CN115570871A - 一种可循环回收的环保复合材料的生产工艺 - Google Patents
一种可循环回收的环保复合材料的生产工艺 Download PDFInfo
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Abstract
本发明提供了一种可循环回收的环保复合材料的生产工艺,它包基布电晕工艺、基布刀刮涂层工艺、TPO膜与基布贴合工艺,基布为丙纶基布;所述基布电晕工艺步骤如下:基布放卷→电晕处理→冷却→卷取;所述基布刀刮涂层工艺步骤如下:基布放卷→准备浆料→刀刮涂层→烘干塑化→冷却→卷取;所述TPO膜与基布贴合工艺步骤如下:基布放卷→加热→压合→冷却→卷取→检验。
Description
技术领域
本发明涉及材料加工技术领域,尤其涉及一种可循环回收的环保复合材料的生产工艺。
背景技术
现有的篷布,灯布由PVC、TPU塑料复合聚酯基布复合而成,大部分的现有层材料之间通过胶水(聚氨酯胶粘剂)粘结加乙酯溶剂,易挥发出有害气体。加工和二次加工中的广泛应用还会对生产环境造成严重污染。现有的复合材料大多为ABA结构复合材料,A为PVC、TPU其它高分子膜类,B为涤沦、玻纤类增强基材;基材与膜类为不同材料类型材料;因此加工过程中边料无法回收,当废料卖下游处理也很困难回收;另外当做成成品废弃时会造成极大白色污染,多时间不能降解,造成成本浪费及白色污染。
发明内容
本发明的目的是针对现有的技术存在上述问题,提出了一种可循环回收的环保复合材料的生产工艺。
为了实现上述目的,本发明采用了如下技术方案:一种可循环回收的环保复合材料的生产工艺,其特征在于,它包基布电晕工艺、基布刀刮涂层工艺、TPO膜与基布贴合工艺,基布为丙纶基布;
所述基布电晕工艺步骤如下:基布放卷→电晕处理→冷却→卷取;
所述基布刀刮涂层工艺步骤如下:基布放卷→准备浆料→刀刮涂层→烘干塑化→冷却→卷取;
所述TPO膜与基布贴合工艺步骤如下:基布放卷→加热→压合→冷却→卷取→检验。
所述基布电晕处理工艺具体步骤如下:
S1)将基布由放卷装置放卷;
S2)进入含电晕设备的复合生产线,其中电晕功率为3-5KW/H,线速为25-30M/MIN,基布达因值为36DYN;
S3)进入烘箱内定型;
S4)进入冷却装置进行冷却;
S5)进入卷取装置进行卷取。
所述基布涂层加工工艺具体步骤如下:
S1)将经电晕处理后的基布由放卷装置放卷;
S2)准备浆料,进行刀刮涂层处理;
S3)刀刮涂层采用多次刮涂工艺;
S4)将涂层后的基布进行烘干塑化;
S5)进入冷却装置进行冷却;
S6)进入卷取装置进行卷取。
所述刀刮涂层采用三次刮涂。
所述第一次涂覆基布涂层处理配方按重量份如下:MAH接枝剂100份;白油80份;白碳黑增稠剂2.8份;滑石粉30份;胶黏剂10份;环保防霉剂0.2份。
所述第二次及第三次涂覆基布涂层配方按重量份如下:MAH接枝剂90份;白油80份;白碳黑增稠剂2.8份;滑石粉32份;胶黏剂11份;环保防霉剂0.4份。
所述第一次涂覆基布温度在150-160℃;所述第二次涂覆基布温度在160-165℃;所述第三次涂覆基布温度在160-200℃。
所述TP0膜与基布贴合工艺参数为:
1)、加热:热水温度为30±2℃;TP0膜预热温度为155±2℃;TPO膜加热温度为180±2℃;涂层基布预热温度为175℃±2℃;涂层基布加热温度为183℃±2℃;
2)、车速:涂层基布预热车速为14.83±2m/min;涂层基布加热车速为14.95±2m/min;TPO膜预热车速为14.69±2m/min;TP0膜加热车速为15.04±2m/min;
3)、压力阀:压花轮组与橡胶轮的压力为50kg。
所述TP0膜配方按重量份如下:PP树脂50份;POE树酯50份;白油5份;滑石粉30-35份;紫外线吸收剂0.5-1份;环保防霉剂0.1-0.3份。
还包括基布网纹辊浸胶加工工艺,所述基布网纹辊浸胶加工工艺具体步骤如下:
S1)将电晕后的基布由放卷装置放卷;
S2)准备浆料后,进行网纹辊辊涂层处理;
S3)网纹辊涂层工艺;
所述基布辊涂涂层处理配方按重量份如下:非极性糊树脂55-10份;白油80-85份;纳米钙30-35份;增稠剂5-10份;环保防霉剂0.1-0.3份。
与现有技术相比,本发明的优点在于:
1、通过优选了基布原料,并进行电晕处理,再经过涂层后通过膜与涂层基布冷贴贴合加工后,与传统产品相比,具有更高的剥离强度,且因基布与膜类同为聚烯烃类同非极性材料,有效解决了TPO环保膜与基布难贴合问题,且剥离达300N以上。
