CN113858732A - 一种轻型防滑耐磨车厢地板及其制备方法 - Google Patents

一种轻型防滑耐磨车厢地板及其制备方法 Download PDF

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CN113858732A
CN113858732A CN202111136310.2A CN202111136310A CN113858732A CN 113858732 A CN113858732 A CN 113858732A CN 202111136310 A CN202111136310 A CN 202111136310A CN 113858732 A CN113858732 A CN 113858732A
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朱华平
赵均乐
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JIANGSU QIYI TECHNOLOGY CO LTD
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Abstract

本发明涉及轻型车厢地板领域，涉及一种轻型防滑耐磨车厢地板及其制备方法，所述车厢地板为连续玻纤增强聚丙烯复合材料地板，从上而下依次包括有防滑耐磨层、无纺布层、上预浸带层、蜂窝芯层、下预浸带层，相邻各层之间通过热压相互复合在一起，预浸带由多层连续纤维增强聚丙烯带状预浸料复合而成，防滑耐磨层材料选自热塑性聚氨酯橡胶膜，无纺布为针刺型聚酯无纺布，蜂窝芯层材质为聚丙烯；此外，本发明还公开了一种制备轻型防滑耐磨车厢地板的方法：先制备预浸带，后热压复合冷却得到目标产品；以此方法生产的复合板具有质量轻，防腐，防潮的优点。

