CN1278209A - 聚合物涂覆纸复合材料 - Google Patents

聚合物涂覆纸复合材料 Download PDF

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CN1278209A
CN1278209A CN98810672A CN98810672A CN1278209A CN 1278209 A CN1278209 A CN 1278209A CN 98810672 A CN98810672 A CN 98810672A CN 98810672 A CN98810672 A CN 98810672A CN 1278209 A CN1278209 A CN 1278209A
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CN1211200C (zh
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马歇尔·梅多夫
阿瑟·拉加斯
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Abstract

本发明公开了一种由聚合物涂覆纸和树脂组成的复合材料及其该复合材料的制备方法。

Description

聚合物涂覆纸复合材料
发明背景
本发明涉及一种聚合物涂覆纸和树脂组成的复合材料。
经聚合物涂覆的纸(poly-coated paper)用途广泛。例如,利用聚合物涂覆纸制成各种食品包装容器,包括单包装的果汁纸盒和适用于冷冻食品的纸盒。
树脂的用途也非常广泛,例如用于食品包装。由聚合物涂覆纸或树脂制成的食品容器一旦被使用后,通常被丢弃。这样,废旧聚合物涂覆纸和废旧树脂的量日渐增多。
发明概述
总的来说,本发明涉及一种织构化(texturized)的聚合物涂覆纸和树脂组成的复合材料。
本发明涉及一种具有至少约2%重量、优选至少约5%重量的织构化的聚合物涂覆纸和树脂(如热塑性树脂)组成的复合材料。该复合材料也可含有纤维素质的或木质纤维素质的纤维。
本发明涉及一种包含聚乙烯和至少约50%重量织构化的聚合物涂覆纸的复合材料。
本发明涉及一种包含聚合物涂覆纸和树脂的复合材料,该复合材料的挠曲强度至少为3000磅/平方英寸或其抗拉强度至少为3000磅/平方英寸。
此外,本发明涉及一种制造复合材料的方法,该方法包括如下步骤:将聚合物涂覆纸剪切成织构化的聚合物涂覆纸,然后将织构化的聚合物涂覆纸与树脂复合。一种优选的制造方法包括使用旋转切割机剪切聚合物涂覆纸的步骤。本发明还涉及一种制造复合材料的方法,该方法包括如下步骤:剪切聚合物涂覆纸,再将其与树脂复合。
本文中使用的术语“织构化的聚合物涂覆纸”是指纸被剪切至其内部纤维基本裸露的程度。至少约50%、优选至少约70%的内部纤维以及外部聚合物纤维的长度/直径比(L/D)至少为10,优选至少为25,更优选至少为50。图1是织构化的聚合物涂覆纸的一个实例。
本发明的复合材料具有强度大、质量轻、价格便宜的特点。用于制造该复合材料的原材料易于获得,例如,它们可以是废弃的由树脂组成的容器和废弃的由聚合物涂覆纸组成的容器。
由于在许多情况下纸与聚合物层必须经分离后分别回收利用,因此聚合物涂覆纸的回收利用难度较大。而在本发明中,纸和聚合物均可利用,这样无需将二者分离。因此本发明在生产实用材料的同时,也可以回收利用废弃的消费后容器。
本发明的其他特征和优点将在优选的实施方案和权利要求书中进一步得以体现。
附图简述
图1是织构化的聚合物涂覆纸一个实施方案的照片(放大50倍)。
优选实施方案详述
优选的复合材料包含织构化的聚合物涂覆纸和树脂。
织构化的聚合物涂覆纸为复合材料提供强度。复合材料可包括约30-90%、优选50%-70%重量的织构化的聚合物涂覆纸。聚合物涂覆纸的实例包括:具有聚合物层和纸层的材料,以及具有聚合物层、纸层和铝层的材料。优选的聚合物涂覆纸为具有聚合物层和纸层的材料。
聚合物涂覆纸可以各种形式获得。例如,从International Paper,New York公司直接购买整张新的聚合物涂覆纸。同样,聚合物涂覆纸废料也可从International Paper,New York公司或其他纸生产厂家购得后用于本发明。废弃的食品和饮料容器形式的聚合物涂覆纸可以从垃圾箱等来源中收集获得。废旧的聚合物涂覆纸也可从这些材料的中间商处购买获得。如果将废旧的聚合物涂覆纸应用于本发明的复合材料中,在使用前应对其进行彻底洗涤。聚合物涂覆纸废料因价格低于整张新纸而优选使用。
树脂将织构化的聚合物涂覆纸包于其中,并有利于复合材料的成型。树脂也将外压负载转移至聚合物涂覆纸上,以保护聚合物涂覆纸免受来自环境和结构上的损坏。优选的复合材料包括约20%-60%、优选约30%-50%重量的树脂。
