CN111154414A - 一种阻燃环保碳纤维 - Google Patents

一种阻燃环保碳纤维 Download PDF

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CN111154414A
CN111154414A CN201911302141.8A CN201911302141A CN111154414A CN 111154414 A CN111154414 A CN 111154414A CN 201911302141 A CN201911302141 A CN 201911302141A CN 111154414 A CN111154414 A CN 111154414A
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retardant
carbon fiber
flame
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杨培良
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Changshu Junyou Plastic Products Co Ltd
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Abstract

本发明公开了一种阻燃环保碳纤维棉贴面，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层上，所述热熔胶层包括纤维过渡层和表面覆层，所述纤维过渡层由热熔胶与纤维棉混合构成，所述表面覆层内为单一的热熔胶。通过上述方式，本发明的产品在良好的隔热抗震性能之外还具有优良的环保阻燃特性，符合铁路客车对防护材料的小分子有害物质挥发的限制性要求。

Description

一种阻燃环保碳纤维
技术领域
本发明涉及保温材料领域，特别是涉及一种阻燃环保碳纤维。
背景技术
碳纤维棉作为一种优秀的阻燃防火保温材料，在高温下仍然能保持松散、柔软和良好的弹性与稳定性，并且高温收缩性和隔热隔温抗震吸音性能良好，是制作客车用保温贴面的良好材料，而常用的保温贴面由于保温棉和表面覆胶的材质的原因虽然保温效果不错，但是胶料中往往会有甲醛和苯类有害小分子挥发性物质出现，而且整体阻燃性能难以达到相关要求，不能直接使用在载人客车里。
发明内容
本发明主要解决的技术问题是提供一种阻燃环保碳纤维，能够具有良好的阻燃性能和散发特性。
为解决上述技术问题，本发明采用的一个技术方案是：提供一种阻燃环保碳纤维棉贴面，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层上，所述热熔胶层包括纤维过渡层和表面覆层，所述纤维过渡层由热熔胶与纤维棉混合构成，所述表面覆层内为单一的热熔胶。
在本发明一个较佳实施例中，所述阻燃碳纤维棉层由预制的阻燃碳纤维丝与低熔点聚酯纤维混合后经梳理机梳理成网，然后经双面针刺和热定型工序后制成。
在本发明一个较佳实施例中，所述热定型工序的定型温度为150~160℃。
在本发明一个较佳实施例中，所述低熔点聚酯纤维含量为纤维总量的3%~5%。
在本发明一个较佳实施例中，所述低熔点聚酯纤维中含有5~10%的有机硅阻燃剂。
在本发明一个较佳实施例中，所述有机硅阻燃剂为聚硼硅氧烷。
在本发明一个较佳实施例中，所述阻燃碳纤维丝由聚丙烯腈纤维炭化制成，所述聚丙烯腈纤维的纺丝原液中添加有纳米级二氧化硅，所述纳米级二氧化锑的添加量不超过所述原液中丙烯腈单体的3%。
在本发明一个较佳实施例中，所述热熔胶层的厚度为0.2~0.5mm，所述纤维过渡层的厚度不超过所述热熔胶层总厚度的2/3。
