WO2021077624A1 - 一种全遮光帘复合面料的生产方法 - Google Patents

一种全遮光帘复合面料的生产方法 Download PDF

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Publication number
WO2021077624A1
WO2021077624A1 PCT/CN2020/000220 CN2020000220W WO2021077624A1 WO 2021077624 A1 WO2021077624 A1 WO 2021077624A1 CN 2020000220 W CN2020000220 W CN 2020000220W WO 2021077624 A1 WO2021077624 A1 WO 2021077624A1
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Prior art keywords
base fabric
hot
fabric layer
parts
pressing
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PCT/CN2020/000220
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English (en)
French (fr)
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向海军
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海宁三帘纺织有限公司
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    • B32B27/40Layered products comprising a layer of synthetic resin comprising polyurethanes
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47HFURNISHINGS FOR WINDOWS OR DOORS
    • A47H23/00Curtains; Draperies
    • A47H23/02Shapes of curtains; Selection of particular materials for curtains
    • A47H23/08Selection of particular materials
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    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
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    • B32B7/04Interconnection of layers
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B9/00Screening or protective devices for wall or similar openings, with or without operating or securing mechanisms; Closures of similar construction
    • E06B9/24Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blinds
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    • B32B2262/02Synthetic macromolecular fibres
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    • B32B2307/10Properties of the layers or laminate having particular acoustical properties
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    • C08K5/1345Carboxylic esters of phenolcarboxylic acids

Definitions

  • the invention relates to the technical field of the preparation of shading roller blinds and fabric curtains, in particular to a production method of a full shading curtain composite fabric.
  • the purpose of the present invention is to provide a method for producing a full shade composite fabric, so that the entire production process is stain-free and environmentally friendly production; and the shade shade prepared not only has 100% shading, but also makes the shade curtain have heat insulation , Sound insulation and anti-ultraviolet, anti-aging for more than 10 years.
  • the present invention relates to a method for producing a full shade composite fabric.
  • the full shade composite fabric includes a first base fabric layer, a TPU black shading film and a second base fabric layer; the first base fabric layer and the shade The film is compounded through the first adhesive layer; the second base fabric layer and the TPU black light-shielding film are compounded through the second adhesive layer; the surfaces of the first base fabric layer and the second base fabric layer are formed by embossing Pattern
  • Treatment of base fabric pre-treat the selected fabrics of the first base fabric layer and the second base fabric layer;
  • the TPU black light-shielding film contains 30-50 parts of polyurethane, 8-12 parts of low-density polyethylene, 20 parts by mass of carbon black, and 30-50 parts by mass of opalizing agent , 8 parts by mass of titanium dioxide, 10-20 parts of nano gelatin beads, and 5-8 parts of phenyl salicylate; said parts are parts by mass;
  • the first step of hot-pressing compounding using a hot-pressing compounding device to coat one side of the first base fabric layer with acrylic resin as the first adhesive layer, and then under the condition of 130-180°C, the TPU
  • the black light-shielding film and the first base fabric layer are hot-pressed and composited; embossing is performed while the hot-pressing composite is performed to form a set pattern on the surface of the first base fabric layer;
  • the second step of hot-pressing compounding using a hot-pressing compounding device to coat acrylic resin on the surface of the second base fabric layer as the second adhesive layer, and then under the condition of 130-180°C, perform hot pressing to The TPU black light-shielding film side of the composite fabric prepared in the step is hot-pressed and composited with the second base fabric layer; embossing is performed while the hot-pressing composite is performed to form a set pattern on the surface of the second base fabric layer.
  • the treatment of the base fabric is to degrease and decontaminate the base fabric.
  • the formed black and white light-shielding film has an areal density of 40-50 grams per square meter.
  • the coating amount of the acrylic resin is 7-10 grams per square meter.
  • step (3) and step (4) the pressure of the hot-pressing compound is 6kg.
  • step (3) and step (4) the compounding speed is 1800-2200 meters per hour.
  • the production method of the full shade composite fabric of the present invention uses the extrusion blow molding method to produce the TPU black shade film, and then it is combined with the first base fabric after degreasing and decontamination treatment. Perform hot-pressing compounding, and then hot-pressing compounding with the second base cloth layer, so that the entire production process is environmentally friendly and pollution-free.
  • phenyl salicylate and titanium dioxide are used in the TPU black light-shielding film to make it have good anti-ultraviolet ability and anti-aging ability. And also has a good heat and sound insulation effect.
