CN110077036A - 一种用于建筑保温的非织造复合材料及其制备方法 - Google Patents
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Abstract
本发明涉及非织造复合材料领域,特别是指一种用于建筑保温的非织造复合材料及其制备方法。所述非织造复合材料包括四层,自上而下依次是中空橘瓣水刺无纺布、熔喷非织造材料、热风非织造布和纺粘布。本发明选择轻质、柔软的材料,利用热熔胶,通过热熔机加热后熔融且经过一定压力的光辊,使得四层不同的材料复合在一起,既不破坏它们原有的特性,又得到了轻质柔软的保温材料。
Description
技术领域
本发明涉及非织造复合材料领域,特别是指一种用于建筑保温的非织造复合材料及其制备方法。
背景技术
随着经济的发展,一栋栋大楼在各个城市拔地而起,用于建筑方面的材料也越来越多,其中研究较多的算是建筑墙体保温了。目前常用的建筑墙体外保温材料有XPS挤塑板、聚苯板、聚氨酯等。但是这些材料阻燃性能不好,存在巨大的安全隐患,而且易产生有毒气体。岩棉板阻燃性好,防火,但保温效果差。市场上用的最多的特卫强防水透气膜与保温层共同使用,有效解决了一系列问题,但其要与保温层配合,增加了原材料的耗费,且施工要求较高,施工麻烦,价格昂贵。
针对市面上的建筑保温材料保温效果不好的问题,本发明采用了中空橘瓣型超细短纤维水刺无纺布,其曲折的孔径分布和超细纤维使得材料高度蓬松,密度小,因此具有良好的保温性。本发明还采用了热风非织造布,其高蓬松性和高孔隙率可以储存大量的静止空气,更进一步地提高了复合材料的保温性。
在潮湿的环境下,由于水汽的作用,会使墙体受潮,造成墙体结构脱落,更严重的是,室内也受到潮气侵袭,使墙体表面结构脱落,不仅影响美观,还在空气中残留一股霉味。针对这一现象,本发明复合了一层PP/PEG熔喷非织造布,通过改变PEG的混合比例,得到了具有三级水平分支结构的熔喷非织造材料。此非织造材料既能够阻挡液体渗透,又不妨碍水汽通过,使墙体结构表面的湿气快速扩散出去,保持墙体和室内相对干燥的环境,有效防潮。
复合后的四层非织造材料又经过拒水处理,能有效防止空气中的水分渗透到墙体,从而进一步保证了室内的干爽条件。
发明内容
本发明提出一种用于建筑保温的非织造复合材料及其制备方法,解决了现有市面上常用保温材料的缺点,如阻燃性能不好,存在安全隐患,易产生有毒气体等,其特有的结构大大提高了墙体的保温性,所用原料简单,价格低廉,且施工方便,具有较好的市场效益。
本发明的技术方案是这样实现的:
一种用于建筑保温的非织造复合材料,所述非织造复合材料包括四层,自上而下依次是中空橘瓣水刺无纺布、熔喷非织造材料、热风非织造布和纺粘布。
所述中空橘瓣水刺无纺布为经过热轧处理的具有双组份PET/PA6的中空橘瓣超细纤维无纺布。
所述熔喷非织造材料的面密度为1-5g/m2,所用的原料为PP和PEG,其中PP的熔点156℃,在230℃下的熔融指数为1500g/10min,密度0.91g/cm3,PEG的羟值26-32mgKOH/g,PEG占熔喷非织造材料的质量分数为10-20%,分子量3600-4400,凝固点54℃;所述熔喷非织造材料的纤维直径分布为800nm以下、800-2000nm和2000nm以上,三种分布的纤维数量以100份计,其中800nm以下的纤维数量为2000nm以上纤维数量的1.8-4.2倍,余量为直径为800-2000nm的纤维。
所述热风非织造布的原料为51mm长的PE/PP皮芯型纤维或ES纤维,纤维细度为1.5旦尼尔,热风非织造材料的面密度为11-26g/m2,孔隙率为92-99%。
所述的用于建筑保温的非织造复合材料的制备方法,步骤如下:
(1)原料准备:中空橘瓣水刺无纺布、热风非织造布和纺粘布、PP切片、PEG切片;
(2)将中空橘瓣水刺无纺布进行热轧处理,增加其硬度;
(3)熔喷非织造材料的制备:将经步骤(2)处理的中空橘瓣水刺无纺布铺放在熔喷纺丝模头下面,然后以PEG切片和PP切片为原料,利用熔喷成型工艺将PEG/PP熔喷超细纤维直接喷射在中空橘瓣超细纤维无纺布表层,形成初级非织造复合材料;
(4)四层复合:在步骤(3)得到的初级非织造复合材料的PEG/PP熔喷面上依次放置热风无纺布和粘纺布,并在每两层中间喷洒热熔粉末,再经过一定温度和压力的热熔机,使四层不同的材料复合在一起,得到用于建筑保温的非织造复合材料。