在本发明一个较佳实施例中，所述热熔胶层使用的热熔胶为EVA基热熔胶，所述EVA基热熔胶中添加有有机硅阻燃剂。
在本发明一个较佳实施例中，所述有机硅阻燃剂为聚硼硅氧烷，所述聚硼硅氧烷的添加量为热熔胶总量的3%。
本发明的有益效果是：本发明的技术方案是使用碳纤维棉作为原料制作铁路客场上用保温贴面，而且在生产过程中对所用的碳纤维和覆胶材料进行采用硅系阻燃处理，从而使整个碳纤维棉在具有良好的隔热抗震性能之外还具有优良的环保阻燃特性，符合铁路客车对防护材料的小分子有害物质挥发的性能要求。
附图说明
图1是本发明一较佳实施例的剖面结构示意图；
附图中各部件的标记如下：
1、阻燃碳纤维棉层、2、表面覆层、3、纤维过渡层。
具体实施方式
下面结合附图对本发明的较佳实施例进行详细阐述，以使本发明的优点和特征能更易于被本领域技术人员理解，从而对本发明的保护范围做出更为清楚明确的界定。
请参阅图1，本发明实施例包括：
实施例1
一种阻燃碳纤维棉贴面，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层1，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层1上，所述热熔胶层包括纤维过渡层3和表面覆层2，所述纤维过渡层3由热熔胶与纤维棉混合构成，所述表面覆层2内为单一的热熔胶。所述热熔胶层的厚度为0.2mm，所述纤维过渡层3的厚度为0.1~0.12mm，可以防止胶层与纤维棉之间结合力不够，导致在将所述碳纤维贴面高温贴附的时候出现纤维棉脱落的问题的同时防止表面覆层2的胶量过少，导致高温贴附时无法贴牢。。
所述阻燃碳纤维棉层1由预制的阻燃碳纤维丝与低熔点PET纤维混合后经梳理机梳理成网，然后经双面针刺和热定型工序后制成，采用双面针刺可以提高纤维交织程度和康分层性能，增强纤维棉层1的抗拉性能。所述热定型工序的定型温度为150~160℃，在此温度下低熔点PET纤维可以熔融后与将碳纤维粘合在一起。
所述低熔点PET纤维含量为纤维总量的3%，PET纤维含量过低，不利于后期定型，含量过高会影响整体性能，所述PET聚酯纤维中含有2%的聚硼硅氧烷阻燃剂,可以降低聚酯纤维燃烧和滴落能力。
所述阻燃碳纤维丝由聚丙烯腈纤维炭化制成，所述聚丙烯腈纤维的纺丝原液中添加有纳米级二氧化硅，所述纳米级二氧化硅的添加量为所述原液中丙烯腈单体总量的2%，通过此方式可以在纤维制作的过程中将纳米级二氧化硅融入最终的碳纤维丝中，从而提高整体的阻燃性能。
所述热熔胶层使用的热熔胶为EVA基热熔胶，所述EVA基热熔胶中添加有机硅阻燃剂，所述有机硅阻燃剂为聚硼硅氧烷，所述聚硼硅氧烷的添加量为热熔胶总量的3%。一方面EVA基热熔胶可以在保证粘合力的基础上降低含苯和含甲醛小分子的助剂使用量，而且与聚硼硅氧烷之间结合性能好，可以有效提高胶料的阻燃特性。
实施例2
一种阻燃碳纤维棉贴面，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层1，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层1上，所述热熔胶层包括纤维过渡层3和表面覆层2，所述纤维过渡层3由热熔胶与纤维棉混合构成，所述表面覆层2内为单一的热熔胶。所述热熔胶层的总厚度为0.3mm，所述纤维过渡层3的厚度0.1~0.2mm，可以防止胶层与纤维棉之间结合力不够，导致在将所述碳纤维贴面高温贴附的时候出现纤维棉脱落的问题的同时防止表面覆层2的胶量过少，导致高温贴附时无法贴牢。
所述碳纤维棉层1由预制的碳纤维丝与低熔点聚酯纤维混合后经梳理机梳理成网，然后经双面针刺和热定型工序后制成，采用双面针刺可以提高纤维交织程度和康分层性能，增强纤维棉层1的抗拉性能。所述热定型工序的定型温度为150~160℃，在此温度下低熔点PET纤维可以熔融后与将碳纤维粘合在一起。
