CN110139753B - 一种遮光性复合膜及其制备方法和应用 - Google Patents

一种遮光性复合膜及其制备方法和应用 Download PDF

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Publication number
CN110139753B
CN110139753B CN201980000564.6A CN201980000564A CN110139753B CN 110139753 B CN110139753 B CN 110139753B CN 201980000564 A CN201980000564 A CN 201980000564A CN 110139753 B CN110139753 B CN 110139753B
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light
fabric
shading
composite film
layer
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CN110139753A (zh
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陈利民
严瑞祥
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Jiangsu Junlin Textile Technology Co ltd
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Jiangsu Junlin Textile Technology Co ltd
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    • A47H23/00—Curtains; Draperies
    • A47H23/02—Shapes of curtains; Selection of particular materials for curtains
    • A47H23/08—Selection of particular materials
    • A—HUMAN NECESSITIES
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Abstract

一种遮光性复合膜及其制备方法和应用，所述遮光性复合膜包括中间的无纺布以及位于所述无纺布每侧的至少一个反光层和至少一个吸光层，所述反光层和所述吸光层交替设置，其中，所述反光层由包含反光粒子和树脂制成，所述吸光层由包含吸光粒子和树脂制成。本发明的遮光性复合膜具有遮光性强、不易卷曲、经久耐用、结构轻巧、色彩美观等优点。

Description

一种遮光性复合膜及其制备方法和应用
技术领域
本发明属于遮光材料技术领域，具体涉及一种遮光性复合膜及其制备方法和应用。
背景技术
在人们的日常生活中，家居环境以及各大宾馆、办公室、会议室等公共建筑时常需要对房间的光亮度进行控制，减少因日光对生活和工作带来的麻烦。
在卧室、影剧院、多媒体室、暗室等对光线要求较高的地方，常常需要一种全遮光的卷帘面料。
对于遮光窗帘织物，不仅要求美观，其关键考量指标是对日光应当具有良好的遮光性，同时还必须具有良好的各项牢度性能。
目前市场上的全遮光面料大多经过涂层处理，但是经涂层的面料其悬垂性能和透气性变差，且涂层易氧化起泡脱落，影响遮光效果。
目前市场上的卷帘面料由于面料材料和膜材料不同，在不同的温度的条件下会出现不同方向的卷曲，影响卷帘的外观和遮光度。
