CN112544300B - 一种宽幅高耐候性转光棚膜及其制备方法 - Google Patents
一种宽幅高耐候性转光棚膜及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种宽幅高耐候性转光棚膜及其制备方法,属于农膜技术领域,所述棚膜具有通过挤出吹塑成型五层或七层结构,芯层中含有转光剂,内层中含有尼龙,增强了棚膜的户外耐候性,延长了转光时间,通过合理调配各层结构的原料及层间顺序,调整层间比,解决了尼脆性高使棚膜表层极易开裂的问题;通过多层共挤工艺,能够将尼龙的含量降低,提升高压低密度聚乙烯的含量,能够生产幅宽达16米的温室棚膜。
Description
技术领域
本发明涉及一种宽幅高耐候性转光棚膜及其制备方法,属于农膜技术领域。
背景技术
随着现代农业科技的飞速发展,农用棚膜的新型功能也越来越多,例如转光功能,在棚膜中增加转光剂可以将阳光中的紫外线转化为作物叶绿素进行光合作用时直接吸收利用的红光和蓝光,能够促进作物生长,在实际应用中获得了非常明显的增产增收效果。然而,聚乙烯的透气性很好,转光剂为稀土有机配合物,在户外水汽和氧气的作用下转光剂会分解,实际使用3个月后棚膜基本失去转光效果。尼龙材料具有阻隔水汽和氧气的特性,与转光剂配合使用可以起到减缓转光剂在水汽、氧气作用下的分解,使棚膜能够达到2年以上的转光期限。
某些专利中虽然公开了将尼龙材料作为棚膜表层以保护内部转光剂的技术,但由于各层材料配合不够合理,制成的棚膜表层脆性较大,在扣棚及使用过程中棚膜表层一旦因划卡出现小裂口就会顺着裂口扩大,导致大片棚膜失效。
其次,尼龙材料的价格是聚乙烯原料的3倍左右,受限于生产工艺和生产设备,目前公开的含尼龙的三层共挤棚膜中尼龙占比大于60%,含尼龙的五层共挤棚膜中尼龙的比例也在40%左右,导致棚膜价格比正常棚膜高一倍以上,非常不利于推广。
再次,尼龙稳泡性能差,高压低密度聚乙烯是挤出吹塑膜生产过程中提供稳泡性能的主要成分,而目前公开的含尼龙的棚膜中尼龙和粘合树脂占的比例很高,以至于高压低密度聚乙烯的比例很少,这就导致制得的棚膜幅宽一般不高于11米,而现在温室大棚的跨度越来越大,基本上在12米以上,目前公开的含尼龙棚膜很难满足棚户的应用要求,并且所含粘合树脂在表层,会造成薄膜粘黏。
需要说明的是,上述内容属于发明人的技术认知范畴,并不必然构成现有技术。
发明内容
本发明的目的在于解决现有技术所存在的问题,提供了一种宽幅高耐候性转光棚膜及其制备方法,能够延长棚膜的转光期限,提升棚内温度,解决棚膜表层极易开裂的问题,还能降低尼龙含量使棚膜价格降低,提升高压低密度聚乙烯的含量,能够生产幅宽达16米的温室棚膜。
本发明通过采取以下技术方案实现上述目的:
一方面,本发明提供了一种五层结构的宽幅高耐候性转光棚膜,所述棚膜具有通过挤出吹塑成型,所述五层结构包括依次设置的表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ;
具体的,所述表层Ⅰ和表层Ⅱ均由以下重量份数的原料制成:粘合树脂40-41份、高压低密度聚乙烯48.3-49份、光稳定剂9.5-10份、抗氧剂0.2-0.22份、水滑石2-2.2份;
所述内层Ⅰ和内层Ⅱ均由以下重量份数的原料制成:尼龙90.3-92份、光稳定剂9.5-10份、抗氧剂0.2-0.22份;
所述芯层由以下重量份数的原料制成:粘合树脂40-42份、高压低密度聚乙烯49.3-50份、光稳定剂9.5-10份、抗氧剂0.2-0.22份、转光剂1-1.2份。
