CN107379695A - 一种闭孔发泡材料及其制造配方与方法 - Google Patents

一种闭孔发泡材料及其制造配方与方法 Download PDF

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CN107379695A
CN107379695A CN201710674997.2A CN201710674997A CN107379695A CN 107379695 A CN107379695 A CN 107379695A CN 201710674997 A CN201710674997 A CN 201710674997A CN 107379695 A CN107379695 A CN 107379695A
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林彬
马训龙
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Guangdong Fortune Industrial Co Ltd
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Abstract

本发明涉及发泡材料技术领域,具体涉及一种闭孔发泡材料及其制造配方与方法,闭孔发泡材料包括本体,本体为连续发泡一体成型,本体包括上表皮、中芯层和下表皮,上表皮、中芯层和下表皮为连续闭孔发泡一体成型,发泡材料配方为:弹性体(EVA、POE、TPE、TPR、MPP)10‑40份;聚乙烯10‑50份;填充料30‑60份;发泡剂6‑20份;催化剂0‑5份;交联剂0.1‑2份;润滑剂0‑3份;色粉0‑2份;发泡材料制造方法是:密炼;挤出;压延形成母片;一次冷却、收卷;将母片投入连续式发泡隧道炉常压下进行闭孔交联发泡;二次冷却;印花、成品、收卷,此方法特别是在甲酰胺方面完全符合欧盟标准及用户要求;本发明不用电子辐照交联和不用模压就可以连续的化学交联闭孔发泡的闭孔发泡材料。

