CN111684125A - 具有改善的柔性、粘附力和表面强度的篷布及其制造方法 - Google Patents

具有改善的柔性、粘附力和表面强度的篷布及其制造方法 Download PDF

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CN111684125A
CN111684125A CN201980011842.8A CN201980011842A CN111684125A CN 111684125 A CN111684125 A CN 111684125A CN 201980011842 A CN201980011842 A CN 201980011842A CN 111684125 A CN111684125 A CN 111684125A
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10min
tarpaulin
ldpe
resin
multifilament yarns
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CN111684125B (zh
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郑恩下
金敬中
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Poly Tyco Co ltd
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Poly Tyco Co ltd
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  • Textile Engineering (AREA)
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  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

所公开的篷布包括：织物层和粘合到所述织物层的至少一个表面的树脂层。所述织物层包括：高密度聚乙烯(HDPE)复丝纱线；聚丙烯(PP)复丝纱线，其布置成与所述HDPE复丝纱线交叉；以及聚对苯二甲酸乙二醇酯(PET)底纱，其将所述HDPE复丝纱线和所述PP复丝纱线结合在一起。所述树脂层包括PP和低密度聚乙烯(LDPE)。

Description

具有改善的柔性、粘附力和表面强度的篷布及其制造方法
技术领域
本发明涉及一种篷布及其制造方法，更具体地涉及一种即使在较低的加工温度下也具有改善的柔性、粘附力和表面强度的篷布及其制造方法。
背景技术
篷布是可以用作防水帐篷、农业设施帐篷、临时帐篷等的防水织物，并且由于其轻便、柔软且耐用而被广泛使用。取决于所使用的原料，这些篷布可以分为聚乙烯(PE)基篷布、聚丙烯(PP)基篷布和聚氯乙烯(PVC)基篷布等。
PE基篷布是通过将低密度聚乙烯(LDPE)膜的一侧或两侧层压在通过纵切(slit)/拉伸高密度聚乙烯(HDPE)膜而获得的纵切纱线的织物或针织物上而形成的产品。PE基篷布具有生产工艺简单、成本节约、产品可回收利用、无毒的优点，但其耐久性和物理强度较弱。
PP基篷布是通过将均聚PP膜的一侧或两侧层压在通过纵切/拉伸均聚PP膜而获得的纵切纱线的织物或针织物上而形成的产品。PP基篷布具有拉伸强度高的优点，但其柔性较低。
PVC基篷布是通过将PVC膜层压或将液体PVC溶胶浸渍在聚酯复丝纱线制成的织物或针织物上而形成的产品。PVC基篷布可能具有良好的耐久性，因此可以长期使用。PVC基篷布具有比PE基篷布柔性更高的优点，但是其由于膜层的毒性而不能被回收和焚化。因此，增加了对生产和使用的限制。
