CN106609469A - 一种物流行业用高强度高耐磨轻型输送带及其制造方法 - Google Patents

一种物流行业用高强度高耐磨轻型输送带及其制造方法 Download PDF

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CN106609469A
CN106609469A CN201611092729.1A CN201611092729A CN106609469A CN 106609469 A CN106609469 A CN 106609469A CN 201611092729 A CN201611092729 A CN 201611092729A CN 106609469 A CN106609469 A CN 106609469A
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代飞
朱传奇
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Abstract

本发明涉及一种物流行业用输送带，特别涉及一种高强度高耐磨轻型输送带及其制造方法。本发明提供的高强度高耐磨轻型输送带自下而上依序由高强度立体织物层、底涂层和高耐磨花纹面层构成；所述底涂层为水性聚氨酯底涂料固化而成，其粘度为3000～5000mPa.s，底涂量为180～220g/mm2；所述高耐磨花纹面层为高耐磨热塑性聚氨酯粉末热定型而成。本发明提供的高强度高耐磨轻型输送带与传统输送带相比，加工工艺简单，采用高强度立体聚酯织物制作成一布一胶即可，输送带表面高耐磨和高摩擦性能，输送带的使用寿命长。

Description

一种物流行业用高强度高耐磨轻型输送带及其制造方法
技术领域
本发明涉及一种物流行业用输送带，特别涉及一种高强度高耐磨轻型输送带及其制造方法。
背景技术
随着物流行业的蓬勃发展，物流流水设备也随之发展，其对作为流水线重要设备的输送带提出了更高要求：产品可用于输送加工各个环节，保证安全、使用寿命长，可应用于温湿度波动的环节。现代物流领域，输送带要求随着货物通过不同的工序要求而改变，这样快捷方便的处理，可以减少工作人员的数量，使现行系统的运行效率提高。
在货物送入阶段，特殊设计的表面花纹能够保证输送带对物品有足够的抓力；在腹式装运系统，要求耐磨的皮带表面和特殊结构的强力织物层，还需要承受较大的有效拉力；在爬坡的过程中，需要提供带花纹表面的输送带。为了满足上述输送需求，目前使用的输送带采用二布二胶结构，用两层常规抗拉织物作为织物层，面层采用聚氯乙烯为材质的花纹表面。但是此方法制作的输送带工艺流程复杂，并且表面耐磨性和机械强度很有限，表面花纹涂层会很快被运输的货物磨掉。
发明内容
本发明目的在于提供一种高强度高耐磨轻型输送带，同时提供一种稳定而高效的制造方法，以克服现有产品耐磨性差的缺陷。
本发明的目的可以通过以下技术方案来实现：
本发明提供的物流行业用高强度高耐磨轻型输送带自下而上依序由高强度立体织物层、底涂层和高耐磨花纹面层构成；所述底涂层为水性聚氨酯底涂料固化而成，其粘度为3000～5000mPa.s，底涂量为180～220g/mm2；所述高耐磨花纹面层为高耐磨热塑性聚氨酯粉末热定型而成。本发明中为了提高聚氨酯粉末与立体织物的粘结性，一般会以和面层或底层结构相似的粘结剂进行粘结，而本发明中选用的是具有一定粘度的水性聚氨酯，而不是常规技术方案中使用的油性聚氨酯。此粘结剂采用水为介质，能够快速渗透，锁住具有一定厚度的立体聚酯纤维，防止输送带在使用过程中出现“掉毛”现象。同时水性粘结剂粘度要适中，粘度太稀容易造成渗料现象，影响立体织物的低噪音特性。
所述高强度立体织物采用立体聚酯织物，其中，经向上下交织采用线密度为1000D低收缩聚酯活化丝，经向直的1根采用线密度为1000D低收缩聚酯活化丝，纬向为两层结构，上下层均采用直径为0.3mm的超低收缩聚酯单丝，织物经向密度为95～100根/inch，织物纬向密度为55～60根/inch，织法采用2/1斜纹，人字型结构。本发明采用特殊织法的立体织物制作成一布一胶输送带，该织物经向除了上下交织的聚酯长丝外，还采用直的1根1000D超低收缩聚酯长丝，与纬向单丝不形成交织，直的一根聚酯长丝始终处于无卷曲状态，不具蠕变松弛，经纱的强度利用率达到了最高，并且本发明的立体织物采用二上一下斜纹和人字纹结构，经纱和纬纱隔两根纱才交织一次，一个完全组织循环内的交织点少，增加经纱外露面积，使织物更平整且具有低噪音、耐磨特性。采用本发明的立体织物作为输送带的骨架材料，其输送带的延伸受力比现有技术的普通立体织物和两层常规抗拉织物制造的输送带都要高，有利于防止输送带在使用过程中被拉长，降低输送机的张紧长度要求。