  • Figure 1 is a schematic diagram of the structure of the first embodiment
  • Fig. 2 is a schematic diagram of the structure of the second embodiment.
  • the embodiment will be described in detail with reference to FIG. 1.
  • This embodiment relates to a method for producing a full blackout curtain composite fabric.
  • the full blackout curtain composite fabric mentioned includes a first base fabric layer 1, a TPU black shading film 2 and The second base cloth layer 3.
  • the first base fabric layer 1 and the light-shielding film 2 are compounded through the first adhesive layer 4, and the second base cloth layer 3 and the TPU black light-shielding film 2 are compounded through the second adhesive layer 5.
  • the surfaces of the first base fabric layer 1 and the second base fabric layer 2 both have patterns formed by embossing.
  • the full-shading curtain composite fabric is produced according to the following steps: (1) treatment of the base fabric, (2) preparation of the TPU black shading film, (3) the first step of hot pressing and compounding, (four) the second step of hot pressing and compounding.
  • the fabrics selected by the first base fabric layer (1) and the second base fabric layer (3) are pretreated.
  • Treatment refers to the degreasing, decontamination or desizing treatment of the fabrics selected by the first base fabric layer and the second base fabric layer, so that the fabric does not have other oil stains or other impurities that affect the hot-pressing compound, and then the The combination of TPU black shading film has an impact, which reduces the bonding strength between the fabric and the black and white shading film, and affects the service life of the shading curtain.
  • the fabrics selected for the first base fabric layer and the second base fabric layer involved in the present invention do not have special requirements.
  • the fabrics sold in the conventional market can be pure polyester fabrics, pure cotton fabrics or polyester-cotton blended fabrics, and Fabrics made of other materials are acceptable.
  • the dyed cloth of pure polyester purchased from the market is used in this embodiment, with a grammage of 120 grams per square meter.
  • the polyester cloth purchased from the market is washed in clean water with degreaser added at a temperature of 50°C. You can also buy washed fabrics from the market.
  • TPU black light-shielding film 30 parts of polyurethane, 8 parts of low-density polyethylene, 20 parts by mass of carbon black, 30 parts by mass of opacifier, 8 parts by mass of titanium dioxide, 10 parts Nano gelatin microbeads, 5 parts of phenyl salicylate are mixed uniformly, and then extruded and blow molded. The parts obtained are parts by mass.
  • the nano-gelatin microspheres used are nano-gelatin microspheres with a particle size of 150 nanometers.
  • the calendering method, the salivation method and the extrusion method can be used to prepare the black and white light-shielding film.
  • an extruder two methods can be used, namely, a blow molding method and a direct extrusion with a slit die head.
  • the extrusion blow molding method is used to produce the black and white light-shielding film.
  • Extrusion blow molding is extrusion blow molding. This method is to add the material to the barrel of the extruder, and the material is melted and plasticized under the action of a certain temperature after the screw is rotated, extruded and stirred, and then driven by the screw After passing through the filter screen and the splitter plate, it is extruded into a thin-walled tube through the annular mouth film gap of the machine head, and then in the flowing state, it is blown with compressed air while it is hot, and then cooled and shaped by the air ring, and then enters the herringbone plate. It is clamped flat, and the guide roller is pressed and pulled into the take-up roller, and finally the film product is produced.
  • the melt flow rate (MFR) after melting is controlled at 0.8g/10min. If the MFR is smaller, the processing is difficult; the larger the MFR, the It is easy to cause sagging. And the solid materials used need to be dried before blow molding.
  • a lower processing temperature is used as much as possible, and 170°C is used in this embodiment.
  • the blow molding pressure is generally controlled at 0.5MPa. For resins with large volume, thinner walls and lower MFR, the blowing pressure should be higher, and vice versa.
  • the inflation ratio in this embodiment is 2, which can ensure a more suitable film thickness.
  • the die gap is 1mm
  • the die diameter is 250mm
  • the diameter of the air ring is 500mm
  • the traction drive power is 0.4KW
  • the traction (coiling) speed is 2-20m/min
  • the length of the roller is 1100mm
  • the diameter of the traction roller is 150mm
  • the center height of the traction roller is 4500mm
  • the length of the herringbone is 1500mm
  • the maximum folding diameter of the blown film is 1000mm
  • the diameter of the screw is 90mm
  • the compression ratio of the screw is 3-4.
  • the thickness of the TPU black shading film is 0.04-0.1mm.
  • the areal density of the TPU black light-shielding film produced in this embodiment is 40-50 grams per square meter, specifically 45 grams per square meter.
