CN110951026A - 一种隔热吸波的自结皮聚氨酯组合物、制备方法及设备 - Google Patents
一种隔热吸波的自结皮聚氨酯组合物、制备方法及设备 Download PDFInfo
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Abstract
本发明公开了一种隔热吸波的自结皮聚氨酯组合物,其由如下重量份比例的原料制成:聚醚多元醇:六十份;聚合物多元醇:四十份;延迟催化剂:一份;改性交联剂:五份;低发泡剂:十份;催化剂:零点五份;吸波填料:一百份,增强扩链剂:一点五份;吸尘材料六十份,其中吸波填料包括氧化铝、氧化镁、氮化硼、氮化铝、氧化铍之一或其混合物,吸尘材料包括活性炭颗粒或脱脂棉或竹炭纤维网之一或三者的混合物。本发明还公开了其制备方法及设备。本发明提供重点通过对材料、工艺及设备同步进行改进,增加了材料的功能、提高了材料的性能,无需在模具内腔喷涂模内漆,改善了工作区域的环境,提高了工作效率。
Description
技术领域
本发明涉及聚氨酯注塑生产技术领域,具体为一种隔热吸波的自结皮聚氨酯组合物、制备方法及设备。
背景技术
聚氨酯材料是一种新兴的通用性有机高分子材料,因其卓越的性能而被广泛应用于国民经济众多领域,产品应用领域涉及轻工、化工、电子、纺织、医疗、建筑、建材、汽车、国防、航天、航空等。
聚氨酯软泡是一种非常理想的垫材材料,垫材也是软泡用量最大的应用领域,应用于座椅、沙发、床垫等;吸音材料—开孔的聚氨酯软泡具有良好的吸声消震功能,可用作室内隔音材料;织物复合材料—垫肩、文胸海绵、化妆棉、玩具;聚氨酯硬泡是冷冻冷藏设备的最理想的绝热材料,应用于冰箱、冰柜、冷库、冷藏车等。
隔热、保温的聚氨酯硬泡可应用在工业设备保温——如储罐、管道、建筑材料的隔热层;交通运输业,如汽车顶篷、内饰件;仿木材,聚氨酯硬泡或玻璃纤维增强硬泡是结构泡沫塑料,又称仿木材,具有强度高、韧性好、结皮致密坚韧、成型工艺简单、生产效率高等特点,强度可比天然木材高,密度可比天然木材低,可替代木材用作各类高档制品,灌封材料—例如防水灌浆材料、堵漏材料、屋顶防水材料,花卉行业—PU花盆、插花泥等,
吸收电磁波以及吸能性的泡沫体,吸能性泡沫体具有优异的电磁屏蔽、减震、缓冲性能,良好的抗压缩负荷性能及变形复原性能,用于制备汽车相关零部件;自结皮泡沫体,用于制备汽车方向盘、扶手、头枕等软化性内功能件和内部饰件,自结皮泡沫制品通常采用反应注射模塑成型加工技术。
目前市面上所有聚氨酯自结皮产品在生产中,都是先在模具里喷一层油漆,俗称模内漆,模内漆是用有机溶剂丁酮溶解稀释的,在生产现场味道很大,虽然各厂家都有安装废气处理系统,但是还是解决不了现场环境恶劣的现状,当下环保问题已经成为各个厂家提出最大的问题,要么找到水性的模内漆,要么不喷模内漆,所以在一些表面要求没有那么高的中小型产品,生产厂家开始向原料厂家提出不喷模内漆的需求。
同时,目前的聚氨酯组合物制备方法及设备还存在下列问题:
1、目前的聚氨酯组合物,由于其组分之间的相容性以及制备工艺的限制,其组分的选择受到较大的限制,在隔热、吸波、吸能等多方面的性能往往不能同时具备,同时其机械强度也往往较差。
2、目前的聚氨酯组合物的成分采用机溶剂丁酮溶解稀释导致生产现场异味严重,采用水性的模内漆在喷完之后最少要两分钟才能干燥,降低了生产效率。