Description

一种闭孔发泡材料及其制造配方与方法
技术领域
本发明涉及发泡材料技术领域,特别是涉及一种闭孔发泡材料及其制造配方与方法。
背景技术
发泡材料是以塑料(PE、EVA等)、橡胶(SBR、CR等)等原材料,加以催化剂、泡沫稳定剂、发泡剂等辅料,通过物理发泡或交联发泡,使塑料和橡胶中出现大量细微泡沫,体积增加,密度减少,软质发泡材料质量轻、柔软度好,具备缓冲、吸音、吸震、保温、过滤等功能,广泛应用于电子、家电、汽车、体育休闲等行业。
但现有发泡材料密度大,价格高等缺点限制了它的使用范围。如何保持发泡材料的性能优点,而又避免其性能缺点,同时降低生产成本,一直是行业研究的热点问题;现已知闭孔发泡技术IXPE需要电子交联才能有较好发泡效果,XPE发泡孔大不密实。
发明内容
为解决上述问题,本发明提供一种不用电子辐照交联和不用模压就可以连续的化学交联闭孔发泡,特别是在甲酰胺方面完全符合欧盟标准及用户要求的闭孔发泡材料及其制造配方及方法。
本发明所采用的技术方案是:一种闭孔发泡材料,包括本体,所述本体为连续发泡一体成型,所述本体包括上表皮、中芯层和下表皮,所述上表皮、中芯层和下表皮为连续闭孔发泡一体成型,所述上表皮与下表皮均为光滑表面,所述中芯层设有孔状体。
对上述方案的进一步改进为,所述孔状体为封闭式孔体,所述孔状体直径大小相同。
对上述方案的进一步改进为,所述孔状体直径大小范围在0.01~0.2mm。
一种闭孔发泡材料制造配方,制造配方如下:
对上述方案的进一步改进为,所述弹性体为EVA、POE、TPE、MPP、IR中的一种或二种以上的混合物。
一种闭孔发泡材料的制备方法,包括以下步骤,
步骤1:密炼;
步骤2:挤出;
步骤3:压延形成母片;
步骤4:一次冷却、收卷;
步骤5:将母片闭孔交联发泡;
步骤6:第二次冷却;
步骤7:印花、成品、收卷。
对上述方案的进一步改进为,步骤1:密练,将权利要求6所述的配方投入密练机内密练处理;
步骤2:挤出、将密练后的胶料投入挤出机滤胶挤出成胶胚,挤出机温度控制为70-95℃;
步骤3:压延中,将挤出后的胶胚通过压延机将其厚度压延一致形成母片;
步骤4:一次冷却、将挤出后的胶胚投入水池中进行水冷;水冷后通过收卷机将母片收卷。
对上述方案的进一步改进为,步骤5:将母片放卷至连续式发泡隧道炉常压下进行闭孔交联发泡,交联发泡时间5-15分钟,交联发泡温度170-230℃,得到发泡体;
步骤6:二次冷却,将闭孔交联后的发泡体进行水冷;
步骤7:将冷却后的发泡材料表面通过印花设备印花,印花完成后收卷成品。
本发明的有益效果为:
1、闭孔发泡材料包括上表皮、中芯层和下表皮,所述上表皮、中芯层和下表皮为连续闭孔发泡一体成型,通过连续发泡一体成型,发泡密度高,机械强度高,制造简单,造价成本低,发泡出来的产品外观与IXPE和EVA模压发泡相同,具体为一种化学交联的闭孔发泡材料,相对于IXPE发泡不需要电子辐照交联,不用投入设备高成本;模压发泡因不能连续化生产,造成人工成本和能耗较高;具体要解决材料的气味,抗菌阻燃;能够进一步提高发泡材料的发泡密度,发泡密度高,造价成本低,更具有无毒无味,抗菌耐磨耐压和阻燃效果。2、闭孔发泡材料发泡材料的配方为:
弹性体为EVA、POE、TPE、MPP、IR中的一种或二种以上的混合物。
EVA的VA含量为5-18%,熔体质量流动速率0.5-6g/10min,埃尔曼多夫抗撕强度为7.0-10g。EVA中的醋酸乙烯的含量与EVA的性能有很重要的关系,当醋酸乙烯的含量低于20%时,可作为塑料使用。本发明的EVA的醋酸乙烯的含量为8-12%,故有很好的耐低温性能,其热分解温度较低,约为230℃左右,随着分子量的增大,EVA的软化点上升,加工性和塑件表面光泽性下降,但强度增加,冲击韧性和耐环境应力开裂性提高,EVA的耐化学药品、耐油性方面较之PE,PVC稍差,并随醋酸乙烯含量的增加,变化更加明显。EVA树脂具有良好的柔软性,橡胶般的弹性,在-50℃下仍能够具有较好的可挠性,透明性和表面光泽性好,化学稳定性良好,抗老化和耐臭氧强度好,无毒性,直充料的掺混性好,着色和成型加工性好,EVA树脂用途很广。
POE为辛烯单体含量在20%-30%的乙烯-辛烯共聚物,通过采用辛烯单体含量在20%-30%的乙烯-辛烯共聚物作为弹性发泡体,能提高材料的韧性和回弹性能,还能提高材料的热变形温度。
TPE具有橡胶的高弹性,高强度,高回弹性,又具有可注塑加工的特征的材料。具有环保无毒安全,应用范围广,有优良的着色性,触感柔软,耐候性,抗疲劳性和耐温性,加工性能优越,无须硫化,可以循环使用降低成本,既可以二次注塑成型。具有良好的曲挠性,阻燃性,耐酸碱等。
MPP(改性聚丙烯)填充碳酸钙来进行改性,改性后的MPP(改性聚丙烯)具有很好的抗冲击性,同时改善印刷性能。
IR(异戊橡胶)具有很好的弹性、耐寒性(玻化温度-68℃)及很高的拉伸强度,发泡。异戊橡胶的化学组成、立体结构与天然橡胶相似,性能也非常接近天然橡胶,矿有合成天然橡胶之称。它具有天然橡胶的大部分优点,耐老化优于天然橡胶,弹性和强力比天然橡胶稍低,加工性能差,成本较高,使用温度范围较大。
通过以上配方制成的闭孔发泡材料,机械强度高,发泡密度大,成本低。
