CN112537106A - 一种聚氨酯板材及其加工工艺和应用 - Google Patents

一种聚氨酯板材及其加工工艺和应用 Download PDF

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CN112537106A
CN112537106A CN202011408627.2A CN202011408627A CN112537106A CN 112537106 A CN112537106 A CN 112537106A CN 202011408627 A CN202011408627 A CN 202011408627A CN 112537106 A CN112537106 A CN 112537106A
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polyurethane
cloth
glass fiber
steel belt
conveying
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陈峻
崔青天
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Ningbo Yaozhong Molding Technology Co ltd
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
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Abstract

本发明公开了一种聚氨酯板材及其加工工艺和应用，包括加强芯层，加强芯层上下表面分别贴合有上表层和下表层，加强芯层由堆叠于玻纤网格布上的聚氨酯发泡料发泡而成。该聚氨酯板材结构简单，强度高，方便成型，成型效果好，使得表面更贴合，并且可提高生产效率，可大幅降低生产成本。

Description

一种聚氨酯板材及其加工工艺和应用
技术领域：
本发明涉及材料领域，具体而言是一种聚氨酯板材及其加工工艺和应用。
背景技术：
现有技术中，聚氨酯板材需要一定的厚度才能保证其强度和韧性，基于这个缺陷，特别是2mm以内的聚氨酯板材，非常脆，而且韧性差，在很多场景中缺少应用价值。
比如汽车遮阳板，为了实现比较好的韧性和强度，通常采用热压法生产汽车遮阳板，也就是说传统汽车遮阳板的原材料选用PU轻质泡沫，生产过程中，先将轻质泡沫双面通过设备涂满聚氨酯胶，之后在泡沫板两面放上玻纤毡，然后进一步放上热扎布，最后正面放上正面面料，背面放上背面面料，之后放到高温压机上，经过150℃高温20Mpa压力挤压120min左右成型，最后经过切割，修整后制成成品，但是这种生产方式过程繁琐，需要的原材料众多，用量也较大，且工艺繁琐，需要高温压制成型，成本较高，而且在生产过程中需要6个人左右进行完成，人力成本高，生产效率低。并且，在面料复合时，容易产生褶皱，甚至渗胶，特别是成型一些凹凸型面时，不容易贴合，此外，这种结构的板材，PU轻质泡沫容易分层，造成合格率不高，只能达到90％左右，而且成型熟化后容易变形。
发明内容：
本发明所要解决的技术问题是，提供一种方便加工，有效节省成本并且节能降耗的聚氨酯板材，该聚氨酯板材应用范围广，可以做到1.5-2mm这样的超薄结构，并且能保证具有较强的强度和韧性，扩展了应用范围。
本发明的技术解决方案是，提供一种聚氨酯板材，包括加强芯层，加强芯层上下表面分别贴合有上表层和下表层，加强芯层由堆叠于玻纤网格布上的聚氨酯发泡料发泡而成。结构简单，便于成型，且表面不易起皱，不易分层，强度高，韧性足，不易变形。
作为优选，玻纤网格布为预浸树脂或特氟龙溶液的预浸玻纤网格布。
作为优选，上表层和下表层为无纺布。
作为优选，无纺布为PP或PE无纺布。
进一步的，本发明还提供一种聚氨酯板材的生产工艺，包括以下步骤，
步骤一，预浸玻纤网格布和下表层布料利用卷送设备的输送，令预浸玻纤网格布叠设于下表层布料上，并通过输料机构向前输送，与此同时，位于输料机构上方的两个高压枪头对向喷射聚氨酯A料和聚氨酯B料并使相互混合的聚氨酯A料和聚氨酯B料堆叠于预浸玻纤网格布上，进入加压成型机构的加热钢带，利用加热钢带对进行加热使聚氨酯A料和聚氨酯B料发泡；
步骤二，然后通过加压成型机构的加热钢带和定厚辊之间留存的空隙进行定厚；
步骤三，上表层布料利用卷送设备输送，输送过程中在上表层布料的下表面辊涂或喷涂粘胶，然后叠合于聚氨酯发泡料上表面，加压成形机构通过多个转动线速度相等的辊轮和缠绕在多个辊轮上滚动的封闭加压钢带使得经加热钢带输送的预浸玻纤网格布、下表层面料以及聚氨酯发泡料和上表层布料在加压钢带上随加压钢带运动；进而使得当上下相叠的预浸玻纤网格布、下表层布料以及聚氨酯发泡料和上表层布料通过时在加压钢带与辊轮的接触位置加压贴合。
作为优选，加热钢带加热温度控制在25-60℃。
作为优选，加压贴合后进行分切，然后在40-50℃下进行熟化，时间控制在 15-80min。
作为优选，步骤三中，加压的压力控制在1-2MPa，压合时温度控制在 60-85℃，时间控制在5-30s。
