CN113293457A - 一种加热毯毡用包覆丝材料、包覆丝及其织成品 - Google Patents
一种加热毯毡用包覆丝材料、包覆丝及其织成品 Download PDFInfo
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- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
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Abstract
本发明提供一种加热毯毡用包覆丝材料、包覆丝及其织成品,包括皮层材料和芯层材料,所述皮层材料包括20~30wt%的粉体熔融混合物和80~70wt%的混熔原料;所述芯层材料包括100wt%的芯层长丝;其中,所述粉体熔融混合物由以下重量份数的成分组成:20wt%的碳纳米管、35wt%的石墨粉、25wt%的紫铜粉和20wt%的玉石矿粉;所述混熔原料包括PET、PA6、PA66、PPS、LCP和PC中的一种或几种;所述芯层长丝包括PET、PA66、PPS和LCP中的一种或几种。本发明提供的加热垫毡材料,具有恒温稳定、耗电少的节能环保功能性优点;同时,本发明有益身体健康,具有特殊的保健功能。
Description
技术领域
本发明主要涉及加热毯技术领域,尤其涉及一种加热毯毡用包覆丝材料、包覆丝及其织成品。
背景技术
加热毯毡是设置在加热毯表层及夹层的一种面料,加热毯内部电阻丝通电时产生的热量通过加热毯毡传递给外部物体,其主要用于人们睡眠时提高被窝里的温度来达到取暖的目的,还可用于被褥的去潮除湿,随着人们生活水平提高,对纺织品的要求除了美观、保暖外,人们开始转向舒适性、环保型、功能保健型,开发各类功能性纺织品已然成为社会的主流。
现有技术存在加热毯毡的功能性不足的问题,一方面,现有加热毯毡材料导热性能较差,加热毯整体升温速率较低,同时加热毯维持恒定温度耗电量较大,不符合节能环保理念;另一方面,现有电热毯并不具备净化空气的作用。
发明内容
为了解决现有加热毯毡材料导热性能较差、耗电量较大等技术问题,本发明提供一种加热毯毡用包覆丝材料、包覆丝及其织成品,与现有技术相比,本发明具有恒温稳定、耗电少的节能环保功能性优点;同时加热电流会与粉体组合碰撞,发射负氧离子,有机中和室内甲醛、二氧化碳等,起到净化空气的作用。
本发明提供的技术方案为:
本发明提供一种加热毯毡用包覆丝材料,包括皮层材料和芯层材料,所述皮层材料包括20~30wt%的粉体熔融混合物和80~70wt%的混熔原料;所述芯层材料包括100wt%的芯层长丝;其中,所述粉体熔融混合物由以下重量份数的成分组成:20wt%的碳纳米管、35wt%的石墨粉、25wt%的紫铜粉和20wt%的玉石矿粉;所述混熔原料包括PET、PA6、PA66、PPS、LCP和PC中的一种或几种,所述混熔原料为熔融状;所述芯层长丝包括PET、PA66、PPS和LCP中的一种或几种,所述芯层长丝为固态长丝状。
由于上述粉体熔融混合物含金属元素钾、钙、镁、铝、锰及其碳化物,故由该粉体熔融混合物制成的皮层具有较强的负氧离子发射功能,从而起到中和室内甲醛、二氧化碳等气体的作用,实现净化空气能效;另外,本发明所采用的玉石矿粉主要为岫岩玉石矿粉,岫岩玉含有人体所需的硒、锌、镍、钴、锰、镁、钙等30多种对人体有益的微量元素,这些元素散发的启动波和人体细胞的启动波是同一种波动状态,人体细胞随着从玉石散发出的波动产生共鸣和共振,使人体细胞组织更具活力,并促进血液循坏、增强新陈代谢、及进排除体内废物有益身体健康,具有特殊保健功能;紫铜粉一方面能够提高加热毯毡导电性能,另一方面能够有效发射负氧离子,有机中和室内甲醛、二氧化碳等;碳纳米管和石墨粉能够实现室内甲醛的物理去除;