所述步骤(3)熔喷成型工艺中螺杆挤出机的参数设置为:一区温度170℃、二区温度190℃、三区温度210℃、四区温度220℃,设置机头温度220-240℃,热风温度230-240℃,气流压力0.04Mpa,计量泵转速10Hz,输网帘速度50Hz。
所述步骤(3)中熔喷纺丝模头的喷丝孔径0.35mm,接收距离10cm。
所述步骤(4)中热熔机的加热温度为130℃,光辊的压力为0.4Mpa。
本发明的工艺参数设定:
表1熔喷工艺参数设定
表2四层复合热熔机工艺参数设定
本发明的有益效果在于:
(1)针对市面上的建筑保温材料保温效果不好的问题,本发明采用了中空橘瓣型超细短纤维水刺无纺布,其曲折的孔径分布和超细纤维使得材料高度蓬松,密度小,给本发明的良好的保温性奠定了基础。本发明还采用了热风非织造布,其高蓬松性和高孔隙率可以储存大量的静止空气,更进一步地提高了复合材料的保温性。
(2)在潮湿的环境下,由于水汽的作用,会使墙体受潮,造成墙体结构脱落,更严重的是,室内也受到潮气侵袭,使墙体表面结构脱落,不仅影响美观,还在空气中残留一股霉味。针对这一现象,本发明复合了一层PP/PEG熔喷非织造布,通过改变PEG的混合比例,得到了具有三级水平分支结构的熔喷非织造材料。此非织造材料能够阻挡液体渗透,但不妨碍水汽通过,使墙体结构表面的湿气快速扩散出去,保持墙体和室内相对干燥的环境,有效防潮。
(3)复合后的四层非织造材料又经过拒水处理,能有效防止空气中的水分渗透到墙体,进一步保证了室内的干爽条件。
(4)本发明选择轻质、柔软的材料,利用热熔胶,通过热熔机加热后融化且经过一定压力的光辊,使得四层不同的材料复合在一起,既不破坏它们原有的特性,又得到了轻质柔软的保温材料。
(5)目前常用的建筑保温板比较厚重,施工要求高且困难,而特卫强需要配合保温层使用,施工繁琐且价格昂贵。本发明设计的四层轻质建筑保温材料质地轻,价格低廉,并且施工简单,单独使用就可以达到建筑用保温材料的要求,以较小的耗费取得巨大的效益。
(6)本发明与性能测试:
表3基本参数
表4保温性能测试数据
从表4可以看出正反面位置的不同,对保温性能的影响非常大,同一块布纺粘面在下克罗值是放纺粘面在上克罗值的1.77倍。究其原因超纤层能阻止热量的散失。因此纺粘布靠近墙体,中空橘瓣水刺无纺布靠近空气层,从表1可以看出本发明的断裂强度非常好,符合建筑用的高强度。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1为本发明非织造材料的结构示意图。
图2为本发明的实物图。
具体实施方式
下面将结合本发明实施例,对本发明的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有付出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
本实施例的一种用于建筑保温非织造材料的制备方法,步骤如下:
(1)将具有双组份PET/PA6中空橘瓣超细纤维无纺布进行热轧处理,增加其硬挺度;
(2)以PEG切片和PP切片为原料,按照60:240的质量比添加投料,然后按照熔喷非织造布的生产工艺加工,将机头温度控制在220℃;热风温度控制在240℃;输网帘速度为50HZ;接收距离为10CM;参数设置好后,将熔体细流在经过高速热空气牵伸后直接喷在中空橘瓣超细纤维无纺布表层,形成一种非织造复合材料,其中熔喷层的面密度为4 g/m2;
(3)热风无纺布的准备:原料为51mm长的PE/PP皮芯型纤维,纤维细度为1.5旦尼尔,面密度为26g/m2,孔隙率为92%;
(4)四层复合:在每两层中间喷洒热熔粉末,再经过一定温度和压力的热熔机,使得四层不同的材料复合在一起,既不破坏它们原有的特性,又得到了轻质柔软的保温材料,其中热熔机温度130℃;光辊的压力为0.4Mpa;
(5)制备成克重为244g/m2,厚度为0.9mm的多层非织造复合材料。
实施例2
本实施例的一种用于建筑保温非织造材料的制备方法,步骤如下:
(1)将具有双组份PET/PA6中空橘瓣超细纤维无纺布进行热轧处理,增加其硬挺度;
(2)以PEG切片和PP切片为原料,按照30:270的质量比添加投料,然后按照熔喷非织造布的生产工艺加工,将机头温度控制在235℃;热风温度控制在220℃;输网帘速度为50HZ;接收距离为10CM;参数设置好后,将熔体细流在经过高速热空气牵伸后直接喷在中空橘瓣超细纤维无纺布表层,形成一种非织造复合材料,其中熔喷层的面密度为4 g/m2;
(3)热风无纺布的准备:原料为51mm长的PE/PP皮芯型纤维,纤维细度为1.5旦尼尔,面密度为11g/m2,孔隙率为99%;
