CN115323795B - 一种tpe方块地毯及其制备方法 - Google Patents
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Abstract
本发明涉及地毯制造技术领域,具体为一种TPE方块地毯及其制备方法,包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层。本发明完全解决了挤出胶膜层工艺,与坯毯和玻纤复合压实成型时粘接性能差的问题,TPE聚烯烃弹性体的创新引入,解决了毯型硬,对铺设地面要求高,易带来边角不贴地、翘曲的情况,同时赋予地毯弹性、舒适的脚感;同样由于TPE聚烯烃弹性体的创新引入,更是一举解决美林肯地毯PP性能脆易碎的问题,又提供的TPE聚烯烃弹性体热熔胶,赋予TPE地毯比PE、PP地毯更好柔韧性和弹性,还提供了新型功能纤维层,以完全解决毯面收缩大而导致的翘曲问题,增强地毯的整体韧性和强度。
Description
技术领域
本发明涉及地毯制造技术领域,具体为一种TPE方块地毯及其制备方法。
背景技术
根据地毯供应的规格不同,地毯可分为卷装地毯和块状地毯,块状地毯中的方块地毯以其搬运、安装及拆除更换方便灵活,耐磨、静音、吸尘,是大型写字楼、办公室、会议室以及公共区域、场所的首选用毯。并日益向住宅、宾馆场所延伸。
方块地毯底背所用胶底材料主要有PVC胶、沥青胶、PU胶及聚烯烃类。现在市场上PVC方块地毯存在因使用聚氯乙烯糊状树脂及所用增塑剂的析出、TVOC较高、不环保及后续回收处理困难问题,PVC方块地毯在有些国家或场所已禁用。同样,沥青地毯也是非环保产品,在生产、使用及回收等方面存在诸多问题。而PU方块地毯尽管环保性能优良,但也存在回收再利用困难、生产不易控制等问题。现在市场上,以美国萧氏地毯为代表的PE方块地毯及美国美林肯为代表的PP底背的聚烯烃方块地毯,为广大客户推崇,因其有低TVOC、环境友好、质量轻、可回收、节约资源等诸多优点。
然而,以美国萧氏地毯为代表的PE方块地毯,其生产工艺,是把PE母粒熔融挤出成膜后,再与坯毯和玻纤复合压实成型,存在PE胶与坯毯粘接牢固强度不足的问题。而以美国美林肯为代表的生产工艺,由于其毯背为PP底背,韧性差,脆性大,很容易折断,特别是在冬季时,脆性更为明显,抗碾压性能差,耐用性能方面均需改善提高。
另外,针对美国萧氏地毯还存在毯型硬,对铺设地面要求高的情况,很容易带来边角不贴地、翘曲的问题,在此情况下,厂家要求打满胶铺装,又势必会带来铺装用胶的气味的挥发问题。同时脚感较硬,这方面也需要解决。
发明内容
本发明的目的在于提供一种TPE方块地毯及其制备方法,以解决上述背景技术中提出的问题。
为实现上述目的,本发明提供如下技术方案:
一种TPE方块地毯及其制备方法,包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层,所述EVA预涂胶层包括以下重量份数的原料制成:30-50份的乙烯-醋酸乙烯酯共聚物,30-50份的碳酸钙,1-2份的辅料,10-20份的水。
作为优选,所述碳酸钙的目数为300-350目,辅料选自渗透剂、分散剂、发泡剂和增稠剂中的一种或多种。
作为优选,所述TPE聚烯烃涂层为聚烯烃弹性体热熔胶,包括马来酸酐接枝物相容剂3-5份,热塑性聚烯烃弹性体10-25份,蜡2-5份,增粘树脂2-5份,填料50-70份,黑母粒0.5-1.5份,增强剂3-8份,其他助剂1-3份。
作为优选,其他助剂采用自白油、分散剂、脱膜剂和抗氧剂中的一种或多种,具体为分散剂、脱膜剂和抗氧剂。
另一方面,本发明还提供一种TPE方块地毯的制备方法,包括上述TPE方块地毯,具体包括如下步骤:
S10:将EVA预涂胶层涂覆于经蒸汽预蒸处理过的坯毯背面,加热反应后,得到有预涂层的坯毯;
S20:将双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S10制得坯毯背面,再与新型功能纤维层复合压实冷却;
S30:将双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,经单螺杆机熔融挤出到涂敷单元,通过涂胶辊转移涂敷到步骤S20制得新型功能纤维、TPE胶及坯毯的复合层背面,复合压实冷却,再经地毯背面压花,得到块状地毯。
作为优选,步骤S10中EVA预涂胶经发泡后涂覆于经蒸汽预蒸处理过的坯毯背面,步骤S10中加热的温度为130℃-170℃。
作为优选,步骤S20中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒的加热熔体温度为130℃-150℃,步骤S20中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒时,采用水下切粒方式,并经过脱水、干燥后备用。
作为优选,步骤S20中单螺杆机熔融挤出机的熔体温度为150℃-170℃,步骤S20中涂敷单元温度为160℃-190℃,步骤S20中复合压实冷却采用复合辊和冷却辊进行复合辊压,冷却辊温度10℃-25℃。