所述水性聚氨酯底涂料的组分，按照质量份数计为水性聚氨酯树脂100份，固化剂5～8份，水性增稠剂0.5～1份。所述固化剂为脂肪族聚氨酯分散液，水性增稠剂为非离子聚氨酯分散液。
所述高耐磨热塑性聚氨酯，邵氏硬度为65A。本发明采用涂覆级聚氨酯颗粒经过冷冻磨粉后作为输送带的面层覆盖胶，此材质比常规聚氨酯粉末硬度低、耐磨性好，方便压制花纹，能够提高输送带表面高耐磨和高摩擦性能，有利于在爬坡的过程中，保证输送带对物品有足够的抓力。
所述高耐磨花纹面层的花纹可以是细直条花纹或者钻石花纹。
上述物流行业用高强度高耐磨轻型输送带的制造方法，所述方法包括如下步骤：
S1：高强度立体织物定型；
S2：在步骤S1的高强度立体织物的粗糙面用水性聚氨酯底涂料底涂，构成底涂层；
S3：在步骤S2的底涂层上涂覆高耐磨热塑性聚氨酯粉末，并在180～200℃下进行热定型；
S4：利用不同的花纹辊筒压制不同类型的花纹，即得物流行业用高强度高耐磨轻型输送带。
本发明与现有技术相比，具有以下优点和效果：
(1)本发明采用特殊立体织物作为增强骨架材料，该织物经纱中含有直的聚酯丝，并采用人字斜纹结构，赋予织物许多优良的力学性能，伸长率大幅度降低，1％延伸受力比常规二层织物提高50％。
(2)本发明的输送带面层采用高强度低硬度涂覆级聚氨酯粉末，该材质有利于压制花纹，在爬坡的过程中，能够保证输送带对物品有足够的抓力，并且提高输送带表面耐磨性能，满足重物输送需求。
(3)本发明的输送带在立体织物上底涂水性胶水工艺，加强了立体聚酯纤维间的固结，提高了立体织物的整体强度，防止织物在使用过程中“掉毛”，从而延长织物的使用寿命。
(4)本发明的输送带采用特殊立体织物制作成一布一胶(共4个工艺步骤)即可满足物流行业轻型输送带的高强度高耐磨要求，而传统输送带需要制作成二布二胶(共8个工艺步骤)，本发明简化了工艺流程，提高了生产效率。
附图说明
图1为本发明一布一胶的轻型输送带的工艺流程图。
图2为本发明高强度高耐磨轻型输送带的结构示意图。
图3为本发明立体织物的纵剖结构示意图。
附图中标号说明
1－输送带面层 2－立体织物
3－纬向单丝(上层) 4－纬向单丝(下层)
5－经向聚酯长丝(上下交织) 6－经向聚酯长丝(上下交织)
7－经向聚酯长丝(直的)
具体实施方式
以下结合具体实例进一步说明本发明。
请参阅图1为本发明一布一胶的轻型输送带的工艺流程图和图2为本发明高强度高耐磨轻型输送带的结构示意图所示，高强度高耐磨轻型输送带的制造方法，包括下述步骤：
S1：高强度立体织物定型；
S2：在步骤S1的高强度立体织物的粗糙面用水性聚氨酯底涂料底涂，构成底涂层；
S3：在步骤S2的底涂层上涂覆高耐磨热塑性聚氨酯粉末，并在180～200℃下进行热定型；
S4：利用不同的花纹辊筒压制不同类型的花纹，即得物流行业用高强度高耐磨轻型输送带。
其中，立体织物请参阅图3，经向上下交织采用线密度为1000D低收缩聚酯活化丝，经向直的1根采用线密度为1000D低收缩聚酯活化丝，纬向为两层结构，上下层均采用直径为0.3mm的超低收缩聚酯单丝，织物经向密度为96根/inch，织物纬向密度为56根/inch，织法采用2/1斜纹，人字型结构。
其中，水性聚氨酯底涂料的配方如表1所示：
表1
其中，水性聚氨酯底涂料底涂的工艺数据如表2所示：
表2
将本实施例中制备得到的轻型输送带进行性能测试，具体测试结果如表3所示。
对比例：
将采用普通织物制作的二布二胶输送带与本实施例1和实施例2中制备的轻型输送带进行性能对比测试，具体测试结果如下所示：
表3对比测试数据表
性能 实施例1 实施例2 对比例
延伸受力(N/mm) 12 12 8
面层磨耗(g) 0.305 0.318 1.120
从表中可看出，实施例1和实施例2中制备得到的轻型输送带延伸受力强度和耐磨性都要明显好于普通工艺制备的输送带。
以上所述为本发明的较佳实施例而已，但本发明不应该局限于该实施例所公开的内容。所以凡是不脱离本发明所公开的精神下完成的等效或修改，都落入本发明保护的范围。