进一步的，本发明的聚氨酯板材用于汽车配件、建材。比如汽车遮阳板，内饰板，家具板材，墙板，地板等。
采用以上技术方案后与现有技术相比，本发明具有以下优点：较好解决了分层的问题，该新型聚氨酯板材，相比现有结构的聚氨酯板材，在确保强度，韧性以及耐候性的前提下，简化了结构，方便成型，成型效果好，并且降低了成本，使得表面更贴合，不易起皱；其生产工艺，采用创新的生产流程和原料加工工艺，较传统的热压生产流程，首先不需要热轧布和PU轻质泡沫，玻纤也由原来的两层节省为一层，对原材料进行了节省，大大的降低了生产的原料成本，经测算，本发明的聚氨酯板材相比现有结构的汽车遮阳板，成本可大幅下降30％左右，其次是流程简单，一次成型，不需要高温挤压，实现了节能降耗的同时，工人的生产环境更为舒适，更加节省人力，整个流程只需要两个人完成，大大的降低了生产的人工成本。同时，通过在生产线上直接发泡和贴合，提高了生产效率，另外，相比在模腔中发泡成型，可减少聚氨酯发泡料的浪费，提高生产效率，如果在模腔中发泡，注射聚氨酯发泡料后，由于存在停歇时间，位于高压喷枪口的聚氨酯发泡料会因为部分发泡而堵塞喷孔，因此每次喷射后都需要及时进行清洗，造成时间和物料的浪费。
具体实施方式：
下面就具体实施方式对本发明作进一步说明：
一种聚氨酯板材，包括加强芯层，加强芯层上下表面分别贴合有上表层和下表层，加强芯层由堆叠于玻纤网格布上的聚氨酯发泡料发泡而成。本发明的聚氨酯板材结构简单，便于成型，且表面的表层不易起皱，各层之间不易分层，强度高，韧性足，不易变形。本实施例中，作为优选，玻纤网格布为预浸特氟龙溶液的预浸玻纤网格布，当然，也可以选用预浸树脂溶液的预浸玻纤网格布，从而提高其牢度和强度。并且，上表层和下表层为无纺布，作为优选，无纺布为PP或PE无纺布。
其中，上表层和下表层可通过粘接、螺丝钉或者卡扣等方式进行连接固定。
为了实现上述结构，聚氨酯板材的生产工艺，包括以下步骤，
步骤一，预浸玻纤网格布和下表层布料利用卷送设备的输送，令预浸玻纤网格布叠设于下表层布料上，并通过输料机构向前输送，与此同时，位于输料机构上方的两个高压枪头对向喷射聚氨酯A料和聚氨酯B料并使相互混合的聚氨酯A料和聚氨酯B料堆叠于预浸玻纤网格布上，进入加压成型机构的加热钢带，利用加热钢带对进行加热使聚氨酯A料和聚氨酯B料发泡，加热钢带加热温度控制在25-60℃，优选35℃；
步骤二，然后通过加压成型机构的加热钢带和定厚辊之间留存的空隙进行定厚，厚度可控制在1.7-8mm；
步骤三，上表层布料利用卷送设备输送，输送过程中在上表层布料的下表面辊涂或喷涂粘胶，然后叠合于聚氨酯发泡料上表面，加压成形机构通过多个转动线速度相等的辊轮和缠绕在多个辊轮上滚动的封闭加压钢带使得经加热钢带输送的预浸玻纤网格布、下表层面料以及聚氨酯发泡料和上表层布料在加压钢带上随加压钢带运动；进而使得当上下相叠的预浸玻纤网格布、下表层布料以及聚氨酯发泡料和上表层布料通过时在加压钢带与辊轮的接触位置加压贴合，加压的压力控制在2MPa，压合时温度控制在65℃，时间控制在10s。
作为优选，加压贴合后进行分切，然后在40℃下进行熟化，时间控制在 25min。
另外，可根据实际需要，待熟化完成后，再根据成型的板材进行边角修整。
需要说的是，本发明涉及的聚氨酯发泡料选用烟台万华市售产品，另外可根据需要添加其他添加剂例如颜料、抗老化剂、光稳定剂、阻燃剂等，这些都可以商业购得，且可以选择聚氨酯泡沫领域中的常用的具体物质，在此不再进行详细描述。
另外，发泡的具体操作步骤等技术手段，都是发泡领域非常公知的常规知识，其操作、工艺参数等都为本领域内的技术人员所熟知并可进行常规调整，在此不再进行详细描述。
本发明制备的聚氨酯板材，可应用多个领域，比如用于汽车配件、建材。更具体的，比如汽车遮阳板，内饰板，家具板材，墙板，地板等。
本发明的聚氨酯板材，相比现有结构的聚氨酯板材，较好解决了分层的问题，该新型聚氨酯板材，相比现有结构的聚氨酯板材，在确保强度，韧性以及耐候性的前提下，简化了结构，方便成型，成型效果好，并且降低了成本，使得表面更贴合，不易起皱；其生产工艺，采用创新的生产流程和原料加工工艺，较传统的热压生产流程，首先不需要热轧布和PU轻质泡沫，玻纤也由原来的两层节省为一层，对原材料进行了节省，大大的降低了生产的原料成本，经测算，本发明的聚氨酯板材相比现有结构的汽车遮阳板，成本可大幅下降30％左右，其次是流程简单，一次成型，不需要高温挤压，实现了节能降耗的同时，工人的生产环境更为舒适，更加节省人力，整个流程只需要两个人完成，大大的降低了生产的人工成本。同时，通过在生产线上直接发泡和贴合，提高了生产效率，另外，相比在模腔中发泡成型，可减少聚氨酯发泡料的浪费，提高生产效率，如果在模腔中发泡，注射聚氨酯发泡料后，由于存在停歇时间，位于高压喷枪口的聚氨酯发泡料会因为部分发泡而堵塞喷孔，因此每次喷射后都需要及时进行清洗，造成时间和物料的浪费。
以上仅就本发明较佳的实施例作了说明，但不能理解为是对权利要求的限制。凡是利用本发明说明书内容所做的等效结构或等效流程变换，均包括在本发明的专利保护范围之内。

