TW202417530A - An infiltration resistant water soluble mandrel material and manufacturing method thereof - Google Patents

Abstract

The present invention reveals an infiltration resistant water-soluble mandrel material containing a piece or whole made of polyvinyl alcohol with molecular weights between 30,000 to 40,000 and viscosities from 6 to 9 cps. This invention utilizes water soluble materials to achieve pressurized water flush defeated and scattered characteristics. In composites manufacturing processes, the curing material does not infiltrate the water soluble body, so the contact areas of the water soluble piece can also be removed.

Description

Water-soluble core material for waterproofing and its manufacturing method

A water-soluble core material.

Fiber composites are gradually being widely used in many industries due to their advantages such as light weight, high strength and high rigidity. Composite molding requires the use of supports. After the composite is solidified and formed on the supports, the supports are removed to form shells or hollow parts. Traditional simple symmetrical shapes may use various materials such as metal tubes, plaster, styrofoam, air bags or rubber/silicone in different processes. For composite molding with more complex shapes or small structures that require heat treatment, not only are the choices limited, but it is also difficult to remove the supports, making it difficult to lighten the parts or products or inconvenient to use. Therefore, some companies have developed water-soluble core materials made of water-soluble polymers.

However, in the existing process, when the composite material is partially or completely covered with a water-soluble core material model, the curing material will diffuse and infiltrate through the micropores. The thickness can reach 3 mm and is difficult to remove, resulting in the composite contact area being hardened synchronously with the surface of the infiltrated core material model for several millimeters, making the lightweight function imperfect. In view of this, finding a water-soluble core material that can prevent the composite from infiltrating during the curing process has become an urgent development goal in related fields.

In order to solve the problem that the fiber layer diffuses and infiltrates through the micropores of the water-soluble core material model before solidification, resulting in the infiltration site being difficult to remove after solidification, the present invention provides a water-soluble core material with anti-seepage properties, which is in block form and comprises a first material, wherein the first material is polyvinyl alcohol with a molecular weight of 30,000 to 40,000 and a viscosity of 6 to 9 cps.

The water-soluble core material for waterproofing includes a second material, which is partially or completely attached to the first material. The second material is formed by mixing 10 to 40 weight percent of a water-soluble polymer polyvinyl alcohol, 60 to 90 weight percent of a solidifying filler, and 1 phr of a dispersing aid.

Further, the curing filler comprises one or a combination of calcium carbonate, sodium bicarbonate, calcium sulfate, barium sulfate, mica, silicon oxide, aluminum oxide, titanium oxide or zirconium oxide; and the dispersing aid comprises one or a combination of silicon-based composite, stearic acid, zinc stearate, calcium stearate or magnesium stearate.

The first material is added with 0.5-5.0 phr of an antibacterial and anti-mold agent.

Furthermore, the antibacterial and antifungal agent component is one or a combination of non-toxic silver-containing particles or a complex thereof, essential oils and preservatives.

The present invention also includes a method for making a water-soluble core material with impermeability, which comprises the following steps:

mixing a second material with water;

After forming the required auxiliary tool, take it out and remove part or all of the water to form a three-dimensional block;

Mixing a first material composed of polyvinyl alcohol having a molecular weight of 30,000 to 40,000 and a viscosity of 6 to 9 cps with water to form a polyvinyl alcohol aqueous solution;

Adhering the polyvinyl alcohol aqueous solution partially or completely to the three-dimensional block;

Draining the three-dimensional block to remove any significant excess polyvinyl alcohol aqueous solution; and

The cube is dehydrated.

The second material is formed by mixing 10 to 40 weight percent of a water-soluble high molecular weight polyvinyl alcohol, 60 to 90 weight percent of a curing filler, and 1 phr of a dispersing aid.

The curing filler comprises one or a combination of calcium carbonate, sodium bicarbonate, calcium sulfate, barium sulfate, mica, silicon oxide, aluminum oxide, titanium oxide or zirconium oxide; and the dispersing aid comprises one or a combination of silicon-based composite, stearic acid, zinc stearate, calcium stearate or magnesium stearate.