目前市场上各种形式的遮光卷帘，遮光性差，为了实现高遮光效果，大多采用多层卷帘、加厚材质的方法，这些遮光卷帘的生产方法，无法满足装饰纺织品的简洁、轻便的流行发展趋势，为此开发高遮光、轻便、简洁的遮光卷帘成为一种市场需求。
发明内容
有鉴于此，本发明提出一种遮光性复合膜及其制备方法和应用，用于改善现有遮光材料的轻便性、耐用性和/或遮光性。
为实现上述目的，一方面，本发明提出一种遮光性复合膜，包括中间的无纺布以及位于所述无纺布每侧的至少一个反光层和至少一个吸光层，所述反光层和所述吸光层交替设置，其中，所述反光层由包含反光粒子的树脂制成，所述吸光层由包含吸光粒子的树脂制成，优选地，所述无纺布面密度小于20g/m2，厚度0.05-0.15mm。
在一些实施例中，所述遮光性复合膜的厚度为0.05-1.0mm(例如0.1mm、0.3mm、0.5mm、0.7mm、0.9mm)，面密度为50-100g/m2(例如60g/m2、70g/m2、80g/m2、90g/m2)。
在一些实施例中，所述遮光性复合膜中各层的厚度相同。
在一些实施例中，所述反光粒子通过将反光材料65-75重量份、分散剂0.5-1.5重量份、树脂24-34重量份混合制备而成，所述吸光粒子通过将吸光材料10-15重量份、分散剂0.5-2重量份、树脂84-89重量份混合制备而成。
在一些实施例中，所述反光层中所述反光粒子的含量为30.0-40.0wt％(例如31.0wt％、32.0wt％、33.0wt％、34.0wt％、35.0wt％、36.0wt％、37.0wt％、38.0wt％、39.0wt％)，所述反光层中所述树脂的含量为59.0-69.0wt％(例如60.0wt％、61.0wt％、62.0wt％、63.0wt％、64.0wt％、65.0wt％、66.0wt％、67.0wt％、68.0wt％)，分散剂的含量为0.5-1.5wt％(例如0.6wt％、0.7wt％、0.8wt％、0.9wt％、1.0wt％、1.1wt％、1.2wt％、1.3wt％、1.4wt％)。
在一些实施例中，所述吸光层中所述吸光粒子的含量为25-35wt％(例如26.0wt％、27.0wt％、28.0wt％、29.0wt％、30.0wt％、31.0wt％、32.0wt％、33.0wt％、34.0wt％)，所述吸光层中所述树脂的含量为64.0-74.0wt％(例如65.0wt％、66.0wt％、67.0wt％、68.0wt％、69.0wt％、70.0wt％、71.0wt％、72.0wt％、73.0wt％)，分散剂的含量为0.5-1.5wt％(例如0.6wt％、0.7wt％、0.8wt％、0.9wt％、1.0wt％、1.1wt％、1.2wt％、1.3wt％、1.4wt％)。
在一些实施例中，所述反光材料选自钛白粉、硫酸钡中的一种或其组合。
在一些实施例中，所述吸光材料选自碳黑、铁黑、石墨中的一种或多种。
在一些实施例中，所述反光材料和所述吸光材料的粒径为0.1-1微米。
出于分散稳定的需要，所述反光材料和所述吸光材料可以经过表面改性处理，以增加其和树脂的相容性。
在一些实施例中，所述树脂选自聚乙烯PE、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、乙烯-醋酸乙烯共聚物EVA、热塑性弹性体TPE、热塑性聚氨酯弹性体TPU、聚烯烃弹性体POE中的一种或多种。
在一些实施例中，所述无纺布的材质选自聚丙烯PP、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、聚酰胺PA中的一种或多种。
在一些实施例中，所述分散剂为苯甲酸乙基己酯(EHBA)。苯甲酸乙基己酯(EHBA)可以提高反光材料和吸光材料在树脂体系中的分散稳定性，减少粒子的团聚作用。
另一方面，本发明还提出一种制备遮光性复合膜的方法，包括如下步骤：
S1、制备反光粒子和吸光粒子；