可选的,所述表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ的厚度比例为1:1:1:1:1,棚膜的总厚度为0.08-0.15mm,优选0.08-0.1mm。
可选的,所述表层Ⅱ的表面还设有涂覆层,所述涂覆层由以下重量份数的原料制成:胶体氧化铝10-11份、胶体二氧化硅2-2.2份、非离子表面活性剂2-2.2份、水85-86份、消泡剂0.04-0.05份,涂覆层每平方米固含量为0.2-0.25g。
上述五层结构的宽幅高耐候性转光棚膜的制备方法,包括如下步骤:
(S1)配料:按比例称量表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ的原料后,分别对应投入挤出吹塑机的五个料斗内;
(S2)加热塑化:控制分别与五个料斗连接的五个料筒的温度,使料斗内的原料混合熔融,分别得到熔融混合物,其中对应表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ原料的料筒温度分别为180-184℃、260-264℃、180-184℃、260-264℃、180-184℃;
(S3)挤出吹塑:将五个料斗内的熔融混合物按照一定的挤出速度同时挤出到模头上,在风环的作用下按照1.8-2.2吹胀比吹出相应直径的膜泡,室温下膜泡在牵引机的牵引下经过稳泡架和人字架逐渐成为片状薄膜,即得所述棚膜,其中挤出转速为60-63r/min,牵引比为5-10,吹气压力为120-150KPa。
进一步的,所述涂覆层的涂覆步骤为:
(S4)电晕处理:对棚膜表层Ⅱ的表面进行电晕处理,使表层Ⅱ的表面能为42-48达因,通过电冲击使棚膜表面起毛变粗糙,增加表面积,当涂覆液与其表面接触时,就可产生良好的浸润,有利于获得良好的涂覆强度;
(S5)涂覆:经电晕处理的棚膜经涂覆机在表层Ⅱ表面涂覆所述涂覆液;
(S6)烘干:涂覆完的棚膜送入干燥箱内进行干燥,风机使空气流动带走涂覆液中的稀释剂,烘干时温度不能过高,过高会使涂覆层形成收缩龟裂纹,影响防雾滴效果,也不能过低,过低则会使涂覆层未干燥而遭到破坏,使用时破坏处产生聚滴现象;具体的,干燥温度为55-70℃,棚膜输送的线速度为15-25m/min,即得带有涂覆层的棚膜。
另一方面,本发明还提供了一种七层宽幅高耐候性转光棚膜,该七层结构在上述五层结构的基础上还包括设置在表层Ⅰ表面的外表层Ⅰ,以及设置在表层Ⅱ表面的外表层Ⅱ;
具体的,所述外表层Ⅰ由以下重量份数的原料制成:茂金属聚乙烯90-92份、光稳定剂9.5-10份、抗氧剂0.2-0.22份、爽滑助剂0.1-0.12份、抗静电剂0.2-0.22份;
所述外表层Ⅱ由以下重量份数的原料制成:高压低密度聚乙烯90.3-91份、光稳定剂9.5-10份、抗氧剂0.2-0.22份;
所述光稳定剂为光稳定剂XT-100或光稳定剂119,抗氧剂为抗氧剂AT-215或抗氧剂225,转光剂为稀土铕有机配合物,爽滑助剂为油酸酰胺或芥酸酰胺,抗静电剂为抗静电剂129或抗静电剂163。
可选的,所述外表层Ⅰ、表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ、外表层Ⅱ的厚度比例为1:1:1:1:1:1:1,棚膜的总厚度为0.08-0.15mm。
可选的,所述外表层Ⅱ的表面还设有涂覆层,所述涂覆层由以下重量份数的原料制成:胶体氧化铝10-11份、胶体二氧化硅2-2.2份、非离子表面活性剂2-2.2份、水85-86份、消泡剂0.04-0.05份,涂覆层每平方米固含量为0.2-0.25g。