作为优选,步骤S30中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒的加热熔体温度为130℃-150℃,步骤S30中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒时,采用水下切粒方式,并经过脱水、干燥后备用。
作为优选,步骤S30中单螺杆机熔融挤出机的熔体温度为150℃-170℃,涂敷单元温度为160℃-190℃;复合压实冷却采用复合辊和冷却辊进行复合辊压,冷却辊温度10℃-25℃;压花单元压花辊内水温为40℃-70℃;压花辊前地毯毯背红外预热温度50℃-80℃。
与现有技术相比,本发明的有益效果是:本TPE方块地毯及其制备方法中,完全解决了挤出胶膜层工艺,与坯毯和玻纤复合压实成型时粘接性能差的问题,TPE聚烯烃弹性体的创新引入,解决了毯型硬,对铺设地面要求高,易带来边角不贴地、翘曲的情况,同时赋予地毯弹性、舒适的脚感;同样由于TPE聚烯烃弹性体的创新引入,更是一举解决美林肯地毯PP性能脆易碎的问题。本发明又提供的一种块状地毯用TPE聚烯烃弹性体热熔胶,赋予了TPE地毯比PE、PP地毯更好柔韧性和弹性。本发明还提供了一种新型功能纤维层应用,以完全解决毯面收缩大而导致的翘曲问题,增强地毯的整体韧性和强度。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
一种TPE方块地毯,包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层。
本实施例中TPE方块地毯的制备方法具体包括如下步骤:
S11:将42重量份的乙烯-醋酸乙烯酯共聚物、45重量份的碳酸钙(325目)、2重量份的辅料、与12重量份的水混合,得到预涂用EVA胶,所述辅料为渗透剂、分散剂和发泡剂。
S12:将步骤S11中得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面,用刮刀刮平后,置于烘箱中155℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重550克/平,下机幅宽2.06米(对应于产品50厘米*4块的幅宽要求)。
S13:首先要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物3份,热塑性聚烯烃弹性体16份,蜡2份,增粘树脂3份,填料68份,黑母粒0.5份,增强剂5.5份,其他助剂2份。并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S12制得坯毯背面,再与新型功能纤维层复合压实冷却。
S14:同样,也要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物3份,热塑性聚烯烃弹性体18份,蜡3份,增粘树脂2份,填料63份,黑母粒1.2份,增强剂6.8份,其他助剂3份。并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S13制得新型功能纤维、TPE胶及坯毯三者的复合层背面,复合压实冷却。再经过地毯背面压花,得到块状地毯。
实施例2
一种TPE方块地毯,包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层。
本实施例中TPE方块地毯的制备方法具体包括如下步骤:
S21:将43重量份的乙烯-醋酸乙烯酯共聚物、44重量份的碳酸钙(325目)、2重量份的辅料、与12重量份的水混合,得到预涂用EVA胶,所述辅料为渗透剂、分散剂和发泡剂。
S22:将步骤S21中得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面,用刮刀刮平后,置于烘箱中155℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重550克/平,下机幅宽2.06米(对应于产品50厘米*4块的幅宽要求)。
S23:首先要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物2份,热塑性聚烯烃弹性体15份,蜡2份,增粘树脂4份,填料68份,黑母粒0.5份,增强剂5.5份,其他助剂3份;并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S22制得坯毯背面,再与新型功能纤维层复合压实冷却。
S24:同样,也要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物4份,热塑性聚烯烃弹性体18份,蜡3份,增粘树脂2份,填料62份,黑母粒1.2份,增强剂6.8份,其他助剂3份;并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到S23制得新型功能纤维、TPE胶及坯毯三者的复合层背面,复合压实冷却;再经过地毯背面压花,得到块状地毯。