2、采用基布电晕技术,提高产品的无胶剥离性,通过对浆料接枝处理配方创新,使产品在保持气密防水的同时又兼顾了其主体的力学性能,保证了产品的拉伸、撕裂强度和剥离负荷,使产品在良好的防水防气基础上兼具高抗冲击等特点。
3、引进了PP丙纶布为增强基材,同为非极性材料,与TPO膜材熔点极性相同,解决了TPO与基布复合难的课题。
4、因PP丙纶基布与TPO熔点极性相同,复合产生基材边料可当余料在生产压延TPO膜时可及时回炉,解决业界边料不可回收及只能当废品处理的业界难题;另做成成品废旧时可低价回收重复制膜利用,解决循环利用,降低白色污染,大大降低损耗及成本。
5、复合方式采取冷贴复合工艺,基布电晕加热到120℃,胶膜复合温度为165±5℃,解决了丙纶基布易收缩(30%以上)加工难题,收缩控制在5-8%以内。
具体实施方式
以下是本发明的具体实施例,对本发明的技术方案作进一步的描述,但本发明并不限于这些实施例。
本可循环回收的环保复合材料的生产工艺,它包基布电晕工艺、基布刀刮涂层工艺、TPO膜与基布贴合工艺,基布为丙纶基布,具体的:基布选用1000D丙纶布,机织布密度为23根/cm×23根/em;在实际中,基布与TPO膜同为非极性材料,TPO膜与丙纶基布采用的是无胶冷贴合工艺,PP丙纶基布电晕增加表面张力及丙纤维与TPO熔点与熔指一致;由于产品主要应用于TPO复合材料领域,所以对产品的各项指标的要求极高,特别是户外用产品的耐用性、气密性和抗冲击性要求高;产品的性能强度主要由原材料和配方决定,因而选择适宜的原材料和添加剂是一个重要环节;
基布电晕工艺步骤如下:基布放卷→电晕处理→冷却→卷取;
基布刀刮涂层工艺步骤如下:基布放卷→准备浆料→刀刮涂层→烘干塑化→冷却→卷取;
TP0膜与基布贴合工艺步骤如下:基布放卷→加热→压合→冷却→卷取→检验;具体的:基布贴合温度保持在120±5℃,收缩控制在5-8%以内,TPO膜贴合温度保持在165±5℃;
基布电晕处理工艺具体步骤如下:
S1)将基布由放卷装置放卷;
S2)进入含电晕设备的复合生产线,其中电晕功率为3-5KW/H,线速为25-30M/MIN,基布达因值为36DYN,是指处理后基布的表面张力达因值为36DYN;具体的:电晕基布温度在120-125℃;还包括将基布以15m/min的车速进入含浸槽中浸轧,其中含浸槽中溶液由去离子水和MAH接枝剂组成,去离子水与MAH接枝剂体积比为100:1-2;
S3)进入烘箱内定型;
S4)进入冷却装置进行冷却;
S5)进入卷取装置进行卷取。
基布涂层加工工艺具体步骤如下:
S1)将经电晕处理后的基布由放卷装置放卷;
S2)准备浆料,进行刀刮涂层处理;
S3)刀刮涂层采用多次刮涂工艺;使制得产品表面更加平整、气密性好;
S4)将涂层后的基布进行烘干塑化;
S5)进入冷却装置进行冷却;
S6)进入卷取装置进行卷取。
刀刮涂层采用三次刮涂。
第一次涂覆基布涂层处理配方按重量份如下:MAH接枝剂100份;白油80份;白碳黑增稠剂2.8份;滑石粉30份;胶黏剂10份;环保防霉剂0.2份。
第二次及第三次涂覆基布涂层配方按重量份如下:MAH接枝剂90份;白油80份;白碳黑增稠剂2.8份;滑石粉32份;胶黏剂11份;环保防霉剂0.4份。
第一次涂覆基布温度在150-160℃;第二次涂覆基布温度在160-165℃;第三次涂覆基布温度在160-200℃。
TPO膜与基布贴合工艺参数为:
1)、加热:热水温度为30±2℃;TP0膜预热温度为155±2℃;TP0膜加热温度为180±2℃;涂层基布预热温度为175℃±2℃;涂层基布加热温度为183℃±2℃;
2)、车速:涂层基布预热车速为14.83±2m/min;涂层基布加热车速为14.95±2m/min;TPO膜预热车速为14.69±2m/min;TPO膜加热车速为15.04±2m/min;
3)、压力阀:压花轮组与橡胶轮的压力为50kg。
TPO膜配方按重量份如下:PP树脂50份;POE树酯50份;白油5份;滑石粉30-35份;紫外线吸收剂0.5-1份;环保防霉剂0.1-0.3份;在实际中,TPO膜为配方相同的两张:环保基膜A和环保基膜B;环保基膜A贴合温度在160-165℃;环保基膜B贴合温度在160-170℃;
还包括基布网纹辊浸胶加工工艺,基布网纹辊浸胶加工工艺具体步骤如下:
S1)将电晕后的基布由放卷装置放卷;
S2)准备浆料后,进行网纹辊辊涂层处理;
S3)网纹辊涂层工艺;
基布辊涂涂层处理配方按重量份如下:非极性糊树脂55-10份;白油80-85份;纳米钙30-35份;增稠剂5-10份;环保防霉剂0.1-0.3份。
采用以上工艺制得的产品,指标如下:
1、单位面积质量(g/m2)1060±25;
2、厚度(mm)0.82±0.03;