  • the first step is hot-pressing compounding: using a hot-pressing compounding device to coat one side of the first base fabric layer (1) with acrylic resin as the first adhesive layer (4), and then at 180°C,
  • the TPU black light-shielding film and the first base fabric layer (1) are hot-pressed and composited by hot pressing; embossing is performed while the hot-pressing composite is performed to form a set pattern on the surface of the first base fabric layer (1).
  • the compound speed is 1800 meters per hour.
  • the acrylic resin used is pure acrylate, and its coating amount is 7 grams per square meter. When performing hot-pressing compounding, the pressure is 6kg.
  • the second step of hot-pressing compounding using a hot-pressing compounding device to coat acrylic resin on the surface of the second base cloth layer (3) as the second adhesive layer, and then under the condition of 180 °C, perform hot pressing to One side of the TPU black light-shielding film of the composite fabric prepared in one step is hot-pressed and composited with the second base fabric layer (3); embossing is performed while the hot-pressing composite material is formed on the surface of the second base fabric layer (3) Set pattern.
  • the compound speed is 1800 meters per hour.
  • the acrylic resin used is pure acrylate, and its coating amount is 10 grams per square meter. When performing hot-compression lamination, the pressure is 8kg.
  • the treatment of the first base fabric layer and the second base fabric layer is the same as that of the first embodiment, and the treatments such as degreasing, decontamination or desizing are carried out, so that the base fabric does not have other oil stains or other impurities that affect the hot-pressing compound, and then It has an impact on the combination with the black and white shading film, which reduces the bonding strength of the base fabric and the black and white shading film, and affects the service life of the shading curtain.
  • step (2) TPU black light-shielding film, 40 parts of polyurethane, 10 parts of low-density polyethylene, 20 parts of carbon black, 40 parts of opacifier, 8 parts of titanium dioxide, 15 parts of The nano-gelatin beads and 7 parts of phenyl salicylate are mixed uniformly, and then extruded and blow molded. The parts obtained are parts by mass.
  • the melt flow rate (MFR) after melting is controlled at 1g/10min. If the MFR is smaller, the processing will be difficult; the larger the MFR, the Easy to cause sagging. And the solid materials used need to be dried before blow molding.
  • a lower processing temperature is used as much as possible, and 175°C is used in this embodiment.
  • the blowing pressure is generally controlled at 0.6 MPa. For resins with large volume, thinner walls and lower MFR, the blowing pressure should be higher, and vice versa.
  • the inflation ratio in this embodiment is 2.5, which can ensure a more suitable film thickness.
  • the die gap is 1.2mm
  • the die diameter is 350mm
  • the air ring diameter is 650mm
  • the traction drive power is 0.8KW
  • the traction (coiling) speed is 2-20m/min
  • the length of the traction roller is 1100mm
  • the diameter of the traction roller is 150mm
  • the center height of the traction roller is 6500mm
  • the length of the herringbone is 1700mm
  • the maximum folding diameter of the blown film is 1500mm
  • the diameter of the screw is 120mm
  • the compression ratio of the screw is 3-4.
  • the thickness of the prepared black and white light-shielding film is 0.04-0.1mm.
  • the areal density of the TPU black light-shielding film produced in this embodiment is 40-50 grams per square meter, specifically 40 grams per square meter.
  • the first step is hot-pressing compounding: using a hot-pressing compounding device to coat one side of the first base fabric layer (1) with acrylic resin as the first adhesive layer (4), and then at 130°C,
  • the TPU black light-shielding film and the first base fabric layer (1) are hot-pressed and composited by hot pressing; embossing is performed while the hot-pressing composite is performed to form a set pattern on the surface of the first base fabric layer (1).
  • the compound speed is 2200 meters per hour.
  • the acrylic resin used is pure acrylate, and its coating amount is 8 grams per square meter. When performing hot-pressing compounding, the pressure is 6kg.
  • a hot-pressing compounding device is used to coat the surface of the second base fabric layer (3) with acrylic resin as the second adhesive layer, and then heat it at 130°C. Press the TPU black light-shielding film side of the composite fabric prepared in the previous step to heat-press compound with the second base fabric layer (3); embossing is performed at the same time as the hot-press compounding, and the second base fabric layer (3)
  • the surface forms a set pattern.
  • the compound speed is 2200 meters per hour.
  • the acrylic resin used is pure acrylate, and its coating amount is 9 grams per square meter. When performing hot-pressing compounding, the pressure is 8kg.
  • the environmental protection waterproof layer 6 is a high-elastic environmental protection waterproof coating film, which uses a modified acrylic emulsion as a base material.
