JP7426037B2 - Ptfe系膜のナノ深さ表面活性化方法 - Google Patents
Ptfe系膜のナノ深さ表面活性化方法 Download PDFInfo
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- JP7426037B2 JP7426037B2 JP2022532598A JP2022532598A JP7426037B2 JP 7426037 B2 JP7426037 B2 JP 7426037B2 JP 2022532598 A JP2022532598 A JP 2022532598A JP 2022532598 A JP2022532598 A JP 2022532598A JP 7426037 B2 JP7426037 B2 JP 7426037B2
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Description
本発明では、PTFE系ナノ機能性複合膜に対してナノ深さ表面活性化を行うことにより、PTFE系ナノ機能性複合膜の表面上にナノ深さの活性構造層を生成することができ、活性構造層は接着剤の官能基と化学的に結合することができる。膜と接着剤の間に非常に強い親和性と高強度の接着性を発生させ、接着剤-膜複合体を形成し、膜/接着剤の接着複合、膜/膜の接着複合、および膜/接着剤の接着後の一体化を実現し、また、接着剤の接着強度、接着剥離力、および接着力の持続性を向上させ、PTFE材料をいずれの材料でも接着できないという技術的課題を解決する。
(1)モノマー融合重合と微重合によるPTFE系ナノ機能性複合膜の製造
1)ブレンド、プリプレス、プッシュプレスによる棒材の製造
PTFE軟化作用を有するシリコーンオイルでPTFE樹脂を含浸し、含浸したPTFE樹脂をブレンドし、温度60~90℃、速度20~30m/min、圧力5~8MPaのホットプリプレスとホットプッシュプレスにより、モノマー重合した表面潤滑性を有するPTFE棒材を得て、
2)熱間圧延を用いた融合重合による成膜
調製されたPTFE棒材を、温度60~90℃、速度20~30m/minの熱間圧延の作用により融合して重合させ、温度の作用下で、PTFE樹脂に混合されかつモノマー重合作用を有するシリコーンオイルを熱間圧延機によって押し出し、ミクロンスケールの細孔を備えたPTFE系ナノ機能性複合膜を得て、ロール状に巻き取り、
温度および熱間圧延による延伸作用の下で、膜が破裂した後、層状に剥離した繊維状構造を発生させ、微細孔を備えたナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を有する厚さ100~120μmの乳白色PTFE系膜を形成し、
3)微重合による均質な膜の製造
ミクロンスケールの微小凹凸表面構造を有するPTFE系ナノ機能性複合膜を温度180~200℃の脱脂オーブン内で温度作用により微重合させ、熱間圧延機によって押し出されておらず、モノマー重合のためにPTFE樹脂に含浸したシリコーンオイルが温度作用により重合反応して、PTFE樹脂内に重合、固定化し、PTFE系の均質な膜を得て、ロール状のPTFE系膜を脱脂オーブン内で6~8m/minの速度で巻き取り、
(2)高温高線形荷重マイクロ共晶法によるPTFE系ナノ機能性複合膜の製造
高温高線形荷重マイクロ共晶キャビティ内の温度を70~420℃に設定し、PTFE系ナノ機能性複合膜を6~8m/minの速度で前へ押し込み、キャビティ内の高温により膜の分子鎖を収縮させ、共晶を生成し、微細孔をナノスケールおよびスーパーミクロンスケールにし、PTFE膜の表面線形荷重を50~80N/mに制御し、PTFE系ナノ機能性複合膜の元のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を維持しながら、膜の色を乳白色から均一に透明な色にする。
(1)本発明は、PTFE系材料の低表面張力特性を最大限に利用することに基づいて、モノマー融合重合および微重合技術を採用し、膜を複数のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態として製造し、それにより、PTFE系膜は、超低表面張力、疎水性、非付着性、高防汚性、抗吸湿性、およびセルフクリーニング性などの機能特性を有する。超高温超高圧マイクロ共晶技術を用いて、膜構造の強度を高め、高温で膜が破裂する時にPTFEが層状に剥離された後に繊維状構造になり、耐摩耗性が低下するという技術的なボトルネックを解消し、温度の作用により孔隙が小さくなり、膜の透明度とその透明度の均一性を向上させ、PTFE系ナノ機能性複合膜の超微細構造表面形態を維持しながら、膜は高い耐摩擦性、耐摩耗性、および耐衝撃性を有する。ナノ深さ表面活性化技術を使用して、膜と接着剤を化学的に結合させ、接着強度と接着剥離力および接着力の持続性を高める。