3、目前的聚氨酯组合物的生产设备使用水性模内漆当前技术无法满足生产工艺的要求,并且水性模内漆喷完之后最少要两分钟才能干燥,大幅降低生产效率。
发明内容
(一)解决的技术问题
针对现有技术的上述不足,本发明提供一种隔热吸波的自结皮聚氨酯组合物、制备方法及设备,通过对材料组分、生产工艺和设备进行同步优化,使材料具备低密度、柔性、隔热、吸能和吸波功能,并且提高材料的机械强度。
(二)技术方案
为实现上述目的,本发明提供如下技术方案:
一种隔热吸波的自结皮聚氨酯组合物,其由如下重量份比例的原料制成:
聚醚多元醇:六十份;聚合物多元醇:四十份;延迟催化剂:一份;改性交联剂:五份;低发泡剂:十份;催化剂:零点五份;吸波填料:一百份,增强扩链剂:一点五份;吸尘材料六十份,其中,吸波填料包括氧化铝、氧化镁、氮化硼、氮化铝、氧化铍之一或其混合物,吸尘材料包括活性炭颗粒或脱脂棉或竹炭纤维网之一或三者的混合物。
前述隔热吸波的自结皮聚氨酯组合物的制备方法,包括以下步骤:
S1:原材料准备:按照设定的重量分别准备聚醚多元醇,聚合物多元醇、延迟催化剂、改性交联剂、低发泡剂、催化剂、吸波填料、增强扩链剂和吸尘材料;
S2:原料搅拌、发泡:将原材料中的聚醚多元醇,聚合物多元醇、吸波填料和吸尘材料输入密封的搅拌容器中,开启搅拌用的机械,在搅拌过程中逐步的注射加入延迟催化剂、改性交联剂、低发泡剂、催化剂和增强扩链剂;
S3:发泡注塑成型:经过充分混合的上述物质在密封的搅拌容器中发泡,当泡沫达到设定想标准后,通过阀门导入注塑机中,通过注塑机定量的向模具中注入设定量的泡沫,当一个模具中的泡沫填充完毕后,换一个模具继续注塑填充;
S4:塑性保持,稳定结构;注射结束的模具在设定的温度和压力状态下保持设定的时间,使得模具中填充的泡沫固化成型,在其表面自结皮,并且达到设定的力学要求;
S5:开模取料、修整裁切:打开经过塑性保持的模具,取出结构稳定的注塑的工件,对注塑工件的表面进行清理,清除多余的毛刺、注塑管,并且对模具的内腔进行清理,为下一次注塑做好准备;制得隔热吸波的自结皮聚氨酯组合物;
S6:成品检测:通过目测注塑产品的表面有无凸点、气孔等瑕疵,根据瑕疵的位置找出对应的模具内腔的部位进行调整,使用导热系数检测模块、吸波性能检测模块、电阻率检测模块、耐电压检测模块、抗拉强度检测模块和硬度检测模块的综合测试机械中,对聚氨酯注塑成品的导热系数、吸波性能、耐温范围、体积电阻率、耐电压、阻燃性、抗拉强度、硬度、厚度等进行测试,并将检测结果整理汇编成表格。
前述隔热吸波的自结皮聚氨酯组合物的制备设备,包括工作台、注塑机和混料罐,所述工作台为矩形板体,所述工作台顶面的一端固定有所述注塑机,所述注塑机的顶端通过支架固定有所述混料罐,所述混料罐的底端连通有放料阀门,所述放料阀门连通所述注塑机的入口,所述注塑机的一侧设有水平注射杆,所述工作台顶面的另一侧固定安装有纵向导轨,所述水平注射杆位于所述纵向导轨中心线的顶面,所述纵向导轨的顶面活动嵌合有滑动块,所述滑动块顶面的中心转动连接有旋转工位台,所述旋转工位台的顶端固定安装有四个规格相同的发泡模具,四个所述发泡模具的一侧均设有入料口,所述水平注射杆与四个所述发泡模具的入料口间歇性配合对接,所述纵向导轨的一端固定有伸缩驱动机构,所述伸缩驱动机构连接并带动所述滑动块和所述旋转工位台沿着所述纵向导轨进行位移。