  • the production method of a full shade composite fabric involved in this embodiment is different from the first embodiment in that in step two, the prepared TPU black shade film is made of 50 parts of polyurethane and 12 parts of low-density polymer.
  • Ethylene, 20 parts by mass of carbon black, 50 parts by mass of opacifier, 8 parts by mass of titanium dioxide, 0 parts of nano gelatin beads, and 8 parts of phenyl salicylate are mixed uniformly, and then formed by extrusion blow molding. The parts obtained are parts by mass.
  • the production method of a full shade composite fabric involved in this comparative example is different from the first embodiment in that it does not include step (4). Only the first base fabric layer fabric and TPU black shading film are hot-pressed and compounded.
  • Base cloth selection and processing choose the same base cloth and the same processing method as in the first embodiment.
  • White paste preparation and first coating White paste includes 19 parts by weight of polyurethane, 32 parts of acrylic acid and 15 parts of titanium dioxide dispersion; 15 parts of foam stabilizer; 1.5 parts of foaming agent; 1 part of ammonia; pH value of white paste is 10; Viscosity is 2500cps; then the white slurry is rolled on one side of the grey fabric with a knife-coating roller to obtain the first coating;
  • the coating knife angle of the first coating is 95°, the knife distance is 0.65mm, the foaming slurry density is 48g/cm3, the foaming ratio is 4 times, and the pressure roller pressure is 0.4MPa. ;
  • the knife head is a flat knife; the speed of the grey cloth passing through the pressing roller is 18m/min.
  • Black paste preparation and second coating Black paste includes 19 parts by weight of polyurethane, 32 parts of acrylic acid; 15 parts of titanium dioxide dispersion; 15 parts of foam stabilizer; 1.5 parts of foaming agent; 1 part of ammonia; 6 parts of black color paste ;
  • Floor
  • the coating knife angle of the second coating is 95°, the knife distance is 0.65mm, the foaming slurry density is 49g/cm3, the foaming ratio is 4 times, and the pressure roller pressure is 0.4MPa. ;
  • the speed of the grey cloth through the pressing roller is 18m/min.
  • Mortar preparation and third coating Black paste includes 19 parts by weight of polyurethane, 32 parts of acrylic acid; 15 parts of titanium dioxide dispersion; 15 parts of foam stabilizer; 1.5 parts of foaming agent; 1 part of ammonia; 2 parts of black color paste; stiff 25 parts of the manufacturing method of the glue full blackout curtain; the pH value of the mortar is 10, the viscosity is 2500cps; then the mortar is rolled on the second coating with a knife-coating roller to obtain the third coating of the first full blackout curtain;
  • the coating knife angle for the third coating is 95°, the knife distance is 0.6mm, the foaming slurry density is 40g/cm3, the production method of the foamed full blackout curtain is 5 times, and the pressure roller pressure is 0.4MPa ; The speed of the grey cloth through the pressing roller is 22m/min.
  • the stiffening glue in black paste or mortar is an anionic emulsion formed by copolymerization of acrylic acid and acrylic ester.
  • face paste includes 60 parts by weight of polyurethane; 15 parts of titanium dioxide dispersion of the manufacturing method of full blackout curtain; 15 parts of foam stabilizer; 2.2 parts of foaming agent; 1.2 parts of ammonia; pH of face paste The value is 10, and the viscosity is 2400cps; after the manufacturing method of the full blackout curtain, the dough paste is rolled on the third coating layer to obtain the fourth coating layer after the manufacturing method of the full blackout curtain.
  • the coating knife angle for the fourth coating is 95°, the knife distance is 0.75mm, the foaming slurry density is 48g/cm3, the foaming ratio is 3.5 times, and the pressure roller pressure is 0.4MPa. ;
  • the speed of the grey cloth through the pressing roller is 22m/min.
  • the black color paste in white paste, black paste, mortar or noodle paste contains titanium dioxide dispersion and water-based black pigment; the production method of titanium dioxide full shading curtain
  • the dispersion is to use titanium dioxide, water, and dispersant in parts by weight of 65:45 :1 Mixed and dispersed.
  • the squeegee includes 28 parts by weight of water-based acrylic emulsion; 8 parts of polyurethane; 0.27 parts of defoamer; 5 parts of penetrant; 1.9 parts of pH stabilizer; viscosity of 30,000 cps; Ran Quan After the manufacturing method of the shade curtain, a sharp knife is used to scrape the fabric surface with a scraping paste on the other side of the grey fabric.