上述七层结构的宽幅高耐候性转光棚膜的制备方法,包括如下步骤:
(P1)配料:按比例称量外表层Ⅰ、表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ、外表层Ⅱ的原料后,分别对应投入挤出吹塑机的七个料斗内;
(P2)加热塑化:控制分别与七个料斗连接的七个料筒的温度,使料斗内的原料混合熔融,分别得到熔融混合物,其中对应外表层Ⅰ、表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ、外表层Ⅱ原料的料筒温度分别为180-184℃、180-184℃、260-264℃、180-184℃、260-264℃、180-184℃、180-184℃;
(P3)挤出吹塑:将七个料斗内的熔融混合物按照一定的挤出速度同时挤出到模头上,在风环的作用下按照1.8-2.2吹胀比吹出相应直径的膜泡,室温下膜泡在牵引机的牵引下经过稳泡架和人字架逐渐成为片状薄膜,即得所述棚膜,其中挤出转速为60-63r/min,牵引比为5-10,吹气压力为120-150KPa。
进一步的,所述涂覆层的涂覆步骤为:
(P4)电晕处理:对棚膜外表层Ⅱ的表面进行电晕处理,使外表层Ⅱ的表面能为42-48达因;
(P5)涂覆:经电晕处理的棚膜经涂覆机在外表层Ⅱ表面涂覆所述涂覆液;
(P6)烘干:涂覆完的棚膜送入干燥箱内进行干燥,干燥温度为55-70℃,棚膜输送的线速度为15-25m/min,即得带有涂覆层的棚膜。
本发明的有益效果包括但不限于:
本发明提供的宽幅高耐候性转光棚膜,(1)通过含尼龙的阻隔层对转光剂形成保护,避免了转光剂在水汽、氧气作用下的分解,极大的增强了棚膜的户外耐候性,延长了转光时间,能够达到2年以上的转光期限;而且尼龙阻隔性好,对于棚膜保温性能的提升有很大的帮助,在和普通薄膜温室的对比中,本发明提供的棚内温度能高2-3℃;(2)合理调配各层结构的原料及层间顺序,调整层间比,解决了尼脆性高使棚膜表层极易开裂的问题;(3)通过多层共挤工艺,尤其是七层结构能够将尼龙的含量降低至20%以下,极大的降低成本,使得棚膜更易于推广;(4)表层使用茂金属聚乙烯,不但可以使棚膜具有很好的平整度和光洁度,薄膜透光率高,而且具有很好的柔韧性、耐磨性,能够避免因棉被来回摩擦造成的开裂问题;(5)七层结构很大程度上提升高压低密度聚乙烯的含量,棚膜生产过程中稳泡性能好,不会出现因高压低密度聚乙烯含量过少造成的塌膜、起网兜等机械性问题,解决了含尼龙棚膜幅宽受限的问题,能够生产幅宽达16米的温室棚膜;(6)棚膜表面增加含有具有流滴性能的涂覆层,具有大于3年的超长流滴消雾期。
具体实施方式
在以下内容中将会对本发明进行进一步的详细描述。但是需要指出的是,以下的具体实施方式仅仅以示例性的方式给出本发明的具体操作实例,但是本发明的保护范围不仅限于此。本发明的保护范围仅仅由权利要求书所限定。本领域技术人员能够显而易见地想到,可以在本发明权利要求书限定的保护范围之内对本发明所述的实施方式进行各种其它的改良和替换,并且仍然能够实现相同的技术效果,达到本发明的最终技术目的。
本发明描述的所有数值范围均包括端值并且可以包括将公开的范围的上限和下限互相任意组合得到的新的数值范围。
如无特殊说明,本说明书中各原料通过商业途径购得。
以下将通过具体实施例对本发明提供的宽幅高耐候性转光棚膜及其制备方法进行详细说明。
原料:
粘合树脂:采用PE粘合树脂,日本三井生产;