The weight percentage concentration of the polyvinyl alcohol in the polyvinyl alcohol aqueous solution is 10 to 30.

Furthermore, 0.5-5.0 phr of a defoaming agent is added to the polyvinyl alcohol aqueous solution, wherein the defoaming agent is one or a combination of silicon-based or non-toxic defoaming agents.

From the above description, it can be seen that the present invention has the following features:

1. By using a first material of polyvinyl alcohol with a specific molecular weight and viscosity to attach to part or all of a second material, the present invention can solve the problem of the hardened material diffusing and penetrating into the core material model during the composite material manufacturing process, making the penetrating part difficult to remove.

2. The invention has a simple formula and is easy to operate. The main material formula is polyvinyl alcohol, which is not only easy to mix with water, but also the core material aqueous solution formed after mixing can be poured into various types of easy-to-release assistive devices. The supply of polyvinyl alcohol raw materials is stable and of high quality, which is conducive to mass production and use in industry.

3. After the composite material is formed in the water-soluble core material of the present invention, the user only needs to soak the exposed area of the core material model or the reserved channel in water to soften the core material model of the present invention and then flush it out with pressurized water.

4. The present invention uses two types of water-soluble materials, namely water-soluble polyvinyl alcohol and water-soluble solidified filling materials. Compared with the existing methods, the present invention can achieve the characteristics of softening and dispersing after soaking in water, which can improve the shortcomings of the existing supporting material process being limited and difficult to be destroyed and removed; the pseudo specific gravity of the anti-seepage core material of the present invention after dehydration is less than 1. If it is used as an embedded part that will not be exposed to water, it has the advantage of being lightweight. It can also be soaked in water to soften and flushed out from the exposed area of the core material model or the reserved channel, and can be appropriately backfilled and reused after draining out without obvious excess water. It is not only economical but also environmentally friendly.

5. The core material of the present invention has a pseudo specific gravity of less than 1 after dehydration, and has the characteristics of heat resistance, pressure resistance, low shrinkage rate, and can be softened by soaking in water and then flushed with pressurized water. It can not only be used to manufacture high value-added lightweight parts or products, but also the raw materials are all environmentally friendly materials, without the need for special recycling and treatment procedures. It can also be mixed and used as a soil conditioner, and is non-toxic and harmless to the ecological environment. It is an excellent environmentally friendly water-soluble core material.

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following is a brief introduction of the drawings required for the description of each embodiment. Obviously, the drawings described below are only some examples or embodiments of the present invention. For ordinary technicians in this field, the present invention can also be applied to other similar scenarios based on these drawings without creative work. Unless it is obvious from the language environment or otherwise explained, the same reference numerals in the figures represent the same structure or operation.

As shown in the present invention and claims, unless the context clearly indicates an exception, the words "a", "an", "an" and/or "the" do not refer to the singular and may also include the plural. Generally speaking, the terms "include" and "comprise" only indicate the inclusion of the steps and elements that have been clearly identified, and these steps and elements do not constitute an exclusive list. The method or apparatus may also include other steps or elements.

It is understood that the "viscosity" used in this article is used to describe the characteristics of the degree of polymerization of polyvinyl alcohol (PVA), which means measuring the viscosity of a polyvinyl alcohol solution with a weight percent concentration of 4 at 20°C, and does not refer to the viscosity of the polyvinyl alcohol in this article actually measured under different states and conditions.

It is understood that "cps" used herein refers to the abbreviation of one hundredth of a poise (centipoise) based on the viscosity unit poise (abbreviated as p), and can be replaced by other expressions if other words can achieve the same purpose.

It is understood that the "phr" used herein refers to the unit of weight percentage of the additional addition relative to the total weight of the material, and other expressions may be used to replace it if other words can achieve the same purpose.

Please refer to Figures 1 to 7, which are schematic diagrams of the steps of the manufacturing process of the water-soluble core material with the anti-hardening material infiltration of the present invention. In Figures 1 to 3, a water-soluble polymer polyvinyl alcohol, a water-soluble curing filler and a dispersing aid are first mixed to form a second material, and then the second material is dissolved in water of a specific proportion to form a second material aqueous solution, and the second material aqueous solution is injected into an auxiliary tool to form, taken out and dehydrated appropriately according to the process requirements to form a three-dimensional block.