近来，已经做出了很多努力来生产替代PVC基篷布的产品。因此，生产了用于在由PP复丝制成的针织物或织物上使用烯烃基共聚物(弹性体)和苯乙烯-乙烯-丁二烯共聚物(合成橡胶)形成防水层的产品。然而，这些产品具有均聚PP(其是织物的基本材料)的高挠曲弹性，并且其柔性显著低于PVC基篷布的聚酯织物的柔性。
另外，由于防水层的材料(弹性体和合成橡胶)的硬度较低，因此表面硬度可能显著低于PVC基篷布的表面硬度。
另外，为了维持PP复丝纱线织物和防水层之间的粘附力，用于形成防水层的加工温度为300℃到330℃，但是此高温加工可能会降低PP复丝纱线的拉伸强度。
此外，由于防水层材料的价格高于其它篷布主要材料(LDPE、均聚PP、PVC树脂糊)的价格，因此可能导致价格竞争力下降。
技术问题
本发明旨在解决这些问题，并提供具有改善的柔性、粘附力和表面硬度的篷布。
本发明的另一目的是提供一种制造篷布的方法。
技术方案
用于实现上述目的的篷布包含织物层和粘合到织物层的至少一个表面的树脂层。织物层可以包含高密度聚乙烯(HDPE)复丝纱线、布置成与HDPE复丝纱线交叉的聚丙烯(PP)复丝纱线，以及将HDPE复丝纱线和PP复丝纱线结合在一起的聚对苯二甲酸乙二醇酯(PET)底纱。树脂层可以包含PP和低密度聚乙烯(LDPE)。
在本发明的一个实施例中，其中HDPE复丝纱线的厚度可以为200旦尼尔到3000旦尼尔，PP复丝纱线的厚度可以为200旦尼尔到3000旦尼尔，并且PET底纱的厚度可以为30旦尼尔到150旦尼尔。
在本发明的一个实施例中，其中树脂层可以包含30到70重量％的LDPE和70到30重量％的PP。
在本发明的一个实施例中，其中树脂层可以包含30到50重量％的LDPE、30到50重量％的PP以及10到20重量％的烯烃基共聚物。
在本发明的一个实施例中，其中烯烃基共聚物可以是包括15到20重量％的乙烯单体和80到85重量％的丙烯单体的单体混合物的共聚物。
在本发明的一个实施例中，其中LDPE的熔融指数可以为5g/10min到20g/10min，PP的熔融指数可以为15g/10min到35g/10min，并且烯烃基共聚物的熔融指数可以为7g/10min到12g/10min。
根据本发明的一个实施例的制造篷布的方法可以包括：在包含螺杆的圆筒中将包含聚丙烯(PP)和低密度聚乙烯(LDPE)的树脂原料混合物捏合及熔融；将熔融树脂原料混合物以恒定量提供到T型模头；通过使熔融树脂原料混合物通过T型模头形成树脂膜；和粘合原料层和树脂膜。织物层包含高密度聚乙烯(HDPE)复丝纱线、布置成与HDPE复丝纱线交叉的PP复丝纱线，以及将HDPE复丝纱线和PP复丝纱线结合在一起的聚对苯二甲酸乙二醇酯(PET)底纱。捏合树脂原料混合物的步骤、将熔融树脂原料混合物提供到T型模头的步骤以及形成树脂膜的步骤在260℃或以下进行。
有利效果
根据本发明，代替昂贵的烯烃基共聚物，使用LDPE和PP来作为树脂层的主要材料。与常规的聚烯烃基篷布相比，它可以改善篷布的柔性、表面强度和抗裂性。另外，在常规的聚烯烃基篷布中，可能需要300℃或以上的高温来粘合树脂层和织物层，并且由于在低温下粘合时粘附强度降低而可能发生分离/剥离。由于本发明中使用的树脂材料可以在比常规树脂材料更低的温度(45℃或更高的温度差)下粘合到织物层，并且织物层的PP复丝纱线可以在高温加工时熔融，因此防止了最终产品的拉伸强度和撕裂强度的降低。
附图说明
图1是示出了根据本发明的一个实施例的篷布的截面图。
图2和3是示出了根据本发明的一个实施例的篷布的放大织物层的透视图。
图4是示出了根据本发明的一个实施例的制造篷布的方法和其中使用的装置的截面图。
图5是示出了根据本发明的一个实施例的制造篷布的方法中的T型模头的温度梯度的图。
具体实施方式