树脂的实施例包括:聚乙烯(如低密度聚乙烯和高密度聚乙烯),聚丙烯,聚苯乙烯,聚碳酸酯,聚丁烯,热塑性聚酯,聚醚,热塑性聚氨酯,聚氯乙烯,聚酰胺,以及其它树脂。熔体流动指数低的树脂优选。优选的树脂包括:熔体流动指数小于3克/10分钟、优选小于1克/10分钟的聚乙烯和聚丙烯。
树脂可以以新料购得或通过废旧材料获得,且通常以粒料形式购买。树脂优选通过废旧树脂获得,这样获得的材料成本较低。优选的树脂来源是旧的聚乙烯牛奶瓶。
复合材料中也可含有偶合剂。偶合剂的作用是将聚合物涂覆纸的亲水纤维与疏水树脂相粘结。偶合剂的实例包括:马来酸酐改性的聚乙烯,如FUSABONE(从Dupont,Delaware公司购得)和POLYBOND(从UniroyalChemical,Connecticut公司购得)系列。优选的偶合剂为马来酸酐改性的高密度聚乙烯,如FUSABONDMB 100D。
复合材料中也可含有纤维素质的或木质纤维素质的纤维。这些纤维可增加复合材料的强度。加入复合材料中的纤维的量根据成品所需的物理和机械性能而变化。复合材料中优选含有约5%-50%、更优选10%-30%重量的纤维素质的或木质纤维素质的纤维。这些纤维的实例包括:纸和纸制品,木材,木质纤维,与木材相关的材料,以及由洋麻、禾草、稻壳、甘蔗渣、棉花、黄麻等其他纤维素质或木质纤维素质材料衍生获得的材料。这些纤维的长度/直径比(L/D)至少为10,优选至少25或50。
复合材料也可含有本领域技术人员熟知的添加剂,如增塑剂、润滑剂、抗氧化剂、遮光剂、热稳定剂、着色剂、撞击改良剂、光稳定剂、阻燃剂、杀生物和抗静电剂。
原材料的制备
如果使用废旧的聚合物涂覆纸,应将其清洗并干燥。在与树脂复合之前必须先将聚合物涂覆纸织构化。聚合物涂覆纸的结构化处理可以使用任何一种机械手段或多种手段结合进行。织构化工艺过程中,聚合物层从纸层上剪切分离,从而露出纸纤维。优选的织构化方法包括:先用标准切纸设备将聚合物涂覆纸切成1/4-1/2英寸的纸片的步骤,然后用旋转刀将这些纸片剪切织构化。旋转刀的实例可参见Perry’s Chem.Eng.Handbook,6th Ed.,8-29页(1984)中的描述(可从Sprout,Waldron Companies公司购得)。剪切后的材料经孔径2mm的网筛过滤后即为织构化的材料。织构化的聚合物涂覆纸可保存于密闭袋中备用。该织构化的材料在使用之前应该先在约105℃的温度下干燥4-18小时,直至其水分含量少于0.5%。图1是织构化的聚合物涂覆纸的扫描电子显微照片。
树脂可以以丸状或颗粒状形式购得,且使用时无需净化或干燥。如果在丸状或颗粒状树脂的表面上存在水分,则在使用前需进行干燥。
如果也使用纤维素质的或木质纤维素质的纤维,它们可采用上述方法将其织构化。
复合材料的制造
复合材料按如下方法制造。将标准的橡胶/塑料开放型二辊式开炼机加热至325-400℃,再将树脂(通常为丸状或颗粒状形式)加入到加热的辊式开炼机中。10分钟后,向辊式开炼机中加入偶合剂。再经过5分钟,将织构化的聚合物涂覆纸加入到熔化的树脂/偶合剂混合物中。织构化的聚合物涂覆纸加入后处理约10分钟。
从辊式开炼机中取出复合材料,切成片状,冷却至室温。然后使用标准压模技术模压形成板坯。
作为选择,在混合机(如Banbury密闭式混合机)中装入上述成分,温度在小于约190℃时,将这些成分充分混合。混合物然后压模成型。
在另一个实施方案中,上述成分在挤出机混合器(如装备有共旋转螺杆的MARIS(Turin)TM 85挤出机)中混合。树脂和偶合剂通过挤出机进料口处加入,聚合物涂覆纸(以及纤维素质的和木质纤维素质的纤维,如果需要使用的话)在挤出机下游1/3处加入到熔化的树脂中。挤出机的内部温度维持在约小于190℃。出口处,复合材料通过冷却铸带切片技术造成丸化颗粒。
作为选择,混合物可首先在混合器中制备,然后转移至挤出机中完成挤出和造粒步骤。
在另一个实施方案中,复合材料可制成针织、包装编织用的长丝,以及制成非织物。在另一个实施方案中,复合材料也可制成薄膜。
复合材料的性能
所获得的复合材料包括由包裹于树脂基质中的纤维制成的网状物。裸露的纤维形成网格状为复合材料提供强度。与未织构化的聚合物涂覆纸制成的复合材料相比,由于本发明的聚合物涂覆纸被织构化,其与树脂粘结的表面积明显增大。树脂粘结于裸露纤维的表面,形成一个纤维网与树脂基质紧密粘结的混合物,进一步增加了复合材料的强度。纤维素质的或木质纤维素质的纤维也可加入其中以进一步增加复合材料的强度。
应用
聚合物涂覆纸/树脂复合材料具有多种用途。该复合材料强度大,质量轻,它们可用作木材的替代品。树脂涂层使得复合材料具有防水功能,可以将其应用于室外。例如,本发明复合材料可制成底板堆放于室外,可延长保存期限。该复合材料也可制成胶合板的基板或骨架。此外,该复合材料用于表面时,其可对其进行表面处理、开槽、碾磨、成型、打印、形成纹理、压制、打孔、着色等。也可将其表面加工得光滑或粗糙。