S2、将所述反光粒子和所述吸光粒子分别加入树脂中混合均匀后共挤出成型得到薄膜，优选地，所述反光粒子与树脂的质量比为(34-40)∶(59-69)；所述吸光粒子和树脂的质量比为(10-15)∶(84-89)；
S3、将两个所述薄膜与无纺布经热压工艺形成所述遮光性复合膜。
又一方面，本发明还涉及遮光复合膜的应用。
本发明提出一种遮光面料，包括所述遮光性复合膜和贴合在所述遮光性复合膜的一个或两个表面上的面料，所述面料的材料与所述遮光性复合膜中的无纺布材料相同。
在一些实施例中，所述面料为机织物、针织物或无纺布。
在一些实施例中，所述遮光面料由所述遮光性复合膜和所述面料通过热熔胶复合贴合而成。
另外，本发明还提出一种帘状物，包括上述遮光面料。
与现有技术相比，本发明具有以下有益效果：
(1)本发明的制备方法简单、成本低、生产效率高，易于工业化生产；
(2)本发明的树脂原料来源广，易加工成各种形状，使用方便；
(3)本发明的遮光复合膜具有遮光性强、不易卷曲、经久耐用、结构轻巧、色彩美观等优点，可以满足当前高档窗帘材料的需求；
(4)本发明的全遮光卷帘的遮光效果好，可应用于家居、医院病房、汽车内部装饰、飞机内部装饰等室内装饰领域，具有广阔的应用前景和市场前景。
附图说明
图1为本发明实施例中的遮光性复合膜；
图2为本发明另一实施例中的遮光性复合膜；
图3为本发明实施例中的T字模成型工艺；
图4为本发明实施例中的一字模成型工艺；
图5为本发明实施例中的遮光面料；
图6为本发明另一实施例中的遮光面料。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚明白，以下结合具体实施例，并参照附图，对本发明作进一步的详细说明。
遮光性复合膜的制备
如图1所示，本发明实施例提供一种遮光性复合膜，其具有反光层1-吸光层2-反光层1-无纺布3-反光层1-吸光层2-反光层1的多层结构(外侧的反光层1可包含颜料以呈现所需要的颜色)，本发明采用挤塑成膜的加工方法，通过两次热压实现了反光层-吸光层-反光层-无纺布-反光层-吸光层-反光层七位一体的遮光高分子膜一次成型技术，该七层高分子膜的结构特征，较之反光层-吸光层-反光层的三层膜结构，在具有更高的遮光效果的同时，又保证了遮光复合膜正、反面均为白色或多元色的视觉效果。通过热压处理，将该六层复合遮光高分子膜和一层无纺布热压成遮光性复合模，其厚度控制在0.05-1.0mm之间，优选地，各层的厚度相同。
如图2所示，在本发明另一例提供的遮光性复合膜具有反光层1-吸光层2-无纺布3-吸光层2-反光层1的多层结构。
当遮光性复合膜的颜色可以为黑色时，吸光层2可以位于遮光性复合膜的最外层。
本发明遮光性复合膜的制备方法，包括：
(1)将一定粒径(例如0.1-1微米)的钛白粉，或高黑炭黑粉，分别加入环保有机酯分散剂EHBA中搅拌混合均匀后，加入树脂(例如聚乙烯PE、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、乙烯-醋酸乙烯共聚物EVA、热塑性弹性体TPE、热塑性聚氨酯弹性体TPU、聚烯烃弹性体POE树脂)搅拌混料，加入双螺杆造粒机造粒，得到白色反光粒子，或黑色吸光粒子，其中，白色反光粒子中的树脂与反光层中的树脂相同，黑色吸光粒子中的树脂与吸光层中的树脂相同。
(2)在聚乙烯PE、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、乙烯-醋酸乙烯共聚物EVA、热塑性弹性体TPE、热塑性聚氨酯弹性体TPU、聚烯烃弹性体POE等原料树脂分别加入上述的反光粒子或吸光粒子，并优选加入分散剂EHBA，经混料均匀后，分别加入不同的三螺杆挤出机(或双螺杆挤出机)中，采用三输入共挤出T字模(或二输入共挤出一字模)，挤出热压得到一薄膜；通过后处理将薄膜厚度控制在0.3-0.4mm。将该薄膜和同方向放卷过来的无纺布在具有一定温度一定压力条件下热压，形成单面膜单面无纺布的遮光膜，打卷。