在本申请中，诸如第一和第二的术语可以用于描述各个组件，但是这些组件不应受到所述术语的限制。所述术语仅用于将一个组件与其它组件区分开的目的。例如，在不脱离本发明的范围的情况下，可以将第一组件称为第二组件，并且类似地，可以将第二组件称为第一组件。
本申请中使用的术语仅用于描述具体实施例，并且并非旨在限制本发明。除非上下文另外明确指示，否则单数表达包含复数表达。在本申请中，诸如“包含”或“具有”的术语旨在指示存在在说明书上描述的特征、数量、步骤、操作、组件、部分或其组合。应当理解，这并不排除一个或多个其它特征或数字、步骤、动作、组件、部分或其组合的存在或增加的可能性。
篷布
图1可以是示出了根据本发明的一个实施例的篷布的截面图。
根据本发明的一个实施例的篷布可以包含织物层10和树脂层20。织物层10可以是织物或针织物。树脂层20可以粘合到织物层10的两侧或一侧。
织物层10可以包含聚乙烯(PE)复丝纱线、聚丙烯(PP)复丝纱线和聚对苯二甲酸乙二醇酯(PET)底纱。优选地，PE复丝是高密度聚乙烯(HDPE)复丝纱线。HDPE复丝纱线和PP复丝纱线可以分别是经纱和纬纱或纬纱和经纱。PET底纱可以用作将经纱和纬纱结合在一起的锚(anchor)。在下文中，高密度聚乙烯(HDPE)和低密度聚乙烯(LDPE)的分类可以根据公知标准。
优选地，HDPE复丝纱线的厚度可以为200旦尼尔至3000旦尼尔，PP复丝纱线的厚度可以为200旦尼尔至3000旦尼尔，并且PET磨碎纱线的厚度可以为30旦尼尔至150旦尼尔。
当HDPE复丝纱线的厚度小于200旦尼尔时，在在织物层10上形成树脂层20的过程中，织物层10可以熔融并粘附到树脂层20。在这种情况下，织物层10的强度可能显著降低。另外，当HDPE复丝纱线的厚度超过3000旦尼尔时，由于织物层10的厚度可能过度增加，因此难以织造织物层10并层压树脂层20。
当PP复丝纱线的厚度小于200旦尼尔时，在在织物层10上形成树脂层20的过程中，织物层10可以熔融并粘附到树脂层20。在这种情况下，织物层10的强度可能显著降低。另外，当PP复丝纱线的厚度超过3000旦尼尔时，由于织物层10的厚度可能过度增加，因此难以织造织物层10并层压树脂层20。
与常规的PP底纱相比，当生产织物层10时，PET底纱可以通过显著减少断纱而大大改善生产效率。另外，PP底纱可能具有较低的熔点并且在形成树脂层20的过程中熔融，使得它可能不能将经纱和纬纱牢固地结合在一起。由此，可能降低织物的强度(撕裂强度)。
当PET底纱的厚度小于30旦尼尔时，断纱现象在织物层10的生产期间可能显著增加。另外，当PET底纱的厚度大于150旦尼尔时，底纱可能在层压树脂层20之后突出穿过树脂层20，从而显著降低防水效果。
根据本发明的一个实施例，树脂层20可以包含LDPE和PP。例如，树脂层20可以包含30到70重量％的LDPE和70到30重量％的PP。PP可以包含均聚PP或无规PP。
根据本发明的另一实施例，树脂层20可以包含LDPE、PP和烯烃基共聚物。例如，树脂层20可以包含10到70重量％的LDPE、10到70重量％的PP和10到70重量％的烯烃基共聚物。优选地，树脂层20可以包含30到50重量％的LDPE、30到50重量％的PP和10到20重量％的烯烃基共聚物。
当用于形成树脂层20的树脂混合物(捏合材料)进一步包含烯烃基共聚物时，熔体的均匀性可以增加，并且在熔体通过T型模头时可以防止减小树脂膜宽度的缩颈现象，并且可以改善膜的数值稳定性。当烯烃基共聚物的含量小于10重量％时，难以期待上述效果，并且当烯烃基共聚物的含量过多时，表面硬度可能降低，并且生产成本可能不必要地增加。根据一个实施例，基于烯烃的共聚物可以是包括15到20重量％的乙烯单体和80到85重量％的丙烯单体的单体混合物的共聚物。
