CN108342063B - 一种彩绒板及其制备方法 - Google Patents

一种彩绒板及其制备方法 Download PDF

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CN108342063B
CN108342063B CN201710686292.2A CN201710686292A CN108342063B CN 108342063 B CN108342063 B CN 108342063B CN 201710686292 A CN201710686292 A CN 201710686292A CN 108342063 B CN108342063 B CN 108342063B
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CN108342063A (zh
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高千钧
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Shanghai Colorbo Industrial Co ltd
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Abstract

本发明公开了一种彩绒板及其制备方法，包括重量份数的如下原料：50‑55份的聚酯乙烯涤纶短纤，45‑50份的聚酯乙烯涤纶长纤，3‑5份的纳米碳纤维和2‑3份的纳米银微粒，其中，聚酯乙烯涤纶短纤的熔点为140‑150℃，聚酯乙烯涤纶长纤的熔点为180‑200℃；本发明的彩绒板采用聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤、纳米碳纤维和纳米银微粒复配，获得阻燃性能优良的彩绒板，纳米微粒的加入还可以吸收室内挥发的有害气体，提高了室内环境的安全系数；本发明的彩绒板达到A阻燃级别，尤其适用于新装修的居室、办公室和公共场所。

Description

一种彩绒板及其制备方法
技术领域
本发明涉及室内板材技术领域，尤其涉及一种能够达到A级阻燃效果的彩绒板及其该彩绒板的制备方法。
背景技术
有害的化学性因子、物理性因子和(或)生物性因子进入室内空气中，将对人体身心健康产生影响。“室内”主要指居室内,广义上也可泛指各种建筑物内,如办公楼、会议厅、医院、教室、旅馆、图书馆、展览厅、影剧院、体育馆、健身房、商场、地下铁道、候车室、候机厅等各种室内公共场所和公众事务场所内。
人们平均每天80％以上的时间在室内度过。随着生产和生活方式的更加现代化，更多的工作和文娱体育活动都可在室内进行,购物也不必每天上街,合适的室内环境使人们不必经常到户外，由此人们的室内活动时间就更多，甚至高达93％以上。因此，室内空气质量与人体健康的关系就显得更加密切，更加重要。
目前，室内所使用的板材绝大多数为聚酯纤维板，聚酯纤维板由木质纤维，醛类胶黏剂和活性炭组成。木质纤维和活性炭混合物中加入醛类胶黏剂，然后进行热压即可制得聚酯纤维板。由于聚酯纤维板使用了醛类胶黏剂，本身会释放有害气体，不够环保，同时聚酯纤维板的阻燃效果不够理想。
发明内容
为了解决现有技术中室内板材阻燃效果不佳及不够环保的问题，本发明的目的是提供一种彩绒板；为此，本发明还将提供该彩绒板的制备方法。
为了实现上述目的，本发明采用如下技术方案：
本发明的第一方面，提供一种彩绒板，包括重量份数的如下原料：50-55份的聚酯乙烯涤纶短纤，45-50份的聚酯乙烯涤纶长纤，3-5份的纳米碳纤维和2-3份的纳米银微粒，其中，聚酯乙烯涤纶短纤的熔点为140-150℃，聚酯乙烯涤纶长纤的熔点为180-200℃。
优选的是，所述聚酯乙烯涤纶短纤为TCK4080短纤。
TCK4080短纤，由改性聚酯原料聚合而成，在水中具有良好的分散性。
优选的是，所述聚酯乙烯涤纶长纤为阻燃化纤，长纤空腔可吸附挥发性有机溶剂，吸湿、消臭，保暖；经过消臭测试，其消臭率高达88％；经过节能测试，其保暖隔热，
能显著降低空调能耗。
优选的是，所述纳米碳纤维和纳米银微粒的总重量份数为5-8份。
优选的是，所述纳米微粒的粒径为20-50nm。
当纳米微粒的粒径小于20nm时，纳米微粒的表面效应显著，纳米微粒表面存在缺陷，具有高度的不饱和性，聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤易对纳米微粒表面产生影响，吸附效果不稳定；当纳米微粒粒径大于50nm时，聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤、纳米微粒三者组成的体系，吸附作用微弱；当纳米微粒粒径为20-50nm时，聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤、纳米微粒组成的体系，吸附效果明显，能够对室内甲醛等对人体有害的物质产生稳定的吸附作用。
本发明的第二方面，提供上述彩绒板的制备方法，包括如下步骤：
S1，称取50-55重量份的聚酯乙烯涤纶短纤，45-50重量份的聚酯乙烯涤纶长纤，3-5重量份的纳米碳纤维和2-3份的纳米银微粒，其中，聚酯乙烯涤纶短纤的熔点为140-150℃，聚酯乙烯涤纶长纤的熔点为180-200℃；
S2，将S1中的聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤混合均匀成聚酯纤维混合棉团；
S3，通过针刺编织机将S2中的混合棉团编织成聚酯纤维薄层，聚酯纤维薄层经层层上铺，第一次热定型，辊压形成聚酯纤维板；
S4，将S3中形成的聚酯纤维板表面分别喷涂纳米碳纤维和纳米银微粒，经第二次热定型，辊压获得彩绒板。
优选的是，所述S3中进行聚酯纤维薄层编织时的针刺密度为1-1.5针/cm2。
在具体操作中，若针刺密度大于1.5针/cm2，容易造成纤维的断裂，进而造成材料强度的下降；若针刺密度小于1针/cm2，容易造成纤维的纠缠程度增加，生产效率降低；当针刺密度为1-1.5针/cm2，能实现相同时间内较高的生产效率以及符合要求的彩绒板。
优选的是，所述S3中第一次热定型的温度为165-175℃，热定型时间为9-12min。