(4)四层复合:在每两层中间喷洒热熔粉末,再经过一定温度和压力的热熔机,使得四层不同的材料复合在一起,既不破坏它们原有的特性,又得到了轻质柔软的保温材料,其中热熔机温度130℃;光辊的压力为0.4Mpa;
(5)制备成克重为235g/m2,厚度为0.8mm的多层非织造复合材料。
实施例3
本实施例的一种用于建筑保温非织造材料的制备方法,步骤如下:
(1)将具有双组份PET/PA6中空橘瓣超细纤维无纺布进行热轧处理,增加其硬挺度;
(2)以PEG切片和PP切片为原料,按照45:275的质量比添加投料,然后按照熔喷非织造布的生产工艺加工,将机头温度控制在220℃;热风温度控制在235℃;输网帘速度为50HZ;接收距离为10CM;参数设置好后,将熔体细流在经过高速热空气牵伸后直接喷在中空橘瓣超细纤维无纺布表层,形成一种非织造复合材料,其中熔喷层的面密度为4 g/m2;
(3)热风无纺布的准备:原料为51mm长的PE/PP皮芯型纤维,纤维细度为1.5旦尼尔,面密度为11g/m2,孔隙率为99%;
(4)四层复合:在每两层中间喷洒热熔粉末,再经过一定温度和压力的热熔机,使得四层不同的材料复合在一起,既不破坏它们原有的特性,又得到了轻质柔软的保温材料,其中热熔机温度130℃;光辊的压力为0.4Mpa;
(5)制备成克重为235g/m2,厚度为0.8mm的多层非织造复合材料。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种用于建筑保温的非织造复合材料,其特征在于:所述非织造复合材料包括四层,自上而下依次是中空橘瓣水刺无纺布、熔喷非织造材料、热风非织造布和纺粘布。
2.根据权利要求1所述的用于建筑保温的非织造复合材料,其特征在于:所述中空橘瓣水刺无纺布为经过热轧处理的具有双组份PET/PA6的中空橘瓣超细纤维无纺布。
3.根据权利要求1所述的用于建筑保温的非织造复合材料,其特征在于:所述熔喷非织造材料的面密度为1-5g/m2,所用的原料为PP和PEG,其中PP的熔点156℃,在230℃下的熔融指数为1500g/10min,密度0.91g/cm3,PEG的羟值26-32mgKOH/g,PEG占熔喷非织造材料的质量分数为10-20%,分子量3600-4400,凝固点54℃;所述熔喷非织造材料的纤维直径分布为800nm以下、800-2000nm和2000nm以上,三种分布的纤维数量以100份计,其中800nm以下的纤维数量为2000nm以上纤维数量的1.8-4.2倍,余量为直径为800-2000nm的纤维。
4.根据权利要求1所述的用于建筑保温的非织造复合材料,其特征在于:所述热风非织造布的原料为51mm长的PE/PP皮芯型纤维,纤维细度为1.5旦尼尔,热风非织造材料的面密度为11-26g/m2,孔隙率为92-99%。
5.权利要求1-4任一项所述的用于建筑保温的非织造复合材料的制备方法,其特征在于,步骤如下:
(1)原料准备:中空橘瓣水刺无纺布、热风非织造布和纺粘布、PP切片、PEG切片;
(2)将中空橘瓣水刺无纺布进行热轧处理,增加其硬度;
(3)熔喷非织造材料的制备:将经步骤(2)处理的中空橘瓣水刺无纺布铺放在熔喷纺丝模头下面,然后以PEG切片和PP切片为原料,利用熔喷成型工艺将PEG/PP熔喷超细纤维直接喷射在中空橘瓣超细纤维无纺布表层,形成初级非织造复合材料;
(4)四层复合:在步骤(3)得到的初级非织造复合材料的PEG/PP熔喷面上依次放置热风无纺布和粘纺布,并在每两层中间喷洒热熔粉末,再经过一定温度和压力的热熔机,使四层不同的材料复合在一起,得到用于建筑保温的非织造复合材料。
6.根据权利要求5所述的用于建筑保温的非织造复合材料的制备方法,其特征在于,所述步骤(3)熔喷成型工艺中螺杆挤出机的参数设置为:一区温度170℃、二区温度190℃、三区温度210℃、四区温度220℃,并设置机头温度220℃,热风温度235℃,气流压力0.04Mpa,计量泵转速10Hz,输网帘速度50Hz。
7.根据权利要求5所述的用于建筑保温的非织造复合材料的制备方法,其特征在于:所述步骤(3)中熔喷纺丝模头的喷丝孔径为0.35mm,接收距离为10cm。
8.根据权利要求5所述的用于建筑保温的非织造复合材料的制备方法,其特征在于:所述步骤(4)中热熔机的加热温度为130℃,光辊的压力为0.4Mpa。
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