Claims (7)

1.一种物流行业用高强度高耐磨轻型输送带，其特征在于:所述物流行业用高强度高耐磨轻型输送带自下而上依序由高强度立体织物层、底涂层和高耐磨花纹面层构成；所述底涂层为水性聚氨酯底涂料固化而成，其粘度为3000～5000mPa.s，底涂量为180～220g/mm2；所述高耐磨花纹面层为高耐磨热塑性聚氨酯粉末热定型而成。
2.根据权利要求1所述的物流行业用高强度高耐磨轻型输送带，其特征在于：所述高强度立体织物采用立体聚酯织物，其中，经向上下交织采用线密度为1000D低收缩聚酯活化丝，经向直的1根采用线密度为1000D低收缩聚酯活化丝，纬向为两层结构，上下层均采用直径为0.3mm的超低收缩聚酯单丝，织物经向密度为95～100根/inch，织物纬向密度为55～60根/inch，织法采用2/1斜纹，人字型结构。
3.根据权利要求1所述的物流行业用高强度高耐磨轻型输送带，其特征在于：所述水性聚氨酯底涂料的组分，按照质量份数计为，水性聚氨酯树脂100份，固化剂5～8份，水性增稠剂0.5～1份。
4.根据权利要求3所述的物流行业用高强度高耐磨轻型输送带，其特征在于：所述固化剂为脂肪族聚氨酯分散液，水性增稠剂为非离子聚氨酯分散液。
5.根据权利要求1所述的物流行业用高强度高耐磨轻型输送带，其特征在于：所述高耐磨热塑性聚氨酯，邵氏硬度为65A。
6.根据权利要求1所述的物流行业用高强度高耐磨轻型输送带，其特征在于：所述高耐磨花纹面层的花纹细直条花纹或者钻石花纹。
7.权利要求1-6所述的任何一种物流行业用高强度高耐磨轻型输送带的制造方法，其特征在于，所述方法包括如下步骤：
S1：高强度立体织物定型；
S2：在步骤S1的高强度立体织物的粗糙面用水性聚氨酯底涂料底涂，构成底涂层；
S3：在步骤S2的底涂层上涂覆高耐磨热塑性聚氨酯粉末，并在180～200℃下进行热定型；
S4：利用不同的花纹辊筒压制不同类型的花纹，即得物流行业用高强度高耐磨轻型输送带。
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