Claims (9)

1.一种聚氨酯板材，其特征在于：包括加强芯层，加强芯层上下表面分别贴合有上表层和下表层，加强芯层由堆叠于玻纤网格布上的聚氨酯发泡料发泡而成。
2.根据权利要求1所述的聚氨酯板材，其特征在于：玻纤网格布为预浸树脂或特氟龙溶液的预浸玻纤网格布。
3.根据权利要求1所述的聚氨酯板材，其特征在于：上表层和下表层为无纺布。
4.根据权利要求3所述的聚氨酯板材，其特征在于：无纺布为PP或PE无纺布。
5.一种聚氨酯板材的加工工艺，其特征在于：包括以下步骤，
步骤一，预浸玻纤网格布和下表层布料利用卷送设备的输送，令预浸玻纤网格布叠设于下表层布料上，并通过输料机构向前输送，与此同时，位于输料机构上方的两个高压枪头对向喷射聚氨酯A料和聚氨酯B料并使相互混合的聚氨酯A料和聚氨酯B料堆叠于预浸玻纤网格布上，进入加压成型机构的加热钢带，利用加热钢带对进行加热使聚氨酯A料和聚氨酯B料发泡；
步骤二，然后通过加压成型机构的加热钢带和定厚辊之间留存的空隙进行定厚；
步骤三，上表层布料利用卷送设备输送，输送过程中在上表层布料的下表面辊涂或喷涂粘胶，然后叠合于聚氨酯发泡料上表面，加压成形机构通过多个转动线速度相等的辊轮和缠绕在多个辊轮上滚动的封闭加压钢带使得经加热钢带输送的预浸玻纤网格布、下表层面料以及聚氨酯发泡料和上表层布料在加压钢带上随加压钢带运动；进而使得当上下相叠的预浸玻纤网格布、下表层布料以及聚氨酯发泡料和上表层布料通过时在加压钢带与辊轮的接触位置加压贴合。
6.根据权利要求5所述的聚氨酯板材的加工工艺，其特征在于：加热钢带加热温度控制在25-60℃。
7.根据权利要求5所述的聚氨酯板材的加工工艺，其特征在于：加压贴合后进行分切，然后在40-50℃下进行熟化，时间控制在15-80min。
8.根据权利要求5所述的聚氨酯板材的加工工艺，其特征在于：步骤三中，加压的压力控制在1-2MPa，压合时温度控制在60-85℃，时间控制在5-30s。
9.一种如权利要求1-4任一项所述的聚氨酯板材的应用，其特征在于，所述聚氨酯板材用于汽车配件、建材。
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