热定型温度低于165℃时，聚酯乙烯涤纶短纤没有完全融化，热压出来的板材密度达不到要求，同时获得的彩绒板出现杂色，影响美观；热定型温度高于175℃时，熔点太高，聚酯乙烯涤纶长纤一并融化，直接成为聚酯塑料制品，无法获得板材；热定型温度为165-175℃时，能实现预期的阻燃效果及板材密度。
热定型时间低于9min时，彩绒板的密度不稳定；热定型时间高于12min时，彩绒板温度过高，湿度大，容易发霉；热定型时间为9-12min时，彩绒板密度稳定，可直接存放，无霉变现象的发生。
优选的是，所述S4中第二次热定型的温度为175-185℃，热定型时间为1-2min。
在喷涂纳米碳纤维和纳米银微粒后，进行第二次热定型，使得纳米碳纤维、纳米银微粒与板体彻底融合，增加彩绒板的均一性。
优选的是，所述S3和S4中的辊压压力均为2.5-3.5Mpa，辊压速度均为1.13m/min-1.26m/min，辊压时的辊间距均为5-15mm。
与现有技术相比，本发明实现的有益效果：本发明的彩绒板采用聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤、纳米碳纤维和纳米银微粒复配，获得阻燃性能优良的彩绒板，纳米微粒的加入还可以吸收室内挥发的有害气体，提高了室内环境的安全系数；本发明的彩绒板达到A阻燃级别，尤其适用于新装修的居室、办公室和公共场所；本发明的彩绒板采用性能相近的聚酯乙烯涤纶短纤与聚酯乙烯涤纶长纤复配，避免了热压过程中胶黏剂的使用，节能环保；经过第一次热定型、第二热定型处理后，聚酯乙烯涤纶短纤和聚酯乙烯涤纶长纤充分融合，成为均一体，使得彩绒板颜色纯正，避免杂色的产生；本发明的彩绒板针对材料配比进行反复实验，发现当聚酯乙烯涤纶短纤为50重量份，聚酯乙烯涤纶长纤为50重量份，纳米碳纤维为3重量份，纳米银微粒为2重量份时，所获得的彩绒板在满足A阻燃级别的同时还具有较佳的吸音性能，其平均吸音系数NRC达到0.8。
具体实施方式
聚酯乙烯涤纶短纤是指纤维长度≤35mm的聚酯乙烯涤纶，聚酯乙烯涤纶长纤是指纤维长度≥50mm的聚酯乙烯涤纶。
实施例1
彩绒板的制备方法，包括如下步骤：
S1，称取5500g聚酯乙烯涤纶短纤(购自天津世韩有限公司的TCK4080)，4800g聚酯乙烯涤纶长纤(购自浙江安顺化纤有限公司的阻燃化纤)，500g纳米碳纤维，300g纳米银；
S2，将S1中的聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤投入搅拌机，反复搅拌，混合均匀成聚酯纤维混合棉团；
S3，通过针刺编织机将S2中的混合棉团编织成聚酯纤维薄层，编织时的针刺密度为1-1.5针/cm2，聚酯纤维薄层经层层上铺，第一次热定型，辊压形成聚酯纤维板，第一次热定型温度为165℃，热定型时间为10min；
S4，将S3中形成的聚酯纤维板表面分别喷涂纳米碳纤维和纳米银微粒，经第二次热定型，辊压获得彩绒板，第二次热定型温度为175℃，热定型时间为1min；
S5，已制成的彩绒板通过切割机，切割成适合包装发货的尺寸。
实施例2
彩绒板的制备方法，包括如下步骤：
S1，称取5200g聚酯乙烯涤纶短纤(购自天津世韩有限公司的TCK4080)，4500g聚酯乙烯涤纶长纤(购自浙江安顺化纤有限公司的阻燃化纤)，400g纳米碳纤维，250g纳米银；
S2，将S1中的聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤投入搅拌机，反复搅拌，混合均匀成聚酯纤维混合棉团；
S3，通过针刺编织机将S2中的混合棉团编织成聚酯纤维薄层，编织时的针刺密度为1-1.5针/cm2，聚酯纤维薄层经层层上铺，第一次热定型，辊压形成聚酯纤维板，第一次热定型温度为175℃，热定型时间为12min；
S4，将S3中形成的聚酯纤维板表面分别喷涂纳米碳纤维和纳米银微粒，经第二次热定型，辊压获得彩绒板，第二次热定型温度为180℃，热定型时间为2min；
S5，已制成的彩绒板通过切割机，切割成适合包装发货的尺寸。
实施例3
彩绒板的制备方法，包括如下步骤：
S1，称取5000g聚酯乙烯涤纶短纤(购自天津世韩有限公司的TCK4080)，5000g聚酯乙烯涤纶长纤(购自浙江安顺化纤有限公司的阻燃化纤)，300g纳米碳纤维，200g纳米银；
S2，将S1中的聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤投入搅拌机，反复搅拌，混合均匀成聚酯纤维混合棉团；
S3，通过针刺编织机将S2中的混合棉团编织成聚酯纤维薄层，编织时的针刺密度为1-1.5针/cm2，聚酯纤维薄层经层层上铺，第一次热定型，辊压形成聚酯纤维板，第一次热定型温度为170℃，热定型时间为9min；
S4，将S3中形成的聚酯纤维板表面分别喷涂纳米碳纤维和纳米银微粒，经第二次热定型，辊压获得彩绒板，第二次热定型温度为185℃，热定型时间为1min；
S5，已制成的彩绒板通过切割机，切割成适合包装发货的尺寸。
以实施例3制备的彩绒板为例，考察其燃烧性能。
彩绒板燃烧性能的测试参照EN13501-1:2007标准。具体方法：用密度900kg/m3、厚度为9mm的硅酸钙板作为基板，以实施例3制备的彩绒板为样品，样品采用机械固定的方式固定于基板上，样品长翼上无水平连接，样品的面密度为2.4kg/m2，厚度为9mm，样品共计12m3，测得的实验数据如表1所示。
表1
Figure GDA0003076154910000051
如表1所示，本发明彩绒板燃烧性能达到A级，阻燃性能好。
将实施例3制得的彩绒板与传统的聚酯纤维板分别进行吸音性能测试，测得传统聚酯纤维板的吸音系数与频率的关系数据如表2，实施例3制得的彩绒板吸音系数与频率的关系数据如表3。
表2
Figure GDA0003076154910000061
表3
Figure GDA0003076154910000062
比较表3与表2的实验数据发现，100-5000Hz的频率范围内，实施例3制得的彩绒板的吸音系数相对于传统的聚酯纤维板均有所升高，特别是100-1250Hz的频率范围内，吸音系数升高得非常明显，说明实施例3制得的彩绒板相对于传统聚酯纤维板，其吸音性能得到极大的改善。
上述的具体实施方式只是示例性的，是为了更好地使本领域技术人员能够理解本专利，不能理解为是对本专利包括范围的限制；只要是根据本专利所揭示精神的所作的任何等同变更或修饰，均落入本专利包括的范围。