实施例
下面的实施例按如下方法制备。将标准的橡胶/塑料开放型二辊式开炼机加热至325-400℃,再将树脂(通常为丸状或颗粒状形式)加入到加热的辊式开炼机中。10分钟后,树脂包辊(即树脂熔化并粘合于辊上)。向辊式开炼机中加入偶合剂。再经过5分钟,将聚合物涂覆纸加入到熔化的树脂/偶合剂混合物中。聚合物涂覆纸加入后处理约10分钟。
从辊式开炼机中取出复合材料,切成片状,冷却至室温。使用标准的压模技术按每80克配料压模形成6英寸×6英寸×1/8英寸的板坯。
一种复合材料中含有如下成分:
                       复合材料1
        成分               含量(g)
    高密度聚乙烯1                 160
    聚合物涂覆纸2                 240
      偶合剂3                  8
  1Marlex 6007,熔体流动指数0.65g/10min,由Phillips公司购买
    2使用旋转切割机将其织构化,并过孔径2mm的网筛
    3POLYBOND3009,由Uniroyal Chemical公司购买
板坯经机器加工成合适的测试样品,并根据测试方法中描述的步骤测试。三种不同的样品均测试每一种性能,计算每个测试的平均值。
复合材料1的性能如下:
    抗拉模量(105磅/平方英寸)     8.63(ASTM D638)
  抗拉强度(断裂)(磅/平方英寸)     6820(ASTM D638)
          极限伸长(%)     <5(ASTM D638)
      挠曲强度(磅/平方英寸)     12,200(ASTM D790)
    挠曲模量(105磅/平方英寸)     6.61(ASTM D790)
另一种复合材料中含有如下成分:
                  复合材料2
       成分        含量(g)
    高密度聚乙烯1          160
    聚合物涂覆纸2          240
    偶合剂3           8
1废旧牛奶壶,熔体流动指数约0.8g/10min
2使用旋转切割机将其织构化,并过孔径2mm的网筛
3POLYBOND3009
复合材料2的性能如下:
    抗拉模量(105磅/平方英寸)     7.38(ASTM D638)
  抗拉强度(断裂)(磅/平方英寸)     6500(ASTM D638)
         极限伸长(%)     <5(ASTM D638)
     挠曲强度(磅/平方英寸)     11,900(ASTM D790)
    挠曲模量(105磅/平方英寸)     6.50(ASTM D790)
第三种复合材料中含有如下成分:
                  复合材料3
      成分          含量(g)
    高密度聚乙烯1            160
    聚合物涂覆纸2            240
    偶合剂3             8
    1废旧牛奶壶,熔体流动指数约0.8g/10min
    2使用旋转切割机将其织构化,并过孔径2mm的网筛
    3FUSABONDMB 100D,由Dupont公司购买
  复合材料3的性能如下:
    抗拉模量(105磅/平方英寸)     7.08(ASTM D638)
    抗拉强度(断裂)(磅/平方英寸)     6480(ASTM D638)
    极限伸长(%)     <5(ASTM D638)
    挠曲强度(磅/平方英寸)     10,200(ASTM D790)
    挠曲模量(105磅/平方英寸)     5.73(ASTM D790)
第四种复合材料中含有如下成分:
                复合材料4
        成分         含量(g)
    高密度聚乙烯1          160
    聚合物涂覆纸2          240
    偶合剂3           8
1Marlex 6007,熔体流动指数0.65g/10min
2使用旋转切割机将其织构化,并过孔径2mm的网筛
3FUSABOND  MB 100D
复合材料4的性能如下:
    抗拉模量(105磅/平方英寸)      7.17(ASTM D638)
    抗拉强度(断裂)(磅/平方英寸)      6860(ASTM D638)
    极限伸长(%)     <5(ASTM D638)
    挠曲强度(磅/平方英寸)     12,200(ASTM D790)
    挠曲模量(105磅/平方英寸)     7.50(ASTM D790)
其他的方案均包括在权利要求书范围之内。