再同样的方法制膜热压形成两边膜中间无纺布结构为一体的遮光膜结构，打卷。
其中，无纺布的材质选自聚丙烯PP、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、聚酰胺PA中的一种或多种。
在一些实施例中，反光粒子和吸光粒子通过以下步骤制备：
将粒径为0.7微米的钛白粉70.0份，加入环保有机酯分散剂EHBA 1.0份拌混合均匀后，加入经过干燥的PE树脂29.0重量份搅拌混料，加入双螺杆造粒机造粒，得到反光白色粒子，
将粒径为0.5微米的高黑炭黑粉12.0重量份，加入环保有机酯分散剂EHBA 1.0份拌混合均匀后，加入经过干燥的PE树脂87.0份搅拌混料，加入双螺杆造粒机造粒，得到吸光黑色粒子。
实施例1
将干燥后的PE树脂原料分别和反光粒子和吸光粒子混合；PE树脂和反光粒子的混合重量比例为64∶35，PE树脂和吸光粒子的混合重量比例为69∶30，然后加入分散剂EHBA1.0份在充分混合的基础上，将混合料分别加入三螺杆挤出机中，确保反光粒子混合树脂、吸光粒子混合树脂和反光粒子混合树脂分别导向挤出模口的上层、中层和下层，如图3所示。
三螺杆挤出机的温度控制为：进料加热区的温度高于树脂熔点30℃，三输入共挤出T字模的温度控制在高于熔点25℃。
将三输入共挤出T字模挤出的薄膜拉伸至0.3mm的厚度，打卷。
将薄膜和同方向放卷过来的PET无纺布在具有一定温度一定压力热压辊条件下热压，形成单面膜单面无纺布的遮光膜，厚度为0.4mm，打卷。
再同样的方法制膜热压形成两边膜中间无纺布结构为一体的遮光膜结构，厚度为0.7mm，打卷。
实施例2
将干燥后的PE树脂原料分别和反光粒子和吸光粒子混合；PE树脂和反光粒子的混合重量比例为70∶29，PE树脂和吸光粒子的混合重量比例为64∶35，然后加入分散剂EHBA1.0份，在充分混合的基础上，将混合料分别加入双螺杆挤出机中，确保反光粒子混合树脂和吸光粒子树脂分别导向挤出膜口的上层和下层，如图4所示。
双螺杆挤出机的温度控制为进料加热区的温度高于树脂熔点30℃，二输入共挤出一字模的温度控制在高于熔点25℃。
将二输入共挤出一字模挤出的薄膜拉伸至0.3mm的厚度。
将薄膜和同方向放卷过来的PET无纺布在具有一定温度一定压力热压辊条件下热压，形成单面膜单面无纺布的遮光膜，厚度为0.4mm，打卷。
再同样的方法制膜热压形成两边膜中间无纺布结构为一体的遮光膜结构，厚度为0.7mm，打卷。
对比例1
将干燥后的PE树脂原料分别和反光粒子和吸光粒子混合；PE树脂和反光粒子的混合重量比例为64∶35，PE树脂和吸光粒子的混合重量比例为69∶30，然后加入分散剂EHBA1.0份，在充分混合的基础上，将混合料分别加入三螺杆挤出机中，确保反光粒子混合树脂导向挤出模口的上下区，吸光粒子混合树脂导向挤出模口的中间区。
三螺杆挤出机的温度控制为：进料加热区的温度高于树脂熔点30℃，T口模的温度控制在高于熔点25℃。
将三输入共挤出T字模挤出的薄膜拉伸至0.7mm的厚度，打卷。
采用JISL1055标准进行遮光性能检查，遮光率要求为100％。
遮光面料的制备
膜材料与纺织面料复合的粘合加工是实现纺织品功能化的前沿技术，采用以湿气固化反应型聚氨酯热熔胶成为层压复合行业中最值得推广使用的胶粘剂，具有对环境无污染的特点；为了制备本专利所述的具有遮光功能的复合纺织品面料，采用热熔复合技术，复合环保发展的方向。
热熔复合具有遮光功能的复合纺织品面料的制备：采用热溶胶和热轧复合技术，在遮光性复合膜的一侧或者两侧实施热复合技术，纺织品热粘在遮光性复合膜的两侧，使之成为具有一定的平整度、牢度又具有全遮光特性的纺织品面料；在此所使用的纺织品，其纤维材料与遮光性复合膜中的无纺布或薄型梭织布的材料相同；就纺织品的组织结构，可以采用机织物、针织物、或无纺布等。
