CN109618554A - 模制体及制造该模制体的方法 - Google Patents
模制体及制造该模制体的方法 Download PDFInfo
- Publication number
- CN109618554A CN109618554A CN201780049038.XA CN201780049038A CN109618554A CN 109618554 A CN109618554 A CN 109618554A CN 201780049038 A CN201780049038 A CN 201780049038A CN 109618554 A CN109618554 A CN 109618554A
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- Prior art keywords
- molding
- polyester
- core
- based fibers
- woven fabrics
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Classifications
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- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
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- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
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- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
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- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
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- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
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- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
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Abstract
本发明涉及模制体以及制造该模制体的方法。根据本发明的模制体适于用作家用和工业材料等,因为该模制体具有高密度和高的例如弯曲和拉伸强度等的材料性能值,并且,即使在长时间使用时由于吸湿引起的重量变化小,并且弯曲强度、拉伸强度等的变化小。
Description
技术领域
本发明涉及模制体以及制造该模制体(molded object)的方法。
背景技术
具有无纺布纤维结构的模制体已被广泛用于从家用材料到工业材料以及用于卫生或医疗目的,比如一次性尿布。
这种具有无纺布纤维结构的模制体利用诸如针刺或热空气热结合的方法制成,从而柔韧且重量轻。然而,硬度低,且难以在从家用材料到工业材料的多个领域中使用。
为对此进行改进,通过使用各种方法提供硬度,制造具有结构刚度接近金属同时相对较轻的无纺布纤维结构的模制体的技术已被广泛研究。
作为制造这种模制体的方法,使用了湿法(wet process),在该湿法中粘合剂被混合到纤维,然后高温蒸汽被喷射以进行粘附,或将所得物(result)浸渍在溶液中,等等。
然而,使用这种湿法制成的模制体密度低,且诸如抗弯强度或抗拉强度的性能差,因此当从外部施加强大重量时存在物件容易弯曲、撕裂等问题,并且足以在家用材料或工业材料中进行使用的性能难以保证。