实施例3
一种TPE方块地毯,包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层。
本实施例中TPE方块地毯的制备方法具体包括如下步骤:
S31:将45重量份的乙烯-醋酸乙烯酯共聚物、43重量份的碳酸钙(325目)、2重量份的辅料、与10重量份的水混合,得到预涂用EVA胶,所述辅料为渗透剂、分散剂和发泡剂。
S32:将步骤S31中得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面,用刮刀刮平后,置于烘箱中155℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重550克/平,下机幅宽2.06米(对应于产品50厘米*4块的幅宽要求)。
S33:首先要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物2份,热塑性聚烯烃弹性体15份,蜡3份,增粘树脂4份,填料68份,黑母粒0.5份,增强剂4.5份,其他助剂3份。并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S32制得坯毯背面,再与新型功能纤维层复合压实冷却。
S34:同样,也要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物4份,热塑性聚烯烃弹性体20份,蜡2份,增粘树脂2份,填料60份,黑母粒1.2份,增强剂7.8份,其他助剂3份。并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S33制得新型功能纤维、TPE胶及坯毯三者的复合层背面,复合压实冷却。再经过地毯背面压花,得到块状地毯。
对比例1
一种TPE方块地毯,包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层。
本实施例中TPE方块地毯的制备方法具体包括如下步骤:
S41:将44重量份的乙烯-醋酸乙烯酯共聚物、43重量份的碳酸钙(325目)、2重量份的辅料、与11重量份的水混合,得到预涂用EVA胶,所述辅料为渗透剂、分散剂和发泡剂。
S42:将步骤41中得到的预涂用EVA胶进行发泡后,涂覆于坯毯的背面,用刮刀刮平后,置于烘箱中155℃进行固化反应并烘干,得到有预涂层的坯毯,其预涂胶层涂敷干胶重550克/平,下机幅宽2.06米(对应于产品50厘米*4块的幅宽要求)。
S43:首先要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物2份,热塑性聚烯烃弹性体14份,蜡2份,增粘树脂4份,填料69份,黑母粒0.5份,增强剂5.5份,其他助剂3份。并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤42制得坯毯背面,再与新型功能纤维层复合压实冷却。
S44:同样,也要制得TPE聚烯烃弹性体颗粒,其组份包括马来酸酐接枝物4份,热塑性聚烯烃弹性体19份,蜡2份,增粘树脂2份,填料63份,黑母粒1.2份,增强剂5.8份,其他助剂1-3份。并且采用双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,再经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤43制得新型功能纤维、TPE胶及坯毯三者的复合层背面,复合压实冷却。再经过地毯背面压花,得到块状地毯。
将本发明的三个实施例制备的TPE方块地毯与对比例1的TPE方块地毯在翘曲值、弹性恢复率、毯背剥离以及在-21℃冷冻4小时折断效果进行性能数据对比,如下表所示:
技术指标 | 翘曲值/mm | 弹性恢复率/% | 毯背剥离/N | -21℃冷冻4小时 |
实施例1 | 1.2 | 61 | 57 | 无折断 |
实施例2 | 0.8 | 62 | 68 | 无折断 |
实施例3 | 1.3 | 60 | 拉断,未测出 | 无折断 |
对比例1 | 0.9 | 61 | 73 | 无折断 |
备注:
1、翘曲值试验方法,执行QB/T2755-2005《拼块地毯》
2、毯背剥离试验方法,执行QB/T26843-2011《地毯背衬剥离强力的测定》
3、弹性恢复率试验方法,执行海马集团质检局备案标准Q/1001WHM 001-2016《PU方块地毯》
4、-21℃冷冻4小时试验:在-21℃冰柜冷冻4小时,马上把地毯向毯面方向对折,至毯面100%接触,看毯背对折痕情况。