  • the coating knife angle is 95°, the knife distance is 42mm, the foaming slurry density is 48g/cm3, the foaming ratio is 4 times that of the manufacturing method of the full blackout curtain, and the pressure of the pressure roller is 0.4MPa; It is a sharp knife; the speed of the grey fabric passing through the pressing roller is 16m/min.
  • the foaming agent in the slurry of each layer is a 1:1 mass mixture of n-butane and a 5% sodium bicarbonate solution; the method for making the penetrant full shade curtain is sodium di-secondary octyl maleate sulfonate;
  • the foam stabilizer is dodecyl dimethyl amine oxide.
  • Example 1 to Example 3 adopt the TPU black light-shielding film produced by extrusion blow molding and the base fabric to compound, and the comparative example It uses multiple coatings to produce shade curtains.
  • the entire production process of Example 1 to Example 3 no waste gas or waste water was generated. Even if the fabric is cleaned with a degreasing agent, the waste water produced can be treated in the enterprise by waste water treatment, which can be processed more conveniently.
  • Example 1 to Example 3 The full shading curtains prepared in Example 1 to Example 3, and Comparative Example 1 and Comparative Example 2 were tested for light-shielding, UV-proof performance, sound insulation and heat insulation.
  • the shading rate test is to use the American AATCC-148-79 "Method for Evaluating the Shading Effect of Curtain Materials” that meets the requirements of the International Commission of Illumination, and the light transmission "box method” is used to judge the shading performance of curtain fabrics.
  • the UV protection index UPF of testing textiles is used to evaluate the UV protection effect of textiles and after 10 washings and 25 washings.
  • the UPF values of Example 1 to Example 3, Comparative Example 1, and Comparative Example 2 were 42.6, 41.3, 43.5, 33.6, and 19.4, respectively.
  • Example 1 to Example 3, Comparative Example 1, and Comparative Example 2 The UPF values were 39.7, 38.4, 40.6, 30.4, 18.3, and the UPF values of Example 1 to Example 3, Comparative Example 1 and Comparative Example 2 after 25 washings were 37.2, 36.1, 38.7, 29.5, 13.4, respectively. It can be seen that, compared with the comparative example, the curtains involved in Examples 1 to 3 have better anti-ultraviolet effects, and after 10 and 25 washings, their anti-ultraviolet effects do not decrease much.
  • the light transmittance of Example 1 to Example 3 is 0%, that is, the light shielding rate is 100%.
  • the light transmittance of Comparative Example 1 is 2%, that is, the light shielding rate is 98%.
  • the light transmittance of Comparative Example 2 is 10%, that is, the light shielding rate is 90%.
  • the heat insulation performance of the fabrics was tested by testing the Cro values of the composite fabrics involved in Examples 1 to 3, and Comparative Examples 1 and 2.
  • the Crowe value is an engineering unit that describes the thermal insulation performance of clothing or fabrics, that is, "thermal resistance”. At a room temperature of 20°C or 21°C, the relative humidity does not exceed 50%, and the air flow rate does not exceed 10cm/s (equivalent to the normal airflow speed in a ventilated room), a person sits quietly or engages in light mental work to maintain comfort
  • the size of the Crowe value indicates the degree of warmth and heat insulation of the fabric. The larger the Crow value, the worse the thermal conductivity of the fabric and the better its thermal insulation. After testing, the Cro values of Example 1 to Example 3 and Comparative Example were 0.85, 0.83, 0.89, 0.69, 0.42, respectively.