Claims (21)

1.一种包含聚合物涂覆纸和树脂的复合材料,其中至少有2%重量的聚合物涂覆纸被织构化。
2.权利要求1的复合材料,其中至少有5%重量的聚合物涂覆纸被织构化。
3.权利要求1的复合材料,其中聚合物涂覆纸内含有聚乙烯和纸。
4.权利要求3的复合材料,其中聚合物涂覆纸还含有铝。
5.权利要求1的复合材料,其中树脂为热塑性树脂。
6.权利要求5的复合材料,其中热塑性树脂为聚乙烯。
7.权利要求5的复合材料,其中热塑性树脂为聚丙烯。
8.权利要求1的复合材料,其中该复合材料含有约50%-70%重量的聚合物涂覆纸和30%-50%重量的树脂。
9.权利要求1的复合材料,其中该复合材料还含有木质纤维素质的纤维。
10.权利要求1的复合材料,其中该复合材料还含有纤维素质的纤维。
11.一种包含聚合物涂覆纸和树脂的复合材料,其中至少有50%重量的聚合物涂覆纸被织构化。
12.一种包含聚合物涂覆纸和树脂的复合材料,该复合材料的挠曲强度至少为3000磅/平方英寸。
13.权利要求12的复合材料,其挠曲强度至少为6000磅/平方英寸。
14.权利要求12的复合材料,其挠曲强度至少为10000磅/平方英寸。
15.一种包含聚合物涂覆纸和树脂的复合材料,该复合材料的抗拉强度至少为3000磅/平方英寸。
16.权利要求15的复合材料,其抗拉强度至少为5000磅/平方英寸。
17.权利要求15的复合材料,其抗拉强度至少为6000磅/平方英寸。
18.一种制造复合材料的方法,包括如下步骤:剪切聚合物涂覆纸形成织构化聚合物涂覆纸,再将织构化的聚合物涂覆纸与树脂复合。
19.权利要求18所述方法,其中树脂为热塑性树脂。
20.权利要求18所述方法,其中剪切聚合物涂覆纸的步骤包括用旋转切割机进行剪切。
21.一种制造复合材料的方法,该方法包括剪切聚合物涂覆纸以及将聚合物涂覆纸与树脂进行复合的步骤。
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