(2)本発明は、PTFE系膜の性能特性、用途要件および使用環境に基づいて、コールドペースト機能を備えた高靭性コールドペースト接着剤を特別に調製し、コールドペースト接着を直接行うことができ、高靭性コールドペースト接着剤は高い剥離強度を有し、引張破断伸び率と衝撃抵抗強度が比較的大きく、硬度と引張弾性率が比較的小さく、耐紫外線劣化時間と耐劣化時間が長く、明らかな塑性変形特性がなく、熱膨張収縮応力が接着剤の弾性限界よりも小さく、それにより、接着剤は常に強靭な状態にあり、高い接着強度と持続的な接着剥離力を有する。
(3)本発明により製造されたPTFE系ナノ機能性複合膜は、より高い透明度を有し、貼り付けられたブレードの元の表面色を変化させず、厚さが100~200μmであり、重さが200~300g/m2であり、表面粗さが0.18μmであり、
ファンブレードの負荷を増やすことなく、ブレード翼の空力性能を向上させ、ブレードの運転効率を向上させることができる。
(4)本発明により製造されたPTFE系ナノ機能性複合膜は、PTFE材料を改質することなく、接着剤の官能基と化学的に結合することができ、接着剤と膜の間に高い親和性と接着強度を有し、接着剤の選択範囲を広げる。
(5)本発明により製造されたPTFE系ナノ機能性複合膜は、ブレードの保護コートに相当するPTFE材料の優れた耐紫外線性および耐候性を有し、ブレードの表面強度を高め、全体的な固定の役割を果たし、ブレードの全体的な負荷能力と侵食に耐える能力を向上させることができ、ブレードの経年劣化やひび割れなどの安全上の潜在的な危険を排除し、さらにファンブレードの耐用年数を延長させる。
1)ブレンド、プリプレス、プッシュプレスによる棒材の製造
ビニルシリコーンオイルとPTFE樹脂を2.5:100の質量比で混合して、PTFE軟化作用を有するシリコーンオイルでPTFE樹脂を含浸し、含浸したPTFE樹脂をブレンドし、温度60℃、速度25m/min、圧力8MPaのホットプリプレスとホットプッシュプレスにより、モノマー重合した表面潤滑性を有するФ17mmのPTFE棒材を得て、
2)熱間圧延を用いた融合重合による成膜
調製されたPTFE棒材を、温度60℃、速度25m/minの熱間圧延の作用により融合して重合させ、温度の作用下で、PTFE樹脂に混合されかつモノマー重合作用を有するシリコーンオイルを熱間圧延機によって押し出し、ミクロンスケールの細孔を備えたPTFE系ナノ機能性複合膜を得て、ロール状に巻き取り、
温度および熱間圧延による延伸作用の下で、膜が破断した後、層状に剥離した後の繊維状構造を発生させ、微細孔を備えたナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を有する厚さ100μmの乳白色PTFE系膜を形成し、
3)微重合による均質な膜の製造
ミクロンスケールの微小凹凸表面構造を有するPTFE系ナノ機能性複合膜を温度200℃の脱脂オーブン内で温度作用により微重合させ、熱間圧延機によって押し出されておらず、モノマー重合のためにPTFE樹脂に含浸したシリコーンオイルが温度作用により重合反応して、PTFE樹脂内に重合、固定化し、PTFE系の均質な膜を得て、ロール状のPTFE系膜を脱脂オーブン内で6m/minの速度で巻き取り、
(2)高温高線形荷重マイクロ共晶法によるPTFE系ナノ機能性複合膜の製造
高温高線形荷重マイクロ共晶キャビティ内の温度を380℃に設定し、PTFE系ナノ機能性複合膜を6m/minの速度で前へ押し込み、キャビティ内の高温により膜の分子鎖を収縮させ、共晶を生成し、微細孔をナノスケールおよびスーパーミクロンスケールにし、PTFE膜の表面線形荷重を60N/mに制御し、PTFE系ナノ機能性複合膜の元のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を維持しながら、膜の色を乳白色から均一に透明な色にし、密度を2.1kg/m3とする。
(付記1)