此外,当在高温和高湿环境下长时间使用这种模制体时,渗入模制体的水分增加,因此,模制体的例如抗弯强度或抗拉强度的特性会降低,从而导致问题。
此外,存在这样的问题:大量的水分被吸收到模制体中,重量减轻的效果可能无法保证。
发明内容
技术问题
鉴于以上所述,本发明的发明人已在干法而非湿法中使用非吸湿性树脂作为粘合剂对具有高密度和诸如抗弯强度或抗拉强度的增强性能的模制体进行了研究,并因此完成了本发明。
因此,本发明的一方面提供了一种模制体,其具有高密度和诸如抗弯强度或抗拉强度的增强性能。
本发明的另一方面提供了一种模制体,该模制体即使在长时间使用时,由吸湿而引起的重量变化小,并且该模制体抗弯强度、抗拉强度等的变化小。
技术方案
根据本发明的一方面,提供了一种具有无纺布纤维结构的模制体,所述模制体包括聚酯基纤维和粘合剂,其中,所述粘合剂是非吸湿性共聚物树脂,所述聚酯基纤维的全部或一部分由所述粘合剂熔合(fused),所述模制体内包含天然孔隙,并且所述模制体具有0.5g/cm3至0.8g/cm3的表观密度、20Mpa或更大的抗弯强度以及50MPa至80MPa的抗拉强度。
这里,所述模制体可以具有1.0GPa至1.5GPa范围内的弯曲模量(flexuralmodulus),和1.0GPa至1.8GPa范围内的抗拉刚度(tension stiffness)。
这里,所述模制体可以具有10%至30%范围内的拉伸伸长率。
这里,所述模制体可以具有150N至200N范围内的抗剥强度(peel-off strength)。
这里,所述聚酯基纤维可以是选自由聚对苯二甲酸乙二醇酯(PET,polyethyleneterephthalate)、聚对苯二甲酸丙二醇酯(polytrimethylene terephthalate)、聚对苯二甲酸丁二醇酯(polybutylene terephthalate)和聚萘二甲酸乙二醇酯(polyethylenenaphthalate)组成的组中的任意一种或多种。
这里,在85℃的温度和85%的相对湿度下保持恒温/恒湿100小时后,所述非吸湿性共聚物树脂可以具有小于0.1%的重量变化率。
这里,所述粘合剂可以具有160℃或更高的熔点。
这里,所述模制体还可以包括鞘芯型双组分纤维(sheath-core typebicomponent fiber),所述鞘芯型双组分纤维包括:聚酯基纤维的芯部;以及鞘部,所述鞘部是包围所述芯部的非吸湿性共聚物树脂。
根据本发明的另一方面,提供了一种用于制造模制体的方法,所述方法包括:a)通过将(A)聚酯基纤维和(B)鞘芯型双组分纤维混合,然后对所得物进行加热和加压来制备无纺布,所述鞘芯型双组分纤维包括聚酯基纤维的芯部以及为包围所述芯部的非吸湿性共聚物树脂的鞘部;b)将所制备的无纺布安装到多个退绕装置上,然后移动到热压机;以及c)通过在170℃至210℃的温度条件和1MPa至10MPa的压力条件下对移动到所述热压机的多个所述无纺布进行加热和加压来制造模制体。
这里,所述方法还可以在b)和c)之间包括d)在160℃至210℃的温度条件下预热3分钟至10分钟。
这里,在a)中,可以将(A)所述聚酯基纤维和(B)所述鞘芯型双组分纤维以1:99至70:30的重量比进行混合,所述鞘芯型双组分纤维包括:聚酯基纤维的芯部;以及鞘部,所述鞘部是包围所述芯部的非吸湿性共聚物树脂。
这里,多个所述无纺布的数量可以为2至10。
这里,所述模制体可以被制成5mm至7mm的厚度。
这里,所述模制体可以用于:家用电器的结构部件;建筑物的内板和外板;汽车的内部材料和外部材料;火车、轮船和飞机的内部材料和外部材料;隔板;或电梯结构部件。
根据本发明的又一实施例,提供了一种夹层板,所述夹层板包括所述模制体。
有益效果
根据本发明的模制体,具有高密度和增强性能(例如抗弯强度或抗拉强度),即使在长时间使用时由吸湿而引起的重量变化也小,并且抗弯强度、抗拉强度等的变化小,并且因此适用于家用电器的结构部件(TV后盖、洗衣机的板等)、建筑物的内板和外板、汽车的内部材料和外部材料、火车/轮船/飞机的内部材料和外部材料、各种隔板、电梯结构部件等。