高压低密度聚乙烯:采用高压低密度聚乙烯2420D,中海壳牌生产;
光稳定剂:光稳定剂XT-100,德国巴斯夫生产;光稳定剂119,德国巴斯夫生产;
抗氧剂:抗氧剂AT-215,北京天罡助剂生产;抗氧剂225,北京天罡助剂生产;
水滑石:日本堺化学生产;
尼龙:美国陶氏生产;
转光剂:稀土铕有机配合物,北大睿尔斯生产;
胶体氧化铝:德国赢创生产;
胶体二氧化硅:德国赢创生产;
非离子表面活性剂:Letensol XL-80,巴斯夫生产;
消泡剂:采用TEGO Antifoam 2290,赢创生产;
茂金属聚乙烯:美国埃克森生产;
爽滑助剂:油酸酰胺,山东海曼拓邦生产;芥酸酰胺,山东海曼拓邦生产;
抗静电剂:抗静电剂129,英国禾大生产;抗静电剂163,英国禾大生产。
实施例1:
本实施例提供的五层共挤宽幅高耐候性转光棚膜展开宽度为16m,所用原料为:
本实施例提供的棚膜生产参数如下表:
实施例2:
本实施例提供的五层共挤宽幅高耐候性转光棚膜展开宽度为16m,所用原料为:
本实施例提供的棚膜生产参数如下表:
实施例3:
本实施例提供的七层共挤宽幅高耐候性转光棚膜展开宽度为17m,所用原料为:
本实施例提供的棚膜生产参数如下表:
实施例4:
本实施例提供的七层共挤宽幅高耐候性转光棚膜展开宽度为17m,所用原料为:
本实施例提供的棚膜生产参数如下表:
实施例5:
本实施例提供的七层共挤宽幅高耐候性转光棚膜展开宽度为18m,所用原料为:
本实施例提供的棚膜生产参数如下表:
对比例1:
本对比例为三层共挤尼龙棚膜,其原料为:
外层Ⅰ:尼龙100%;
内层:PE粘合树脂100%;
外层Ⅱ:尼龙100%;
外层Ⅰ、内层、外层Ⅱ的厚度比为1:1:1。
本对比例提供的棚膜生产参数为:
对比例2:
本对比例为普通三层棚膜,其原料为:
外层Ⅰ:茂金属聚乙烯91.8%、光稳定剂119为8%、抗氧剂225为0.2%;
内层:高压低密度聚乙烯50%、EVA树脂41.8%、光稳定剂119为8%、抗氧剂225为0.2%;
外层Ⅱ:高压低密度聚乙烯91.8%、光稳定剂119为8%、抗氧剂225为0.2%;
外层Ⅰ、内层、外层Ⅱ的厚度比为1:1:1。
本对比例提供的棚膜生产参数为:
参照国标GB/T 4455-2019,对本发明实施例1-5以及对比例1、对比例2制备的棚膜进行检测,表1中数据均为多次试验所取平均值。
表1检测结果
由表1中数据可知,本发明实施例1-5提供的棚膜中,尼龙含量降低后棚膜的拉伸强度仍满足要求,远高于国标要求18MPa。实施例3-5中七层结构的棚膜各种原料的搭配更加合理,尼龙含量进一步减少并未造成透光率的大幅变化,而且雾度值降低,意味着薄膜透明度更好。从数据来看,实施例2提供的0.08mm厚的棚膜红外阻隔率要比对比例2中0.1mm厚的普通PO膜红外阻隔率还要高40%左右,这意味着棚膜的保温性更好。
七层结构的棚膜,做到0.08mm左右厚度时成本和普通PO膜基本一致,但各方面性能比普通PO膜要好,尤其是透明度、机械强度和保温性。
此外,实施例1、4、5提供的棚膜,初滴时间为180-240s,流滴性能良好。
上述具体实施方式不能作为对本发明保护范围的限制,对于本技术领域的技术人员来说,对本发明实施方式所做出的任何替代改进或变换均落在本发明的保护范围内。
本发明未详述之处,均为本技术领域技术人员的公知技术。
Claims (4)
1.一种宽幅高耐候性转光棚膜,其特征在于,所述棚膜具有通过挤出吹塑成型多层结构,所述多层结构包括依次设置的表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ;
