CN109304874A - 一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺 - Google Patents

一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺 Download PDF

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CN109304874A
CN109304874A CN201811088566.9A CN201811088566A CN109304874A CN 109304874 A CN109304874 A CN 109304874A CN 201811088566 A CN201811088566 A CN 201811088566A CN 109304874 A CN109304874 A CN 109304874A
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resin matrix
fiber
continuous fiber
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刘振
侯学杰
谢文蓓
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Luoyang Kebo Si New Mstar Technology Ltd
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Abstract

一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，工艺流程为：连续纤维排布→浇注树脂基体材料→添加短切纤维→增强材料与树脂基体材料均匀浸润→发泡固化成型→定长切割；本发明属于玻纤增强发泡树脂的复合材料板材，与传统胶木地板和竹木地板相比具有绿色环保、质量稳定、性能优异、适宜大批量连续化生产等优点，尤其是玻纤增强聚氨酯发泡板材，不仅具有胶木和竹木地板的特性而且具有比胶木和竹木地板更加优异的力学性能和耐候性；与金属材料地板相比，具有轻质高强、结构简单、生产效率高等优点，能够完美解决和金属地板系固货物困难和自重大而导致船舶载货能力下降的难题。

Description

一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺
技术领域
本发明涉及复合材料生产领域，尤其涉及一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺。
背景技术
集装箱地板是集装箱的重要组成部分和主要承载配件。传统的集装箱地板通常为28mm厚的19层胶合板或其他尺寸规格的胶合板，主要采用印尼、马来西亚等地产的大花龙脑香，如阿必通、克隆等热带硬阔叶树材制造。然而随着硬木资源的逐年锐减以及地板生产工艺的落后，集装箱地板产业的发展已经受到严重制约。随着现代运输业的发展，我国已成为集装箱地板第一生产大国，但生产集装箱地板的大部分原材料来源于进口，其中大部分为不合格的非法进口原木。国际集装箱出租人协会IICL与各国企业合作研究开发的替代材料主要有竹子、金属材料和塑料等。这些材料各自存在难以解决的问题，如：竹子资源有限，金属材料自重大，导致船舶载货能力下降，并且金属地板系固货物困难，塑料在技术上不过关；因此对集装箱地板可替材料以及结构优化的研究迫在眉睫。
鉴于上述原因，现研发出一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺。
发明内容
本发明的目的是为了克服现有技术中的不足，提供一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，绿色环保、质量稳定、性能优异、适宜大批量连续化生产等优点，可以解决目前集装箱胶木地板存在的原料短缺、质量下降以及可行性替代材料不足等制约集装箱地板行业发展的问题。
本发明为了实现上述目的，采用如下技术方案：一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，所述的一种纤维增强聚氨酯泡沫塑料板材，是由：树脂基体、连续纤维、短切纤维、纤维毡构成；至少两张相互平行的纤维毡之间设置树脂基体，树脂基体内均匀分布连续纤维和短切纤维，相邻两行的连续纤维交错设置，位于树脂基体下方的纤维毡的底端与位于树脂基体上方的纤维毡的顶端之间的距离为H1，H1为5～50mm；
一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，工艺流程为：连续纤维排布→浇注树脂基体材料→添加短切纤维→增强材料与树脂基体材料均匀浸润→发泡固化成型→定长切割；
第一步，连续纤维排布：将连续纤维按照指定的顺序均匀分布在两张纤维毡之间，排布后的连续纤维和纤维毡经牵引输送至层压输送机的型腔内；
第二步，浇注树脂基体：将树脂基体通过布胶机浇注到层压输送机的型腔内的连续纤维和纤维毡上，使树脂基体与连续纤维、纤维毡初步混合浸润，完成初步混合浸润树脂基体、连续纤维和纤维毡构成一级坯体；
第三步，添加短切纤维：将预裁好的短切纤维通过机械或人工的方式按照指定的比例添加到所述的一级坯体；