附图说明
图1是使用场发射扫描电子显微镜(FE-SEM)观察根据本发明的模制体的图像。
具体实施方式
下文将参照附图详细描述本发明的实施例,使得本领域技术人员可以容易实施本发明。然而,本发明可以各种不同的形式来体现,而不限于这里所描述的实施例。
模制体
本发明提供了一种具有无纺布纤维结构的模制体,所述模制体包括聚酯基纤维和粘合剂,其中,所述粘合剂是非吸湿性共聚物树脂,所述聚酯基纤维的整体或一部分由所述粘合剂熔合,所述模制体内包含天然孔隙,并且所述模制体具有0.5g/cm3至0.8g/cm3的表观密度、20MPa或更大的抗弯强度以及50MPa至80MPa的抗拉强度。
基于本发明的发明人的实验结果,使用吸湿性树脂作为粘合剂并采用湿法制造的模制体在家用电器的结构部件(TV后盖、洗衣机的板等)、建筑物的内板和外板、汽车的内部材料和外部材料、火车/轮船/飞机的内部材料和外部材料、各种隔板、电梯结构部件等中的使用存在问题,原因在于所制造的模制体具有降低了的性能(例如抗弯强度或抗拉强度),并且当在高温高湿环境下长时间使用时,模制体经历各种性能的严重变化。
然而,通过使用非吸湿性共聚物树脂作为粘合剂及使用干法来制造模制体,本发明的发明人制造了适合用作家用材料、工业材料等的模制体,制造的该模制体具有改进的性能(例如抗弯强度或抗拉强度),并且即使在高温高湿环境下长时间使用时各种性能也几乎没有变化。
根据本发明的模制体具有包括聚酯基纤维和粘合剂的无纺布纤维结构。本发明的模制体具有无纺布纤维结构(其中的纤维相互缠结(entangled)),因此,由于模制体内包含天然孔隙,所以透气性变得良好,并且可以增强轻量化。换言之,包含通过相互缠结的纤维形成的天然孔隙,并且与使用添加剂(例如发泡剂)人工形成孔隙的情况不同,制造成本可以降低,并且可以不包含发泡工序,提高了工艺效率。
包含在根据本发明的模制体中的聚酯基纤维的平均长度优选为5mm至100mm。当纤维的平均长度小于5mm时,由于纤维长度较短,可能难以期望高伸长率的效果。相反,当平均长度大于100mm时,相互缠结的纤维的含量增加,从而减小了模制体中的间隙所占据的空间。此外,当平均长度大于100mm时,在制造模制体时,纤维分散不平滑(smooth),这可能会降低模制体的性能。
包含在根据本发明的模制体中的粘合剂是非吸湿性共聚物树脂。
本发明中所使用的非吸湿性共聚物树脂指的是具有不吸收空气中水分的特性的树脂,具体地,基于本发明的使用该树脂制造的模制体,在85℃的温度和85%的相对湿度下无人看管(being left unattended)100小时后,模制体重量变化率(即水分量的增加率)小于0.1%(优选小于0.08%,更优选小于0.07%)的那些非吸湿性共聚物树脂可被使用。
就包含在模制体中的PET纤维的吸湿度一般小于0.05%而言,模制体重量变化率大于0.05%意为由粘合剂(模制体中的另一种组成)所吸收的水分的量相当大。在该方面,本发明所用的非吸湿性共聚物树脂是指基于最终制造的模制体,在85℃的温度和85%的相对湿度下无人看管100小时后,具有小于0.1%(优选小于0.08%,更优选小于0.07%)的模制体重量变化率(即水分量的增加率)的低吸收率。
那些通过使聚酯基纤维与具有高结晶度和优异弹性的二醇基单体(diol-basedmonomer)以及能够提供柔韧性的酸组分共聚而制备的并且满足吸收率的共聚物树脂,可以用作这种非吸湿性共聚物树脂。