3、拉伸负荷(N/5cm)经向≥3200;纬向≥2500;
4、撕裂负荷(N)经向≥250;纬向≥250;
5、剥离强度(N)经向≥120;纬向≥110;
6、耐受压力(KPA/25分室温)≥36;
7、防霉0级;
8、耐寒-50℃以上。
本文中所描述的具体实施例仅仅是对本发明精神作举例说明。本发明所属技术领域的技术人员可以对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代,但并不会偏离本发明的精神或者超越所附权利要求书所定义的范围。
Claims (10)
1.一种可循环回收的环保复合材料的生产工艺,其特征在于,它包基布电晕工艺、基布刀刮涂层工艺、TPO膜与基布贴合工艺,基布为丙纶基布;
所述基布电晕工艺步骤如下:基布放卷→电晕处理→冷却→卷取;
所述基布刀刮涂层工艺步骤如下:基布放卷→准备浆料→刀刮涂层→烘干塑化→冷却→卷取;
所述TPO膜与基布贴合工艺步骤如下:基布放卷→加热→压合→冷却→卷取→检验。
2.根据权利要求1所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述基布电晕处理工艺具体步骤如下:
S1)将基布由放卷装置放卷;
S2)进入含电晕设备的复合生产线,其中电晕功率为3-5KW/H,线速为25-30M/MIN,基布达因值为36DYN;
S3)进入烘箱内定型;
S4)进入冷却装置进行冷却;
S5)进入卷取装置进行卷取。
3.根据权利要求1所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述基布涂层加工工艺具体步骤如下:
S1)将经电晕处理后的基布由放卷装置放卷;
S2)准备浆料,进行刀刮涂层处理;
S3)刀刮涂层采用多次刮涂工艺;
S4)将涂层后的基布进行烘干塑化;
S5)进入冷却装置进行冷却;
S6)进入卷取装置进行卷取。
4.根据权利要求3所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述刀刮涂层采用三次刮涂。
5.根据权利要求4所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述第一次涂覆基布涂层处理配方按重量份如下:MAH接枝剂100份;白油80份;白碳黑增稠剂2.8份;滑石粉30份;胶黏剂10份;环保防霉剂0.2份。
6.根据权利要求5所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述第二次及第三次涂覆基布涂层配方按重量份如下:MAH接枝剂90份;白油80份;白碳黑增稠剂2.8份;滑石粉32份;胶黏剂11份;环保防霉剂0.4份。
7.根据权利要求4所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述第一次涂覆基布温度在150-160℃;所述第二次涂覆基布温度在160-165℃;所述第三次涂覆基布温度在160-200℃。
8.所根据权利要求1所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述TPO膜与基布贴合工艺参数为:
1)、加热:热水温度为30±2℃;TPO膜预热温度为155±2℃;TPO膜加热温度为180±2℃;涂层基布预热温度为175℃±2℃;涂层基布加热温度为183℃±2℃;
2)、车速:涂层基布预热车速为14.83±2m/min;涂层基布加热车速为14.95±2m/min;TPO膜预热车速为14.69±2m/min;TPO膜加热车速为15.04±2m/min;
3)、压力阀:压花轮组与橡胶轮的压力为50kg。
9.根据权利要求1所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,所述TPO膜配方按重量份如下:PP树脂50份;POE树酯50份;白油5份;滑石粉30-35份;紫外线吸收剂0.5-1份;环保防霉剂0.1-0.3份。
10.根据权利要求1所述的一种可循环回收的环保复合材料的生产工艺,其特征在于,还包括基布网纹辊浸胶加工工艺,所述基布网纹辊浸胶加工工艺具体步骤如下:
S1)将电晕后的基布由放卷装置放卷;
S2)准备浆料后,进行网纹辊辊涂层处理;
S3)网纹辊涂层工艺;
所述基布辊涂涂层处理配方按重量份如下:非极性糊树脂55-10份;白油80-85份;纳米钙30-35份;增稠剂5-10份;环保防霉剂0.1-0.3份。
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