Preferably, the weight percentage of the water-soluble polymer polyvinyl alcohol in the water-soluble core material is 10 to 40; the weight percentage of the water-soluble curing filler in the water-soluble core material is 60 to 90; and the proportion of the dispersing aid in the water-soluble core material is 0.5 to 1.5 phr.

The water-soluble curing filler includes one or more of calcium carbonate, sodium bicarbonate, calcium sulfate, barium sulfate, mica, silicon oxide, aluminum oxide, titanium oxide or zirconium oxide. The dispersing aid includes one or more of silicon-based composite, stearic acid, zinc stearate, calcium stearate or magnesium stearate. The so-called "water-soluble" in the water-soluble curing material means that the filler can be dispersed in an aqueous solution before molding.

Furthermore, in addition to the above-mentioned molding process, the second material model can also be applied to injection, hot pressing, extrusion, and various coating processes after removing water, and can be used as a lightweight embedded part, or reserved with appropriate flow channels to be foamed and punched out to become a shell or hollow part.

In Figures 4 to 7, a first material composed of polyvinyl alcohol with a molecular weight of 30,000 to 40,000 and a viscosity of 6 to 9 cps is mixed with water to form a polyvinyl alcohol aqueous solution, and then the aforementioned three-dimensional block is partially or completely attached to the polyvinyl alcohol aqueous solution in a timely manner, and the three-dimensional block is drained to remove obvious excess polyvinyl alcohol aqueous solution, and the water is removed to form the waterproof water-soluble core material of the present invention.

Preferably, the polyvinyl alcohol weight percent concentration of the polyvinyl alcohol aqueous solution is 10 to 30.

Preferably, in order to avoid the growth of microorganisms or fungi during material storage or manufacturing, 0.5-5.0 phr of an antibacterial and antifungal agent may be added to the first material. The composition of the antibacterial and antifungal agent may be selected from one or a combination of non-toxic silver-containing particles or their complexes, essential oils, and preservatives.

Preferably, in order to prevent the foam generated by the polyvinyl alcohol aqueous solution from interfering with the process, 0.5-5.0 phr of a silicon-based or non-toxic defoaming agent or a combination of the two can be appropriately added to the polyvinyl alcohol aqueous solution to eliminate the foam.

The above steps of timely attaching the polyvinyl alcohol aqueous solution to the entire three-dimensional block or the part that needs to be waterproof, draining the three-dimensional block until there is no obvious excess polyvinyl alcohol aqueous solution, and dehydrating the three-dimensional block to meet the process requirements can be repeated multiple times. Preferably, the three-dimensional block is timely attached to the polyvinyl alcohol aqueous solution for about 10 to 30 seconds. After the three-dimensional block is drained until there is no obvious excess polyvinyl alcohol aqueous solution, as shown in Figure 6, the first material can be attached to part or all of the second material in the three-dimensional block by appropriate dehydration. If the protective effect is to be enhanced, the steps of timely attaching the three-dimensional block to the polyvinyl alcohol aqueous solution, appropriate draining and dehydration can be repeated as needed.

Further, please refer to Figures 8 to 10, a composite material to be molded can be wrapped in the above-mentioned waterproof water-soluble core material model, and molded in the waterproof water-soluble core material model of the present invention according to the solidification characteristics of the composite material to be molded. Finally, the waterproof water-soluble core material model of the present invention and the solidified composite material to be molded are soaked with water, and the waterproof water-soluble core material model of the present invention can be softened in the exposed area or the reserved channel and then flushed out with pressurized water. In one embodiment, the composite material to be molded is a carbon fiber epoxy resin prepreg.

The present invention uses two types of water-soluble materials, water-soluble polyvinyl alcohol and water-soluble curing filling materials. Compared with the existing methods, the present invention can achieve the characteristics of softening and erosion when soaked in water, and can improve the shortcomings of the existing support material process being limited and difficult to be broken and removed. The first material formed by polyvinyl alcohol is attached to part or all of the second material, which can prevent the composite material from penetrating into the core material model, resulting in the infiltration area being difficult to remove after solidification and remaining, resulting in the problem of reduced lightweight.