Description

一种轻型防滑耐磨车厢地板及其制备方法
技术领域
本发明涉及轻型车厢地板领域，具体涉及一种轻型防滑耐磨车厢地板。
背景技术
目前轻型车厢地板主要使用木头、树脂复合地板、金属板、GMT板等材料，主要的缺点是：木头易吸水，导致发霉，降解，强度降低；树脂复合地板不环保，在制备过程中大量的使用胶水做粘接，对环境影响大；金属板价格较高，重量大；GMT材料强度差，刚性不够，耐冲击性能差。
同时随着时代技术的变迁，人们对客车地板的防滑和耐磨性能要求也是越来越高，尤其目前车厢地板大多存在抗湿滑性能差的问题。为了提高防滑性能，人们通过采取铺装耐磨层地板的方式，比如PVC弹性地板、橡胶地板等，此方法安装工序较为复杂，使用胶水，且成本较高，为此，我们提出一种表面复合有防滑耐磨层的一次成型轻型热塑性复合材料车厢地板。
发明内容
本发明的目的在于针对现有技术的缺陷和不足，提供一种结构简单、设计合理、使用方便的轻型车厢用连续玻纤增强热塑性复合材料地板，具有连续生产，效率高，生产过程中完全环保，无任何有机的溶剂挥发，质量轻，防腐，防潮等优点。另外，还可以减轻车厢重量，减少车辆能源消耗，实现绿色减排。
为实现上述目的，本发明采用的技术方案如下：
一种带有防滑耐磨层的连续玻纤增强聚丙烯复合材料，主要用于车厢地板，从上而下依次包括有防滑耐磨层、无纺布层、上预浸带层、蜂窝芯层、下预浸带层，相邻各层之间通过热压相互复合在一起。
进一步的，所述防滑耐磨层的厚度为0.1～2mm,所述无纺布层的厚度为0.5～1.0mm,所述上预浸带层或者下预浸带层的厚度为0.4～5mm,所述蜂窝芯层的厚度为8～50mm。
进一步的，所述防滑耐磨层为热塑性聚氨酯橡胶制成。
进一步的，所述无纺布层为针刺型聚酯无纺布，克重为50～150g/m2。
进一步的，所述上预浸带层或下预浸带层为连续纤维增强聚丙烯预浸料，包括35％～50％重量份的聚丙烯和50～65％重量份的连续纤维，所述上预浸带层和下预浸带层中含有热塑性树脂。
进一步的，所述蜂窝芯层材质为聚丙烯，蜂窝芯单元为圆管或者正六边形。
优选的，连续纤维为预浸带的增强纤维，所述连续纤维可以采用玻璃纤维、碳纤维或者玄武岩纤维之一，连续纤维也可以混合使用前述不同纤维。
进一步的，上预浸带层或下预浸带层包含2～16层单层的连续纤维增强聚丙烯预浸带，上预浸带层和下预浸带层应以蜂窝芯层为中心，成对称结构。
优选的，所述圆管的直径为直径6～10mm，壁厚0.4～0.8mm，所述正六边形边长3～10mm，壁厚0.4～0.8mm。
此外，本发明还公开了一种制备轻型防滑耐磨车厢地板的方法，包括下列步骤：
第一步：上或下预浸带层的制备：
将35％～50％重量份的热塑性树脂加入挤出机中，通过模头预浸的工艺，选择合适的连续纤维股数，控制连续纤维含量为50～65％，将连续纤维平行排列成带状，导到挤出模头下方，将熔融树脂淋到带状纤维上面，接着通过品字形加热辊加压，之后通过品字形冷却辊冷却，最后收卷得到单层连续纤维增强聚丙烯带状预浸料；
第二步：按照从上到下依次叠放好防滑耐磨层、无纺布层、上预浸带层、蜂窝芯层、下预浸带层；
第三步：将第二步中铺放好的材料放入复合机中，以一定的速度和压力，先热压定型再冷压；
第四步：冷却过后通过牵引辊引出复合板，然后锯切到要求尺寸。
优选的，第二步中预浸带层由2～16层单层预浸料按照角度0～90°铺放。
优选的，第三步中热压温度为170～230℃，热压时间为1.5～2min；在原有基础的厚度上，下压2.0～3.5mm。
进一步的，第三步中使用的是复合机，这种复合机的加热是通过电加热将热量传递到铝方通，铝方通再将热量传递给接触的蜂窝板材实现的；冷却是通过冷却水带走蜂窝板材递给铝方通的热量实现的；在复合的过程中加热段和冷却段铝方通并不是直接作用在蜂窝板上，而是先将能量传递给不断转动的特氟龙皮带，然后特氟龙皮带再传递热量。
优选的，第四步中冷却温度为5～10℃，冷却时间为1.5～2min。
优选的，所述特氟龙皮带有网格状花纹，网格大小1x1mm～4x4mm。
本发明具有以下优点：
1、本发明所述的车厢用连续玻纤增强热塑性复合材料地板，可连续生产，效率高，生产过程中完全环保，无任何有机的溶剂挥发，质量轻、防腐、防潮，且具有结构简单、设置合理、制作成本低等优点。
2、本发明制备的连续玻纤增强聚丙烯复合材料地板具有强度高、模量高、耐腐蚀、耐水性、介电强度高、不导电、加工简单、抗湿滑、使用寿命长等优点。同时设计灵活性高，可选择多种纤维和多种耐磨膜层，且生产中的废料可100％回收再利用，是一种理想的轻型车厢地板材料。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。