实验结果表明:本发明的TPE方块地毯及其制备方法完全解决了挤出胶膜层工艺,与坯毯和玻纤复合压实成型时粘接性能差的问题,TPE聚烯烃弹性体的创新引入,解决了毯型硬,对铺设地面要求高,易带来边角不贴地、翘曲的情况,同时赋予地毯弹性、舒适的脚感;同样由于TPE聚烯烃弹性体的创新引入,更是一举解决美林肯地毯PP性能脆易碎的问题。本发明又提供的一种块状地毯用TPE聚烯烃弹性体热熔胶,赋予了TPE地毯比PE、PP地毯更好柔韧性和弹性。本发明还提供了一种新型功能纤维层应用,以完全解决毯面收缩大而导致的翘曲问题,增强地毯的整体韧性和强度,以上实施例中所用试剂均为市售。
值得说明的是,新型特种纤维层,包括以下百分比重量的原料:耐高温聚酯纤维60-90%,低熔点聚酯纤维5-20%,芳纶纤维3-15%和植物性纤维3-5%,完全消除了玻璃纤维的严重环境健康危害,并且可完全地替代玻璃纤维层在方块地毯生产中的使用,满足纤维层对方块地毯稳定外形、稳定尺寸的作用,同时消除了在玻璃丝布使用中带来的地毯毯背易碎、易断等质量问题,同时也易引发地毯翘曲等严重质量问题,并实现方块地毯100%的环保和100%的回收再利用。
本发明中所述坯毯的来源并无特殊的限制,可为市售,也为自制的坯毯,但出于其后续处理中幅宽收缩的考虑,结合实际成品规格要求,对其坯毯幅宽要给予考虑,同时对预涂及上胶工艺参数有特殊要求。其制备方法为本领域技术人员熟知的方法。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的仅为本发明的优选例,并不用来限制本发明,在不脱离本发明精神和范围的前提下,本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (9)
1.一种TPE方块地毯,其特征在于:包括多层结构,依次为坯毯层、EVA涂层、TPE聚烯烃涂层、新型功能纤维层、TPE涂层,所述EVA预涂胶层包括以下重量份数的原料制成:30-50份的乙烯-醋酸乙烯酯共聚物,30-50份的碳酸钙,1-2份的辅料,10-20份的水;所述TPE聚烯烃涂层为聚烯烃弹性体热熔胶,包括马来酸酐接枝物相容剂3-5份,热塑性聚烯烃弹性体10-25份,蜡2-5份,增粘树脂2-5份,填料50-70份,黑母粒0.5-1.5份,增强剂3-8份,其他助剂1-3份。
2.根据权利要求1所述的TPE方块地毯,其特征在于:所述碳酸钙的目数为300-350目,辅料选自渗透剂、分散剂、发泡剂和增稠剂中的一种或多种。
3.根据权利要求1所述的TPE方块地毯,其特征在于:其他助剂采用自白油、分散剂、脱膜剂和抗氧剂中的一种或多种,具体为分散剂、脱膜剂和抗氧剂。
4.一种如权利要求1-3任一项所述的TPE方块地毯的制备方法,其特征在于:具体包括如下步骤:
S10:将EVA预涂胶层涂覆于经蒸汽预蒸处理过的坯毯背面,加热反应后,得到有预涂层的坯毯;
S20:将双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,经单螺杆挤出机熔融挤出到涂敷单元,通过涂胶辊转移到步骤S10制得坯毯背面,再与新型功能纤维层复合压实冷却;
S30:将双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒,经单螺杆机熔融挤出到涂敷单元,通过涂胶辊转移涂敷到步骤S20制得新型功能纤维、TPE胶及坯毯的复合层背面,复合压实冷却,再经地毯背面压花,得到块状地毯。
5.根据权利要求4所述的TPE方块地毯的制备方法,其特征在于:步骤S10中EVA预涂胶经发泡后涂覆于经蒸汽预蒸处理过的坯毯背面,步骤S10中加热的温度为130℃-170℃。
6.根据权利要求4所述的TPE方块地毯的制备方法,其特征在于:步骤S20中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒的加热熔体温度为130℃-150℃,步骤S20中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒时,采用水下切粒方式,并经过脱水、干燥后备用。
7.根据权利要求4所述的TPE方块地毯的制备方法,其特征在于:步骤S20中单螺杆机熔融挤出机的熔体温度为150℃-170℃,步骤S20中涂敷单元温度为160℃-190℃,步骤S20中复合压实冷却采用复合辊和冷却辊进行复合辊压,冷却辊温度10℃-25℃。
8.根据权利要求4所述的TPE方块地毯的制备方法,其特征在于:步骤S30中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒的加热熔体温度为130℃-150℃,步骤S30中双螺杆造粒机制得的聚烯烃弹性体热熔胶颗粒时,采用水下切粒方式,并经过脱水、干燥后备用。
9.根据权利要求4所述的TPE方块地毯的制备方法,其特征在于:步骤S30中单螺杆机熔融挤出机的熔体温度为150℃-170℃,涂敷单元温度为160℃-190℃;复合压实冷却采用复合辊和冷却辊进行复合辊压,冷却辊温度10℃-25℃;压花单元压花辊内水温为40℃-70℃;压花辊前地毯毯背红外预热温度50℃-80℃。
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