具体地,选自由聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丙二醇酯、聚对苯二甲酸丁二醇酯和聚萘二甲酸乙二醇酯组成的组中的任意一种或多种可以用作聚酯基纤维;选自由新戊二醇(neopentyl glycol)、二甘醇(diethylene glycol)、乙二醇(ethyleneglycol)、聚(四亚甲基)乙二醇(poly(tetramethylene)glycol)、1,4-丁二醇(1,4-butanediol)、1,3-丙二醇(1,3-propanediol)、1,6-己二醇(1,6-hexanediol)、1,4-环己烷二甲醇(1,4-cyclohexanedimethanol)等组成的组中的任意一种或多种可以用作二醇基单体;选自由间苯二甲酸(isophthalic acid)、己二酸(adipic acid)、2,6-萘二甲酸(2,6-naphthalenedicarboxylic acid)、癸二酸(sebacic acid)、琥珀酸(succinic acid)等组成的组中的任意一种或多种可以用作酸组分。
包含在根据本发明的模制体中的聚酯基纤维的全部或一部分由粘合剂熔合,该粘合剂是非吸湿性树脂且可以具有160℃或更高的熔点。
根据本发明的模制体具有0.5g/cm3至0.8g/cm3的表观密度。通过满足该密度范围,可以获得足以用于大型货物的包装材料等的机械强度。
具体地,根据本发明的模制体具有良好的机械强度,具有20MPa或更大的抗弯强度以及50MPa至80MPa的抗拉强度。模制体的抗弯强度基于ASTM D790而测得,模制体的抗拉强度基于ASTM D638而测得。
此外,根据本发明的模制体具有良好的机械刚性(mechanical rigidity),具有1.0GPa到1.5GPa范围内的弯曲模量和1.0GPa到1.8GPa范围内的抗拉刚度。模制体的弯曲模量基于ASTM D790而测得,模制体的抗拉刚度基于ASTM D638而测得。
根据本发明的模制体具有10%至30%范围内的拉伸伸长率和150N至200N范围内的抗剥强度,从而具有即使在施加外力时不易撕裂的优点。模制体的拉伸伸长率基于ASTMD638而测得,模制体的抗剥强度基于KSF 4737而测得。
根据本发明的模制体满足这种机械强度,因此可以用作:家用电器的结构部件(TV后盖、洗衣机的板等)、建筑物的内板和外板、汽车的内部材料和外部材料、火车/轮船/飞机的内部材料和外部材料(板,例如隔墙)、各种隔板、电梯结构部件等。
根据本发明的模制体还可以包括鞘芯型双组分纤维。鞘芯型双组分纤维包括:聚酯基纤维的芯部;以及鞘部,鞘部是包围芯部的非吸湿性共聚物树脂。鞘芯型双组分纤维可以,通过在制造根据本发明的模制体的步骤中引入的纤维中保持未熔化的鞘部的树脂,包含在根据本发明的模制体中。
选自由聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丙二醇酯、聚对苯二甲酸丁二醇酯和聚萘二甲酸乙二醇酯组成的组中的任意一种或多种可以用作鞘芯型双组分纤维中的聚酯基纤维的芯部。
与包含在根据本发明的模制体中的粘合剂相同的非吸湿性共聚物树脂可以用作鞘芯型双组分纤维中的鞘部。
具体地,非吸湿性共聚物树脂指的是具有不吸收空气中水分的特性的树脂,具体地,基于本发明的使用该树脂制造的模制体,在85℃的温度和85%的相对湿度下无人看管100小时后,模制体重量变化率(即水分量的增加率)小于0.1%(优选小于0.08%,更优选小于0.07%)的那些非吸湿性共聚物树脂可被使用。
就包含在模制体中的PET纤维的吸湿度一般小于0.05%而言,模制体重量变化率大于0.05%意为由粘合剂(模制体中的另一种组成)所吸收的水分量相当大。在该方面,本发明所用的非吸湿性共聚物树脂是指基于最终制造的模制体,在85℃的温度和85%的相对湿度下无人看管100小时后,具有小于0.1%(优选小于0.08%,更优选小于0.07%)的模制体重量变化率(即水分量的增加率)的低吸收率。
那些通过使聚酯基纤维与具有高结晶度和良好弹性的二醇基单体以及能够提供柔韧性的酸组分共聚而制备的并且满足吸收率的共聚物树脂,可以用作这种非吸湿性共聚物树脂。
