CN111038010B - 一种泡沫压填式蜂窝复合板及制备方法 - Google Patents

一种泡沫压填式蜂窝复合板及制备方法 Download PDF

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CN111038010B
CN111038010B CN201911413613.7A CN201911413613A CN111038010B CN 111038010 B CN111038010 B CN 111038010B CN 201911413613 A CN201911413613 A CN 201911413613A CN 111038010 B CN111038010 B CN 111038010B
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丁响亮
徐钢
翁柳燕
王亚南
刘国旺
楼娣
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Zhejiang Huajiang Technology Co ltd
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Abstract

本发明公开了一种泡沫压填式蜂窝复合板及制备方法，复合板从上到下依次是面料层、蜂窝复合芯层和面料层，蜂窝复合芯层是通过平板压力机将聚氨酯吸音泡沫直接压填至蜂窝芯制得，特殊多元醇组合料配方为55～70重量份的多元醇A；20～30重量份的多元醇B；8～15重量份的泡沫脆化剂等，本发明制备的泡沫压填式蜂窝复合板，采用聚氨酯吸音泡沫压填至蜂窝芯、再复合面料的工艺，制备方法简便、易操作，生产过程无三废污染，安全环保，聚氨酯吸音泡沫利用大量的低成本泡沫脆化剂，泡沫脆性大，可快速直接压填至蜂窝芯中，一步到位，生产效率高。

Description

一种泡沫压填式蜂窝复合板及制备方法
技术领域
本发明涉及结构复合材料领域，具体地说，涉及一种抗压、轻质、吸音的泡沫压填式蜂窝复合板及制备方法。
背景技术
常见的蜂窝板芯材包括芳纶蜂窝、铝蜂窝、聚丙烯蜂窝、纸蜂窝等，蜂窝芯为轻质材料，垂直于孔格展开方向的剪切强度高。蜂窝板由于特殊的结构，具有高抗压强度和质量轻的优点，被广泛地应用在轻量化产品中，应用领域包括航空、船舶、汽车、列车、电信、建筑和体育器材等。
蜂窝材料的应用领域中经常要求产品需要良好的吸音性能，而普通的蜂窝材料往往难以实现。专利CN 107825788 A公开了一种吸音蜂窝板，由蜂窝板上下两层热压复合含胶水的玻纤板和微穿孔吸音板构成。微穿孔吸音板的引入，尽管对材料的吸音性能有所帮助，但是复合在蜂窝板表面上的微穿孔吸音板容易遭到破坏，有效使用期短。另外微穿孔吸音板重量大，这种吸音蜂窝板很难实现轻量化。
发明内容
本发明目的在于克服上述不足，提供一种吸音有效期长、轻量化、制备工艺简单和高抗压强度的泡沫压填式蜂窝复合板及制备方法。
本发明是通过以下技术方案来实现的：
本发明公开了一种轻质吸音的泡沫压填式蜂窝复合板，复合板从上到下依次是面料层、蜂窝复合芯层和面料层。
作为进一步地改进，本发明蜂窝复合芯层是通过平板压力机将聚氨酯吸音泡沫直接压填至蜂窝芯制得，蜂窝芯为通孔柱形结构蜂窝芯，蜂窝芯为金属蜂窝芯或纸蜂窝芯或塑料蜂窝芯；聚氨酯吸音泡沫是由特殊多元醇组合料和异氰酸酯发泡制得。
作为进一步地改进，本发明所述的特殊多元醇组合料配方如下：
55～70重量份的多元醇A；
20～30重量份的多元醇B；
8～15重量份的泡沫脆化剂；
3.5～8重量份的发泡剂；
0.8～1.2重量份的硅油匀泡剂；
0.8～1.2重量份的开孔剂；
0.35～0.6重量份的催化剂；
0.8～1.2重量份的抗氧剂。
作为进一步地改进，本发明所述的多元醇A是以蔗糖为起始剂的聚醚多元醇，羟值为450±20mgKOH/g；多元醇B是以丙三醇为起始剂的聚醚多元醇，羟值为33±2mgKOH/g。