第四步，增强材料与树脂基体材料均匀浸润：通过人工或机械揉搓的方式将树脂基体、短切纤维与连续纤维、纤维毡充分、均匀的混合浸润，完成混合浸润后的树脂基体、短切纤维、连续纤维和纤维毡构成二级坯体；
第五步，发泡固化成形：二级坯体经输送带输送至层压输送机加热，进行发泡固化成形，加热温度为40～50°；
第六步，定长切割：发泡固化成形后的二级坯体经输送带输送至锯切位置，经锯切机裁成指定长度的板块。
所述的连续纤维和短切纤维采用玻璃纤维、或芳纶纤维、或玄武岩纤维、或碳纤维，其中的一种或一种以上的组合。
所述的树脂基体采用硬质聚氨酯泡沫、或交联聚氯乙烯泡沫、或聚醚酰亚胺泡沫、或聚丙烯腈泡沫、或聚酯泡沫，其中的一种；树脂基体中的协助剂采用发泡剂、阻燃剂、匀泡剂、抗氧化剂、紫外线吸收剂和催化剂中的任意一种或一种以上的组合。
本发明的有益效果是：本板材成形后的宽度为50mm—1500mm，厚度为5mm—50mm，密度为100Kg/m3—1500Kg/m3，长度和宽度根据需求而定，连续纤维和短切纤维所占质量比为0.3～0.7，树脂基体所占质量比为0.7—0.3。
质量比为1:1的连续纤维增强发泡树脂成型板材毛坯经过表面去皮加工，得到新型集装箱地板产品，测得其主要性能如下表所示：
质量比为1:1的连续纤维与短切纤维增强发泡树脂成型板材毛坯经过表面去皮加工，得到新型集装箱地板产品，测得其主要性能如下表所示
项目 测试结果
表观总密度/g/cm<sup>3</sup> 0.78
集中载荷/KN 73.4
抗弯载荷/KN 7.6
竖向压缩强度/MPa 70.5
剪切强度/MPa 11.8
质量比为1:1的连续纤维与纤维毡增强发泡树脂成型板材毛坯经过表面去皮加工等，得到新型集装箱地板产品。测得其主要性能如下表所示
项目 测试结果
表观总密度/g/cm<sup>3</sup> 0.78
集中载荷/KN 85.6
抗弯载荷/KN 8.7
竖向压缩强度/MPa 69
剪切强度/MPa 13.5
质量比为1:1的连续纤维与纤维毡以及短切纤维增强发泡树脂成型板材毛坯经过表面去皮加工，得到新型集装箱地板产品。测得其主要性能如下表所示
项目 测试结果
表观总密度/g/cm<sup>3</sup> 0.78
集中载荷/KN 90.7
抗弯载荷/KN 9.2
竖向压缩强度/MPa 75
剪切强度/MPa 16.8
本发明属于玻纤增强发泡树脂的复合材料板材，与传统胶木地板和竹木地板相比具有绿色环保、质量稳定、性能优异、适宜大批量连续化生产等优点，尤其是玻纤增强聚氨酯发泡板材，不仅具有胶木和竹木地板的特性而且具有比胶木和竹木地板更加优异的力学性能和耐候性；与金属材料地板相比，具有轻质高强、结构简单、生产效率高等优点，能够完美解决和金属地板系固货物困难和自重大而导致船舶载货能力下降的难题；本发明具有性能优异、生产连续稳定、易加工、绿色环保、轻质高强等特点，有效的解决集装箱地板产业发展的制约问题。连续化制造方法操作简单、高效稳定，可以成型不同尺寸规格的产品，完全满足集装箱地板的需求，并且成型板材具有性能优异、易加工、绿色环保、轻质高强、耐候性好、阻燃等特点，是集装箱地板的理想应用材料，可以解决目前集装箱胶木地板存在的原料短缺、质量下降以及可行性替代材料不足等制约集装箱地板行业发展的问题。
附图说明
下面结合附图对本发明作进一步说明：
图1是总装剖视结构示意图；
图2是连续化生产示意图；
图1、2中：树脂基体1、连续纤维2、短切纤维3、纤维毡4、布胶机5、层压输送机6、锯切机7。
具体实施方式
下面结合实施例与具体实施方式对本发明作进一步详细说明：
实施例1
至少两张相互平行的纤维毡4之间设置树脂基体1，树脂基体1内均匀分布连续纤维2和短切纤维3，相邻两行的连续纤维2交错设置，位于树脂基体1下方的纤维毡4的底端与位于树脂基体1上方的纤维毡4的顶端之间的距离为H1，H1为5～50mm；
一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，工艺流程为：连续纤维排布→浇注树脂基体材料→添加短切纤维→增强材料与树脂基体材料均匀浸润→发泡固化成型→定长切割；
第一步，连续纤维排布：将连续纤维2按照指定的顺序均匀分布在两张纤维毡4之间，排布后的连续纤维2和纤维毡4经牵引输送至层压输送机6的型腔内；
第二步，浇注树脂基体：将树脂基体1通过布胶机5浇注到层压输送机6的型腔内的连续纤维2和纤维毡4上，使树脂基体1与连续纤维2、纤维毡4初步混合浸润，完成初步混合浸润树脂基体1、连续纤维2和纤维毡4构成一级坯体；
第三步，添加短切纤维：将预裁好的短切纤维3通过机械或人工的方式按照指定的比例添加到所述的一级坯体；
第四步，增强材料与树脂基体材料均匀浸润：通过人工或机械揉搓的方式将树脂基体1、短切纤维3与连续纤维2、纤维毡4充分、均匀的混合浸润，完成混合浸润后的树脂基体1、短切纤维3、连续纤维2和纤维毡4构成二级坯体；
第五步，发泡固化成形：二级坯体经输送带输送至层压输送机6加热，进行发泡固化成形，加热温度为40～50°；
第六步，定长切割：发泡固化成形后的二级坯体经输送带输送至锯切位置，经锯切机7裁成指定长度的板块。
实施例2
所述的连续纤维2和短切纤维3采用玻璃纤维、或芳纶纤维、或玄武岩纤维、或碳纤维，其中的一种或一种以上的组合。
实施例3
所述的树脂基体1采用硬质聚氨酯泡沫、或交联聚氯乙烯泡沫、或聚醚酰亚胺泡沫、或聚丙烯腈泡沫、或聚酯泡沫，其中的一种；树脂基体1中的协助剂采用发泡剂、阻燃剂、匀泡剂、抗氧化剂、紫外线吸收剂和催化剂中的任意一种或一种以上的组合。

