CN106985476A - 一种用于保温箱的层状材料及其制备方法 - Google Patents
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Abstract
本发明公开一种用于保温箱的层状材料及其应用，层状材料依次包括：超薄铝箔层，纵向膜层，硬质聚氨酯发泡层、增粘层一、增强层、增粘层二和阻水膜层，其中，纵向膜层中均匀分布纵向气泡，所述纵向气泡中贯穿气泡比例低于3%，采用硬质聚氨酯发泡层以及增强层，综合得到了一种保温效果优异、防水性好、机械强度高，使用方面的用于保温箱的新型层状材料，满足了现有技术对保温箱用层状材料的基本需求。
Description
技术领域
本发明涉及层状材料领域，具体涉及用于保温箱的层状材料，特别涉及具有优异保温、阻水、高强度的适用于保温箱的层状材料领域。
背景技术
随着互联网行业的高速发展，国家对“互联网+”的大力支持，物流、快递，外卖行业蓬勃发展，并且呈现高速发展。在此大好背景下，越来越多的饭店、小吃店对互联网销售的依赖程度增强，但是有一个因素影响外卖的质量和客户的满意度，由于派送过程中热量损失，饭菜温度下降明显，严重影响了食品的口感和风味。除了在食品包装中进行改进外(发明人也进行了相关的研究)，派送员在运输中使用的保温箱也起到了重要的作用。除了外面运输中使用，家庭外出也需要使用保温箱。
现在市场上使用的配送用保温箱的保温措施主要就是内层的金属薄膜，在外部没有过多的保温设置，保温效果较差，同时，由于制备保温箱的材质较软，箱体强度不足，运输中有诸多不方便之处。手提式保温箱也存在类似问题，在提拉过程中，箱体变形十分严重。
为了解决现有技术中保温箱对保温、防水、强度以及使用周期的需要，发明人进行了细致的研究，得到本发明的方案，具体方案如下。
发明内容
发明目的：保温箱通常是具有多层结构的层状材料制备得到，本发明通过对用于保温箱的层状材料结构、各层组成以及结构的选择，采用了至少7层层叠的结构，对每一层的组成以及厚度等进行了相关的选择，该特定选择的组合得到一种保温效果优异、防水性好、机械强度高，使用方面的用于保温箱的新型层状材料，满足了现有技术对保温箱用层状材料的基本需求。
为了达到该技术效果，本发明提出如下解决方案:
一种用于保温箱的层状材料，依次包括：超薄铝箔层，纵向膜层，硬质聚氨酯发泡层、增粘层一、增强层、增粘层二和阻水膜层。该层状材料至少包含上述7层的结构，其分别根据对不同性能需要进行了不同的结构设置，超薄铝箔层、纵向膜层、硬质聚氨酯发泡层都为了提高保温性的需要，增强层是为了提高层状材料的强度和硬度，硬质聚氨酯发泡层也起到了增强的效果，而阻水层是为了提高耐水性，同时，为了提高层间作用力，尤其是增强层与两侧膜层的粘接性，在其两侧设置了增粘层一和增粘层二。
一般热量散失的方式为热传导和热辐射，本申请就采用了两种方式综合降低两者的热散失作用。所述超薄铝箔层采用的是一具有热反射效果的材料，可以有效的阻碍热辐射的降温，起到保温作用。所述纵向膜层是为了形成一个空气隔层，有效的减少热传导，这是十分重要的保温方式，热传导是热量散失的重要方式。聚氨酯发泡层也有相同保温的效果，两者同时利用，提高了保温的效果，大幅度提高了使用效果。
纵向膜层结构选择
本发明中使用纵向膜层是一个重要的发明侧重点，其中所述纵向膜层中均匀分布纵向气泡，所述气泡中贯穿气泡比例低于3％。优选低于2.5％，2％，1.5％，1％。其中贯穿气泡是指在纵向膜表面上以开放孔的形式存在的气泡，其比例是以开孔面积占纵向膜表面的比例计算得到。
如果贯穿孔含量过大时，空气阻隔效果明显会有降低，保温效果很差，降低在20百分数以上，这点在现有产品中受到关注很少，没有意识到发泡中孔结构的影响。但由于制备工艺的可达到的效果，难以达到完全没有贯穿孔，实际操作中越低越好。
同时，纵向膜层中孔结构最优选的方式是膜层垂直方向尺寸大于膜层切线或平行方向的尺寸，这样加大了单位面积的实际孔密度，同时阻碍热量散失中，垂直膜层方向的尺寸。该结构源自制备过程中的发泡过程的垂直方向上的慢速牵引，该技术未有报道，且该技术不会引起生产成本费明显增高。