3、一种闭孔发泡材料的制备方法:步骤1:密练,将权利要求6所述的配方投入密练机内密练处理;密练A、将闭孔发泡材料发泡材料的配方投入密炼机内捏炼3-5分钟,然后将聚乙烯、填充料、发泡剂投入密炼机内捏炼3-5分钟;将催化剂、色粉的1/2投入密炼机内;将交联剂、润滑剂投入密炼机内;再将催化剂、色粉剩余的1/2投入密炼机内;工作效率高,密练效果好;步骤2:挤出、将密练后的胶料投入挤出机滤胶挤出成胶胚,挤出机温度控制为70-95℃;挤出成型效果好步骤3:压延中,将挤出后的胶胚通过压延机将其厚度压延一致形成母片;效率高,成型效果好;步骤4:一次冷却、将挤出后的胶胚投入水池中进行水冷;水冷后通过收卷机将母片收卷;步骤5:将母片放卷至连续式发泡隧道炉常压下进行闭孔交联发泡,交联发泡时间25-45分钟,交联发泡温度134±5℃,得到发泡体;步骤6:二次冷却,将闭孔交联后的发泡体进行水冷;步骤7:将冷却后的发泡材料表面通过印花设备印花,印花完成后收卷成品;由上述制作方法制造的避空发泡材料,发泡密度大,机械强度高,成本低,此方法特别是在甲酰胺方面完全符合欧盟标准及用户要求。
附图说明
图1为本发明的构示意图。
附图标识:本体100、上表皮110、中芯层120、下表皮130、孔状体140。
具体实施方式
下面将结合附图对本发明作进一步的说明。
如图1所示,为本发明的示意图。
一种闭孔发泡材料,包括本体100,所述本体100为连续发泡一体成型,所述本体100包括上表皮110、中芯层120和下表皮130,所述上表皮110、中芯层120和下表皮130为连续闭孔发泡一体成型,所述上表皮110与下表皮130均为光滑表面,所述中芯层120设有孔状体140。
本发明连续闭孔发泡一体成型,发泡出来的产品外观与IXPE和EVA模压发泡相同,具体为一种化学交联的闭孔发泡材料,相对于IXPE发泡不需要电子辐照交联,不用投入设备高成本;模压发泡因不能连续化生产,造成人工成本和能耗较高;具体要解决材料的气味,抗菌阻燃;能够进一步提高发泡材料的发泡密度,发泡密度高,造价成本低,更具有无毒无味,抗菌耐磨耐压和阻燃效果。
所述孔状体140为封闭式孔体,闭孔式孔体具有恢复效率高、密度大等效果。
所述孔状体140直径大小范围在0.01~0.2mm,优选为0.1mm,密度大,发泡效率高,制造效率高。
闭孔发泡材料发泡材料的配方为:
弹性体为EVA、POE、TPE、MPP、IR中的一种或二种以上的混合物。
EVA的VA含量为5-18%,熔体质量流动速率0.5-6g/10min,埃尔曼多夫抗撕强度为7.0-10g。EVA中的醋酸乙烯的含量与EVA的性能有很重要的关系,当醋酸乙烯的含量低于20%时,可作为塑料使用。本发明的EVA的醋酸乙烯的含量为8-12%,故有很好的耐低温性能,其热分解温度较低,约为230℃左右,随着分子量的增大,EVA的软化点上升,加工性和塑件表面光泽性下降,但强度增加,冲击韧性和耐环境应力开裂性提高,EVA的耐化学药品、耐油性方面较之PE,PVC稍差,并随醋酸乙烯含量的增加,变化更加明显。EVA树脂具有良好的柔软性,橡胶般的弹性,在-50℃下仍能够具有较好的可挠性,透明性和表面光泽性好,化学稳定性良好,抗老化和耐臭氧强度好,无毒性,直充料的掺混性好,着色和成型加工性好,EVA树脂用途很广。
POE为辛烯单体含量在20%-30%的乙烯-辛烯共聚物,通过采用辛烯单体含量在20%-30%的乙烯-辛烯共聚物作为弹性发泡体,能提高材料的韧性和回弹性能,还能提高材料的热变形温度。
TPE具有橡胶的高弹性,高强度,高回弹性,又具有可注塑加工的特征的材料。具有环保无毒安全,应用范围广,有优良的着色性,触感柔软,耐候性,抗疲劳性和耐温性,加工性能优越,无须硫化,可以循环使用降低成本,既可以二次注塑成型。具有良好的曲挠性,阻燃性,耐酸碱等。
MPP(改性聚丙烯)填充碳酸钙来进行改性,改性后的MPP(改性聚丙烯)具有很好的抗冲击性,同时改善印刷性能。
IR(异戊橡胶)具有很好的弹性、耐寒性(玻化温度-68℃)及很高的拉伸强度,发泡。异戊橡胶的化学组成、立体结构与天然橡胶相似,性能也非常接近天然橡胶,矿有合成天然橡胶之称。它具有天然橡胶的大部分优点,耐老化优于天然橡胶,弹性和强力比天然橡胶稍低,加工性能差,成本较高,使用温度范围较大。
通过以上配方制成的闭孔发泡材料100,机械强度高,发泡密度大,成本低。
一种闭孔发泡材料的制备方法,包括以下步骤,
步骤1:密炼;
步骤2:挤出;
步骤3:压延形成母片;
步骤4:一次冷却、收卷;
步骤5:将母片闭孔交联发泡;
步骤6:第二次冷却;
步骤7:印花、成品、收卷。
步骤1:密练,将权利要求6所述的配方投入密练机内密练处理;密练A、将闭孔发泡材料发泡材料的配方投入密炼机内捏炼3-5分钟,然后将聚乙烯、填充料、发泡剂投入密炼机内捏炼3-5分钟;将催化剂、色粉的1/2投入密炼机内;将交联剂、润滑剂投入密炼机内;再将催化剂、色粉剩余的1/2投入密炼机内;工作效率高,密练效果好;步骤2:挤出、将密练后的胶料投入挤出机滤胶挤出成胶胚,挤出机温度控制为80-125℃;挤出成型效果好步骤3:压延中,将挤出后的胶胚通过压延机将其厚度压延一致形成母片;效率高,成型效果好;步骤4:一次冷却、将挤出后的胶胚投入水池中进行水冷;水冷后通过收卷机将母片收卷;步骤5:将母片放卷至连续式发泡隧道炉常压下进行闭孔交联发泡,交联发泡时间5-15分钟,交联发泡温度170-230℃,得到发泡体;步骤6:二次冷却,将闭孔交联后的发泡体进行水冷;步骤7:将冷却后的发泡材料表面通过印花设备印花,印花完成后收卷成品;由上述制作方法制造的避空发泡材料,发泡密度大,机械强度高,成本低,此方法特别是在甲酰胺方面完全符合欧盟标准及用户要求。
以上所述实施例仅表达了本发明的几种实施方式,其描述较为具体和详细,但并不能因此而理解为对本发明专利范围的限制。应当指出的是,对于本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。因此,本发明专利的保护范围应以所附权利要求为准。