本发明还提供一种由上述包覆丝材料制备而成的包覆丝,所述粉体熔融混合物与PET混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成涤纶包覆丝;所述芯层长丝选用PPS 和LCP中的一种或两种。
本发明还提供一种由上述包覆丝材料制备而成的包覆丝,所述粉体熔融混合物与PA6混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成尼龙6包覆丝;所述芯层长丝选用 PET、PA66、PPS和LCP中的一种或几种。
皮层PA6结构有利常温,酸性可染,色彩更加鲜艳多彩,PA6本身含有吸湿基团,物理吸附水分,有利于吸湿率,产生表层凉感。
本发明还提供一种由上述包覆丝材料制备而成的包覆丝,所述粉体熔融混合物与PA66混合熔融后,采用双螺杆挤出机挤出形成皮层;所述包覆所述芯层长丝制成尼龙66包覆丝;所述芯层长丝选用PPS 和LCP中的一种或两种。
PA66在较高温度也能保持较强的强度和刚度,PA66在成型后仍然具有吸湿性,实际操作热熔温度范围采用250-270℃,同时PA66 具有优良的耐磨性,机械强度较高。
本发明还提供一种由上述包覆丝材料制备而成的包覆丝,所述粉体熔融混合物与PPS混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成树脂包覆丝;所述芯层长丝选用LCP。
PPS是含硫芳香族聚合物,具有难燃、热稳定性好、机械强度较高、电性能优良等优点。
本发明还提供一种由上述包覆丝材料制备而成的包覆丝,所述粉体熔融混合物与LCP混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成塑胶包覆丝;所述芯层长丝选用LCP。
优选的,所述皮层材料包覆芯层材料时,模具温度为260-335℃。
本发明还提供一种织成品,该织成品由上述包覆丝中的一种或几种纺织而成。
该织成品具有上述加热毯毡用包覆丝材料和物种包覆丝的组合优势。
优选的,上述包覆丝材料、包覆丝或纺织品应用领域包括床垫、靠垫、坐垫、沙发垫、汽车垫、地热及壁暖基材。
综上所述,本发明的有益效果如下:
1、本发明提供的加热垫毡材料,具有恒温稳定、耗电少的节能环保功能性优点;同时加热电流会与粉体组合碰撞,发射负氧离子,物理化学吸附室内甲醛、二氧化碳等,起到净化空气的作用。
2、采用上述材料制成的5种包覆丝,具有产生表层凉感,同时有益身体健康,具有特殊保健功能。
具体实施方式
需要说明的是,在不冲突的情况下,本申请中的实施例及实施例中的特征可以相互组合。需要注意的是,本发明所使用的术语仅是为了描述具体实施方式,而非意图限制根据本申请的示例性实施方式。
应当理解的是,当在本说明书中如使用术语“包含”和/或“包括”时,其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
如出现术语“第一”、“第二”、“第三”仅用于描述目的,而不能理解为指示或暗示相对重要性。
除非另有明确的规定和限定,如出现术语“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以具体情况理解上述术语在本发明中的具体含义。
实施例1
为了解决现有加热毯毡材料耗电量较大,不具备净化空气功能的技术问题,本发明的实施例提供一种加热毯毡用包覆丝材料,包括皮层材料和芯层材料,所述皮层材料包括20~30wt%的粉体熔融混合物和80~70wt%的混熔原料;所述芯层材料包括100wt%的芯层长丝;其中,所述粉体熔融混合物由以下重量份数的成分组成:20wt%的碳纳米管、35wt%的石墨粉、25wt%的紫铜粉和20wt%的玉石矿粉;所述混熔原料包括PET、PA6、PA66、PPS、LCP和PC中的一种或几种,所述混熔原料为熔融状;所述芯层长丝包括PET、PA66、PPS和LCP 中的一种或几种,所述芯层长丝为固态长丝状。