The water-soluble core material of the present invention has the advantages of heat resistance, pressure resistance and low shrinkage rate after being molded and dehydrated. The so-called heat resistance and pressure resistance mean that the present invention can not only withstand the curing temperature range of the composite material without deformation during the subsequent composite material molding process, but also has sufficient strength to support the stress formed on it by the appropriate amount of composite material without being compressed and damaged. The so-called low shrinkage rate means that after the water-soluble core material aqueous solution of the present invention is molded, the original molding volume will not be reduced due to heating or water reduction during the process, and the auxiliary shape of the mold can still be maintained. The water-soluble core material of the present invention can be baked in an oven at 130-150℃ for several hours without obvious yellowing. If the temperature is raised further, it will gradually yellow but still be usable. However, it is not recommended to be heated above 180℃, especially near 190℃, as it will begin to deteriorate. The deformation during this period can be ignored. After the water is removed from the water-soluble core material of the present invention, it can also withstand the use of rubber injection pressure of 10~20Mpa, and the deformation meets the needs of the industry. In addition, the water-soluble core material of the present invention has a pseudo specific gravity of less than 1 after the water is removed. If it is used as an embedded part that will not be exposed to water, it has a lightweight effect and can also be softened and flushed out from the exposed area of the core material model or the reserved channel. In one embodiment, a core material model with a volume of 30 to 50 cubic centimeters is surrounded by a composite material with both ends exposed. The whole is heated to 150°C for 1 hour. After the composite material is solidified and formed, the sample is soaked in room temperature (25°C) water until it is fully absorbed. Then, the water-soluble core material model can be cleaned in a household general 130bar cleaning machine for about 3 to 10 seconds to form an integrally formed hollow shell-shaped composite material.

From the above description, it can be seen that the present invention achieves the following effects:

1. By using a first material formed by polyvinyl alcohol in a specific molecular weight and viscosity range to adhere to a second material, the present invention can prevent the fiber layer from diffusing through micropores and infiltrating into the core material model before solidification, thereby causing a residue of several millimeters in thickness.

2. The invention has a simple formula and is easy to operate. The main material formula is polyvinyl alcohol, which is not only easy to mix with water, but also the core material aqueous solution formed after mixing can be poured into many types of easy-to-release auxiliary tools. The supply of polyvinyl alcohol raw materials is stable and of high quality, which is conducive to mass production and use in industry.

3. When the composite material is solidified and formed in the water-soluble core material model of the present invention, the user only needs to soften the exposed area of the core material model or the reserved channel by soaking it in water and then use pressurized water to flush out the core material model of the present invention in a short time.

4. The present invention uses two types of water-soluble materials, namely water-soluble polyvinyl alcohol and water-soluble curing filling materials. Compared with the existing methods, the present invention can achieve the characteristics of absorbing water and then dispersing with pressurized water, which can improve the shortcomings of the existing support material process being limited and difficult to be destroyed and removed. The present invention can quickly flush out the self-molding composite material by softening the exposed area of the core material or the reserved channel with pressurized water. After draining off the excess water, it can also be backfilled and utilized in appropriate amounts according to the strength requirements of the next batch of objects. It is not only economical but also environmentally friendly.

5. The core material of the present invention has a pseudo specific gravity of less than 1 after being formed and dehydrated. It has heat resistance, pressure resistance, low shrinkage rate, and can be removed by pressurized water flushing after being softened in water. It can not only be used to manufacture high value-added and lightweight products, but the raw materials are all environmentally friendly materials, and the recycling process does not require special treatment procedures. It is non-toxic and harmless to the ecological environment and can also be used as a soil conditioner. It is an excellent environmentally friendly water-soluble core material.