作为进一步地改进，本发明所述的泡沫脆化剂是由重量比为1:1的工业级丙三醇和无机填料组成，无机填料为高岭土、碳酸钙、蒙脱土中的一种或多种，粒径为0.5-6微米。泡沫脆化剂是由重量之比为1:1的工业级丙三醇和无机填料组成，是不可或缺的组分。丙三醇分子量低、活性高，发泡过程与异氰酸酯快速反应，形成的聚氨酯分子链段苯环之间距离短，形成很长的硬段，从而起到泡沫脆化的作用；无机填料的加入，使原料中的官能团接触率降低，阻碍了部分凝胶反应，从而弱化泡沫的延伸率，达到泡沫脆化的效果。
作为进一步地改进，本发明所述的发泡剂为水；硅油匀泡剂为开孔型硅油和成核型硅油的混合物，重量比为1:0.5～2；开孔剂为ALLCHEM 3363；抗氧剂为巴斯夫的PUR70。发泡剂为水，根据发泡剂的添加量控制泡沫的密度；硅油匀泡剂，调整合适的泡孔；一般催化剂对泡沫产生的气味贡献大，本发明催化剂为反应型平衡胺类催化剂，降低了操作者对聚氨酯泡沫的不舒适度；抗氧剂为巴斯夫的PUR70，散发性非常低，并且具有优异的抗气熏变色性能。
作为进一步地改进，本发明所述的异氰酸酯为MDI体系异氰酸酯，NCO的含量为30.5～32.0wt％，多元醇组合料与异氰酸酯的重量比为1:1.4～1:2.1。之所以控制在此范围内，是因为：两者重量比低于1:1.4，泡沫无法达到脆性目的，重量比高于1:2.1，发泡过程的平衡难以控制，容易出现发泡异常。
作为进一步地改进，本发明所述的多元醇组合料与异氰酸酯的重量比为1:1.65～1:1.85。之所以控制在此范围内，泡沫脆性高、开孔好，发泡工艺宽容度高，发泡的工艺更容易掌控，不会因发泡环境的温湿差异大导致得到的泡沫差异大。
本发明还公开了一种轻质吸音的泡沫压填式蜂窝复合板的制备方法，将同等厚度和大小的聚氨酯吸音泡沫板和蜂窝芯叠放于平板压力机的平板之间，采用泡沫板上蜂窝芯下或者蜂窝芯上泡沫板下的叠放方式，利用平板压力机将聚氨酯吸音泡沫快速压填至蜂窝芯，泡沫填满蜂窝孔，得到同原有厚度的蜂窝复合芯层；再利用复合机将面料粘合在蜂窝复合芯层上下表面，制备出泡沫压填式蜂窝复合板。
作为进一步地改进，本发明所述的聚氨酯吸音泡沫的制备步骤如下：
1)、先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌2～3小时，得到均匀的体系A，控制料温在20～28℃；
2)、控制异氰酸酯的料温在20～28℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应。控制好料温可保证发泡过程平稳，不会出现塌泡、裂泡，泡沫开孔好。
与现有技术相比，本发明的有益效果如下：
1)、本发明制备的泡沫压填式蜂窝复合板，采用聚氨酯吸音泡沫压填至蜂窝芯、再复合面料的工艺，制备方法简便、易操作，生产过程无三废污染，安全环保。
2)、本发明制备的聚氨酯吸音泡沫利用大量的低成本泡沫脆化剂，泡沫脆性大，可快速直接压填至蜂窝芯中，一步到位，生产效率高。
3)、本发明泡沫配方在引入泡沫脆化剂的前提下，合理地选择其它原料，调整发泡平衡，制备的泡沫密度低、开孔率高。
4)、本发明结合了泡沫吸音性能好、蜂窝材料抗压强度高、两者重量轻的优势，制备的复合板能够适用于特殊降噪、抗压要求的场合，生产成本低，能够实现批量生产。
5)、本发明的泡沫脆化剂是由重量之比为1:1的工业级丙三醇和无机填料组成，是不可或缺的组分，丙三醇分子量低、活性高，发泡过程与异氰酸酯快速反应，形成的聚氨酯分子链段苯环之间距离短，形成很长的硬段，从而起到泡沫脆化的作用，无机填料为高岭土、碳酸钙、蒙脱土中的一种或多种，粒径0.5-6微米，无机填料的加入，使原料中的官能团接触率降低，阻碍了部分凝胶反应，从而弱化泡沫的延伸率，达到泡沫脆化的效果。
