CN110744902B - 斗提机带及其制备方法和应用 - Google Patents
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Abstract
本发明提供了一种斗提机带及其制备方法和应用,其由上层和下层的聚氨酯弹性体材料和中间层的骨架层通过流延工艺复合构成,骨架层由整芯织物浸渍在聚氯乙烯胶浆中并塑化得到;其制备方法为将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物;将预处理的整芯织物加热塑化,成型得到骨架层;在骨架层的表面采用聚氨酯树脂底涂,并在其正面和反面流延聚氨酯弹性体材料;本发明的聚氯乙烯胶浆中采用特定组分的增塑剂,从而在满足斗提机带的1%延伸强度的基础上,满足后续的安装和使用;本发明的斗提机带分别采用食品级的聚氨酯材料和聚氯乙烯胶浆,从而符合食品接触安全性,满足法规要求,因此在粮食输送方面具有较大优势,也是今后使用的趋势。
Description
技术领域
本发明属于粮食行业用环保节能材料技术领域,具体涉及一种斗提机带及其制备方法和应用。
背景技术
近年来,随着科学技术的不断发展、国民的生活水平日益提高,人们对环保的意识也在不断提高,因此粮食输送方面各类粮企对节能减排也有着越来越高的控制,目前此行业畚斗输送粮食所使用的斗提机皮带大部分为橡胶带,此皮带优点是强度高,使用寿命长,但是此类橡胶带也存在能耗高和不环保两个问题,首先皮带整体重量较大,对设备负荷较大,能耗高,代价高,不符合目前大环境节能减排的方针。其次橡胶斗提机带对于食品接触存在安全隐患,橡胶固化会用到各类硫化剂,在粮食输送中不可避免会接触到粮食并造成一定污染,这也是目前各类法律法规所限制的方面。因此一款环保型的节能斗提机带具有较好的发展前景。
发明内容
针对现有技术中的不足,本发明提供了一种粮食行业用环保节能型的斗提机带及其制备方法,其以聚氨酯弹性体(TPU)材料为表面胶层,与聚氯乙烯浸渍整芯织物复合得到骨架层,从而减小了单位体积带体的重量,降低了设备能耗且与食品的接触安全性好。
为达到上述目的,本发明的解决方案是:
一种斗提机带,其由表层和骨架层复合构成,表层为聚氨酯弹性体材料,骨架层由整芯织物浸渍在聚氯乙烯胶浆中并塑化得到。
聚氯乙烯胶浆的组分包括:
优选地,整芯织物为双经轴织造的复合涤纶织物,该织物的经向和纬向均使用涤纶短纤,S向加捻,120±10转/米。
优选地,聚氯乙烯胶浆的粘度为800-1500mpa.s。
一种上述的斗提机带的制备方法,其包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物;
(2)、将预处理的整芯织物加热塑化,成型得到骨架层;
(3)、在骨架层的表面涂布聚氨酯树脂,并在其正面和反面流延聚氨酯弹性体材料,得到斗提机带。
优选地,步骤(1)中,整芯织物浸渍的速度为3±0.5m/min。
优选地,步骤(1)中,聚氯乙烯胶浆的组分包括:
优选地,步骤(2)中,塑化的温度为190±10℃,塑化的速度为4.5±0.5m/min。
优选地,步骤(3)中,聚氨酯树脂的固含量为15-20%,打底的速度为8±1m/min;流延的温度为175±10℃,流延的速度为3.5±0.5m/min。
一种上述的斗提机带在粮食输送领域中的应用。
由于采用上述方案,本发明的有益效果是:
第一、本发明的聚氯乙烯胶浆中采用特定组分的增塑剂,从而在满足斗提机带的1%延伸强度的基础上,进一步满足后续的安装和使用。
第二、本发明的斗提机带分别采用食品级的聚氨酯材料和聚氯乙烯胶浆,从而符合食品接触安全性,满足法规要求,因此在粮食输送方面具有较大优势,也是今后使用的趋势。
第三、本发明的制备方法中聚氨酯材料的重量远低于同等的橡胶材料,因此本发明的斗提机带同比质量小于橡胶带,能够满足节能要求的使用,因此可以降低生产或设备成本,从而提高企业收益。
第四、本发明的斗提机带能够降低能耗,从而减小设备负荷。
附图说明
图1为本发明的斗提机带的结构示意图。
具体实施方式
本发明提供了一种斗提机带及其制备方法和应用。
<斗提机带>
如图1所示,本发明的斗提机带由上层、下层的聚氨酯弹性体(TPU)材料(即表层)和中间层的骨架层通过流延工艺复合构成,骨架层由整芯织物浸渍在聚氯乙烯胶浆中并塑化得到。本发明的斗提机带的强度符合GB/T 11352-1989的要求。
实际上,聚氯乙烯胶浆的组分包括:
增塑剂的不同组分会直接影响胶浆的软硬度以及胶浆糊粘度,一方面,增塑剂的组分越多,胶料的粘度越小,在浸浆工艺中,浆料渗透越充分,产品1%延伸强度越高,而本发明的产品1%延伸强度要求为35N/mm以上;另一方面,增塑剂的组分越少,胶料粘度越大,产品的表面硬度越高,产品表面硬度越大越有利于产品的安装和使用,即安装畚斗时,产品硬度越高越有利于承载畚斗,硬度太低会因承载重量可能产生弯折现象,从而影响产品的使用,也会大大降低产品的使用寿命。
聚氯乙烯胶浆的粘度为800-1500mpa.s。
增塑剂和稳定剂均为环保级,增塑剂为DINP,起到塑化从而调整糊树脂浆料软硬度的作用。稳定剂为CZ稳定剂,起到体系受热稳定的作用,使糊树脂浆料塑化过程中不发生黄变。
稳定剂和环氧大豆油主要作用于稳定体系,故稳定剂和环氧大豆油使用固定组分量添加,目的防止加工过程中高温导致胶料黄变。
其中,聚氨酯弹性体(TPU)材料为TPU粒料,符合食品级别,且TPU材料具有良好的物理性能,能够满足环保及耐磨等要求。
拉断强度达到400N/mm以上的整芯织物作为骨架材料,食品级的聚氯乙烯(PVC)胶浆作为填充材料,浸渍塑化后得到骨架层。
具体地,整芯织物为双经轴织造的复合涤纶织物,该织物的经向和纬向均使用涤纶短纤,S向加捻,120±10转/米。
<斗提机带的制备方法>
本发明的斗提机带的制备方法包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物;
(2)、将预处理的整芯织物加热塑化,成型得到骨架层;
(3)、在骨架层的表面采用聚氨酯树脂(PU胶水)底涂,并在其正面和反面流延聚氨酯弹性体材料,然后在底面压花纹,得到斗提机带。
其中,在步骤(1)中,整芯织物浸渍的速度可以为3±0.5m/min。
在步骤(1)中,聚氯乙烯胶浆的粘度可以为800-1500mpa.s,聚氯乙烯胶浆的组分包括:
在步骤(2)中,塑化的温度可以为190±10℃,塑化时塑化车的速度可以为4.5±0.5m/min。
在步骤(3)中,聚氨酯树脂的固含量可以为15-20%,打底的速度可以为8±1m/min,打底是指在骨架层表面用刮刀刮一遍固含量为15-20%的PU胶水,目的在于粘接骨架层和下步骤流延的PU材料层。流延的温度可以为175±10℃,流延的速度可以为3.5±0.5m/min。
<斗提机带的应用>
本发明的斗提机带可以在粮食输送领域中得以应用。
以下结合实施例对本发明作进一步的说明。
实施例1:
本实施例的斗提机带的制备方法包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物,其中,整芯织物浸渍的速度为2.5m/min;
(2)、将预处理的整芯织物加热塑化,塑化的温度为180℃,塑化时塑化车的速度为4m/min,成型得到骨架层;
(3)、在骨架层的表面采用聚氨酯树脂(PU胶水)底涂,打底的速度为7m/min,并在其正面和反面流延聚氨酯弹性体材料,流延的温度为165℃,流延的速度为3m/min,然后在底面压花纹,得到斗提机带。
其中,步骤(1)中,聚氯乙烯胶浆的组分包括:100份糊树脂、40份增塑剂、2份稳定剂和2份环氧大豆油。
实施例2:
本实施例的斗提机带的制备方法包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物,其中,整芯织物浸渍的速度为3m/min;
(2)、将预处理的整芯织物加热塑化,塑化的温度为190℃,塑化时塑化车的速度为4.5m/min,成型得到骨架层;
(3)、在骨架层的表面采用聚氨酯树脂(PU胶水)底涂,打底的速度为8m/min,并在其正面和反面流延聚氨酯弹性体材料,流延的温度为175℃,流延的速度为3.5m/min,然后在底面压花纹,得到斗提机带。
其中,步骤(1)中,聚氯乙烯胶浆的组分包括:100份糊树脂、50份增塑剂、3份稳定剂和3份环氧大豆油。
实施例3:
本实施例的斗提机带的制备方法包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物,其中,整芯织物浸渍的速度为3.5m/min;
(2)、将预处理的整芯织物加热塑化,塑化的温度为200℃,塑化时塑化车的速度为5m/min,成型得到骨架层;
(3)、在骨架层的表面采用聚氨酯树脂(PU胶水)底涂,打底的速度为9m/min,并在其正面和反面流延聚氨酯弹性体材料,流延的温度为185℃,流延的速度为4m/min,然后在底面压花纹,得到斗提机带。