作为本发明的优选技术方案,所述混料罐的底端嵌套连接有电加热圈,所述混料罐顶端的边侧连通有主料输送阀门和辅料加注器,所述辅料加注器包含有单向阀门,所述混料罐的内腔设有搅拌机。
作为本发明的优选技术方案,所述注塑机中设有定量加注泵,所述定量加注泵为螺杆泵或柱塞泵。
作为本发明的优选技术方案,所述伸缩驱动机构为伺服电机-滚珠丝杆驱动副或伸缩气缸驱动副。
作为本发明的优选技术方案,所述滑动块的边侧固定有伸缩销轴,所述旋转工位台的边侧设有定位销孔,所述伸缩销轴间歇性嵌合与之对应的定位销孔。
作为本发明的优选技术方案,所述工作台的一侧设有立柱,所述立柱上活动嵌合有升降保温扣罩,所述升降保温扣罩扣合与之对应的所述发泡模具。
(三)有益效果
与现有技术相比,本发明提供的隔热吸波的自结皮聚氨酯组合物、制备方法及设备,具备以下有益效果:
1、本发明提供的隔热吸波的自结皮聚氨酯组合物制备方法及设备,重点通过对材料、工艺及设备同步进行改进,增加了材料的功能、提高了材料的性能,无需在模具内腔喷涂模内漆,改善了工作区域的环境,提高了工作效率。
2、本发明提供的隔热吸波的自结皮聚氨酯组合物,通过独特的配方设计,使材料具备低密度、柔性、隔热、吸尘及吸波的功能,采用多种扩链剂组合搭配降低,解决有表面纹理、图案产品的微孔问题。
3、本发明提供的隔热吸波的自结皮聚氨酯组合物的制备方法,通过采用采用延迟催化剂解决产品发泡线色差问题,使生产工序与检测工序紧密结合,加快了产品生产效率和质量,简化了设备和工艺步骤,使产品易于产业化,并且降低了设备和生产成本。
4、本发明提供的隔热吸波的自结皮聚氨酯组合物的制备设备,设置旋转工位台安装四个发泡模具,旋转工位台在伸缩驱动机构的带动下与注塑机上的水平注射杆互相离合,并设置了升降保温扣罩对发泡后的模具进行保温处理,使得模具中填充的泡沫固化成型,在其表面自结皮,达到设定的力学要求。
附图说明
图1为本发明聚氨酯注塑生产设备整体外形立体结构示意图;
图2为本发明聚氨酯注塑生产设备整体外形另一视角的立体结构示意图;
图3为本发明聚氨酯注塑生产设备整体剖视结构示意图。
图中:1、工作台;2、注塑机;201、定量加注泵;3、混料罐;301、电加热圈;302、主料输送阀门;303、辅料加注器;304、搅拌机;4、放料阀门;5、水平注射杆;6、纵向导轨;7、滑动块;701、伸缩销轴;8、旋转工位台;801、定位销孔;9、发泡模具;10、伸缩驱动机构;11、立柱;12、升降保温扣罩。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中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做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:
请参阅图1-3,本发明实施例提供的隔热吸波的自结皮聚氨酯组合物,其由如下重量份比例的原料制成:
聚醚多元醇:六十份;聚合物多元醇:四十份;延迟催化剂:一份;改性交联剂:五份;低发泡剂:十份;催化剂:零点五份;吸波填料:一百份,增强扩链剂:一点五份;吸尘材料六十份,其中,吸波填料包括氧化铝、氧化镁、氮化硼、氮化铝、氧化铍之一或其混合物,吸尘材料包括活性炭颗粒或脱脂棉或竹炭纤维网之一或三者的混合物。