具体地,选自由聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丙二醇酯、聚对苯二甲酸丁二醇酯和聚萘二甲酸乙二醇酯组成的组中的任意一种或多种可以用作聚酯基纤维;选自由新戊二醇、二甘醇、乙二醇、聚(四亚甲基)乙二醇、1,4-丁二醇、1,3-丙二醇、1,6-己二醇、1,4-环己烷二甲醇等组成的组中的任意一种或多种可以用作二醇基单体;选自由间苯二甲酸、己二酸、2,6-萘二甲酸、癸二酸、琥珀酸等组成的组中的任意一种或多种可以用作酸组分。
鞘芯型双组分纤维利用芯部组分和鞘部组分通过熔融纺丝和拉伸而制得。
此外,当使用非吸湿性树脂作为鞘芯型双组分纤维的鞘部组分时,抗弯强度和抗拉强度增强,并且模制体可以使用干法制成,因此易于制造高密度的模制体。此外,当用于大型货物的包装材料等时,即使在高温高湿氛围中性能和形状保持性能也是有利的,因此,可以防止无纺布的下垂(sagging)。
除此之外,根据本发明的模制体还可以包括诸如玻璃纤维、碳纤维或聚合物纤维的填充物。此外,还可以包括诸如溴基有机阻燃剂的阻燃剂。除此之外,还可以包括诸如抗冲击改性剂或热稳定剂的添加剂。
制造模制体的方法
根据本发明的制造模制体的方法可以实施如下。
根据本发明的制造模制体的方法可以包括:
a)通过将(A)聚酯基纤维和(B)鞘芯型双组分纤维混合,然后对所得物进行加热和加压来制备无纺布,该鞘芯型双组分纤维包括聚酯基纤维的芯部以及为包围该芯部的非吸湿性共聚物树脂的鞘部;b)将所制备的无纺布安装到多个退绕装置上,然后移动到热压机;以及c)通过在170℃至210℃的温度条件和1MPa至10MPa的压力条件下对移动到热压机的多个无纺布进行加热和加压来制造模制体。
首先,在a)中,通过将(A)聚酯基纤维和(B)鞘芯型双组分纤维混合,然后对所得物进行加热和加压来制备无纺布,该鞘芯型双组分纤维包括:聚酯基纤维的芯部;以及鞘部,鞘部是包围芯部的非吸湿性共聚物树脂。
在a)中,将(A)聚酯基纤维和(B)鞘芯型双组分纤维可以以1:99至80:20的重量比进行混合并使用。当(B)鞘芯型双组分纤维的含量小于上述范围时,纤维之间的熔合不充分,从而降低无纺布的性能。
在a)中,制备无纺布的一般方法可用作通过加热和加压制备无纺布的方法,并且作为一个示例,可通过使用罗拉梳理机(roller carding machine)梳理混合纤维,然后使用热压机在160℃到210℃的温度下将所得物热结合(thermal bond)5秒至30秒来制备无纺布。
接下来,在b)中,将所制备的无纺布安装到多个退绕装置上,然后移动到热压机。
在将b)中制备的2至10个无纺布安装到与无纺布数量相匹配的多个退绕装置上后,可以将无纺布移动到用于制造模制体的热压机。当使用利用了上述多个退绕装置的多个无纺布时,无纺布的每一个的厚度变小,并且缠绕在一个退绕装置上的无纺布的长度变长。因此,用于连接在连续过程中连续地引入的无纺布的连接机(joining machine)的使用次数可以减少,从而带来简化工艺的优点。
然后,在c)中,在170℃至210℃的温度条件和1MPa至10MPa的压力条件下,对移动到热压机的多匹无纺布进行加热和加压,以制造模制体。
在c)中使用的热压机不受特别限制,只要其在本领域中普遍使用即可,并且作为一个具体示例,可以使用双带式压力机等。
在c)中制造的模制体可以被制造成0.1mm至10mm的厚度。厚度小于0.1mm具有难以维持良好机械强度的问题,而厚度大于10mm具有当弯曲模制体时或当深拉成型时可塑性(moldability)下降的问题。所制造的模制体的性能与本发明上述的模制体的性能相同。
此外,根据本发明的制造模制体的方法还可以包括:
在b)和c)之间的d),即在160℃至210℃的温度条件下预热3分钟至10分钟。
当还包括上述的预热时,将热能预先施加到无纺布中鞘芯型双组分纤维的鞘部的非吸湿性共聚物树脂,因此,具有可以缩短c)中加热和加压工序的时间的优点。
夹层板
本发明提供了一种包括所述模制体的夹层板。
当参照图2时,根据本发明的夹层板包括:形成有根据本发明的模制体的芯层(10);层压在芯层的一个或多个表面上的表层(20);以及将芯层与表层粘合的粘合层。