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Abstract

一种全遮光帘复合面料的生产方法,所提到的全遮光帘复合面料包括第一基布层(1)、第一胶粘层(4)、TPU黑遮光膜(2)、第二胶粘层(5)和第二基布层(3);第一基布层(1)和第二基布层(3)表面均具有压花所形成的花纹。按如下步骤生产:基布的处理、TPU黑遮光膜(2)的制备、第一步热压复合、第二步热压复合。所述一种全遮光帘复合面料的生产方法,使用挤压吹塑的方法生产TPU黑遮光膜(2),再与经过去油去污处理后的第一基布层(1)进行热压复合,并再与第二基布层(3)热压复合,使得整个生产过程环保无污染。并且在TPU黑遮光膜(2)中使用了水杨酸苯酯及二氧化钛,使其具有良好的抗紫外能力及抗老化能力,还具有良好的隔热隔音的效果。

Description

一种全遮光帘复合面料的生产方法 技术领域
本发明涉及遮光卷帘及布艺帘的制备技术领域,尤其是一种全遮光帘复合面料的生产方法。
背景技术
在常规的遮光卷帘及布艺帘的制作方法多次涂层的方式来达到遮光的效果。但是在涂层过程中会存在废气、废水污染等环保方面的问题,会严重破坏生态环境;而且多次涂层还存在生产能耗及成本过大。而且现有技术中所制备的卷帘或布艺帘不能进行水洗、干洗及熨烫,使得对于现有的卷帘或布艺帘存在清洁方面的问题。并且现在所使用过程中还具有防紫外性能不强,抗老化性不够。并且现在所使用的全遮光帘复合面料对的遮光效果达不到100%完全遮光。
发明内容
本发明的目的是提供一种全遮光帘复合面料的生产方法,,使得整个生产过程无污渍,做到环保生产;并且所制备的遮光帘不仅具有100%遮光,还使得该遮光帘具有隔热、隔音及抗紫外线、抗老化10年以上。
为解决上述技术问题,本发明的目的是这样实现的:
本发明所涉及的一种全遮光帘复合面料的生产方法,所述全遮光帘复合面料包括第一基布层、TPU黑遮光膜和第二基布层;所述第一基布层与遮光膜通过第一胶粘层相复合;所述第二基布层与TPU黑遮光膜通过第二胶粘层相复合;第一基布层和第二基布层表面均具有压花所形成的花纹;
按如下步骤生产:
(一)、基布的处理:对第一基布层和第二基布层所选择的面料进行预处 理;
(二)、TPU黑遮光膜的制备:所述TPU黑遮光膜含有30-50份的聚氨酯、8-12份的低密度聚乙烯,20质量份的炭黑、30-50质量份的乳白剂、8质量份的二氧化钛、10-20份的纳米明胶微珠、5-8份的水杨酸苯酯;所述的份为质量份;
(三)、第一步热压复合:采用热压复合设备在第一基布层的一侧涂覆丙烯酸树脂作为第一粘合层,再在130-180℃条件下,进行热压将TPU黑遮光膜与第一基布层热压复合;在热压复合的同时进行压花处理,在第一基布层的表面形成设定的图案;
(四)、第二步热压复合:采用热压复合设备在第二基布层的表面涂覆丙烯酸树脂作为第二粘合层,再在130-180℃条件下,进行热压将上一步骤所制备的复合面料的TPU黑遮光膜一侧与第二基布层热压复合;在热压复合的同时进行压花处理,在第二基布层的表面形成设定的图案。
作为上述方案的进一步说明,对于基布的处理是对基布进行去油去污。
作为上述方案的进一步说明,所形成的黑白遮光膜的面密度为40-50克每平方米。
作为上述方案的进一步说明,步骤(三)和步骤(四)中,丙烯酸树脂的涂覆量为7-10克每平方米。
作为上述方案的进一步说明,步骤(三)和步骤(四)中,热压复合的压力为6kg。
作为上述方案的进一步说明,步骤(三)和步骤(四)中,复合速度为1800-2200米每小时。
本发明的有益效果是:本发明所涉及的一种全遮光帘复合面料的生产方法, 使用挤压吹塑的方法生产TPU黑遮光膜,再与经过去油去污处理后的第一基布进行热压复合,并再与第二基布层热压复合,使得整个生产过程环保无污染。并且在TPU黑遮光膜中使用了水杨酸苯酯及二氧化钛,使其具有良好的抗紫外能力及抗老化能力。并且还具有良好的隔热隔音的效果。
附图说明
图1是实施例一的结构示意图;
图2是实施例二的结构示意图。
图中标记说明如下:1-第一基布层;2-聚氨酯遮光膜;3-第二基布层;4-第一胶粘层;5-第二胶粘层;6-环保防水层。