本实施例中,聚醚多元醇的毒性很低,常用作药物赋形剂和乳化剂,在口腔、鼻喷雾剂、眼、耳滴剂和洗发剂中都经常使用,聚醚多元醇系列产品在聚氨酯工业中,主要用于聚氨酯泡沫塑料,主要品种有聚氧化丙烯多元醇和聚四氢呋喃醚多元醇等用于制备硬质聚氨酯泡沫塑料,广泛应用于冰箱、冰柜、冷藏车、隔热板、管道保温等领域,在本发明中采用聚醚多元醇制得的组合物材料导热系数低,尺寸稳定好。
聚合物多元醇是以通用聚醚多元醇为基础聚醚,加丙烯腈、苯乙烯、甲基丙烯酸甲酯、醋酸乙烯酯、氯乙烯等乙烯基单体及引发剂,在100摄氏度左右和氮气保护下进行自由基接枝聚合而成,目前它是模塑及块状软质及半硬质聚氨酯泡沫塑料用多元醇的一类重要品种,可取代无机填料,不仅能使聚氨酯泡沫具有较高的承载能力和良好的回弹性能,还使泡沫的泡孔结构、物理机械性能得到改进。
延迟催化剂为DY225或DY8154,DY225即改性二甲氨基乙基醚二元醇溶液,具有延迟作用的发泡催化剂,可推迟乳白时间提高流动性,缩短脱模时间;DY8154为改性三乙烯二胺二元醇溶液,具有延迟作用的凝胶催化剂,可提高流动性和缩短脱模时间延迟凝胶催化剂,改善流动性,开孔性好.用于模塑高回弹、自结皮等。
改性交联剂采用三羟甲基丙烷或蓖麻油或季戊四醇,三者按照1:1:1混合制成的混合物,交联剂是聚烃类光致抗蚀剂的重要组成部分,具有光化学固化作用,依赖于带有双感光性官能团的交联剂参加反应,交联剂曝光后产生双自由基,它和聚烃类树脂相作用,在聚合物分子链之间形成桥键,变为三维结构的不溶性物质,提升主体结构的物理性能。
低发泡剂采用碳酸盐或烷烃和氟碳化合物,碳酸盐为一种无机发泡剂,使用较多的主要是碳酸钙、碳酸镁、碳酸氢钠,其中碳酸氢钠是白色粉末,分解温度约为100-1四十℃,并放出部分CO2,到270℃时失去全部CO2,溶于水而不溶于醇;烷烃和氟碳化合物发泡剂是复配型物理发泡剂,具有发泡倍数高、泡沫稳定性好、泌水量低等优点。
催化剂为脂肪族胺类催化剂和有机金属催化剂,其中,脂肪族胺类催化剂为DY-1双二甲氨基乙基醚或DY-5五甲基二乙烯三胺或DY-8二甲基环己胺或DY-12二月桂酸二丁基锡或DY-20有机铋或DY-41三嗪类三聚催化剂之一;脂肪族胺类催化剂在聚氨酯泡沫塑料的生产中,增强聚氨酯弹性体以及胶黏性,它对促进异氰酸酯基与羟基反映很有效,在有水分的配方中对水与异氰酸酯的反应也有一定的加速作用,有机金属化合物包括羧酸盐、金属烷基化合物等,所含的金属元素主要有锡、钾、铅、汞、锌等,最常用的是有机锡化合物。
本发明采用的增强扩链剂,是能与线型聚合物链上的官能团反应而使分子链扩展、分子量增大的物质,用于提高聚氨酯、聚酯等产品的力学性能和工艺性能,其工作原理是:在生产中,常用一些含活泼氢的化合物与异氰酸酯端基预聚物反应,致使分子链扩散延长,从而实现树脂的固化成形,对聚氨酯胶黏剂和密封剂的合成非常重要,直接影响产品的力学性能和工艺性能;本发明中增强扩链剂为2-咪唑烷酮常或1,4一丁二醇(BDO)或1,6一己二醇或甘油或三羟甲基丙烷或二甘醇(DEG)或三甘醇或新戊二醇(NPG)或山梨醇或二乙氨基乙醇等;胺类扩链剂有MOCA和用甲醛改性制得的液体MOCA或乙二胺(DA)或N,N-二羟基(二异丙基)苯胺(HPA)或氢醌一二(β一羟乙基)醚(HQEE)。