根据本发明的夹层板的芯层(10)形成有上述根据本发明的模制体。芯层的厚度优选0.1mm至10mm。厚度小于0.1mm具有难以维持良好机械强度的问题,而厚度大于10mm具有当弯曲夹层板时或当深拉成型时可塑性下降的问题。
根据本发明的夹层板的表层(20)可以形成有金属材料,并且可以优选包含选自由铝、铁、不锈钢(SUS)、镁和电镀锌铁(EGI)组成的组中的任意一种或多种。作为一个示例,为了具有良好的可塑性和弯曲模量,包含电镀锌铁(EGI)的表层(20)可以用于夹层板。此外,为了轻量化,包含铝的表层(20)可以用于夹层板。
表层(20)的厚度可以为从0.1mm至0.5mm。当厚度小于0.1mm时,表层的结构刚度难以维持,而厚度大于0.5mm具有降低夹层板的轻量化效果并增加原料成本的问题。
根据本发明的夹层板的粘合层涂覆在芯层(10)和表层(20)之间以将芯层(10)和表层(20)粘合。考虑到粘性,粘合层优选涂覆成均匀的厚度。在本发明中,夹层板可以通过层压芯层(10)和表层(20),然后将层压所得物固化来制造。这里,在固化工序期间,粘合剂生长到芯层(10)中,从而与形成芯层(10)的组分产生机械结合以及化学键合,其导致了增强表层(20)和芯层(10)之间的粘合强度的效果。化学键合是指粘合剂与芯层的上表面和下表面形成共价键、氢键、范德华键(Van der Waals bond)、离子键等。
机械结合是指粘合剂在渗入芯层的同时像相互钩连(hooked)的环一样在物理上钩连。这种形式也被称为机械联锁。通过包含在芯层中的天然孔隙,粘合剂渗入芯层的上表面和下表面。
形成粘合层的粘合剂可以包括烯烃基(olefin-based)粘合剂、聚氨酯基(urethane-based)粘合剂、丙烯酸基(acryl-based)粘合剂及环氧基(epoxy-based)粘合剂中的一种或多种类型。选自由聚乙烯、聚丙烯和无定形聚α烯烃(amorphouspolyalphaolefin)粘合剂组成的组中的一种或多种类型可以用作烯烃基粘合剂。聚氨酯基粘合剂的使用可以无限制,只要其是包含聚氨酯结构(-NH-CO-O-)的粘合剂即可。丙烯酸树粘合剂可以包括聚甲基丙烯酸甲酯(polymethyl methacrylate)粘合剂、含羟基聚丙烯酸酯(hydroxyl group-containing polyacrylate)粘合剂和含羧基聚丙烯酸酯(carboxylgroup-containing polyacrylate)粘合剂中的一种或多种类型。环氧基粘合剂可以包括双酚A型环氧(bisphenol-A-type epoxy)粘合剂、双酚F型环氧(bisphenol-F-type epoxy)粘合剂、酚醛环氧(novolac epoxy)粘合剂、线性脂肪族环氧(linear aliphatic epoxy)粘合剂(线性脂肪族环氧树脂)和脂环族环氧(cycloaliphatic epoxy)粘合剂(脂环族环氧树脂)中的一种或多种类型。
此外,粘合剂可以包括光固化粘合剂、热熔型粘合剂或热固化粘合剂,并且可以使用光固化方法和热固化方法中的任一种。例如,夹层板可以通过将包含表层、芯层和粘合剂的叠层(laminate)进行热固化来制造。热固化可以在50℃至110℃(环氧树脂的固化温度)下进行约5小时至2小时,并且该固化也可以在室温下进行1小时至10小时。
粘合层可以涂覆成约20μm至300μm的厚度,然而厚度不限于此。
将粘合层涂覆至表层的一个表面上的方法可以使用从模涂(die coating)法、凹版涂布(gravure coating)法、刮刀涂布(knife coating)法或喷涂法中选择的任一种方法。
根据本发明的夹层板通过例如连续地将表层、芯层和表层层压而形成。固化和压制可在层压后进行,但其形成并不限于此。
如上所述,通过使用表现出良好机械性能的模制体,根据本发明的夹层板具有良好的可塑性和机械强度。此外,夹层板具有高密度和增强性能(例如抗弯强度或抗拉强度),即使在长时间使用时由吸湿而引起的重量变化小,并且抗弯强度、抗拉强度等的变化小,因此适合用作:家用电器的结构部件(TV后盖、洗衣机的板等)、建筑物的内板和外板、汽车的内部材料和外部材料、火车/轮船/飞机的内部材料和外部材料(板,例如隔墙)、各种隔板、电梯结构部件等。