所述低熔点PET纤维含量为纤维总量的4%，PET纤维含量过低，不利于后期定型，含量过高会影响整体性能，所述PET聚酯纤维中含有3%的聚硼硅氧烷阻燃剂,可以降低聚酯纤维燃烧和滴落能力。
所述碳纤维丝由聚丙烯腈纤维炭化制成，所述聚丙烯腈纤维的纺丝原液中添加有纳米级二氧化硅，所述纳米级二氧化硅的添加量为所述原液中丙烯腈单体总量的2%，通过此方式可以在纤维制作的过程中将二氧化硅融入最终的碳纤维丝中，从而提高整体的阻燃性能。
所述热熔胶层使用的热熔胶为EVA基热熔胶，所述EVA基热熔胶中添加有机硅阻燃剂，所述有机硅阻燃剂为聚硼硅氧烷，所述聚硼硅氧烷的添加量为热熔胶总量的3%。一方面EVA基热熔胶可以在保证粘合力的基础上降低含苯和含甲醛小分子的助剂使用量，而且与聚硼硅氧烷之间结合性能好，可以有效提高胶料的阻燃特性。
实施例3
一种阻燃碳纤维棉贴面，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层1，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层1上，所述热熔胶层包括纤维过渡层3和表面覆层2，所述纤维过渡层3由热熔胶与纤维棉混合构成，所述表面覆层2内为单一的热熔胶。所述热熔胶层的厚度为0.5mm，所述纤维过渡层3的厚度为0.2~0.3mm，可以防止胶层与纤维棉之间结合力不够，导致在将所述碳纤维贴面高温贴附的时候出现纤维棉脱落的问题的同时防止表面覆层2的胶量过少，导致高温贴附时无法贴牢。
所述碳纤维棉层1由预制的碳纤维丝与低熔点聚酯纤维混合后经梳理机梳理成网，然后经双面针刺和热定型工序后制成，采用双面针刺可以提高纤维交织程度和康分层性能，增强纤维棉层1的抗拉性能。所述热定型工序的定型温度为150~160℃，在此温度下低熔点PET纤维可以熔融后与将碳纤维粘合在一起。
所述低熔点PET纤维含量为纤维总量的5%，PET纤维含量过低，不利于后期定型，含量过高会影响整体性能，所述PET聚酯纤维中含有3%的聚硼硅氧烷阻燃剂,可以降低聚酯纤维燃烧和滴落能力。
所述碳纤维丝由聚丙烯腈纤维炭化制成，所述聚丙烯腈纤维的纺丝原液中添加有纳米级二氧化硅，所述纳米级二氧化硅的添加量为所述原液中丙烯腈单体总量的3%，通过此方式可以在纤维制作的过程中将二氧化硅融入最终的碳纤维丝中，从而提高整体的阻燃性能。
所述热熔胶层使用的热熔胶为EVA基热熔胶，所述EVA基热熔胶中添加有机硅阻燃剂，所述有机硅阻燃剂为聚硼硅氧烷，所述聚硼硅氧烷的添加量为热熔胶总量的3%。一方面EVA基热熔胶可以在保证粘合力的基础上降低含苯和含甲醛小分子的助剂使用量，而且与聚硼硅氧烷之间结合性能好，可以有效提高胶料的阻燃特性。
实施例4
一种阻燃碳纤维棉贴面，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层1，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层1上，所述热熔胶层包括纤维过渡层3和表面覆层2，所述纤维过渡层3由热熔胶与纤维棉混合构成，所述表面覆层2内为单一的热熔胶。所述热熔胶层的厚度为0.4mm，所述纤维过渡层3的厚度的0.2~0.25mm，可以防止胶层与纤维棉之间结合力不够，导致在将所述碳纤维贴面高温贴附的时候出现纤维棉脱落的问题的同时防止表面覆层2的胶量过少，导致高温贴附时无法贴牢。
所述碳纤维棉层由预制的碳纤维丝与低熔点PET纤维混合后经梳理机梳理成网，然后经双面针刺和热定型工序后制成，采用双面针刺可以提高纤维交织程度和康分层性能，增强纤维棉层的抗拉性能。所述热定型工序的定型温度为150~160℃，在此温度下低熔点PET纤维可以熔融后与将碳纤维粘合在一起。
