料及废料进行处理，具体做法为将边角料与废料及时进行破碎并标识好。
一种使用上述工序制造出来的复合镀铝膜综合性能如下：
从上表中可以看出，本发明所制的轻质发泡聚丙烯隔热板材具有质量轻，剥离强度好，撕裂强度高，气味低，采用的特殊工艺很好的保证了PET镀铝膜的隔热性能，非常适合在汽车，游艇等需要隔热的场合使用。
以上所述仅为本发明的较佳实施例，并不用以限制本发明，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 (4)

1.一种轻质发泡聚丙烯复合隔热板材包括从上到下依次逐层贴合的PET镀铝膜、中间复合层、PP发泡板；所述PET镀铝膜、中间复合层加工为复合镀铝膜，其特征在于：所述PP发泡板的加工原料包括固体颗粒状的聚丙烯-K8003、聚丙烯-T30S、茂金属PE-1018LA、POE-6202、钙母粒-EG808，化妆品级白油以及粉末状的成核剂-Sandostab 4030、发泡剂-HYDROCEROL CF；一种轻质发泡聚丙烯复合隔热板材的制备方法，其步骤如下：
一、配料：按照PP发泡板配方单要求称取各种原料；
二、混料：将步骤一中称取得的配料聚丙烯-K8003、聚丙烯-T30S、茂金属PE-1018LA、POE-6202加白油在高速混合机里面预混1min，然后投入成核剂-Sandostab 4030、发泡剂-HYDROCEROL CF混合1-3min；
三、上料：将步骤二中混合好的原料加入到挤出机料斗；
四、挤出发泡：在加热通道中对加入到挤出机中的物料进行加热融化，然后将熔融塑化后的熔融体混合料输送到挤出模具，挤出胚板料；
五、三辊压光：将从步骤四中挤出模具出来的胚板料引入三辊压光机，将三辊转速设定为上中棍转速同步，下棍转速比中棍快150-700RPM，三辊压光机温度控制如下：上棍80-90℃，中棍60-80℃，下棍50-70℃；
六、复合；将所述复合PET镀铝膜固定在步骤五中所述三辊压光机放卷架上调整好张力，经过三辊压光机下棍让PET镀铝膜面与下棍接触，复合层与挤出的胚板料热合，然后将热合后的板料通过三辊压光装置复合；
七、牵引定型：将从步骤六中输出的板材通过牵引机构从板材前部进行牵引拉动，在牵引过程中板材自然冷却至室温定型；
八、纵向裁切；通过刀具对步骤七中成型的板材两侧边沿进行切割；
九、记米横切：根据板材规格要求，步骤八中输出的板材进行横向切割，获取整片的板材；
十、检验：用肉眼查看外观，使用游标卡尺和卷尺检查步骤九中裁剪好的板材尺寸规格；
十一、包装入库：在步骤十中产品检验合格后对板材进行包装，将包装好的板材放入仓库。
2.根据权利要求1所述的一种轻质发泡聚丙烯复合隔热板材的制备方法，其特征在于：在步骤四的中挤出发泡过程中，所述挤出机的加热区域分为五个区域，所述加热区域的五个区域的温度分别设定为：一区150℃，二区160℃，三区170℃，四区175℃，五区180℃，五区后部的连接处180℃，换网区180℃，流道区180℃。
3.根据权利要求1所述的一种轻质发泡聚丙烯复合隔热板材的制备方法，其特征在于：在将步骤四中熔融塑化后的熔融体混合料输送到挤出模具时，所述模头模具也分为五个部分，每个区域的温度设定为：一区175℃，二区170℃，三区170℃；四区170℃，五区175℃。
4.根据权利要求1所述的一种轻质发泡聚丙烯复合隔热板材，其特征在于：所述PP发泡板的加工原料使用以下重量配比：聚丙烯-K8003使用45kg，聚丙烯-T30S使用35kg，所述茂金属PE-1018LA使用12kg，所述POE-6202使用7kg，钙母粒-EG808使用2KG，化妆品级白油使用0.3KG，所述成核剂-Sandostab 4030使用0.4KG，所述发泡剂-HYDROCEROL CF使用0.3KG；所述中间复合层使用EPE泡棉材料，所述中间复合层的EPE泡棉厚度为2.0mm，所述中间复合层的EPE泡棉与PET镀铝膜之间采用热合方式粘结。
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