前述隔热吸波的自结皮聚氨酯组合物的制备方法,其包括以下步骤:
S1:原材料准备:按照设定的重量分别准备聚醚多元醇,聚合物多元醇、延迟催化剂、改性交联剂、低发泡剂、催化剂、吸波填料、增强扩链剂和吸尘材料;
S2:原料搅拌、发泡:将原材料中的聚醚多元醇,聚合物多元醇、吸波填料和吸尘材料输入密封的搅拌容器中,开启搅拌用的机械,在搅拌过程中逐步的注射加入延迟催化剂、改性交联剂、低发泡剂、催化剂和增强扩链剂。
S3:发泡注塑成型:经过充分混合的上述物质在密封的搅拌容器中发泡,当泡沫达到设定想标准后,通过阀门导入注塑机中,通过注塑机定量的向模具中注入设定量的泡沫,当一个模具中的泡沫填充完毕后,换一个模具继续注塑填充;
S4:塑性保持,稳定结构;注射结束的模具在设定的温度和压力状态下保持设定的时间,使得模具中填充的泡沫固化成型,在其表面自结皮,并且达到设定的力学要求;
S5:开模取料、修整裁切:打开经过塑性保持的模具,取出结构稳定的注塑的工件,对注塑工件的表面进行清理,清除多余的毛刺、注塑管,并且对模具的内腔进行清理,为下一次注塑做好准备;制得隔热吸波的自结皮聚氨酯组合物;
S6:成品检测:通过目测注塑产品的表面有无凸点、气孔等瑕疵,根据瑕疵的位置找出对应的模具内腔的部位进行调整,使用导热系数检测模块、吸波性能检测模块、电阻率检测模块、耐电压检测模块、抗拉强度检测模块和硬度检测模块的综合测试机械中,对聚氨酯注塑成品的导热系数、吸波性能、耐温范围、体积电阻率、耐电压、阻燃性、抗拉强度、硬度、厚度等进行测试,并将检测结果整理汇编成表格。
前述隔热吸波的自结皮聚氨酯组合物的制备设备,包括工作台1、注塑机2和混料罐3,工作台1为矩形板体,工作台1顶面的一端固定有注塑机2,注塑机2的顶端通过支架固定有混料罐3,混料罐3的底端连通有放料阀门4,放料阀门4连通注塑机2的入口,注塑机2的一侧设有水平注射杆5,工作台1顶面的另一侧固定安装有纵向导轨6,水平注射杆5位于纵向导轨6中心线的顶面,纵向导轨6的顶面活动嵌合有滑动块7,滑动块7顶面的中心转动连接有旋转工位台8,旋转工位台8的顶端固定安装有四个规格相同的发泡模具9,四个发泡模具9的一侧均设有入料口,水平注射杆5与四个发泡模具9的入料口间歇性配合对接,纵向导轨6的一端固定有伸缩驱动机构10,伸缩驱动机构10连接并带动滑动块7和旋转工位台8沿着纵向导轨6进行位移。
本实施例中,将设定比例的聚醚多元醇,聚合物多元醇、延迟催化剂、改性交联剂、低发泡剂、催化剂、吸波填料、增强扩链剂和吸尘材料按照工艺流程灌注进入混料罐3中,上述物料在其中进行发泡,待发泡丰富后,泡沫通过放料阀门4进入注塑机2中,与此同时,伸缩驱动机构10推动旋转工位台8靠近注塑机2,使得四个发泡模具9中的第一个注射模具模单体的开口与水平注射杆5对接导通,此时注塑机2通过水平注射杆5射出定量的泡沫注入与之对应的注射模具模单体的开口,当前的注射模具模单体充分灌注了发泡材料后,伸缩驱动机构10拉动旋转工位台8远离注塑机2,使得水平注射杆5与当前的注射模具模单体脱离,然后旋转工位台8旋转一个工位,将第二个注射模具模单体的开口对准水平注射杆5,然后伸缩驱动机构10重新推动旋转工位台8靠近注塑机2,使得第二个注射模具模单体的开口与水平注射杆5对接导通进行注塑,此时第一个注射模具模单体中的泡沫材料进行固化、成型,等到水平注射杆5对第三个注射模具模单体灌注泡沫时,第一个注射模具模单体可以进行开模、取料操作,等到水平注射杆5对第四个注射模具模单体灌注泡沫时,第一个注射模具模单体可以进行模具内腔的清理,为下一轮的发泡注塑进行准备。
