CN116396546A - 一种高弹性泡棉材料及其制作工艺 - Google Patents
一种高弹性泡棉材料及其制作工艺 Download PDFInfo
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Abstract
本发明提供一种高弹性泡棉材料及其制作工艺,涉及泡棉材料技术领域。该高弹性泡棉材料,包括以下质量份数原料:聚乙烯废弃物16~38份、聚酯多元醇6~15份、热塑性弹性体8~13份、发泡剂4~8份、硅橡胶20~30份、乙烯基硅油10~18份、交联剂9~16份、导热填料7~14份、环氧树脂1~5份、阻燃剂3~5份、抗老化剂3~4份。通过利用聚乙烯废弃物、硅橡胶和乙烯基硅油制得的泡孔均匀的泡棉材料,材质整体的拉伸强度、拉断伸长率、热导率、电气强度和阻燃等级,均性能优异,并且采用聚乙烯废弃物作为原料制备,有利于节约经济成本,同时制备工艺简单、操作难度大幅降低,有利于提高泡棉的产量以及应用范围。
Description
技术领域
本发明涉及泡棉材料技术领域,具体为一种高弹性泡棉材料及其制作工艺。
背景技术
泡棉是塑料粒子发泡过的材料,简称泡棉,泡棉分为PU泡棉,防静电泡棉、导电泡棉、EPE和防静电EPE等多个种类,并且泡棉具有弹性、重量轻、快速压敏固定、使用方便、弯曲自如、体积超薄和性能可靠等一系列优异特点,使得泡棉材料广泛应用于家居用品和建筑工程。
现有的泡棉主要包括普通泡棉和高弹泡棉,对于普通泡棉而言,其为常用的泡棉层,由于拉伸强度、断裂伸长率、撕裂强度都很差,所以在很多应用场合无法达到使用要求,对于高弹泡棉而言,其在常用泡棉原材料内掺入弹性体或玻纤材料,以改善其力学性能,掺入弹性体的高弹泡棉,虽然断裂伸长率等力学性能有所提高,但是由于该泡棉很软,容易被拉伸而变形,再加上生产成本很高,所以应用和使用范围也较为有限。
基于上述分析,现有的泡棉材料不管是普通泡棉或者高弹泡棉,整体的弹性和拉伸性都不是较为理想,并且制备的工艺较为复杂、操作难度较高,导致泡棉产量有限以及应用有限,因此,为解决上述存在的问题,提供一种高弹性泡棉材料及其制作工艺。
发明内容
针对现有技术的不足,本发明提供了一种高弹性泡棉材料及其制作工艺,解决了现有的泡棉材料整体的弹性和拉伸性都不是较为理想,并且制备的工艺较为复杂、操作难度较高,导致泡棉产量有限以及应用有限的问题。
为实现以上目的,本发明通过以下技术方案予以实现:一种高弹性泡棉材料,包括以下质量份数原料:聚乙烯废弃物16~38份、聚酯多元醇6~15份、热塑性弹性体8~13份、发泡剂4~8份、硅橡胶20~30份、乙烯基硅油10~18份、交联剂9~16份、导热填料7~14份、环氧树脂1~5份、阻燃剂3~5份、抗老化剂3~4份。
优选的,所述阻燃剂为聚氰胺磷酸盐、三氧化二锑和氢氧化铝按质量比15∶2∶6复配制成。
优选的,所述导热填料为碳纤维与硅微粉、纳米氧化铝、氮化物中任意一种复配的组合物。
一种高弹性泡棉材料的制作工艺,使用一种高弹性泡棉材料,包括以下步骤:
S1、废弃物处理:首先将聚乙烯废弃物进行表面喷淋清洗和紫外线杀菌,再将废弃物送入粉碎装置中粉碎成2~3mm颗粒,再将颗粒加入吸附剂静置,形成的静置液再通过200~300目的过滤器过滤,得到的滤液添加有机溶剂析出聚乙烯粉状物,并通过分离得到聚乙烯粉状物的混浊液,最后通过离心机脱液,得到的沉积物洗涤干燥后,得到聚乙烯粉末;
S2、原料选配:
S201、按配方比选用热塑性弹性体和聚酯多元醇,并且与S1步骤中得到的聚乙烯粉末同步送入搅拌釜中进行2~3h的混合搅拌,搅拌阶段分3~5次加入全部当量的发泡剂,发泡完成后,即得发泡原料A;
S202、按配方比选硅橡胶和乙烯基硅油作为基础料,进行搅拌混合后,再加入交联剂和导热填料,在90~120℃进行二次混合,再将环氧树脂、阻燃剂和抗老化剂与水混合的溶液,通过喷雾形式进行添加,即得到强化原料B;
S3、注胶处理:将得到的发泡原料A和强化原料B分别输送到注胶机中,将注胶机首先升温到预设的6~30℃温度后,再在15~35℃的工作温度下,向两个单层平面模具中分别注入发泡原料A和强化原料B,并进行锁紧,完成后打开模具,等待冷却后分别取出制作的发泡胶体A和强化胶体B;
S4、胶层叠加:将得到的发泡胶体A和强化胶体B通过熔融的方式进行层层叠加,叠加方式采用发泡胶体A叠加二层、强化胶体B叠加一层的方式进行累积,当到达8~10cm后,通过挤压模具将挤压,使厚度变成4~5cm,并进行切边和尺寸调整,即完成高弹性泡棉材料的制备。
优选的,所述S201步骤中,所述发泡过程的温度为36℃~47℃,发泡时间为80mi n~100mi n。
优选的,所述S202步骤中,所述吸附剂为活性白土、硅藻土或活性炭中的任意一种,所述有机溶剂为二甲苯、三氯苯或丙酮中的任意一种。
优选的,所述S202步骤中,所述硅橡胶为黏度22000mPa·s的107硅橡胶,所述乙烯基硅的黏度为110000mPa·s。
优选的,所述S202步骤中,所述交联剂为黏度为2200mPa·s、活性氢摩尔分数为1.8%的含氢硅油。
本发明提供了一种高弹性泡棉材料及其制作工艺。具备以下有益效果:
1、本发明通过利用聚乙烯废弃物、硅橡胶和乙烯基硅油制得的泡孔均匀的泡棉材料,该材质的拉伸强度、拉断伸长率、热导率、电气强度和阻燃等级,均性能优异,并且采用聚乙烯废弃物作为原料制备,有利于节约经济成本,提高资源利用率。
2、本发明通过热塑性弹性体和聚酯多元醇为原料,配合发泡剂,发泡制得发泡原料A,再通过硅橡胶和乙烯基硅油作为基础料,配合交联剂和导热填料,和环氧树脂、阻燃剂和抗老化剂与水混合的溶液喷雾,制得强化原料B,发泡原料A和强化原料B经过注胶机,分别制得发泡胶体A和强化胶体B,并通过熔融的方式进行层层叠加,最后挤压厚度,切边和尺寸调整,完成高弹性泡棉材料的制备,整体的制备工艺较为简单、操作难度大幅缩减,有利于促进泡棉产量提升以及应用范围的扩展。
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:
根据本发明的一方面。本发明实施例提供一种高弹性泡棉材料,包括以下质量份数原料:聚乙烯废弃物16份、聚酯多元醇6份、热塑性弹性体8份、发泡剂4份、硅橡胶20份、乙烯基硅油10份、交联剂9份、导热填料7份、环氧树脂1份、阻燃剂3份、抗老化剂3份。
阻燃剂为聚氰胺磷酸盐、三氧化二锑和氢氧化铝按质量比15∶2∶6复配制成。
导热填料为碳纤维与硅微粉、纳米氧化铝、氮化物中任意一种复配的组合物。
根据本发明的另一方面,本发明实施例提供了一种高弹性泡棉材料的制作工艺,并且使用一种高弹性泡棉材料中的原料进行制备,包括以下步骤:
S1、废弃物处理:首先将聚乙烯废弃物进行表面喷淋清洗和紫外线杀菌,再将废弃物送入粉碎装置中粉碎成2~3mm颗粒,再将颗粒加入吸附剂静置,形成的静置液再通过200~300目的过滤器过滤,得到的滤液添加有机溶剂析出聚乙烯粉状物,并通过分离得到聚乙烯粉状物的混浊液,最后通过离心机脱液,得到的沉积物洗涤干燥后,得到聚乙烯粉末;
S2、原料选配:
S201、按配方比选用热塑性弹性体和聚酯多元醇,并且与S1步骤中得到的聚乙烯粉末同步送入搅拌釜中进行2~3h的混合搅拌,搅拌阶段分3~5次加入全部当量的发泡剂,发泡完成后,即得发泡原料A;
S202、按配方比选硅橡胶和乙烯基硅油作为基础料,进行搅拌混合后,再加入交联剂和导热填料,在90~120℃进行二次混合,再将环氧树脂、阻燃剂和抗老化剂与水混合的溶液,通过喷雾形式进行添加,即得到强化原料B;
S3、注胶处理:将得到的发泡原料A和强化原料B分别输送到注胶机中,将注胶机首先升温到预设的6~30℃温度后,再在15~35℃的工作温度下,向两个单层平面模具中分别注入发泡原料A和强化原料B,并进行锁紧,完成后打开模具,等待冷却后分别取出制作的发泡胶体A和强化胶体B;
S4、胶层叠加:将得到的发泡胶体A和强化胶体B通过熔融的方式进行层层叠加,叠加方式采用发泡胶体A叠加二层、强化胶体B叠加一层的方式进行累积,当到达8~10cm后,通过挤压模具将挤压,使厚度变成4~5cm,并进行切边和尺寸调整,即完成高弹性泡棉材料的制备。
进一步的,S201步骤中,发泡过程的温度为36℃~47℃,发泡时间为80mi n~100mi n。
进一步的,202步骤中,吸附剂为活性白土、硅藻土或活性炭中的任意一种,有机溶剂为二甲苯、三氯苯或丙酮中的任意一种。
202步骤中,硅橡胶为黏度22000mPa·s的107硅橡胶,乙烯基硅的黏度为110000mPa·s。
S202步骤中,交联剂为黏度为2200mPa·s、活性氢摩尔分数为1.8%的含氢硅油。
实施例2:
本发明实施例提供一种高弹性泡棉材料,包括以下质量份数原料:聚乙烯废弃物18份、聚酯多元醇12份、热塑性弹性体9份、发泡剂6份、硅橡胶25份、乙烯基硅油14份、交联剂13份、导热填料9份、环氧树脂3份、阻燃剂4份、抗老化剂3份。
其他的步骤以及制备方法与实施例1的制备步骤和方法保持一致,最后得到高弹性泡棉材料,采用相同的方法进行后续实验表征,具体参数如下表1所示。
实施例3:
本发明实施例提供一种高弹性泡棉材料,包括以下质量份数原料:聚乙烯废弃物38份、聚酯多元醇15份、热塑性弹性体13份、发泡剂8份、硅橡胶30份、乙烯基硅油18份、交联剂16份、导热填料14份、环氧树脂5份、阻燃剂5份、抗老化剂4份。
其他的步骤以及制备方法与实施例1的制备步骤和方法保持一致,最后得到高弹性泡棉材料,采用相同的方法进行后续实验表征,具体参数如下表1所示。
根据上述实施例1~3进行的高弹性泡棉材料的制备,作为实验组,并且为了说明本发明的技术效果,设置三组对比例1~3,作为对照组,以便于进行效果比对。
对比例1:
本对比例采用的高弹性泡棉材料制作工艺与实施例1相同,区别在于不使用实施例1中的环氧树脂、阻燃剂和抗老化剂与水混合的溶液,其他的步骤与实施例1的步骤和方法保持一致,并且采用相同的方法进行表征,后续观察得到的参数如下表1所示。
对比例2:
本对比例采用的高弹性泡棉材料制作工艺与实施例1相同,区别在于不添加实施例1中的交联剂和导热填料,其他的步骤与实施例1的步骤和方法保持一致,并且采用相同的方法进行表征,后续观察得到的参数如下表1所示。
对比例3:
本对比例采用的高弹性泡棉材料制作工艺与实施例1相同,区别在于不使用实施例1中的胶层叠加步骤,其他的步骤与实施例1的步骤和方法保持一致,并且采用相同的方法进行表征,后续观察得到的参数如下表1所示。
通过实施例1~3和对比例1~3的制备工艺生产的泡棉材料,进行效果对比,并将数据记录在表1中。
表1:
基于上述表1的数据,得到本发明使用的高弹性泡棉材料制作工艺,可以得到泡孔均匀的泡棉材料,并且该材质的拉伸强度、拉断伸长率、热导率、电气强度和阻燃等级,均性能优异,并且制备的工艺简单、操作难度大幅降低,有利于提高泡棉的产量以及应用范围。
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (8)
1.一种高弹性泡棉材料,其特征在于:包括以下质量份数原料:聚乙烯废弃物16~38份、聚酯多元醇6~15份、热塑性弹性体8~13份、发泡剂4~8份、硅橡胶20~30份、乙烯基硅油10~18份、交联剂9~16份、导热填料7~14份、环氧树脂1~5份、阻燃剂3~5份、抗老化剂3~4份。
2.根据权利要求1所述的一种高弹性泡棉材料,其特征在于:所述阻燃剂为聚氰胺磷酸盐、三氧化二锑和氢氧化铝按质量比15∶2∶6复配制成。
3.根据权利要求1所述的一种高弹性泡棉材料,其特征在于:所述导热填料为碳纤维与硅微粉、纳米氧化铝、氮化物中任意一种复配的组合物。
4.一种高弹性泡棉材料的制作工艺,其特征在于:使用权利要求1~3任一项所述的一种高弹性泡棉材料,包括以下步骤:
S1、废弃物处理:首先将聚乙烯废弃物进行表面喷淋清洗和紫外线杀菌,再将废弃物送入粉碎装置中粉碎成2~3mm颗粒,再将颗粒加入吸附剂静置,形成的静置液再通过200~300目的过滤器过滤,得到的滤液添加有机溶剂析出聚乙烯粉状物,并通过分离得到聚乙烯粉状物的混浊液,最后通过离心机脱液,得到的沉积物洗涤干燥后,得到聚乙烯粉末;
S2、原料选配:
S201、按配方比选用热塑性弹性体和聚酯多元醇,并且与S1步骤中得到的聚乙烯粉末同步送入搅拌釜中进行2~3h的混合搅拌,搅拌阶段分3~5次加入全部当量的发泡剂,发泡完成后,即得发泡原料A;
S202、按配方比选硅橡胶和乙烯基硅油作为基础料,进行搅拌混合后,再加入交联剂和导热填料,在90~120℃进行二次混合,再将环氧树脂、阻燃剂和抗老化剂与水混合的溶液,通过喷雾形式进行添加,即得到强化原料B;
S3、注胶处理:将得到的发泡原料A和强化原料B分别输送到注胶机中,将注胶机首先升温到预设的6~30℃温度后,再在15~35℃的工作温度下,向两个单层平面模具中分别注入发泡原料A和强化原料B,并进行锁紧,完成后打开模具,等待冷却后分别取出制作的发泡胶体A和强化胶体B;
S4、胶层叠加:将得到的发泡胶体A和强化胶体B通过熔融的方式进行层层叠加,叠加方式采用发泡胶体A叠加二层、强化胶体B叠加一层的方式进行累积,当到达8~10cm后,通过挤压模具将挤压,使厚度变成4~5cm,并进行切边和尺寸调整,即完成高弹性泡棉材料的制备。
5.根据权利要求4所述的一种高弹性泡棉材料的制作工艺,其特征在于:所述S201步骤中,所述发泡过程的温度为36℃~47℃,发泡时间为80min~100min。
6.根据权利要求4所述的一种高弹性泡棉材料的制作工艺,其特征在于:所述S202步骤中,所述吸附剂为活性白土、硅藻土或活性炭中的任意一种,所述有机溶剂为二甲苯、三氯苯或丙酮中的任意一种。
7.根据权利要求4所述的一种高弹性泡棉材料的制作工艺,其特征在于:所述S202步骤中,所述硅橡胶为黏度22000mPa·s的107硅橡胶,所述乙烯基硅的黏度为110000mPa·s。
8.根据权利要求4所述的一种高弹性泡棉材料的制作工艺,其特征在于:所述S202步骤中,所述交联剂为黏度为2200mPa·s、活性氢摩尔分数为1.8%的含氢硅油。
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