下文将提供优选示例以说明本发明,然而,以下示例仅用于说明性的目的,并且对于本领域技术人员而言,显而易见可在本发明的类别和技术理念内进行各种变化和修改,且这些变化和修改同样属于所附权利要求。
示例:示例1至示例3以及比较例1至比较例4
(1)模制体的制造
[示例1]
在制备聚对苯二甲酸乙二醇酯(PET)纤维(Toray Chemical Inc.,RPF,细度为4旦尼尔,纤维长度为51mm)和鞘芯型PET纤维(在鞘芯型PET纤维中,鞘部是非吸湿性树脂(Toray Chemical Inc.,EZBON-L,细度为4旦尼尔,鞘部熔点为164℃,纤维长度为64mm))之后,将聚对苯二甲酸乙二醇酯(PET)纤维和鞘芯型PET纤维以30:70的重量比进行混合。
混合纤维使用罗拉梳理机进行梳理,并使用热压机在190℃的温度下热结合10秒以制备无纺布。
将无纺布安装到6个退绕装置上后,将6个无纺布引入内室温度为180℃的预热室,然后预热3分钟。
之后,将无纺布以5米/分钟的速度转移到双带式压力机上。这里,双带式压力机的加热温度为180℃且压力为5MPa,并且进行加热/加压处理2分钟以制造厚度为5.5mm的模制体。
[示例2]
以与示例1中相同的方式制造模制体,不同之处在于以50:50的重量比混合聚对苯二甲酸乙二醇酯(PET)纤维和鞘芯型PET纤维(其中鞘部为非吸湿性树脂)。
[示例3]
以与示例1中相同的方式制造模制体,不同之处在于使用鞘芯型PET纤维,在鞘芯型PET纤维中,鞘部为非吸湿性树脂(Toray Chemical Inc.,EZBON-L,细度为4旦尼尔,鞘部熔点为110℃,纤维长度为64mm)。
[比较例1]
聚对苯二甲酸乙二醇酯(PET)纤维(Toray Chemical Inc.,RPF,细度为4旦尼尔,纤维长度为51mm)使用罗拉梳理机进行梳理,并使用热压机在190℃的温度下热结合10秒以制备无纺布。
在制备7个无纺布后,在每个无纺布之间放置作为吸湿性共聚物的聚酯基热熔粘合膜(Chemitec Korea,Co.Ltd.,PE),并将无纺布以5米/分钟的速度转移到双带式压力机。这里,双带式压力机的加热温度为110℃,且压力为5MPa,并且进行加热/加压处理2分钟以制造厚度为5.5mm的模制体。
[比较例2]
在将玻璃纤维与聚对苯二甲酸乙二醇酯(PET)纤维(Toray Chemical Inc.,RPF,细度为4旦尼尔,纤维长度为51mm)以1:1的重量比混合后,所得物使用罗拉梳理机进行梳理以制备梳棉网,然后将这些网中的6个重叠后,将所得物转移到配备有蒸汽喷嘴的输送带。之后,在梳棉网的厚度方向上从蒸汽喷嘴喷出高温蒸汽,并且所得物穿过网厚度调节辊,以制造厚度为5.5mm的模制物体。
[比较例3]
以与示例1中相同的方式制造模制体,不同之处在于双带式压力机的加热温度采用160℃。
[比较例4]
以与示例1中相同的方式制造模制体,不同之处在于双带式压力机的压力采用0.5MPa。
实验例:模制体性能的测量
在将示例1至示例3和比较例1至比较例4中制造的模制体的每一个制备成样品后,使用以下方法进行测量,测量结果显示在下方表1中。
(1)密度(g/cm3)和孔隙度(%):
通过切割至15mm×15mm×1mm的尺寸来制备样品后,使用电子重力仪(VIBRA,DME-220E)测量3次密度,并测量平均值。随后,利用各样品的密度,用下面的通用公式推导出孔隙度。
[通用公式]
孔隙度(%)={1-(样品密度/原料密度)}x100
(2)抗弯强度(MPa)和弯曲模量(GPa):基于ASTM D790进行3次测量,并测量平均值。
(3)抗拉强度(MPa)、抗拉刚度(GPa)和拉伸伸长率(%):基于ASTM D638测量3次,并测量平均值。
(4)抗剥强度(N):基于KSF 4737测量3次,并测量平均值。
*在80℃下无人看管10分钟后进行测量。
【表1】