图1是本发明中某一具体实施例结构的示意图。
图2是本发明中制备轻型防滑耐磨车厢地板流程图。
图中各编号：1-蜂窝芯层、2-上预浸带层、3-下预浸带层、4-防滑耐磨层、5-无纺布层。
具体实施方式
以下将结合附图和具体实施例对本发明提出的一种预制拼装混凝土栈桥及其施工方法作进一步详细说明，以充分了解本发明的目的、特征和效果。需说明的是，附图均采用非常简化的形式且均使用非精准的比例，仅用以方便、明晰地辅助说明本发明实施例的目的；所述仅是对本发明较佳实施例的描述，并非对本发明范围的任何限定，本发明领域的普通技术人员根据上述内容通过逻辑分析或者有限实验做出的任何变更和修饰，均属于权利要求书的保护范围。
实施例1
一种连续纤维增强防滑耐磨车厢地板，主要包括：
防滑耐磨层4：TPU(热塑性聚氨酯橡胶)材质，厚度0.15mm；
无纺布层5：聚酯材质，厚度0.2mm；
蜂窝芯层1：材质为聚丙烯，形状选自圆管，壁厚0.5mm，孔径8.0mm，厚度为11mm；
预浸带增强纤维：采用玻璃纤维，单向平行紧密排列的连续纤维束；
预浸带树脂基体：采用聚丙烯树脂；
预浸带纤维质量含量：60％；
预浸带层的厚度：0.6mm；
预浸带层铺层方式：上下预浸带层均由2层单层预浸料以0～90°正交铺层；
热复合得到的复合板厚度：10mm。
上述纤维增强防滑耐磨车厢地板制备过程：
S1：将40重量份的热塑性树脂加入挤出机中，通过模头预浸的工艺，选择合适的连续纤维股数，控制纤维含量为60％，将连续纤维平行排列成带状，导到挤出模头下方，将熔融树脂淋到带状纤维上面，接着通过品字形加热辊加压，之后通过品字形冷却辊冷却，最后收卷得到单层连续纤维增强聚丙烯带状预浸料,将单层连续纤维增强聚丙烯预浸料裁剪为1500mmx650mm，以0/90方式铺放，然后通过复合机连续热压再冷压成型，得到上或下预浸带；
S2：按照防滑耐磨层4、无纺布层5、上预浸带层2、蜂窝芯层1、下预浸带层3的顺序，从上到下依次铺放各种材料；
S3：将上述步骤中铺好的各种材料放入复合机中热压，然后冷却，最后裁切，加热温度210℃，在原有基础上下压2.5mm，加热时间为2min；冷却温度为5-10℃，冷却时间为2min。
S4：冷却过后通过牵引辊引出复合板，然后锯切到要求尺寸。
实施例2
另一种连续纤维增强防滑耐磨车厢地板，主要包括：
防滑耐磨层4：TPU材质，厚度0.15mm；
无纺布层5：聚酯材质，厚度0.2mm；
蜂窝芯层1：材质为高密度聚乙烯，形状选自正六边形，边长5mm，孔径10mm，壁厚0.8mm，厚度为11mm；
预浸带增强纤维：碳纤维，单向平行紧密排列的连续纤维束；
预浸带树脂基体：高密度聚乙烯树脂；
预浸带纤维质量含量：50％；
预浸带层的厚度：0.6mm；
预浸带层的铺层方式：上下预浸带层均由2层单层预浸料以0～90°正交铺层；
热复合得到的复合板厚度：10mm。
上述纤维增强防滑耐磨车厢地板制备过程：
S1：将50重量份的热塑性树脂加入挤出机中，通过模头预浸的工艺，选择合适的连续纤维股数，控制纤维含量为50％，将连续纤维平行排列成带状，导到挤出模头下方，将熔融树脂淋到带状纤维上面，接着通过品字形加热辊加压，之后通过品字形冷却辊冷却，最后收卷得到单层连续纤维增强聚丙烯带状预浸料,将单层连续纤维增强聚丙烯预浸料裁剪为1500mmx650mm，以0～90°方式铺放，然后通过复合机连续热压再冷压成型；
S2：按照防滑耐磨层4、无纺布层5、上预浸带层2、蜂窝芯层1、下预浸带层3的顺序，从上到下依次铺放各种材料；
S3：将上述步骤中铺好的各种材料放入复合机中热压，然后冷却，最后裁切，加热温度190℃，在原有基础上下压2.5mm，加热时间为2min；冷却温度为5-10℃，冷却时间为2min。
S4：冷却过后通过牵引辊引出复合板，然后锯切到要求尺寸。
对上述实施例1和实施例2中产品的性能进行测试，测试结果见表1：
测试项目 摩擦系数(MPa) 弯曲强度(MPa) 弯曲模量(GPa) 压缩强度(MPa)
实施例1 0.83 24 2.3 2.2
实施例2 0.85 20 3.0 2.2
本发明经过广泛而深入的研究，首次将连续纤维增强热塑性复合材料应用于车厢地板，并可以通过快速一次热成型生产质量轻、刚度和强度高的防滑耐磨车厢地板，且在制备过程中无有毒有害挥发性气体产生，生产过程环保，应用的材料可回收再利用，产品绿色环保。
连续纤维增强热塑性复合材料相比传统的热固性复合材料和金属材料优势主要体现在：可连续生产，效率高，生产过程中完全环保，无任何有机的溶剂挥发，质量轻、防腐、防潮，且具有结构简单、设置合理、制作成本低等优点。