具体的,混料罐3的底端嵌套连接有电加热圈301,混料罐3顶端的边侧连通有主料输送阀门302和辅料加注器303,辅料加注器303包含有单向阀门,混料罐3的内腔设有搅拌机304。
本实施例中,主料输送阀门302开启时向混料罐3中输入聚醚多元醇,聚合物多元醇、吸波填料和吸尘材料等主要原料,辅料加注器303开启时向混料罐3中输入延迟催化剂、改性交联剂、低发泡剂、催化剂和增强扩链剂等不可或缺的辅助原料,当混料罐3中填充有上述的混合物料后,搅拌机304开始搅拌,使得上述物料均匀的混合,电加热圈301对混料罐3的内腔和其中盛装的混合物进行加热,使得混合物处于最佳的发泡温度,令发泡更加的均匀。
具体的,注塑机2中设有定量加注泵201,定量加注泵201为螺杆泵或柱塞泵。
本实施例中,螺杆泵或柱塞泵均能够根据设定的发泡工艺定量、定速的将泡沫通过水平注射杆5输送至发泡模具9中,既能够令发泡模具9中灌注满泡沫,也避免输出多余的泡沫造成浪费。
具体的,伸缩驱动机构10为伺服电机-滚珠丝杆驱动副或伸缩气缸驱动副。
本实施例中,伺服电机-滚珠丝杆驱动副或伸缩气缸驱动副均能够安装设定的速度和行程带动旋转工位台8靠近或远离注塑机2,使得四个发泡模具9中的注射模具模单体的开口与水平注射杆5对接导通以及在发泡完毕后撤回,对下一个注射模具模单体进行注射泡沫。
具体的,滑动块7的边侧固定有伸缩销轴701,旋转工位台8的边侧设有定位销孔801,伸缩销轴701间歇性嵌合与之对应的定位销孔801。
本实施例中,当旋转工位台8旋转一个工位后,伸缩销轴701前伸嵌入与之对应的定位销孔801中,对旋转工位台8的转动角度进行精确的定位,以便水平注射杆5于当前处于注塑工位的注射模具模单体开口进行对接。
具体的,工作台1的一侧设有立柱11,立柱11上活动嵌合有升降保温扣罩12,升降保温扣罩12扣合与之对应的发泡模具9。
本实施例中,升降保温扣罩12对经过注塑的注射模具模单体进行保温,使其在最佳的温度固化成型,在其表面自结皮,并且使其内部达到设定的力学要求。
本发明的工作原理和工作流程是:将设定比例的聚醚多元醇,聚合物多元醇、延迟催化剂、改性交联剂、低发泡剂、催化剂、吸波填料、增强扩链剂和吸尘材料按照工艺流程灌注进入混料罐3中,上述物料在其中进行发泡,待发泡丰富后,泡沫通过放料阀门4进入注塑机2中,与此同时,伸缩驱动机构10推动旋转工位台8靠近注塑机2,使得四个发泡模具9中的第一个注射模具模单体的开口与水平注射杆5对接导通,此时注塑机2通过水平注射杆5射出定量的泡沫注入与之对应的注射模具模单体的开口,当前的注射模具模单体充分灌注了发泡材料后,伸缩驱动机构10拉动旋转工位台8远离注塑机2,使得水平注射杆5与当前的注射模具模单体脱离,然后旋转工位台8旋转一个工位,将第二个注射模具模单体的开口对准水平注射杆5,然后伸缩驱动机构10重新推动旋转工位台8靠近注塑机2,使得第二个注射模具模单体的开口与水平注射杆5对接导通进行注塑,此时第一个注射模具模单体中的泡沫材料通过升降保温扣罩12提供的温度区间内固化成型,在其表面自结皮,并且使其内部达到设定的力学要求,等到水平注射杆5对第三个注射模具模单体灌注泡沫时,第一个注射模具模单体可以进行开模、取料操作,等到水平注射杆5对第四个注射模具模单体灌注泡沫时,第一个注射模具模单体可以进行模具内腔的清理,为下一轮的发泡注塑进行准备。