ナノスケールおよびマイクロスケールの凹凸幾何学的形状の超微細構造形態を有するPTFE系ナノ機能性複合膜の機能面を被覆処理した後、接着剤が塗布された膜の片面に対して、真空環境および40℃未満の窒素-水素混合媒体の雰囲気で、1.5~3m/minの速度で表面活性化処理を行い、膜の接着剤塗布面にナノ深さを有する活性化構造層を形成し、
機械的接着剤塗布装置を用いて、高靭性冷間接着テープをPTFE系ナノ機能性複合膜の活性化構造層を備えた面に遷移し複合し、接着剤の官能基と膜の活性化構造層を化学的に結合させて、接着剤-膜複合体を形成し、
高靭性冷間接着テープの製造は、0.2kgのPVA-1788、18kgのアクリル酸ブチル、0.5kgのアクリル酸、1.0kgの酢酸ビニル、1.0kgのメチルメタクリレート、1.5kgのシリコーンモノマー、0.01kgのTO-7、0.01kgのドデシルベンゼンスルホン酸ナトリウム、0.05kgの過酸化ベンゾイル、80kgの水を、調製タンクに入れ、調製温度を85℃、調製時間を5hとし、真空引きおよび脱水を行って、固形分18.7%の帯状感圧接着テープを得て、剥離紙を複合して、PVCチューブコアに巻き付けることである、
ことを特徴とするPTFE系膜のナノ深さ表面活性化方法。
PTFE系ナノ機能性複合膜の機能面をPE膜で被覆処理する、
ことを特徴とする付記1に記載のPTFE系膜のナノ深さ表面活性化方法。
ナノスケールおよびマイクロスケールの凹凸幾何学的形状の超微細構造形態を有するPTFE系ナノ機能性複合膜を以下のように製造し、
(1)モノマー融合重合と微重合によるPTFE系ナノ機能性複合膜の製造
1)ブレンド、プリプレス、プッシュプレスによる棒材の製造
PTFE軟化作用を有するシリコーンオイルでPTFE樹脂を含浸し、含浸したPTFE樹脂をブレンドし、温度60~90℃、速度20~30m/min、圧力5~8MPaのホットプリプレスとホットプッシュプレスにより、モノマー重合した表面潤滑性を有するPTFE棒材を得て、
2)熱間圧延を用いた融合重合による成膜
調製されたPTFE棒材を、温度60~90℃、速度20~30m/minの熱間圧延の作用により融合して重合させ、温度の作用下で、PTFE樹脂に混合されかつモノマー重合作用を有するシリコーンオイルを熱間圧延機によって押し出し、ミクロンスケールの細孔を備えたPTFE系ナノ機能性複合膜を得て、ロール状に巻き取り、
温度および熱間圧延による延伸作用の下で、膜が破裂した後、層状に剥離した繊維状構造を発生させ、微細孔を備えたナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を有する厚さ100~120μmの乳白色PTFE系膜を形成し、
3)微重合による均質な膜の製造
ミクロンスケールの微小凹凸表面構造を有するPTFE系ナノ機能性複合膜を温度180~200℃の脱脂オーブン内で温度作用により微重合させ、熱間圧延機によって押し出されておらず、モノマー重合のためにPTFE樹脂に含浸したシリコーンオイルが温度作用により重合反応して、PTFE樹脂内に重合、固定化し、PTFE系の均質な膜を得て、ロール状のPTFE系膜を脱脂オーブン内で6~8m/minの速度で巻き取り、
(2)高温高線形荷重マイクロ共晶法によるPTFE系ナノ機能性複合膜の製造
高温高線形荷重マイクロ共晶キャビティ内の温度を70~420℃に設定し、PTFE系ナノ機能性複合膜を6~8m/minの速度で前へ押し込み、キャビティ内の高温により膜の分子鎖を収縮させ、共晶を生成し、微細孔をナノスケールおよびスーパーミクロンスケールにし、PTFE膜の表面線形荷重を50~80N/mに制御し、PTFE系ナノ機能性複合膜の元のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を維持しながら、膜の色を乳白色から均一に透明な色にする、
ことを特徴とする付記1に記載のPTFE系膜のナノ深さ表面活性化方法。
ビニルシリコーンオイルとPTFE樹脂を(2~3):100の質量比で添加する、
ことを特徴とする付記3に記載のPTFE系膜のナノ深さ表面活性化方法。
ナノスケールおよびマイクロスケールの凹凸幾何学的形状の超微細構造形態を有するPTFE系ナノ機能性複合膜を以下のように製造し、
(1)モノマー融合重合と微重合によるPTFE系ナノ機能性複合膜の製造
1)ブレンド、プリプレス、プッシュプレスによる棒材の製造
ビニルシリコーンオイルとPTFE樹脂を2.5:100の質量比で混合して、PTFE軟化作用を有するシリコーンオイルでPTFE樹脂を含浸し、含浸したPTFE樹脂をブレンドし、温度60℃、速度25m/min、圧力8MPaのホットプリプレスとホットプッシュプレスにより、モノマー重合した表面潤滑性を有するФ17mmのPTFE棒材を得て、