通过选择和无纺布或薄型梭织布相同材料的纺织品为复合材料，可以保证纺织品和遮光性复合膜在一定温度条件下热变形温度一致，保持复合后不卷曲。
遮光面料的具体制备过程包括：
第一、对遮光性复合膜进行前期电晕表面处理，改变膜的表面化学结构，提高遮光膜的表面张力、增加粘结点，提高牢度。
第二、采用湿气固化反应型聚氨酯热熔胶，在90-110℃熔化热熔胶，并注入热复合机中，将遮光性复合膜的一个面和面料4进行复合，固化熟成24小时然后，将遮光复合膜的另一个面，和面料4进行相同的热复合，将遮光性复合膜热粘结在两层面料4中间，形成图5结构的遮光面料。
在一些实施例中，可以仅在全遮光复合膜的其中一个面和织物进行相同的热复合，如图6所示。
实施例3
该实施例以实施例1中的遮光性复合膜制备两面均与PET面料复合的双面复合遮光面料。制备方法包括：
第一、对实施例1中的遮光性复合膜进行前期电晕表面处理。
第二、采用湿气固化反应型聚氨酯热熔胶，在95℃熔化热熔胶，并注入热复合机中，将遮光性复合膜的一个面和PET材料的面料进行复合，固化熟成24小时。
第三、将遮光性复合膜的另一面采用湿气固化反应型聚氨酯热熔胶与PET面料复合，固化熟成24小时后得出双面复合遮光面料。
实施例4
该实施例以实施例1中的遮光性复合膜制备单面与PET面料复合的遮光面料。制备方法包括：
第一、对实施例1中的遮光性复合膜进行前期电晕表面处理。
第二、采用湿气固化反应型聚氨酯热熔胶，在95℃熔化热熔胶，并注入热复合机中，将遮光性复合膜的一个面和PET材料的面料进行一次复合，固化熟成24小时后得到遮光面料。
实施例5
该实施例以实施例2中的遮光性复合膜制备单面与PET面料复合的遮光面料。制备方法包括：
第一、对实施例2中的遮光性复合膜进行前期电晕表面处理。
第二、采用湿气固化反应型聚氨酯热熔胶，在95℃熔化热熔胶，并注入热复合机中，将遮光性复合膜的一个面和PET材料的面料进行复合，固化熟成24小时。
第三、将遮光性复合膜的另一面采用湿气固化反应型聚氨酯热熔胶与PET面料复合，固化熟成24小时后得出双面复合遮光面料。
对比例2
将实施例3中的面料替换为聚酰胺PA，其余与实施例3相同。
对比例3
将实施例3中的遮光性复合膜替换为对比例1中的遮光性复合膜，其余与实施例3相同。
表1
Figure BDA0002051355880000081
Figure BDA0002051355880000091
注：遮光面料的宽度设定为100cm，卷曲度在2％内为合格。
由表1可知，当遮光性复合膜中不包含中间的无纺布时(对比例3)，遮光面料在温度变化过程中会出现明显的卷曲，而采用本发明的遮光性复合膜时可以显著降低遮光面料的卷曲度。另外，当遮光性复合膜与面料的材质不相同时(对比例2)，遮光面料出现明显的卷曲，这是由于遮光性复合膜与面料的热变形温度不同所致。
遮光卷帘的制备
在上述全遮光功能复合纺织品面料的基础上，采用常规剪裁、缝制的方法加工生产出不同结构、形式的卷帘。
本发明采用上述技术方案获得的全遮光不卷曲卷帘，通过将遮光性复合膜和面料复合，实现全遮光卷帘的高遮光性和平整度。
以上所述的具体实施例，对本发明的目的、技术方案和有益效果进行了进一步详细说明，应理解的是，以上所述仅为本发明的具体实施例而已，并不用于限制本发明，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (19)

1.一种遮光面料，其特征在于，包括遮光性复合膜和贴合在所述遮光性复合膜的一个或两个表面上的面料，所述遮光性复合膜包括中间的无纺布以及位于所述无纺布每侧的至少一个反光层和至少一个吸光层，所述反光层和所述吸光层交替设置，其中，所述反光层由包含反光粒子的树脂制成，所述吸光层由包含吸光粒子的树脂制成，所述贴合在所述遮光性复合膜的一个或两个表面上的面料的材料与所述无纺布的材料相同，所述无纺布面密度小于20g/m2，厚度0.05-0.15mm。