实施例2:
本实施例提供的隔热吸波的自结皮聚氨酯组合物、制备方法及设备,基本上与实施例1相同,其不同之处在于:
本实施例中,该隔热吸波的自结皮聚氨酯组合物其具体由如下重量的组分制备而成:
聚醚多元醇:五十五份;聚合物多元醇:四十五份;延迟催化剂:一份;改性交联剂:五份;低发泡剂:十份;催化剂:零点五份;吸波填料:一百份,增强扩链剂:一点五份;吸尘材料六十份。
实施例3:
本实施例提供的隔热吸波的自结皮聚氨酯组合物制备方法及设备,基本上与实施例1、2均相同,其不同之处在于:
本实施例中,该隔热吸波的自结皮聚氨酯组合物,其具体由如下重量的组分制备而成:
聚醚多元醇:六十五份;聚合物多元醇:三十五份;延迟催化剂:一份;改性交联剂:五份;低发泡剂:十份;催化剂:零点五份;吸波填料:一百份,增强扩链剂:一点五份;吸尘材料六十份。
在其他实施例中,具体的组分及配比、工艺条件、组分及配比,可以在上述记载的范围内,根据需求选择,均可以达到本发明的技术效果;本发明不再一一列出。
本发明提供的隔热吸波的自结皮聚氨酯组合物制备方法及设备,重点通过对材料、工艺及设备同步进行改进,增加了材料的功能、提高了材料的性能,无需在模具内腔喷涂模内漆,改善了工作区域的环境,提高了工作效率。
最后应说明的是:以上仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。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 (9)
1.一种隔热吸波的自结皮聚氨酯组合物,其特征在于,其由如下重量份比例的原料制成:
聚醚多元醇:六十份;聚合物多元醇:四十份;延迟催化剂:一份;改性交联剂:五份;低发泡剂:十份;催化剂:零点五份;吸波填料:一百份,增强扩链剂:一点五份;吸尘材料六十份,其中,吸波填料包括氧化铝、氧化镁、氮化硼、氮化铝、氧化铍之一或其混合物,吸尘材料包括活性炭颗粒或脱脂棉或竹炭纤维网之一或三者的混合物。
2.根据权利要求1所述隔热吸波的自结皮聚氨酯组合物的制备方法,其特征在于:包括以下步骤:
S1:原材料准备:按照设定的重量分别准备聚醚多元醇,聚合物多元醇、延迟催化剂、改性交联剂、低发泡剂、催化剂、吸波填料、增强扩链剂和吸尘材料;
S2:原料搅拌、发泡:将原材料中的聚醚多元醇,聚合物多元醇、吸波填料和吸尘材料输入密封的搅拌容器中,开启搅拌用的机械,在搅拌过程中逐步的注射加入延迟催化剂、改性交联剂、低发泡剂、催化剂和增强扩链剂;
S3:发泡注塑成型:经过充分混合的上述物质在密封的搅拌容器中发泡,当泡沫达到设定想标准后,通过阀门导入注塑机中,通过注塑机定量的向模具中注入设定量的泡沫,当一个模具中的泡沫填充完毕后,换一个模具继续注塑填充;
S4:塑性保持,稳定结构;注射结束的模具在设定的温度和压力状态下保持设定的时间,使得模具中填充的泡沫固化成型,在其表面自结皮,并且达到设定的力学要求;