所述表层Ⅰ和表层Ⅱ均由以下重量份数的原料制成:粘合树脂40-41份、高压低密度聚乙烯48.3-49份、光稳定剂9.5-10份、抗氧剂0.2-0.22份、水滑石2-2.2份;
所述内层Ⅰ和内层Ⅱ均由以下重量份数的原料制成:尼龙90.3-92份、光稳定剂9.5-10份、抗氧剂0.2-0.22份;
所述芯层由以下重量份数的原料制成:粘合树脂40-42份、高压低密度聚乙烯49.3-50份、光稳定剂9.5-10份、抗氧剂0.2-0.22份、转光剂1-1.2份;
还包括设置在表层Ⅰ表面的外表层Ⅰ,以及设置在表层Ⅱ表面的外表层Ⅱ;
所述外表层Ⅰ由以下重量份数的原料制成:茂金属聚乙烯90-92份、光稳定剂9.5-10份、抗氧剂0.2-0.22份、爽滑助剂0.1-0.12份、抗静电剂0.2-0.22份;
所述外表层Ⅱ由以下重量份数的原料制成:高压低密度聚乙烯90.3-91份、光稳定剂9.5-10份、抗氧剂0.2-0.22份;
所述光稳定剂为光稳定剂XT-100或光稳定剂119,抗氧剂为抗氧剂AT-215或抗氧剂225,转光剂为稀土铕有机配合物,爽滑助剂为油酸酰胺或芥酸酰胺,抗静电剂为抗静电剂129或抗静电剂163;
所述外表层Ⅱ的表面还设有涂覆层,所述涂覆层由以下重量份数的原料制成:胶体氧化铝10-11份、胶体二氧化硅2-2.2份、非离子表面活性剂2-2.2份、水85-86份、消泡剂0.04-0.05份,涂覆层每平方米固含量为0.2-0.25g。
2.根据权利要求1所述的宽幅高耐候性转光棚膜,其特征在于,所述外表层Ⅰ、表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ、外表层Ⅱ的厚度比例为1:1:1:1:1:1:1,棚膜的总厚度为0.08-0.15mm。
3.一种根据权利要求1或2所述的宽幅高耐候性转光棚膜的制备方法,其特征在于,包括如下步骤:
(P1)配料:按比例称量外表层Ⅰ、表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ、外表层Ⅱ的原料后,分别对应投入挤出吹塑机的七个料斗内;
(P2)加热塑化:控制分别与七个料斗连接的七个料筒的温度,使料斗内的原料混合熔融,分别得到熔融混合物,其中对应外表层Ⅰ、表层Ⅰ、内层Ⅰ、芯层、内层Ⅱ、表层Ⅱ、外表层Ⅱ原料的料筒温度分别为180-184℃、180-184℃、260-264℃、180-184℃、260-264℃、180-184℃、180-184℃;
(P3)挤出吹塑:将七个料斗内的熔融混合物按照挤出速度同时挤出到模头上,在风环的作用下按照1.8-2.2吹胀比吹出相应直径的膜泡,室温下膜泡在牵引机的牵引下经过稳泡架和人字架逐渐成为片状薄膜,即得所述棚膜,其中挤出转速为60-63r/min,牵引比为5-10,吹气压力为120-150KPa。
4.根据权利要求3所述的宽幅高耐候性转光棚膜的制备方法,其特征在于,所述涂覆层的涂覆步骤为:
(P4)电晕处理:对棚膜外表层Ⅱ的表面进行电晕处理,使外表层Ⅱ的表面能为42-48达因;
(P5)涂覆:经电晕处理的棚膜经涂覆机在外表层Ⅱ表面涂覆所述涂覆层;
(P6)烘干:涂覆完的棚膜送入干燥箱内进行干燥,干燥温度为55-70℃,棚膜输送的线速度为15-25m/min,即得带有涂覆层的棚膜。
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