Claims (13)

1.一种轻型防滑耐磨车厢地板，其特征在于，从上而下依次包括，防滑耐磨层(4)、无纺布层(5)、上预浸带层(2)、蜂窝芯层(1)和下预浸带层(3)，相邻各层之间通过热压相互复合在一起。
2.根据权利要求1所述的一种轻型防滑耐磨车厢地板，其特征在于，所述防滑耐磨层(4)的厚度为0.1～2mm,所述无纺布层(5)的厚度为0.5～1.0mm,所述上预浸带层(2)或者下预浸带层(3)的厚度为0.4～5mm,所述蜂窝芯层(1)的厚度为8～50mm。
3.根据权利要求1所述的一种轻型防滑耐磨车厢地板，其特征在于，所述防滑耐磨层(4)为热塑性聚氨酯橡胶制成；
所述无纺布层(5)为针刺型聚酯无纺布，克重为50～150g/m2；
所述上预浸带层(2)或下预浸带层(3)为连续纤维增强聚丙烯预浸料，包括35％～50％重量份的聚丙烯和50～65％重量份的连续纤维，所述上预浸带层(2)和下预浸带层(3)中含有热塑性树脂；
所述蜂窝芯层(1)材质为聚丙烯，蜂窝芯单元为圆管或者正六边形。
4.根据权利要求3所述的一种轻型防滑耐磨车厢地板，其特征在于，连续纤维为预浸带的增强纤维，所述连续纤维为玻璃纤维、碳纤维或者玄武岩纤维之一，所述连续纤维也可以混合使用不同纤维。
5.根据权利要求3所述的一种轻型防滑耐磨车厢地板，其特征在于，热塑性树脂为预浸带的树脂基体，包括聚乙烯、聚丙烯、聚己内酰胺、聚己二酸己二胺、聚碳酸酯、聚苯硫醚和聚醚醚酮。
6.根据权利要求3所述的一种轻型防滑耐磨车厢地板，其特征在于，所述的上预浸带层(2)或下预浸带层(3)包含2～16层单层的连续纤维增强聚丙烯预浸带。
7.根据权利要求3所述的一种轻型防滑耐磨车厢地板，其特征在于，所述圆管的直径为直径6～10mm，壁厚0.4～0.8mm，所述正六边形边长3～10mm，壁厚0.4～0.8mm。
8.一种轻型防滑耐磨车厢地板的制备方法，其特征在于，包括下列步骤：
S1:上或下预浸带层的制备：将35％～50％重量份的热塑性树脂加入挤出机中，通过模头预浸的工艺，选择合适的连续纤维股数，控制连续纤维含量为50～65％，将连续纤维平行排列成带状，导到挤出模头下方，将熔融树脂淋到带状纤维上面，接着通过品字形加热辊加压，之后通过品字形冷却辊冷却，最后收卷得到单层连续纤维增强聚丙烯带状预浸料；
S2:按照从上到下依次叠放好防滑耐磨层、无纺布层、上预浸带层、蜂窝芯层、下预浸带层；
S3:将S2中铺放好的材料放入复合机中，以一定的速度和压力，先热压定型再冷压；
S4:冷却过后通过牵引辊引出复合板，然后锯切到要求尺寸。
9.根据权利要求8所述的一种轻型防滑耐磨车厢地板的制备方法，其特征在于，所述S2中预浸带层由2～16层单层预浸料按照角度0～90°铺放。
10.根据权利要求8所述的一种轻型防滑耐磨车厢地板的制备方法，其特征在于，所述S3中热压温度为170～230℃，热压时间为1.5～2min；在原有基础的厚度上，下压2.0～3.5mm。
11.根据权利要求8所述的一种轻型防滑耐磨车厢地板的制备方法，其特征在于，S3步骤中复合机中设置有加热段铝方通、冷却段铝方通和转动的特氟龙皮带，加热段铝方通和冷却段铝方通不与复合板直接接触，加热段铝方通通过特氟龙皮带传递热量加热复合板，冷却水通过带走复合板递给冷却段铝方通的热量进行冷却。
12.根据权利要求8所述的一种轻型防滑耐磨车厢地板的制备方法，其特征在于，S4步骤中冷却温度为5～10℃，冷却时间为1.5～2min。
13.根据权利要求11所述的一种轻型防滑耐磨车厢地板的制备方法，其特征在于，所述特氟龙皮带有网格状花纹，网格大小1x1mm～4x4mm。
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