如表1所示,可见,示例1至示例3中制造的模制体在具有高密度的同时,具有良好的抗弯强度、弯曲模量、抗拉强度、抗拉刚度、拉伸伸长率和抗剥强度。
同时,可见,比较例1至比较例4与示例相比具有较差的机械性能,尤其是,使用了吸湿性共聚物的比较例1由于异质材料结合而容易剥离,而使用了湿法制造的比较例2具有含水区域的结合力下降以及由含水引起的模制体密度增加的问题。在低加热温度下制造的比较例3具有因粘合剂的熔合程度降低而引起的易剥离的问题,而在低压下制造的比较例4压力低,并且没有适当地获得加压,因此,存在因纤维之间的结合由于密度较低而变弱而引起的易剥离的问题。
Claims (15)
1.一种具有无纺布纤维结构的模制体,所述模制体包括:
聚酯基纤维;以及
粘合剂,
其中,所述粘合剂是非吸湿性共聚物树脂,
所述聚酯基纤维的全部或一部分由所述粘合剂熔合,
所述模制体内包含天然孔隙,并且
所述模制体具有0.5g/cm3至0.8g/cm3的表观密度、20MPa或更大的抗弯强度以及50MPa至80MPa的抗拉强度。
2.根据权利要求1所述的模制体,具有1.0GPa至1.5GPa范围内的弯曲模量、1.0GPa至1.8GPa范围内的抗拉刚度、10%至30%范围内的拉伸伸长率以及150N至200N范围内的抗剥强度。
3.根据权利要求1所述的模制体,其中,所述聚酯基纤维是选自由聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯、聚对苯二甲酸丁二醇酯和聚萘二甲酸乙二醇酯组成的组中的任意一种或多种。
4.根据权利要求1所述的模制体,其中,在85℃的温度和85%的相对湿度下保持恒温/恒湿100小时后,所述非吸湿性共聚物树脂具有小于0.1%的重量变化率。
5.根据权利要求1所述的模制体,其中,所述粘合剂具有160℃或更高的熔点。
6.根据权利要求1所述的模制体,还包括鞘芯型双组分纤维,所述鞘芯型双组分纤维包括:聚酯基纤维的芯部;以及鞘部,所述鞘部是包围所述芯部的非吸湿性共聚物树脂。
7.根据权利要求6所述的模制体,其中,所述聚酯基纤维是选自由聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二醇酯、聚对苯二甲酸丁二醇酯和聚萘二甲酸乙二醇酯组成的组中的任意一种或多种。
8.根据权利要求6所述的模制体,其中,在85℃的温度和85%的相对湿度下保持恒温/恒湿100小时后,为非吸湿性共聚物树脂的所述鞘部具有小于0.1%的重量变化率。
9.一种用于制造模制体的方法,包括:
a)通过将(A)聚酯基纤维和(B)鞘芯型双组分纤维混合,然后对所得物进行加热和加压来制备无纺布,所述鞘芯型双组分纤维包括聚酯基纤维的芯部以及为包围所述芯部的非吸湿性共聚物树脂的鞘部;
b)将制备的所述无纺布安装到多个退绕装置上,然后移动到热压机;以及
c)通过在170℃至210℃的温度条件和1MPa至10MPa的压力条件下对移动到所述热压机的多个所述无纺布进行加热和加压来制造模制体。
10.根据权利要求9所述的用于制造模制体的方法,在b)和c)之间还包括:d)在160℃至210℃的温度条件下预热3分钟至10分钟。
11.根据权利要求9所述的用于制造模制体的方法,其中,在a)中,将(A)所述聚酯基纤维和(B)所述鞘芯型双组分纤维以1:99至70:30的重量比进行混合,所述鞘芯型双组分纤维包括聚酯基纤维的芯部以及为包围所述芯部的非吸湿性共聚物树脂的鞘部。
12.根据权利要求9所述的用于制造模制体的方法,其中,多个所述无纺布的数量为2至10。
13.根据权利要求9所述的用于制造模制体的方法,所述模制体被制成5mm至7mm的厚度。
14.根据权利要求1所述的模制体,其用于:家用电器的结构部件;建筑物的内板和外板;汽车的内部材料和外部材料;火车、轮船和飞机的内部材料和外部材料;隔板;或电梯结构部件。
15.一种夹层板,所述夹层板包括权利要求1所述的模制体。
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