具体实施方式
下面结合附图和具体实施例对本发明进一步说明。
实施例一
结合图1对实施例作详细说明,本实施例所涉及的一种全遮光帘复合面料的生产方法,所提到的全遮光帘复合面料包括第一基布层1、TPU黑遮光膜2和第二基布层3。第一基布层1与遮光膜2通过第一胶粘层4相复合,第二基布层3与TPU黑遮光膜2通过第二胶粘层5相复合。第一基布层1和第二基布层2表面均具有压花所形成的花纹。
全遮光帘复合面料是按如下步骤生产:(一)基布的处理、(二)TPU黑遮光膜的制备、(三)第一步热压复合、(四)第二步热压复合。
在步骤(一)基布的处理中,对第一基布层(1)和第二基布层(3)所选择的面料进行预处理。处理是指对第一基布层和第二基布层所选择的面料进行去油去污或退浆等处理,使得面料上不具有其他的油污或其他影响热压复合的 杂质,进而对与TPU黑遮光膜的复合产生影响,使得面料与黑白遮光膜的粘结强度降低,影响遮光帘的使用寿命。
在本发明所涉及的第一基布层和第二基布层所选择的面料,不作特殊要求,常规市场上所出售的面料均可,纯涤面料、纯棉面料或涤棉混纺面料,以及其他材质所制备的面料均可。为了说明本发明,在在本实施例中所使用的是从市场上所购买的纯涤纶的染色布,克重为120克每平方米。并将从市场上所购买的涤纶布在加入了去油剂的清水中进行水洗,水洗温度为50℃。也可从市场上购买经过清洗的面料。
在步骤(二)TPU黑遮光膜的制备中,是将30份的聚氨酯、8份的低密度聚乙烯,20质量份的炭黑、30质量份的乳白剂、8质量份的二氧化钛、10份的纳米明胶微珠、5份的水杨酸苯酯混合均匀,再经过挤压吹塑而成。所得到的份为质量份。所使用的纳米明胶微珠即纳米明胶微球,其粒径为150纳米。
制备黑白遮光膜可以采用压延法、流涎法以及挤出法。采用挤出机又可以采用吹塑法和用狭缝机头直接挤出两种方法,在本实施例中采用挤出吹塑法进行生产黑白遮光膜。
挤压吹塑即挤出吹塑,此种方法是将物料加入至挤出机的机筒后,经螺杆的转动、挤压和搅拌,物料在一定温度作用下熔融塑化,并在螺杆推动下,经过滤网、分流板后通过机头环形口膜间隙挤出成薄壁管,然后在流动状态下趁热用压缩空气将其吹胀,再经风环冷却定型,进入人字板后夹平,由导辊压紧牵引入卷取辊,最后制得薄膜制品。
在本实施例中,由于组份包括了聚氨酯、低密度聚乙烯等材质,控制熔融后的熔体流动速度(MFR)在0.8g/10min,若MFR越小,则加工困难;MFR 越大,则容易引起下垂。并且在进行吹塑前需要对所用到的固态物质进行干燥。在保证挤出坯的光滑的情况下,尽可能的采用较低的加工温度,在本实施例中采用170℃。为了保证挤出坯紧贴模腔壁而得到所需要开关的产品,吹塑压力一般控制在0.5MPa。对于容积大、壁较薄的和MFR较低的树脂,吹塑压力要高此,反之则相反。并且本实施例中的吹胀比采用2,可保证较为合适的膜厚。
所使用的挤出机的基本参数中,模口间隙为1mm,模口直径为250mm,风环直径为500mm,牵引驱动功率为0.4KW,牵引(卷取)速度为2-20m/min;牵引辊筒长度为1100mm,牵引辊直径为150mm,牵引辊中心高为4500mm,人字板长度为1500mm,吹膜最大折径为1000mm,螺杆直径为90mm,螺杆的压缩比为3-4,所制备的TPU黑遮光膜的厚度在0.04-0.1mm。在本实施例中所制务的TPU黑遮光膜的面密度为40-50克每平方米,具体为45克每平方米。
在步骤(三)第一步热压复合:采用热压复合设备在第一基布层(1)的一侧涂覆丙烯酸树脂作为第一粘合层(4),再在180℃条件下,进行热压将TPU黑遮光膜与第一基布层(1)热压复合;在热压复合的同时进行压花处理,在第一基布层(1)的表面形成设定的图案。复合速度为1800米每小时。所使用丙烯酸树脂为纯丙烯酸脂,其涂覆量为7克每平方米。在进行热压复合时,压力为6kg。
(四)、第二步热压复合:采用热压复合设备在第二基布层(3)的表面涂覆丙烯酸树脂作为第二粘合层,再在180℃条件下,进行热压将上一步骤所制备的复合面料的TPU黑遮光膜一侧与第二基布层(3)热压复合;在热压复合的同时进行压花处理,在第二基布层(3)的表面形成设定的图案。复合速度为1800米每小时。所使用丙烯酸树脂为纯丙烯酸脂,其涂覆量为10克每平方米。在进 行热压复合时,压力为8kg。