6)、本发明所用发泡剂为水，根据发泡剂的添加量控制泡沫的密度；硅油匀泡剂为开孔型硅油和成核型硅油的混合物，重量比为1:0.5～2，调整合适的泡孔；一般催化剂对泡沫产生的气味贡献大，催化剂为反应型平衡胺类催化剂，降低了操作者对聚氨酯泡沫的不舒适度；抗氧剂为巴斯夫的PUR70，散发性非常低，并且具有优异的抗气熏变色性能。
7)、本发明多元醇组合料与异氰酸酯的重量比为1:1.4～1:2.1。之所以控制在此范围内，是因为：两者重量比低于1:1.4，泡沫无法达到脆性目的，重量比高于1:2.1，发泡过程的平衡难以控制，容易出现发泡异常。优选多元醇组合料与异氰酸酯的重量比为1:1.65～1:1.85，之所以控制在此范围内，泡沫脆性高、开孔好，发泡工艺宽容度高，发泡的工艺更容易掌控，不会因发泡环境的温湿差异大导致得到的泡沫差异大。
8)、本发明工艺是控制异氰酸酯的料温在20～28℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应，控制好料温可保证发泡过程平稳，不会出现塌泡、裂泡，泡沫开孔好。
附图说明
图1为本发明吸音复合板的正视图；
图2为图1的A-A剖视图；
其中：蜂窝复合芯层1、面料2、蜂窝孔3、聚氨酯吸音泡沫4。
具体实施方式
本发明公开了一种轻质吸音的泡沫压填式蜂窝复合板，图1为本发明吸音复合板的正视图，图2为图1的A-A剖视图；复合板从上到下依次是面料2层、蜂窝复合芯层1和面料2层，蜂窝复合芯层1是通过平板压力机将聚氨酯吸音泡沫4直接压填至蜂窝芯制得，蜂窝芯为通孔柱形结构蜂窝芯，蜂窝芯为金属蜂窝芯或纸蜂窝芯或塑料蜂窝芯；聚氨酯吸音泡沫4是由特殊多元醇组合料和异氰酸酯发泡制得。
下面通过具体实施例对本发明的技术方案作进一步地说明：
实施例1
聚氨酯吸音泡沫4是由多元醇组合料和异氰酸酯经发泡制得，多元醇组合料和异氰酸酯的重量比为1:2.1，其中：
多元醇组合料各组份为，以重量份数计：
Figure BDA0002350609670000051
先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌2小时，得到均匀的体系A，控制料温28℃；控制异氰酸酯的料温28℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应。
将制备出的聚氨酯吸音泡沫4切割出规格1m*1m*15mm的裸板和同规格的圆柱形结构纸蜂窝芯叠放于平板压力机的平板之间，采用泡沫板上蜂窝芯下的叠放方式，利用平板压力机将聚氨酯吸音泡沫4快速压填至蜂窝芯，泡沫填满蜂窝孔3，得到同规格的蜂窝复合芯层1；利用复合机将面料2粘合在蜂窝复合芯层1上下表面，制备出泡沫压填式蜂窝复合板。
实施例2
聚氨酯吸音泡沫4是由多元醇组合料和异氰酸酯经发泡工艺制得，多元醇组合料和异氰酸酯的重量比为1:1.4，其中：
多元醇组合料各组份为，以重量份数计：
Figure BDA0002350609670000052
Figure BDA0002350609670000061
先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌3小时，得到均匀的体系A，控制料温20℃；控制异氰酸酯的料温20℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应。
将制备出的聚氨酯吸音泡沫4切割出规格1m*1m*20mm的裸板和同规格的六棱柱结构纸蜂窝芯叠放于平板压力机的平板之间，采用泡沫板上蜂窝芯下的叠放方式，利用平板压力机将聚氨酯吸音泡沫4快速压填至蜂窝芯，泡沫填满蜂窝孔3，得到同规格的蜂窝复合芯层1；利用复合机将面料2粘合在蜂窝复合芯层1上下表面，制备出泡沫压填式蜂窝复合板。
实施例3
聚氨酯吸音泡沫4是由多元醇组合料和异氰酸酯经发泡工艺制得，多元醇组合料和异氰酸酯的重量比为1:1.65，其中：
多元醇组合料各组份为，以重量份数计：
Figure BDA0002350609670000062