Claims (5)

1.一种彩绒板，其特征在于，包括重量份数的如下原料：50-55份的聚酯乙烯涤纶短纤，45-50份的聚酯乙烯涤纶长纤，3-5份的纳米碳纤维和2-3份的纳米银微粒，其中，聚酯乙烯涤纶短纤的熔点为140-150℃，聚酯乙烯涤纶长纤的熔点为180-200℃；其中，聚酯乙烯涤纶短纤购自天津世韩有限公司的TCK4080，聚酯乙烯涤纶长纤购自浙江安顺化纤有限公司的阻燃化纤；聚酯乙烯涤纶短纤是指纤维长度≤35mm的聚酯乙烯涤纶，聚酯乙烯涤纶长纤是指纤维长度≥50mm的聚酯乙烯涤纶；所述纳米银微粒的粒径为20-50nm；彩绒板的制备方法，包括如下步骤：
S1，称取50-55重量份的聚酯乙烯涤纶短纤，45-50重量份的聚酯乙烯涤纶长纤，3-5重量份的纳米碳纤维和2-3份的纳米银微粒；
S2，将S1中的聚酯乙烯涤纶短纤、聚酯乙烯涤纶长纤混合均匀成聚酯纤维混合棉团；
S3，通过针刺编织机将S2中的混合棉团编织成聚酯纤维薄层，聚酯纤维薄层经层层上铺，第一次热定型，辊压形成聚酯纤维板；
S4，将S3中形成的聚酯纤维板表面分别喷涂纳米碳纤维和纳米银微粒，经第二次热定型，辊压获得彩绒板。
2.如权利要求1所述的彩绒板，其特征在于，所述S3中进行聚酯纤维薄层编织时的针刺密度为1-1.5针/cm2。
3.如权利要求1所述的彩绒板，其特征在于，所述S3中第一次热定型的温度为165-175℃，热定型时间为9-12min。
4.如权利要求1所述的彩绒板，其特征在于，所述S4中第二次热定型的温度为175-185℃，热定型时间为1-2min。
5.如权利要求1所述的彩绒板，其特征在于，所述S3和S4中的辊压压力均为2.5-3.5Mpa，辊压速度均为1.13m/min-1.26m/min，辊压时的辊间距均为5-15mm。
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