本实施例中,碳纳米管、石墨粉、紫铜粉和玉石矿粉与其他原料混合时,运用萃取和纳米技术,使粉体达到亚纳米级粒径,粒径正态分布范围为60-150nm;分布均匀的手段:1、使用设备螺杆后段动态连续混合器,2、按粉体熔融混合物总量1-3.5千分比加入无机分散剂;加工后的皮层强度为2.1-4.2CN/dtex,伸长率为35-70%,瞬间凉感值为0.25-0.6。通电情况下,由于本发明的包覆丝比表面积大、发热面积大,热量极易积聚集中,制热效率较快;同时粉体熔融混合物含金属元素钾、钙、镁、铝、锰及其碳化物,这使得皮层材料具有较强的负氧离子发射功能,从而起到物理化学吸附室内甲醛、二氧化碳等气体的作用,同时,在不通电情况下,在气温较高的夏季里,皮层材料与肌肤接触,无机材料及金属粉体传递热量速率快,产生凉感。
实施例2
涤纶包覆丝的皮层粉体熔融混合物与PET混合熔融后,采用双螺杆挤出机挤出形成,皮层包覆芯层长丝制成涤纶包覆丝,其中芯层长丝选用PPS和LCP中的一种或两种同时使用。
芯层长丝PPS长丝规格为250-290dtex/96f,LCP长丝直径为 0.1-1mm,强度≥18CN/dtex;皮层采用260-270℃加工温度,同时加工时间决定受热时间,加工时间过快,热定型不充分,加工时间过慢,丝条产品质量下降,本发明加工时间在400-410min之间。模具温度很显著地影响结晶度,而结晶度又影响着塑件的机械特性。对于结构部件来说结晶度很重要,因此建议模具温度为290-335℃。对于薄壁的,流程较长的塑件也建议施用较高的模具温度。注射压力 100-160MPa;背压2-8Mpa,背压需准确调节,因为背压太高会造成塑化不均。具体工艺过程为本领域技术人员的公知常识,这里不再赘述。
实施例3
粉体熔融混合物与PA6混合熔融后,采用双螺杆挤出机挤出形成皮层,皮层包覆芯层长丝制成尼龙6包覆丝,其中芯层长丝选用PET、 PA66、PPS和LCP中的一种或几种同时使用。
本实施例中芯层长丝PPS和LCP规格如实施例1所述,芯层长丝 PET规格为150-200dtex/96f,PA6规格为200-250dtex/36f,皮层采用240-250℃加工温度,加工时间在150-160min之间。本实施例中皮层材料包覆芯层材料温度为270-325℃;注射压力100-160MPa;背压2-8MPa。皮层PA6色彩更加鲜艳多彩,PA6本身含有吸湿基团,物理吸附水分,有利于吸湿率,产生表层凉感。
实施例4
粉体熔融混合物与PA66混合熔融后,采用双螺杆挤出机挤出形成皮层,皮层包覆芯层长丝制成尼龙66包覆丝,其中芯层长丝选用 PPS和LCP中的一种或两种同时使用。
本实施例中芯层长丝PPS和LCP规格如实施例1所述,皮层采用 250-270℃加工温度,加工时间在140-155min之间。本实施例中皮层模具温度在280-330℃之间,注射压力80-120MPa;背压2-6MPa。 PA66在较高温度也能保持较强的强度和刚度,PA66在成型后仍然具有吸湿性,同时PA66具有优良的耐磨性,机械强度较高。
实施例5
粉体熔融混合物与PPS混合熔融后,采用双螺杆挤出机挤出形成皮层,皮层包覆芯层长丝制成树脂包覆丝,其中芯层长丝选用LCP。
皮层采用300-330℃加工温度,加工时间在410-430min之间。本实施例中皮层模具温度在260-300℃之间,注射压力80-120MPa;背压3-8MPa。PPS是含硫芳香族聚合物,具有难燃、热稳定性好、机械强度较高、电性能优良等优点。
实施例6
粉体熔融混合物与LCP混合熔融后,采用双螺杆挤出机挤出形成皮层,皮层包覆芯层长丝制成塑胶包覆丝,其中芯层长丝选用LCP。
本实施例中芯层长丝LCP规格如实施例1所述,皮层采用 350-380℃加工温度,加工时间在430-450min之间。本实施例中皮层模具温度在280-315℃之间,注射压力100-150MPa;背压4-10MPa。LCP具有全芳香族聚酯和共聚酯结构;它还具有密集排列的直链聚合物链结构,形成的产品具有良好保温性能。