所述纵向膜层厚度为100-500微米，优选厚度为200-400微米，最优选厚度为350微米。纵向膜层厚度方面优选具有较大的厚度，如果厚度过大，纵向膜层成型存在一定的限制，成材率较低，但是如果过小，保温效果不足，同时会导致层状材料的总厚度不足，强度降低。
硬质聚氨酯发泡层的选择
硬质聚氨酯发泡层同样是具有孔洞结构，其孔结构没有明显的要求，最优选也是贯穿孔结构少。同时，聚氨酯起到了一定程度的粘合力作用，提高层状材料的强度，但由于为了强度的需要采用了硬质聚氨酯，粘接强度仍有不足，需要增粘层作为进一步补充，保证足够的层间粘合力。
所述硬质聚氨酯发泡层采用超柔聚氨酯发泡制备得到，其中多元醇采用了聚酯多元醇或含有芳环结构的聚醚多元醇，其分子量优选2000-13000，使用的异氰酸酯采用芳香族异氰酸酯。采用硬质聚氨酯是为了提高层状材料的层间粘合力。为了层状材料的总体硬度、强度，优选了硬质聚氨酯，而非软质的聚氨酯。满足了层状材料对粘合力的基本要求和强度需要，强度的提高保证了层状材料制备得到的保温箱的质量，损坏率低，降低企业内耗。
所述聚氨酯发泡层厚度为200-1000微米，优选厚度为450-900微米，最优选厚度为700-800微米。膜层厚度没有明显限定，根据实际使用要求可以随意选择，一般厚度越大保温性越好，且强度好。综合考虑保温性、强度以及成本，最优选为800微米左右。
增强层的选择
层状材料结构选择是为了满足后续其在保温箱方面的应用，由于为了保温效果，其他层材质的选择强度均不是很大，难以满足保温箱的实际使用需求，因此，在层状材料中加入了增强层，可以大幅度提高层状材料的强度。
所述增强层为高结晶聚丙烯或硬质聚氯乙烯，高结晶聚丙烯的强度较大，硬质聚氯乙烯的硬度较大，都可以满足对层状材料增强的需要。增强膜层的厚度大于500微米，厚度的提高可以提高强度，但也不宜过大，最大值优选小于1mm。
阻水膜层的选择
阻水膜层的作用已经在先说明，为了兼顾强度和阻水性。实际使用时可以选择聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯或聚对苯二甲酸丁二醇酯。
为了保证层状材料的柔韧性，保证其随型性，最优选聚对苯二甲酸丙二醇脂，其属于一种生物源聚酯，废弃后具有一定的生物分解性能。
所述阻水膜层厚度为50-150微米，优选厚度为80-130微米，最优选厚度为100微米。由于作为保温箱的用途，其可能会有印刷广告等，为了保证对印刷层的保护，优选较厚。
增粘层的选择
增粘层的设置是为了弥补增强层设置后，层间粘合力下降的需要，其组成没有也别的要求，但从实际实验情况来看，作为增粘层的涂层组合物优选包含增粘树脂和硅烷偶联剂，其中增粘树脂和偶联剂的占涂料组合物固体份分别为的8％和3％。增强层两侧的增粘层优选组成相同。所述增粘层一和增粘层二厚度均小于50微米。
超薄铝箔层的选择
超薄铝箔层的选择基本采用市售产品即可，没有明确的限制。所述超薄铝箔层厚度为50-200微米，优选厚度为150微米。其结构优选表面粗糙度的产品，粗糙度低热反射能力强，减少热辐射效果较好。
本发明中层状材料可以在合适的位置设置印刷层，优选在增强层表面设置。
本发明还请求保护一种应用：用于保温箱的层状材料在低温保温箱或高温保温箱中的应用。
有益的技术效果
本发明通过对用于保温箱的层状材料结构、各层组成以及结构的选择，采用了至少7层层叠的结构，对每一层的组成以及厚度等进行了相关的选择，该特定选择的组合得到一种保温效果优异、防水性好、机械强度高，使用方面的用于保温箱的新型层状材料，满足了现有技术对保温箱用层状材料的基本需求。该结构在本领域没有报道，也没有发现具体结构和厚度综合效果的选择启示，属于一种性能十分有益的膜层材料，优于现有市售产品。
具体实施方式
为了便于技术人员详细的连接本发明的技术方案，在此仅以示例的方式介绍若干种实施方式，但该实施方式的示例不够成对技术保护范围任何限定。任何不背离本发明构思的方案均在保护范围内。
实施例1
一种用于保温箱的层状材料，其通过层合的方式制备得到，其中层状材料依次包括：超薄铝箔层150μm、纵向膜层(贯穿气泡比例约1％)350μm，硬质聚氨酯发泡层(分子量10000的聚酯多元醇与MDI反应制备得到)750μm、增粘层一20μm、增强层(高结晶聚丙烯)600μm、增粘层二30μm和阻水膜层(PTT)100μm。增粘层组成中增粘树脂和偶联剂的占涂料组合物固体份分别为的8％和3％。