2)熱間圧延を用いた融合重合による成膜
調製されたPTFE棒材を、温度60℃、速度25m/minの熱間圧延の作用により融合して重合させ、、温度の作用下で、PTFE樹脂に混合されかつモノマー重合作用を有するシリコーンオイルを熱間圧延機によって押し出し、ミクロンスケールの細孔を備えたPTFE系ナノ機能性複合膜を得て、ロール状に巻き取り、
温度および熱間圧延による延伸作用の下で、膜が破断した後、層状に剥離した後の繊維状構造を発生させ、微細孔を備えたナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を有する厚さ100μmの乳白色PTFE系膜を形成し、
3)微重合による均質な膜の製造
ミクロンスケールの微小凹凸表面構造を有するPTFE系ナノ機能性複合膜を温度200℃の脱脂オーブン内で温度作用により微重合させ、熱間圧延機によって押し出されておらず、モノマー重合のためにPTFE樹脂に含浸したシリコーンオイルが温度作用により重合反応して、PTFE樹脂内に重合、固定化し、PTFE系の均質な膜を得て、ロール状のPTFE系膜を脱脂オーブン内で6m/minの速度で巻き取り、
(2)高温高線形荷重マイクロ共晶法によるPTFE系ナノ機能性複合膜の製造
高温高線形荷重マイクロ共晶キャビティ内の温度を380℃に設定し、PTFE系ナノ機能性複合膜を6m/minの速度で前へ押し込み、キャビティ内の高温により膜の分子鎖を収縮させ、共晶を生成し、微細孔をナノスケールおよびスーパーミクロンスケールにし、PTFE膜の表面線形荷重を50~80N/mに制御し、PTFE系ナノ機能性複合膜の元のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を維持しながら、膜の色を乳白色から均一に透明な色にし、密度を2.1kg/m3とする、
ことを特徴とする付記4に記載のPTFE系膜のナノ深さ表面活性化方法。
Claims (5)
- ナノスケールおよびマイクロスケールの凹凸幾何学的形状の超微細構造形態を有するPTFE系ナノ機能性複合膜の機能面を被覆処理した後、前記機能面の裏面である接着剤塗布面に対して、接着剤塗布前に、真空環境および40℃未満の窒素-水素混合媒体の雰囲気で、1.5~3m/minの速度で表面活性化処理を行い、前記接着剤塗布面にナノ深さを有する活性化構造層を形成し、
機械的接着剤塗布装置を用いて、高靭性冷間接着テープをPTFE系ナノ機能性複合膜の活性化構造層を備えた面に遷移し複合し、接着剤の官能基と膜の活性化構造層を化学的に結合させて、接着剤-膜複合体を形成し、
高靭性冷間接着テープの製造は、0.2kgのPVA-1788、18kgのアクリル酸ブチル、0.5kgのアクリル酸、1.0kgの酢酸ビニル、1.0kgのメチルメタクリレート、1.5kgのシリコーンモノマー、0.01kgの界面活性剤、0.01kgのドデシルベンゼンスルホン酸ナトリウム、0.05kgの過酸化ベンゾイル、80kgの水を、調製タンクに入れ、調製温度を85℃、調製時間を5hとし、真空引きおよび脱水を行って、固形分18.7%の帯状感圧接着テープを得て、剥離紙を複合して、PVCチューブコアに巻き付けることである、
ことを特徴とするPTFE系膜のナノ深さ表面活性化方法。 - PTFE系ナノ機能性複合膜の機能面をPE膜で被覆処理する、
ことを特徴とする請求項1に記載のPTFE系膜のナノ深さ表面活性化方法。 - ナノスケールおよびマイクロスケールの凹凸幾何学的形状の超微細構造形態を有するPTFE系ナノ機能性複合膜を以下のように製造し、
(1)モノマー融合重合と微重合によるPTFE系ナノ機能性複合膜の製造
1)ブレンド、プリプレス、プッシュプレスによる棒材の製造
PTFE軟化作用を有するシリコーンオイルでPTFE樹脂を含浸し、含浸したPTFE樹脂をブレンドし、温度60~90℃、速度20~30m/min、圧力5~8MPaのホットプリプレスとホットプッシュプレスにより、モノマー重合した表面潤滑性を有するPTFE棒材を得て、
2)熱間圧延を用いた融合重合による成膜
調製されたPTFE棒材を、温度60~90℃、速度20~30m/minの熱間圧延の作用により融合して重合させ、温度の作用下で、PTFE樹脂に混合されかつモノマー重合作用を有するシリコーンオイルを熱間圧延機によって押し出し、ミクロンスケールの細孔を備えたPTFE系ナノ機能性複合膜を得て、ロール状に巻き取り、