Claims (3)

1.一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，所述的一种纤维增强聚氨酯泡沫塑料板材，是由：树脂基体(1)、连续纤维(2)、短切纤维(3)、纤维毡(4)构成；其特征在于：至少两张相互平行的纤维毡(4)之间设置树脂基体(1)，树脂基体(1)内均匀分布连续纤维(2)和短切纤维(3)，相邻两行的连续纤维(2)交错设置，位于树脂基体(1)下方的纤维毡(4)的底端与位于树脂基体(1)上方的纤维毡(4)的顶端之间的距离为H1，H1为5～50mm；
一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，工艺流程为：连续纤维排布→浇注树脂基体材料→添加短切纤维→增强材料与树脂基体材料均匀浸润→发泡固化成型→定长切割；
第一步，连续纤维排布：将连续纤维(2)按照指定的顺序均匀分布在两张纤维毡(4)之间，排布后的连续纤维(2)和纤维毡(4)经牵引输送至层压输送机(6)的型腔内；
第二步，浇注树脂基体：将树脂基体(1)通过布胶机(5)浇注到层压输送机(6)的型腔内的连续纤维(2)和纤维毡(4)上，使树脂基体(1)与连续纤维(2)、纤维毡(4)初步混合浸润，完成初步混合浸润树脂基体(1)、连续纤维(2)和纤维毡(4)构成一级坯体；
第三步，添加短切纤维：将预裁好的短切纤维(3)通过机械或人工的方式按照指定的比例添加到所述的一级坯体；
第四步，增强材料与树脂基体材料均匀浸润：通过人工或机械揉搓的方式将树脂基体(1)、短切纤维(3)与连续纤维(2)、纤维毡(4)充分、均匀的混合浸润，完成混合浸润后的树脂基体(1)、短切纤维(3)、连续纤维(2)和纤维毡(4)构成二级坯体；
第五步，发泡固化成形：二级坯体经输送带输送至层压输送机(6)加热，进行发泡固化成形，加热温度为40～50°；
第六步，定长切割：发泡固化成形后的二级坯体经输送带输送至锯切位置，经锯切机(7)裁成指定长度的板块。
2.根据权利要求1所述的一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，其特征在于：所述的连续纤维(2)和短切纤维(3)采用玻璃纤维、或芳纶纤维、或玄武岩纤维、或碳纤维，其中的一种或一种以上的组合。
3.根据权利要求1所述的一种纤维增强聚氨酯泡沫塑料板材的连续生产工艺，其特征在于：所述的树脂基体(1)采用硬质聚氨酯泡沫、或交联聚氯乙烯泡沫、或聚醚酰亚胺泡沫、或聚丙烯腈泡沫、或聚酯泡沫，其中的一种；树脂基体(1)中的协助剂采用发泡剂、阻燃剂、匀泡剂、抗氧化剂、紫外线吸收剂和催化剂中的任意一种或一种以上的组合。
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