实施例2
实施例1中高结晶聚丙烯增强层替换为硬质PVC增强层，其他结构组成同实施例1。
实施例3
实施例1中纵向膜层的贯穿孔比例替换为2％的纵向膜，其他结构组成同实施例1。
对比例1
实施例1中纵向膜层的贯穿孔比例替换为3.5％的纵向膜，其他结构组成同实施例1。
对比例2
实施例1中纵向膜层的厚度设置为80μm，其他结构组成同实施例1
对比例3
实施例1中硬质聚氨酯发泡层替换为软质聚氨酯泡沫，软质聚氨酯泡沫采用分子量10000的聚醚多元醇和HDI反应得到，其软硬段摩尔比例同硬质聚氨酯发泡层的组成相近，其他结构组成同实施例1
对比例4
实施例1中的硬质聚氨酯发泡层组成修改为分子量20000的聚酯多元醇与MDI反应制备得到，软硬段质量比例与实施例1相同，其他结构组成同实施例1。
对比例5
实施例1中硬质发泡层的厚度修改为450μm，其他结构组成同实施例1。
对比例6
不使用增强层，其他结构组成同实施例1。
对比例7
增强层厚度设置为350μm，其他结构组成同实施例1。
对比例8
两侧均不使用增粘层，其他结构组成同实施例1。.
对比例9
增粘层中不含有偶联剂，增粘树脂比例11％，其他结构组成同实施例1。
对比例10
增粘层中不含有增粘树脂，偶联剂的比例为11％，其他结构组成同实施例1。
测试方法
(1)层状材料的导热系数测试：
实施例和对比例的样品的导热系数测试参考ASTM D5470-2012进行。
(2)层状材料的弯曲模量性能测试：
实施例和对比例的样品的弯曲模量测试参考GB/T 9341-2000。
(3)层状材料的剥离测试
实施例和对比例的样品采用GB8808-88进行，增强层和阻水层分别进行夹持，测试速度采用B法(200+/-50mm/min)。
测试结果
实施例1-3和对比例1-10的测试结果参见下表：
由上述测试结果可以发现，层状材料每一层的厚度、组成都对最终性能有中药的影响。纵向膜层的贯穿孔比例对导热系数、弯曲模量、剥离强度的性能有十分重要的影响，优选含有少量的贯穿孔；同时，增粘层组成中增粘树脂和偶联剂存在一定的相互促进的、超出常规预期的效果，大幅度提高了剥离强度；聚氨酯发泡层中多元醇的种类、分子量也对产品的弯曲模量有决定性的影响。增强层的厚度也是一个重要的因素。只有通过上述几种组分的综合选择和配合，才得到了如实施例1-3所述的优异的、平衡的技术效果。
Claims (10)
1.一种用于保温箱的层状材料，其特征在于：层状材料依次包括：超薄铝箔层，纵向膜层，硬质聚氨酯发泡层、增粘层一、增强层、增粘层二和阻水膜层。
2.根据权利要求1所述的用于保温箱的层状材料，其特征在于：所述纵向膜层中均匀分布纵向气泡，所述纵向气泡中贯穿气泡比例低于3%。
3.根据权利要求1所述的用于保温箱的层状材料，其特征在于：所述硬质聚氨酯发泡层采用硬质聚氨酯发泡制备得到。
4.根据权利要求1所述的用于保温箱的层状材料，其特征在于：所述增强层为高结晶聚丙烯或硬质聚氯乙烯。
5.根据权利要求1所述的用于保温箱的层状材料，其特征在于：所述阻水膜层选自聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯或聚对苯二甲酸丁二醇酯中的一种。
6.根据权利要求1所述的用于保温箱的层状材料，其特征在于：所述增粘层一和增粘层二的组成相同，组成为包含增粘树脂和硅烷偶联剂的涂层组合物。
7.根据权利要求1-6所述任一用于保温箱的层状材料，其特征在于：所述超薄铝箔层厚度为50-200微米，所述纵向膜层厚度为100-500 微米，所述聚氨酯发泡层厚度为200-1000微米，所述阻水膜层厚度为50-150微米。
8.根据权利要求1-6所述任一用于保温箱的层状材料，其特征在于：所述增粘层一和增粘层二厚度均小于50微米。
9.根据权利要求1-6所述任一用于保温箱的层状材料，其特征在于：所述增强膜层的厚度大于500微米。
10.权利要求1-9中所述任一用于保温箱的层状材料在低温保温箱或高温保温箱中的应用。
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