S5:开模取料、修整裁切:打开经过塑性保持的模具,取出结构稳定的注塑的工件,对注塑工件的表面进行清理,清除多余的毛刺、注塑管,并且对模具的内腔进行清理,为下一次注塑做好准备;制得隔热吸波的自结皮聚氨酯组合物。
3.根据权利要求2所述的隔热吸波的自结皮聚氨酯组合物的制备方法,其特征在于,其还包括以下步骤:
S6:成品检测:通过目测注塑产品的表面有无凸点、气孔等瑕疵,根据瑕疵的位置找出对应的模具内腔的部位进行调整,使用导热系数检测模块、吸波性能检测模块、电阻率检测模块、耐电压检测模块、抗拉强度检测模块和硬度检测模块的综合测试机械中,对聚氨酯注塑成品的导热系数、吸波性能、耐温范围、体积电阻率、耐电压、阻燃性、抗拉强度、硬度、厚度等进行测试,并将检测结果整理汇编成表格。
4.一种实施权利要求2-3所述方法的隔热吸波的自结皮聚氨酯组合物的制备设备,其特征在于:包括工作台(1)、注塑机(2)和混料罐(3),所述工作台(1)为矩形板体,所述工作台(1)顶面的一端固定有所述注塑机(2),所述注塑机(2)的顶端通过支架固定有所述混料罐(3),所述混料罐(3)的底端连通有放料阀门(4),所述放料阀门(4)连通所述注塑机(2)的入口,所述注塑机(2)的一侧设有水平注射杆(5),所述工作台(1)顶面的另一侧固定安装有纵向导轨(6),所述水平注射杆(5)位于所述纵向导轨(6)中心线的顶面,所述纵向导轨(6)的顶面活动嵌合有滑动块(7),所述滑动块(7)顶面的中心转动连接有旋转工位台(8),所述旋转工位台(8)的顶端固定安装有四个规格相同的发泡模具(9),四个所述发泡模具(9)的一侧均设有入料口,所述水平注射杆(5)与四个所述发泡模具(9)的入料口间歇性配合对接,所述纵向导轨(6)的一端固定有伸缩驱动机构(10),所述伸缩驱动机构(10)连接并带动所述滑动块(7)和所述旋转工位台(8)沿着所述纵向导轨(6)进行位移。
5.根据权利要求4所述的隔热吸波的自结皮聚氨酯组合物的制备设备,其特征在于:所述混料罐(3)的底端嵌套连接有电加热圈(301),所述混料罐(3)顶端的边侧连通有主料输送阀门(302)和辅料加注器(303),所述辅料加注器(303)包含有单向阀门,所述混料罐(3)的内腔设有搅拌机(304)。
6.根据权利要求4所述的隔热吸波的自结皮聚氨酯组合物的制备设备,其特征在于:所述注塑机(2)中设有定量加注泵(201),所述定量加注泵(201)为螺杆泵或柱塞泵。
7.根据权利要求4所述的隔热吸波的自结皮聚氨酯组合物的制备设备,其特征在于:所述伸缩驱动机构(10)为伺服电机-滚珠丝杆驱动副或伸缩气缸驱动副。
8.根据权利要求4所述的隔热吸波的自结皮聚氨酯组合物的制备设备,其特征在于:所述滑动块(7)的边侧固定有伸缩销轴(701),所述旋转工位台(8)的边侧设有定位销孔(801),所述伸缩销轴(701)间歇性嵌合与之对应的定位销孔(801)。
9.根据权利要求4所述的隔热吸波的自结皮聚氨酯组合物的制备设备,其特征在于:所述工作台(1)的一侧设有立柱(11),所述立柱(11)上活动嵌合有升降保温扣罩(12),所述升降保温扣罩(12)扣合与之对应的所述发泡模具(9)。
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