所述低熔点PET纤维含量为纤维总量的4%，PET纤维含量过低，不利于后期定型，含量过高会影响整体性能，所述PET聚酯纤维中含有2%的聚硼硅氧烷阻燃剂,可以降低聚酯纤维燃烧和滴落能力。
所述碳纤维丝由聚丙烯腈纤维炭化制成，所述聚丙烯腈纤维的纺丝原液中添加有纳米级二氧化硅，所述纳米级二氧化硅的添加量为所述原液中丙烯腈单体总量的2%，通过此方式可以在纤维制作的过程中将二氧化硅融入最终的碳纤维丝中，从而提高整体的阻燃性能。
所述热熔胶层使用的热熔胶为EVA基热熔胶，所述EVA基热熔胶中添加有机硅阻燃剂，所述有机硅阻燃剂为聚硼硅氧烷，所述聚硼硅氧烷的添加量为热熔胶总量的3%。一方面EVA基热熔胶可以在保证粘合力的基础上降低含苯和含甲醛小分子的助剂使用量，而且与聚硼硅氧烷之间结合性能好，可以有效提高胶料的阻燃特性。
按照上述实施例1~4中所述内容制成的碳纤维保温贴面的阻燃性能检测结果见下表1：
表1炭纤维棉贴面阻燃性能检测表
Figure RE-321209DEST_PATH_IMAGE001
所述检测标准为ASTM E162 表面燃烧性能，所用检测方法为ASTM E162-15B用辐射热源评定材料表面燃烧性能的试验方法。
上述实施例1~4中使用的聚硅氧烷添加量为3%的EVA基热熔胶的游离甲醛检测结果见表2：
Figure RE-644874DEST_PATH_IMAGE002
上述实施例1~4中使用的聚硅氧烷添加量为3%的EVA基热熔胶的苯、甲苯+二甲苯挥发性检测结果见表3：
Figure RE-532934DEST_PATH_IMAGE003
上述实施例1~4中使用的聚硅氧烷添加量为3%的EVA基热熔胶的挥发性有机物质检测结果见表4：
Figure RE-708569DEST_PATH_IMAGE004
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

1.一种阻燃环保碳纤维棉贴面，其特征在于，所述阻燃碳纤维棉贴面为两层结构，其中一层为阻燃碳纤维棉层，另一层为热熔胶层，所述热熔胶层涂覆在所述阻燃碳纤维棉层上，所述热熔胶层包括纤维过渡层和表面覆层，所述纤维过渡层由热熔胶与纤维棉混合构成，所述表面覆层内为单一的热熔胶。
2.根据权利要求1所述的阻燃环保碳纤维，其特征在于，所述阻燃碳纤维棉层由预制的阻燃碳纤维丝与低熔点聚酯纤维混合后经梳理机梳理成网，然后经双面针刺和热定型工序后制成。
3.根据权利要求2所述的阻燃环保碳纤维，其特征在于，所述热定型工序的定型温度为150~160℃。
4.根据权利要求2所述的阻燃环保碳纤维，其特征在于，所述低熔点聚酯纤维含量为纤维总量的3%~5%。
5.根据权利要求2所述的阻燃环保碳纤维，其特征在于，所述低熔点聚酯纤维中含有5~10%的有机硅阻燃剂。
6.根据权利要求5所述的阻燃环保碳纤维，其特征在于，所述有机硅阻燃剂为聚硼硅氧烷。
7.根据权利要求2所述的阻燃碳纤维棉贴面，其特征在于，所述阻燃碳纤维丝由聚丙烯腈纤维炭化制成，所述聚丙烯腈纤维的纺丝原液中添加有纳米级二氧化硅，所述纳米级二氧化锑的添加量不超过所述原液中丙烯腈单体的3%。
8.根据权利要求1所述的阻燃环保碳纤维，其特征在于，所述热熔胶层的厚度为0.2~0.5mm，所述纤维过渡层的厚度不超过所述热熔胶层总厚度的2/3。
9.根据权利要求1所述的阻燃环保碳纤维，其特征在于，所述热熔胶层使用的热熔胶为EVA基热熔胶，所述EVA基热熔胶中添加有有机硅阻燃剂。
10.根据权利要求9所述的阻燃环保碳纤维，其特征在于，所述有机硅阻燃剂为聚硼硅氧烷，所述聚硼硅氧烷的添加量为热熔胶总量的3%。
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