根据一个实施例，树脂层20的LDPE的熔融指数可以优选为5g/10min到20g/10min。当LDPE的熔融指数低于5g/10min时，可能阻碍与其它原料的熔融捏合，并且树脂膜可能在T型模头头处不规则地破裂或掉落。另外，当LDPE的熔融指数超过20g/10min时，T型模头口处的颈缩现象可能大大增加。
根据一个实施例，树脂层20的PP的熔融指数可以优选为15g/10min到35g/10min。当PP的熔融指数低于15g/10min时，可能阻碍与其它原料的熔融捏合，并且树脂膜可能在T型模头头处不规则地破裂或掉落。另外，当PP的熔融指数超过35g/10min时，T型模头口处的颈缩现象可能大大增加。更优选地，PP的熔融指数为20g/10min到30g/10min。
根据一个实施例，用于形成树脂层20的树脂混合物的熔融指数可以为5g/10min到15g/10min。当树脂混合物的熔融指数低于5g/10min时，挤出涂层的生产率可能降低，并且可能对圆筒和T型模头施加过大的压力，因此所述过程难以进行。另外，当树脂混合物的熔融指数大于15g/10min时，可能发生颈缩现象。
优选地，树脂混合物的熔融指数可以为8g/10min到12g/10min。为了获得在上述范围内的熔融指数，烯烃基共聚物的熔融指数可以为7g/10min到12g/10min，并且LDPE和PP混合物的熔融指数可以优选为6g/10min到15g/10min。
除了所描述的原材料之外，树脂混合物可以进一步包含添加剂。例如，可以根据产品的目的和用途加入添加剂，例如填料、着色剂、紫外线稳定剂、阻燃剂和抗静电剂。
图2和3是示出了根据本发明的一个实施例的篷布的放大织物层的透视图。
参照图2，织物层10可以包含经纱11、纬纱12和底纱13a。经纱11和纬纱12中的任何一个可以是HDPE复丝纱线，并且另一个可以是PP复丝纱线。底纱13a可以是PET纱线。
例如，纬纱12可以设置在经纱11上，底纱13a可以具有沿着经纱11跨经纱11和纬纱12的交叉点加捻的Z排列结构。
参照图3，纬纱12可以设置在经纱11上。底纱13b可以在与经纱11相同的方向上延伸，并具有在经纱11和纬纱12的交点处加捻的I排列结构。
图2和3中示出的织物层的结构是示例性的，并且本发明可以不限于此并且可以具有已知适用于篷布的各种结构。
篷布的制造方法
图4是示出了根据本发明的一个实施例的制造篷布的方法和其中使用的装置的截面图。
参照图4，根据本发明的一个实施例的制造篷布的方法可以包含将树脂层20粘合到织物层10的步骤，并且可以使用树脂涂覆装置。
首先，可以通过树脂涂覆装置的料斗700输入树脂层的原料(例如，LDPE、PP和烯烃共聚物)。可以将树脂层的原料提供到圆筒600。施加到圆筒600的热量以及圆筒600内部的螺杆的旋转和线性运动可以使树脂层的原料熔融混合。
根据一个实施例，树脂层原料可以包含LDPE和PP。例如，树脂层原料可以包含30到70重量％的LDPE和70到30重量％的PP。PP可以包含均聚PP或无规PP。
根据本发明的另一实施例，树脂层原料可以包含LDPE、PP和烯烃基共聚物。例如，树脂层原料可以包含10到70重量％的LDPE、10到70重量％的PP和10到70重量％的烯烃基共聚物。优选地，树脂层原料可以包含30到50重量％的LDPE、30到50重量％的PP和10到20重量％的烯烃基共聚物。
由于树脂层原料可以与先前描述相同，因此将省略详细描述。
可以将熔融树脂混合物作为配接器500提供，并且配接器500可以以恒定量将熔融树脂混合物提供到T型模头100。筛网400可以设置在配接器500和T型模头100之间，并且异物等可以在使熔融树脂混合物通过筛网400的过程中被去除。
T型模头100可以由熔融树脂混合物形成树脂膜25。传送辊200和压紧辊300可以设置在T型模头100的下方。传送辊200可以传送织物层10，并且树脂膜25可以通过压紧辊300的压力耦合到织物层10的一个表面。例如，传送辊200可以是受压紧辊300的压力的橡胶辊，并且压紧辊300可以是压花辊。