先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌2小时，得到均匀的体系A，控制料温23℃；控制异氰酸酯的料温22℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应。
将制备出的聚氨酯吸音泡沫4切割出规格1m*2m*30mm的裸板和同规格的六棱柱结构纸蜂窝芯叠放于平板压力机的平板之间，采用蜂窝芯上泡沫板下的叠放方式，利用平板压力机将聚氨酯吸音泡沫4快速压填至蜂窝芯，泡沫填满蜂窝孔3，得到同规格的蜂窝复合芯层1；利用复合机将面料2粘合在蜂窝复合芯层1上下表面，制备出泡沫压填式蜂窝复合板。
实施例4
聚氨酯吸音泡沫4是由多元醇组合料和异氰酸酯经发泡工艺制得，多元醇组合料和异氰酸酯的重量比为1:1.85，其中：
多元醇组合料各组份为，以重量份数计：
Figure BDA0002350609670000071
先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌2.5小时，得到均匀的体系A，控制料温25℃；控制异氰酸酯的料温22℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应。
将制备出的聚氨酯吸音泡沫4切割出规格1m*0.5m*10mm的裸板和同规格的六棱柱结构聚丙烯蜂窝芯叠放于平板压力机的平板之间，采用蜂窝芯上泡沫板下的叠放方式，利用平板压力机将聚氨酯吸音泡沫4快速压填至蜂窝芯，泡沫填满蜂窝孔3，得到同规格的蜂窝复合芯层1；利用复合机将面料2粘合在蜂窝复合芯层1上下表面，制备出泡沫压填式蜂窝复合板。
实施例5
聚氨酯吸音泡沫4是由多元醇组合料和异氰酸酯经发泡工艺制得，多元醇组合料和异氰酸酯的重量比为1:1.78，其中：
多元醇组合料各组份为，以重量份数计：
Figure BDA0002350609670000081
先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌2.5小时，得到均匀的体系A，控制料温20℃；控制异氰酸酯的料温22℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应。
将制备出的聚氨酯吸音泡沫4切割出规格1m*0.5m*10mm的裸板和同规格的六棱柱结构聚丙烯蜂窝芯叠放于平板压力机的平板之间，采用蜂窝芯上泡沫板下的叠放方式，利用平板压力机将聚氨酯吸音泡沫4快速压填至蜂窝芯，泡沫填满蜂窝孔3，得到同规格的蜂窝复合芯层1；利用复合机将面料2粘合在蜂窝复合芯层1上下表面，制备出泡沫压填式蜂窝复合板。
实施例6
与实施例4相比，仅仅将蜂窝芯和泡沫裸板规格都变为1m*0.5m*20mm，其它制备工艺均不变，制备出泡沫压填式蜂窝复合板。
实施例7
与实施例4相比，仅仅将压板时叠放方式变为泡沫板上蜂窝芯下，其它制备工艺均不变，制备出泡沫压填式蜂窝复合板。
对比例1
与实施例4相比，仅仅发泡时多元醇组合料中不加入开孔剂，其它制备工艺均不变，制备出泡沫压填式蜂窝复合板。
对比例2
与实施例4相比，仅仅发泡时多元醇组合料中不加入泡沫脆化剂，其它制备工艺不变，制备出泡沫压填式蜂窝复合板。
对比例3
与实施例4相比，仅仅改变发泡时多元醇组合料中多元醇A为90重量份、多元醇B为0，其它制备工艺不变，制备出泡沫压填式蜂窝复合板。
对比例4
与实施例4相比，仅仅改变发泡时多元醇组合料中多元醇A为0、多元醇B为90，其它制备工艺不变，制备出泡沫压填式蜂窝复合板。
对比例5
与实施例4相比，仅仅改变发泡时泡沫脆化剂为18重量份，其它制备工艺不变，制备出泡沫压填式蜂窝复合板。表1实施例和对比例的产品物性
Figure BDA0002350609670000091
Figure BDA0002350609670000101