Claims (8)

1.一种闭孔发泡材料,其特征在于:包括本体,所述本体为连续发泡一体成型,所述本体包括上表皮、中芯层和下表皮,所述上表皮、中芯层和下表皮为连续闭孔发泡一体成型,所述上表皮与下表皮均为光滑表面或为压纹表面,所述中芯层设有孔状体。
2.根据权利要求1所述的一种闭孔发泡材料,其特征在于,所述孔状体为封闭式孔体,所述孔状体直径大小相同。
3.根据权利要求2所述的一种闭孔发泡材料,其特征在于:所述孔状体直径大小范围在0.01~0.2mm。
4.根据权利要求1~3任意一项所述的一种闭孔发泡材料制造配方,其特征在于:制造配方如下:
5.根据权利要求5所述的一种闭孔发泡材料制造配方,其特征在于:所述弹性体为EVA、POE、TPE、MPP、IR中的一种或二种以上的混合物。
6.根据权利要求1~5任意一项所述的一种闭孔发泡材料的制备方法,其特征在于:包括以下步骤,
步骤1:密炼;
步骤2:挤出;
步骤3:压延形成母片;
步骤4:一次冷却、收卷;
步骤5:将母片闭孔交联发泡;
步骤6:第二次冷却;
步骤7:印花、成品、收卷。
7.根据权利要求6所述的一种闭孔发泡材料的制备方法,其特征在于:
步骤1:密练,将权利要求6所述的配方投入密练机内密练处理;
步骤2:挤出、将密练后的胶料投入挤出机滤胶挤出成胶胚,挤出机温度控制为70-95℃;
步骤3:压延中,将挤出后的胶胚通过压延机将其厚度压延一致形成母片;
步骤4:一次冷却、将挤出后的胶胚投入水池中进行水冷;水冷后通过收卷机将母片收卷。
8.根据权利要求6所述的一种闭孔发泡材料的制备方法,其特征在于:
步骤5:将母片放卷至连续式发泡隧道炉常压下进行闭孔交联发泡,交联发泡时间25-45分钟,交联发泡温度134±5℃,得到发泡体;
步骤6:二次冷却,将闭孔交联后的发泡体进行水冷;
步骤7:将冷却后的发泡材料表面通过印花设备印花,印花完成后收卷成品。
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