温度および熱間圧延による延伸作用の下で、膜が破裂した後、層状に剥離した繊維状構造を発生させ、微細孔を備えたナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を有する厚さ100~120μmの乳白色PTFE系膜を形成し、
3)微重合による均質な膜の製造
ミクロンスケールの微小凹凸表面構造を有するPTFE系ナノ機能性複合膜を温度180~200℃の脱脂オーブン内で温度作用により微重合させ、熱間圧延機によって押し出されておらず、モノマー重合のためにPTFE樹脂に含浸したシリコーンオイルが温度作用により重合反応して、PTFE樹脂内に重合、固定化し、PTFE系の均質な膜を得て、ロール状のPTFE系膜を脱脂オーブン内で6~8m/minの速度で巻き取り、
(2)高温高線形荷重マイクロ共晶法によるPTFE系ナノ機能性複合膜の製造
高温高線形荷重マイクロ共晶キャビティ内の温度を70~420℃に設定し、PTFE系ナノ機能性複合膜を6~8m/minの速度で前へ押し込み、キャビティ内の高温により膜の分子鎖を収縮させ、共晶を生成し、微細孔をナノスケールおよびスーパーミクロンスケールにし、PTFE膜の表面線形荷重を50~80N/mに制御し、PTFE系ナノ機能性複合膜の元のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を維持しながら、膜の色を乳白色から均一に透明な色にする、
ことを特徴とする請求項1に記載のPTFE系膜のナノ深さ表面活性化方法。 - ビニルシリコーンオイルとPTFE樹脂を(2~3):100の質量比で添加する、
ことを特徴とする請求項3に記載のPTFE系膜のナノ深さ表面活性化方法。 - ナノスケールおよびマイクロスケールの凹凸幾何学的形状の超微細構造形態を有するPTFE系ナノ機能性複合膜を以下のように製造し、
(1)モノマー融合重合と微重合によるPTFE系ナノ機能性複合膜の製造
1)ブレンド、プリプレス、プッシュプレスによる棒材の製造
ビニルシリコーンオイルとPTFE樹脂を2.5:100の質量比で混合して、PTFE軟化作用を有するシリコーンオイルでPTFE樹脂を含浸し、含浸したPTFE樹脂をブレンドし、温度60℃、速度25m/min、圧力8MPaのホットプリプレスとホットプッシュプレスにより、モノマー重合した表面潤滑性を有するФ17mmのPTFE棒材を得て、
2)熱間圧延を用いた融合重合による成膜
調製されたPTFE棒材を、温度60℃、速度25m/minの熱間圧延の作用により融合して重合させ、温度の作用下で、PTFE樹脂に混合されかつモノマー重合作用を有するシリコーンオイルを熱間圧延機によって押し出し、ミクロンスケールの細孔を備えたPTFE系ナノ機能性複合膜を得て、ロール状に巻き取り、
温度および熱間圧延による延伸作用の下で、膜が破断した後、層状に剥離した後の繊維状構造を発生させ、微細孔を備えたナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を有する厚さ100μmの乳白色PTFE系膜を形成し、
3)微重合による均質な膜の製造
ミクロンスケールの微小凹凸表面構造を有するPTFE系ナノ機能性複合膜を温度200℃の脱脂オーブン内で温度作用により微重合させ、熱間圧延機によって押し出されておらず、モノマー重合のためにPTFE樹脂に含浸したシリコーンオイルが温度作用により重合反応して、PTFE樹脂内に重合、固定化し、PTFE系の均質な膜を得て、ロール状のPTFE系膜を脱脂オーブン内で6m/minの速度で巻き取り、
(2)高温高線形荷重マイクロ共晶法によるPTFE系ナノ機能性複合膜の製造
高温高線形荷重マイクロ共晶キャビティ内の温度を380℃に設定し、PTFE系ナノ機能性複合膜を6m/minの速度で前へ押し込み、キャビティ内の高温により膜の分子鎖を収縮させ、共晶を生成し、微細孔をナノスケールおよびスーパーミクロンスケールにし、PTFE膜の表面線形荷重を50~80N/mに制御し、PTFE系ナノ機能性複合膜の元のナノスケールおよびミクロンスケールの凹凸幾何学的形状の超微細構造形態を維持しながら、膜の色を乳白色から均一に透明な色にし、密度を2.1kg/m3とする、
ことを特徴とする請求項4に記載のPTFE系膜のナノ深さ表面活性化方法。
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