使用本发明制备的泡沫压填式蜂窝复合板具有良好的吸音性能，并且泡沫压填至蜂窝内工艺简单、易操作。通过实施例4和对比例1-5的结果：开孔剂的有无对泡沫的吸音性能关键作用；泡沫脆化剂的加入并控制在合适范围内，使泡沫容易压填至蜂窝内并且泡沫不会受损；多元醇A和多元醇B的合理配比，赋予泡沫对本发明复合板优异的基础适用性，不会使泡沫过于回弹或过于坚硬，导致泡沫无法实现压填。
最后，还需要注意的是，以上列举的仅是本发明的具体实施例。显然，本发明不限于以上实施例，还可以有许多变形。本领域的普通技术人员能从本发明公开的内容直接导出或联想到的所有变形，均应认为是本发明的保护范围。

Claims (3)

1.一种轻质吸音的泡沫压填式蜂窝复合板，其特征在于，所述的复合板从上到下依次是面料(2)层、蜂窝复合芯层(1)和面料(2)层，所述的蜂窝复合芯层(1)是通过平板压力机将聚氨酯吸音泡沫(4)直接压填至蜂窝芯制得，所述的蜂窝芯为通孔柱形结构蜂窝芯，所述的蜂窝芯为金属蜂窝芯或纸蜂窝芯或塑料蜂窝芯；所述的聚氨酯吸音泡沫(4)是由特殊多元醇组合料和异氰酸酯发泡制得，所述的特殊多元醇组合料配方如下：
55～70重量份的多元醇A；
20～30重量份的多元醇B；
8～15重量份的泡沫脆化剂；
3.5～8重量份的发泡剂；
0.8～1.2重量份的硅油匀泡剂；
0.8～1.2重量份的开孔剂；
0.35～0.6重量份的催化剂；
0.8～1.2重量份的抗氧剂；
所述的多元醇A是以蔗糖为起始剂的聚醚多元醇，羟值为450±20mgKOH/g；所述的多元醇B是以丙三醇为起始剂的聚醚多元醇，羟值为33±2mgKOH/g；
所述的泡沫压填式蜂窝复合板的制备方法如下：
将同等厚度和大小的聚氨酯吸音泡沫(4)板和蜂窝芯叠放于平板压力机的平板之间，采用泡沫板上蜂窝芯下或者蜂窝芯上泡沫板下的叠放方式，利用平板压力机将聚氨酯吸音泡沫(4)快速压填至蜂窝芯，泡沫填满蜂窝孔(3)，得到同原有厚度的蜂窝复合芯层(1)；再利用复合机将面料(2)粘合在蜂窝复合芯层(1)上下表面，制备出泡沫压填式蜂窝复合板；
所述的聚氨酯吸音泡沫(4)的制备步骤如下：
1)、先将称量好的多元醇组合料的各个组分，除了无机填料，将其它成份加入反应釜中搅拌2～3小时，得到均匀的体系A，控制料温在20～28℃；
2)、控制异氰酸酯的料温在20～28℃，将体系A先和无机填料混合均匀，再注入异氰酸酯混合均匀进行发泡反应；
所述的泡沫脆化剂是由重量比为1:1的工业级丙三醇和无机填料组成，所述的无机填料为高岭土、碳酸钙、蒙脱土中的一种或多种，粒径为0.5-6微米；
所述的异氰酸酯为MDI体系异氰酸酯，NCO的含量为30.5～32.0wt％，所述的多元醇组合料与异氰酸酯的重量比为1:1.4～1:2.1。
2.根据权利要求1所述的轻质吸音的泡沫压填式蜂窝复合板，其特征在于，所述的发泡剂为水，所述的硅油匀泡剂为开孔型硅油和成核型硅油的混合物，重量比为1:0.5～2，所述的开孔剂为ALLCHEM3363，所述的抗氧剂为巴斯夫的PUR70。
3.根据权利要求1所述的轻质吸音的泡沫压填式蜂窝复合板，其特征在于，所述的多元醇组合料与异氰酸酯的重量比为1:1.65～1:1.85。
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CN105418878B (zh) * 2015-12-21 2018-05-04 浙江华江科技股份有限公司 一种以再生聚醚多元醇为原料生产的高密度高韧性聚氨酯泡沫及其制备方法
CN205553379U (zh) * 2015-12-31 2016-09-07 莱州市金田复合材料有限公司 饰面蜂窝强化复合板
CN106432677B (zh) * 2016-09-29 2019-07-09 上海东大聚氨酯有限公司 组合聚醚、聚氨酯原料组合物、仿木材料及制备方法
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