其中,步骤(1)中,聚氯乙烯胶浆的组分包括:100份糊树脂、60份增塑剂、3份稳定剂和3份环氧大豆油。
对比例:
本对比例的斗提机带的制备方法包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物,其中,整芯织物浸渍的速度为3m/min;
(2)、将预处理的整芯织物加热塑化,塑化的温度为190℃,塑化时塑化车的速度为4.5m/min,成型得到骨架层;
(3)、在骨架层的表面采用聚氨酯树脂(PU胶水)底涂,打底的速度为8m/min,并在其正面和反面流延聚氨酯弹性体材料,流延的温度为175℃,流延的速度为3.5m/min,然后在底面压花纹,得到斗提机带。
其中,步骤(1)中,聚氯乙烯胶浆的组分包括:100份糊树脂、30份增塑剂、2份稳定剂和2份环氧大豆油。
表1上述实施例和对比例的聚氯乙烯胶浆性能数据
粘度/mpa.s | 硬度 | 1%延伸强度/N/mm | |
实施例1 | 1500 | 85 | 35 |
实施例2 | 1000 | 80 | 36 |
实施例3 | 800 | 75 | 38 |
对比例 | 1800 | 90 | 29 |
由表1可知,增塑剂组分越少,聚氯乙烯胶浆的粘度越大,同时硬度越大,在浸渍过程中聚氯乙烯胶浆不易渗透并填充到整芯织物内部,导致骨架层结构填充不充分,故形成产品1%延伸强度相对低,而反之增塑剂组分越多,聚氯乙烯胶浆粘度越小,能够充分填充骨架层,从而提升产品1%延伸强度的性能,越有利于产品的安装和使用。经过试验,增塑剂组分达到80份时,1%延伸最高可达到45N/mm,但是胶料硬度太低,不适于后续加工及使用。
<实验>
将本发明的斗提机带和橡胶斗提机带(对比例)分别进行重量和能耗测试的实验。
<实验1>
本实验将斗提机带和橡胶斗提机带各取1平方米,然后使用电子秤进行准确称量,所得结果如表1所示。
表1重量对比测试:单位(Kg/㎡)
本发明斗提机带 | 橡胶斗提机带 | |
产品重量 | 6Kg/㎡ | 10Kg/㎡ |
由表1可知,本发明的斗提机带的重量较轻,因此,本发明的斗提机带能够降低设备的成本,从而提高企业收益。
<实验2>
本实验将斗提机带和橡胶斗提机带分别接成长度为1600mm,宽度为400mm的环带,在能耗试验机进行能耗测试,所得结果如表2所示。
表2能耗对比测试:单位(A、W)
本发明斗提机带 | 橡胶斗提机带 | |
运行电机电流(A) | 4.68 | 5.96 |
运行电机功率(W) | 478 | 623 |
由表2可知,本发明的斗提机带的能耗较小,从而能够减小设备负荷。
上述对实施例的描述是为了便于该技术领域的普通技术人员能理解和使用本发明。熟悉本领域技术人员显然可以容易的对这些实施例做出各种修改,并把在此说明的一般原理应用到其他实施例中,而不必经过创造性的劳动。因此,本发明不限于上述实施例。本领域技术人员根据本发明的原理,不脱离本发明的范畴所做出的改进和修改都应该在本发明的保护范围之内。
Claims (7)
2.根据权利要求1所述的斗提机带在粮食输送领域中的应用,其特征在于:所述整芯织物为双经轴织造的复合涤纶织物,该织物的经向和纬向均使用涤纶短纤,S向加捻,120±10转/米。
3.根据权利要求1所述的斗提机带在粮食输送领域中的应用,其特征在于:所述聚氯乙烯胶浆的粘度为800-1500mPa·s。
4.一种根据权利要求1-3任一项所述的斗提机带的制备方法,其特征在于:包括如下步骤:
(1)、将整芯织物浸渍在聚氯乙烯胶浆内,得到预处理的整芯织物;
(2)、将所述预处理的整芯织物加热塑化,成型得到骨架层;
(3)、在所述骨架层的表面涂布聚氨酯树脂,并在其正面和反面流延聚氨酯弹性体材料,得到斗提机带。
5.根据权利要求4所述的制备方法,其特征在于:步骤(1)中,所述整芯织物浸渍的速度为3±0.5m/min。
6.根据权利要求4所述的制备方法,其特征在于:步骤(2)中,所述塑化的温度为190±10℃,所述塑化的速度为4.5±0.5m/min。
7.根据权利要求4所述的制备方法,其特征在于:步骤(3)中,所述聚氨酯树脂的固含量为15-20%,打底的速度为8±1m/min;所述流延的温度为175±10℃,所述流延的速度为3.5±0.5m/min。
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