2.根据权利要求1所述的遮光面料，其中，所述遮光性复合膜的厚度为0.05-1.0mm，面密度为50-100g/m2。
3.根据权利要求1所述的遮光面料，其中，所述遮光性复合膜的厚度为0.1mm、0.3mm、0.5mm、0.7mm或0.9mm，面密度为60g/m2、70g/m2、80g/m2或90g/m2。
4.根据权利要求1所述的遮光面料，其中，所述遮光性复合膜中各层的厚度相同。
5.根据权利要求1所述的遮光面料，其中，所述反光粒子通过将反光材料65-75重量份、分散剂0.5-1.5重量份、树脂24-34重量份混合制备而成，所述吸光粒子通过将吸光材料10-15重量份、分散剂0.5-2重量份、树脂84-89重量份混合制备而成。
6.根据权利要求5所述的遮光面料，其中，所述分散剂为苯甲酸乙基己酯(EHBA)。
7.根据权利要求1所述的遮光面料，其中，所述反光层中所述反光粒子的含量为30.0-40.0wt％,所述反光层中所述树脂的含量为59.0-69.0wt％，分散剂的含量为0.5-1.5wt％。
8.根据权利要求1所述的遮光面料，其中，所述反光层中所述反光粒子的含量为31.0wt％、32.0wt％、33.0wt％、34.0wt％、35.0wt％、36.0wt％、37.0wt％、38.0wt％或39.0wt％,所述反光层中所述树脂的含量为60.0wt％、61.0wt％、62.0wt％、63.0wt％、64.0wt％、65.0wt％、66.0wt％、67.0wt％、68.0wt％，分散剂的含量为0.6wt％、0.7wt％、0.8wt％、0.9wt％、1.0wt％、1.1wt％、1.2wt％、1.3wt％或1.4wt％。
9.根据权利要求7或8所述的遮光面料，其中，所述分散剂为苯甲酸乙基己酯(EHBA)。
10.根据权利要求1所述的遮光面料，其中，所述吸光层中所述吸光粒子的含量为25-35wt％，所述吸光层中所述树脂的含量为64.0-74.0wt％，分散剂的含量为0.5-1.5wt％。
11.根据权利要求1所述的遮光面料，其中，所述吸光层中所述吸光粒子的含量26.0wt％、27.0wt％、28.0wt％、29.0wt％、30.0wt％、31.0wt％、32.0wt％、33.0wt％或34.0wt％，所述吸光层中所述树脂的含量为65.0wt％、66.0wt％、67.0wt％、68.0wt％、69.0wt％、70.0wt％、71.0wt％、72.0wt％或73.0wt％，分散剂的含量为0.6wt％、0.7wt％、0.8wt％、0.9wt％、1.0wt％、1.1wt％、1.2wt％、1.3wt％或1.4wt％。
12.根据权利要求10或11所述的遮光面料，其中，所述分散剂为苯甲酸乙基己酯(EHBA)。
13.根据权利要求1所述的遮光面料，其中，所述反光材料选自钛白粉、硫酸钡中的一种或其组合，所述吸光材料选自碳黑、铁黑、石墨中的一种或多种。
14.根据权利要求1所述的遮光面料，其中，所述反光材料和所述吸光材料的粒径为0.1-1微米。
15.根据权利要求1所述的遮光面料，其中，所述树脂选自聚乙烯PE、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、乙烯-醋酸乙烯共聚物EVA、热塑性弹性体TPE、热塑性聚氨酯弹性体TPU、聚烯烃弹性体POE中的一种或多种。
16.根据权利要求1所述的遮光面料，其中，所述无纺布的材质选自聚丙烯PP、聚对苯二甲酸乙二酯PET、聚对苯二甲酸丙二醇酯PTT、聚酰胺PA中的一种或多种。
17.根据权利要求1所述遮光面料，其中，所述面料为机织物、针织物或无纺布。
18.根据权利要求1所述遮光面料，其中，所述遮光面料由所述遮光性复合膜和所述面料通过热熔胶复合贴合而成。
19.一种帘状物，包括权利要求1-18任一项所述遮光面料。
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