通过使用树脂涂覆装置或具有相同配置的另一涂覆装置，可以在织物层的另一表面上进一步形成树脂层。
在树脂涂覆装置中，可以将热量施加到圆筒600、配接器500、筛网400和T型模头100以具有适当的加工温度。
根据一个实施例，圆筒600的温度可以为90℃到260℃，配接器500的温度可以为230℃到260℃，筛网400的温度可以为225℃到255℃。优选地，圆筒600的温度可以为90℃到245℃，配接器500的温度可以为230℃到245℃，筛网400的温度可以为225℃到240℃。
圆筒600的温度可以取决于位置而不同。例如，圆筒600的温度在靠近料斗700的区域中可以相对较低，并且可以随着其接近配接器500而逐渐升高。
图5可以是示出了根据本发明的一个实施例的制造篷布的方法中的T型模头的温度梯度的图。
T型模头100的温度可以取决于区域而不同。例如，T型模头100的温度可以沿着与排出树脂膜25的方向D1垂直的方向而不同。
例如，T型模头100的膜形成部分可以包含与中心区域C1间隔开的第一外围区域(P1)、在与第一外围区域P1相反的方向上与中心区域C1间隔开的第二外围区域P2、设置在中心区域C1和第一外围区域P1之间的第一中间区域M1以及设置在中心区域C1和第二外围区域P2之间的第二中间区域M2。
根据一个实施例，可以将中心区域C1、第一外围区域P1和第二外围区域P2加热到相同的第一温度，并且可以将第一中间区域M1和第二中间区域M2加热到高于第一温度的第二温度。
例如，第一温度可以为220℃到240℃，并且第二温度可以为230℃到250℃。
根据本发明的一个实施例，如上所述，可以通过T型模头100的温度分布来改善树脂层的平滑性。
根据本发明，代替昂贵的烯烃基共聚物，使用LDPE和PP来作为树脂层的主要材料。与常规的聚烯烃基篷布相比，它可以改善篷布的柔性、表面强度和抗裂性。另外，在常规的聚烯烃基篷布中，可能需要300℃或以上的高温来粘合树脂层和织物层，并且由于在低温下粘合时粘附强度降低而可能发生分离/剥离。由于本发明中使用的树脂材料可以在比常规树脂材料更低的温度(45℃或更高的温度差)下粘合到织物层，并且织物层的PP复丝纱线可以在高温加工时熔融，因此防止了最终产品的拉伸强度和撕裂强度的降低。
在下文中，将通过比较例的性能实验来描述根据本发明的一个实施例的篷布和本发明的效果。
实验例1
使用HDPE复丝纱线和PP复丝纱线作为经纱和纬纱，通过使用图4的树脂涂覆装置，在使用PET纱线作为底纱织造的织物(0.48mm厚，XTE350，Polytech IND)的两侧上形成树脂层(0.12mm厚)。
将用于形成树脂层的树脂原料与40重量％的LDPE(LDPE 963，HanwhaPetrochemical)、45重量％的均聚PP(4017M，Daehan Emulsion)和15重量％的烯烃基共聚物(CA207A，Lyondell Basell)混合，并根据以下表1和表2的温度条件进行加热/挤出/层压。在表1中，#1是靠近料斗的区域，并且#6是靠近配接器的区域。在表2中，#1和#9是最外面的区域，#5是中心区域，并且#2、#3、#6和#7是最外面的区域和中心区域之间的中间区域。
表1
部分 温度(℃)
圆筒#1 90～100
圆筒#2 110～130
圆筒#3 140～160
圆筒#4 170～200
圆筒#5 190～220
圆筒#6 200～240
配接器 240
筛网 235
表2
部分 温度(℃)
T型模头#1 230
T型模头#2 240
T型模头#3 240
T型模头#4 235
T型模头#5 230
T型模头#6 235
T型模头#7 240
T型模头#8 240
T型模头#9 230