实施例7
本发明还提供一种由上述包覆丝纺织而成的织成品,具有恒温稳定、耗电少的节能环保功能性优点;同时加热电流会与粉体组合碰撞,发射负氧离子,物理化学吸附室内甲醛、二氧化碳等,起到净化空气的作用。
1、相对于常规加热毯毡性能参数对比如下:
材料 | 升温速率(35℃) | 耗电量(6h) |
常规 | 12-15min | 0.3-0.6kW |
本发明 | 3-5min | 0.25kW |
因本实施例中,包覆丝的皮层均采用复合导电粉体(碳纳米管、石墨粉、紫铜粉和玉石矿粉),比表导热面积大,且皮层包覆芯层长丝的结构不易散失热量。
2、以2.5m2的本实施例中所涉及的加热毯毡为参照对象,20m2 室内,可持续产生6000-10000个/cm2负氧离子,减少0.02-0.03mg/m3的甲醛含量,按大气总体积降低0.01-0.02%CO2含量,原理在实施例 1中已提及,此处不再赘述。
上述实施例仅例示性说明本专利申请的原理及其功效,而非用于限制本专利申请。任何熟悉此技术的人士皆可在不违背本专利申请的精神及范畴下,对上述实施例进行修饰或改变。因此,举凡所属技术领域中具有通常知识者在未脱离本专利申请所揭示的精神与技术思想下所完成的一切等效修饰或改变,仍应由本专利请的权利要求所涵盖。
Claims (9)
1.一种加热毯毡用包覆丝材料,包括皮层材料和芯层材料,其特征在于:
所述皮层材料包括20~30wt%的粉体熔融混合物和80~70wt%的混熔原料;
所述芯层材料包括100wt%的芯层长丝;
其中,所述粉体熔融混合物由以下重量份数的成分组成:20wt%的碳纳米管、35wt%的石墨粉、25wt%的紫铜粉和20wt%的玉石矿粉;
所述混熔原料包括PET、PA6、PA66、PPS、LCP和PC中的一种或几种,所述混熔原料为熔融状;
所述芯层长丝包括PET、PA66、PPS和LCP中的一种或几种,所述芯层长丝为固态长丝状。
2.一种由权利要求1所述的包覆丝材料制备而成的包覆丝,其特征在于:所述粉体熔融混合物与PET混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成涤纶包覆丝;所述芯层长丝选用PPS和LCP中的一种或两种。
3.一种由权利要求1所述的包覆丝材料制备而成的包覆丝,其特征在于:所述粉体熔融混合物与PA6混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成尼龙6包覆丝;所述芯层长丝选用PET、PA66、PPS和LCP中的一种或几种。
4.一种由权利要求1所述的包覆丝材料制备而成的包覆丝,其特征在于:所述粉体熔融混合物与PA66混合熔融后,采用双螺杆挤出机挤出形成皮层;所述包覆所述芯层长丝制成尼龙66包覆丝;所述芯层长丝选用PPS和LCP中的一种或两种。
5.一种由权利要求1所述的包覆丝材料制备而成的包覆丝,其特征在于:所述粉体熔融混合物与PPS混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成树脂包覆丝;所述芯层长丝选用LCP。
6.一种由权利要求1所述的包覆丝材料制备而成的包覆丝,其特征在于:所述粉体熔融混合物与LCP混合熔融后,采用双螺杆挤出机挤出形成皮层;所述皮层包覆所述芯层长丝制成塑胶包覆丝;所述芯层长丝选用LCP。
7.根据权利要求2-6所述的包覆丝,其特征在于:所述皮层材料包覆所述芯层材料时,模具温度为260-335℃。
8.一种织成品,其特征在于:该织成品由权利要求2-6中的一种或几种所述的包覆丝纺织而成。
9.根据权利要求1-6或8任意一个所述的包覆丝材料、包覆丝或织成品,其特征在于:应用领域包括床垫、靠垫、坐垫、沙发垫、汽车垫、地热及壁暖基材。
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