It should be noted that, according to the explanation and elaboration of the above specification, the technical personnel in the field to which the present disclosure belongs can also change and modify the above implementation. Therefore, the present disclosure is not limited to the specific implementation disclosed and described above, and some equivalent modifications and changes to the present disclosure should also be within the scope of protection of the claims of the present disclosure. In addition, although this specification uses some specific terms, these terms are only for the convenience of explanation and do not constitute any limitation to the invention.

without

Figure 1 is a schematic diagram of the mixing of the second material of the present invention with water. Figure 2 is a schematic diagram of the injection of the second material aqueous solution into the auxiliary device of the present invention. Figure 3 is a schematic diagram of the molding, removal and dehydration of the second material aqueous solution of the present invention. Figure 4 is a schematic diagram of the mixing of the first material of the present invention with water. Figure 5 is a schematic diagram of the polyvinyl alcohol aqueous solution being attached to part or all of the three-dimensional block of the present invention in a timely manner. Figure 6 is a schematic diagram of the three-dimensional block of the present invention after draining away the polyvinyl alcohol aqueous solution without obvious excess. Figure 7 is a schematic diagram of the dehydration of part or all of the protected three-dimensional block of the present invention. Figure 8 is a schematic diagram of covering the composite material to be molded on the water-soluble core material model of the present invention. Figure 9 is a schematic diagram of covering the composite material to be molded on the water-soluble core material model of the present invention for solidification molding. Figure 10 is a schematic diagram of the waterproof water-soluble core material model of the present invention being softened by water and then being punched through the hollow shell composite material.

Claims (10)

A water-soluble core material with waterproofing is in block shape and comprises a first material, wherein the first material is polyvinyl alcohol with a molecular weight of 30,000 to 40,000 and a viscosity of 6 to 9 cps. The waterproof water-soluble core material as described in claim 1 comprises a second material which is partially or completely coated on the first material, and the second material is formed by mixing 10 to 40 weight percent of a water-soluble polymer polyvinyl alcohol, 60 to 90 weight percent of a curing filler and 1 phr of a dispersing aid. The waterproof water-soluble core material as described in claim 2, wherein the curing filler comprises one or a combination of calcium carbonate, sodium bicarbonate, calcium sulfate, barium sulfate, mica, silicon oxide, aluminum oxide, titanium oxide, zirconium oxide; and the dispersing aid comprises one or a combination of silicon-based complex, stearic acid, zinc stearate, calcium stearate, magnesium stearate. The water-soluble core material as claimed in claim 1, wherein the first material is added with 0.5-5.0 phr of an antibacterial and anti-mold agent. The water-soluble core material with impermeability as described in claim 4, wherein the antibacterial and antifungal agent component is one or a combination of non-toxic silver-containing particles or a complex thereof, essential oils, and preservatives. A method for making a water-soluble core material with waterproofing, comprising the following steps: Mixing a second material with water; Forming a three-dimensional block by using an auxiliary tool and removing part or all of the water; Mixing a first material composed of polyvinyl alcohol with a molecular weight of 30,000 to 40,000 and a viscosity of 6 to 9 cps with water to form a polyvinyl alcohol aqueous solution; Attaching the polyvinyl alcohol aqueous solution partially or completely to the three-dimensional block; Draining the excess polyvinyl alcohol aqueous solution from the three-dimensional block; and Dehydrating the three-dimensional block. A method for producing a water-soluble anti-seepage core material as described in claim 6, wherein the second material is formed by mixing 10 to 40 weight percent of a water-soluble polymer polyvinyl alcohol, 60 to 90 weight percent of a curing filler, and 1 phr of a dispersing aid. The method for making a water-soluble core material for waterproofing as described in claim 7, wherein: The solidified filler comprises one or a combination of calcium carbonate, sodium bicarbonate, calcium sulfate, barium sulfate, mica, silicon oxide, aluminum oxide, titanium oxide, zirconium oxide; the dispersing aid comprises one or a combination of silicon-based composite, stearic acid, zinc stearate, calcium stearate, magnesium stearate. A method for producing a water-soluble impermeable core material as described in claim 6, wherein the weight percent concentration of polyvinyl alcohol in the polyvinyl alcohol aqueous solution is 10 to 30. A method for preparing a water-soluble core material for waterproofing as described in claim 6, wherein 0.5-5.0 phr of a defoaming agent is added to the polyvinyl alcohol aqueous solution, wherein the defoaming agent is one or a combination of silicon-based or non-toxic defoaming agents.

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