作为比较例，在以下表3中示出了实验例1的篷布样本以及在PP复丝织物层上具有树脂层(由乙烯-丙烯-烯烃基共聚物和苯乙烯-乙烯-丁二烯共聚物组成)的篷布样本的撕裂强度(ASTM D751-06：梯形法)、耐磨性(表面硬度，ASTM D3884：泰伯(Taber)方法)和粘附力(分离织物层-树脂层后的目视观察)的估计结果。
表3
Figure BDA0002618841680000111
参照表3，可以看出，与常规的烯烃基篷布相比，根据本发明制造的篷布具有优异的撕裂强度、耐磨性和粘附力。
尽管参考如上所述的本发明的示例性实施例进行了描述，但是本领域技术人员可以在不脱离如以下权利要求所阐述的本发明的精神和范围的范围内改变本发明。可以理解，可以对其进行修改和更改。
工业适用性
本发明可以用于防水帐篷、农业设施帐篷、临时帐篷等。

Claims (11)

1.一种篷布，其包括：
织物层，其包含高密度聚乙烯(HDPE)复丝纱线、布置成与所述HDPE复丝纱线交叉的聚丙烯(PP)复丝纱线，以及将所述HDPE复丝纱线和所述PP复丝结合在一起的聚对苯二甲酸乙二醇酯(PET)底纱；和
树脂层，其粘合到所述织物层的至少一个表面；
其中所述树脂层包含所述PP和低密度聚乙烯(LDPE)。
2.根据权利要求1所述的篷布，其特征在于，所述HDPE复丝纱线的厚度为200旦尼尔到3000旦尼尔，所述PP复丝纱线的厚度为200旦尼尔到3000旦尼尔，并且所述PET底纱的厚度为30旦尼尔到150旦尼尔。
3.根据权利要求1所述的篷布，其特征在于，所述树脂层包含30到70重量％的所述LDPE和70到30重量％的所述PP。
4.根据权利要求1所述的篷布，其特征在于，所述树脂层包含30到50重量％的所述LDPE、30到50重量％的所述PP以及10到20重量％的烯烃基共聚物。
5.根据权利要求4所述的篷布，其特征在于，所述烯烃基共聚物是含有15到20重量％的乙烯单体和80到85重量％的丙烯单体的单体混合物的共聚物。
6.根据权利要求4所述的篷布，其特征在于，所述LDPE的熔融指数为5g/10min到20g/10min，所述PP的熔融指数为15g/10min到35g/10min，并且所述烯烃基共聚物的熔融指数为7g/10min到12g/10min。
7.一种制造篷布的方法：
在包含螺杆的圆筒中将含有聚丙烯(PP)和低密度聚乙烯(LDPE)的树脂原料混合物捏合及熔融；
将熔融树脂原料混合物以恒定量提供到T型模头；
通过使所述熔融树脂原料混合物通过所述T型模头形成树脂膜；和
梳理织物层和所述树脂膜，所述织物层包含高密度聚乙烯(HDPE)复丝纱线、布置成与所述HDPE复丝纱线交叉的PP复丝纱线，以及将所述HDPE复丝纱线和所述PP复丝结合在一起的聚对苯二甲酸乙二醇酯(PET)底纱；
捏合所述树脂原料混合物的步骤、将所述熔融树脂原料混合物提供到所述T型模头的步骤以及形成所述树脂膜的步骤在260℃或以下进行。
8.根据权利要求7所述的方法，其特征在于，所述树脂层包含30到70重量％的所述LDPE和70到30重量％的所述PP。
9.根据权利要求7所述的方法，其特征在于，所述树脂层包含30到50重量％的所述LDPE、30到50重量％的所述PP和10到20重量％的烯烃基共聚物。
10.根据权利要求9所述的方法，其特征在于，所述烯烃基共聚物是含有15到20重量％的乙烯单体和80到85重量％的丙烯单体的单体混合物的共聚物。
11.根据权利要求9所述的方法，其特征在于，所述LDPE的熔融指数为5g/10min到20g/10min，所述PP的熔融指数为15g/10min到35g/10min，并且所述烯烃基共聚物的熔融指数为7g/10min到12g/10min，并且所述混合树脂原料混合物的熔融指数为8g/10min到12g/10min。
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