实施例二
结合图2,对本实施例作详细说明。本实施例所涉及的一种全遮光帘复合面料的生产方法,(一)基布的处理、(二)TPU黑遮光膜的制备、(三)第一步热压复合、(四)第二步热压复合。
对第一基布层和第二基布层的处理与实施例一相同,进行去油去污或退浆等处理,使得基布上不具有其他的油污或其他影响热压复合的杂质,进而对与黑白遮光膜的复合产生影响,使得基布与黑白遮光膜的粘结强度降低,影响遮光帘的使用寿命。
在步骤(二)TPU黑遮光膜的制备中,是将40份的聚氨酯、10份的低密度聚乙烯,20质量份的炭黑、40质量份的乳白剂、8质量份的二氧化钛、15份的纳米明胶微珠、7份的水杨酸苯酯混合均匀,再经过挤压吹塑而成。所得到的份为质量份。
在本实施例中,由于组份包括了聚氨酯、低密度聚乙烯等材质,控制熔融后的熔体流动速度(MFR)在1g/10min,若MFR越小,则加工困难;MFR越大,则容易引起下垂。并且在进行吹塑前需要对所用到的固态物质进行干燥。在保证挤出坯的光滑的情况下,尽可能的采用较低的加工温度,在本实施例中采用175℃。为了保证挤出坯紧贴模腔壁而得到所需要开关的产品,吹塑压力一般控制在0.6MPa。对于容积大、壁较薄的和MFR较低的树脂,吹塑压力要高此,反之则相反。并且本实施例中的吹胀比采用2.5,可保证较为合适的膜厚。
所使用的挤出机的基本参数中,模口间隙为1.2mm,模口直径为350mm,风环直径为650mm,牵引驱动功率为0.8KW,牵引(卷取)速度为2-20m/min; 牵引辊筒长度为1100mm,牵引辊直径为150mm,牵引辊中心高为6500mm,人字板长度为1700mm,吹膜最大折径为1500mm,螺杆直径为120mm,螺杆的压缩比为3-4,所制备的黑白遮光膜的厚度在0.04-0.1mm。在本实施例中所制务的TPU黑遮光膜的面密度为40-50克每平方米,具体为40克每平方米。
在步骤(三)第一步热压复合:采用热压复合设备在第一基布层(1)的一侧涂覆丙烯酸树脂作为第一粘合层(4),再在130℃条件下,进行热压将TPU黑遮光膜与第一基布层(1)热压复合;在热压复合的同时进行压花处理,在第一基布层(1)的表面形成设定的图案。复合速度为2200米每小时。所使用丙烯酸树脂为纯丙烯酸脂,其涂覆量为8克每平方米。在进行热压复合时,压力为6kg。
在步骤(四)、第二步热压复合中,采用热压复合设备在第二基布层(3)的表面涂覆丙烯酸树脂作为第二粘合层,再在130℃条件下,进行热压将上一步骤所制备的复合面料的TPU黑遮光膜一侧与第二基布层(3)热压复合;在热压复合的同时进行压花处理,在第二基布层(3)的表面形成设定的图案。复合速度为2200米每小时。所使用丙烯酸树脂为纯丙烯酸脂,其涂覆量为9克每平方米。在进行热压复合时,压力为8kg。
并且在步骤(四)所制备的复合面料的第二基布层表面在涂覆一层环保防水层6。环保防水层6为高弹环保防水涂膜,以改性丙烯酸酯乳液为基料。
实施例三
本实施例所涉及的一种全遮光帘复合面料的生产方法,与实施例一的区别在于,在步骤二中,所制备的TPU黑遮光膜是将50份的聚氨酯、12份的低密度聚乙烯,20质量份的炭黑、50质量份的乳白剂、8质量份的二氧化钛、0份 的纳米明胶微珠、8份的水杨酸苯酯混合均匀,再经过挤压吹塑而成。所得到的份为质量份。
对比例一
本对比例所涉及的一种全遮光帘复合面料的生产方法,与实施例一的区别在于,不包括步骤(四)。只是第一基布层面料与TPU黑遮光膜进行热压复合。
对比例二
基布选择和处理,选择与实施例一相同的基布及相同的处理方式。
白浆调制和第一涂层:白浆按重量份包括聚氨酯19份,丙烯酸32份二氧化钛分散体15份;稳泡剂15份;发泡剂1.5份;氨水1份;白浆pH值10;粘度2500cps;然后采用涂刀压辊将白浆碾压在坯布一面上获得第一涂层;
其中,第一涂层时的涂刀角度为95°、刀距为0.65mm、发泡浆料密度为48g/cm3、发全遮光帘的制作方法泡倍率为4倍、压辊气压在0.4MPa;刀头为平刀;坯布经过压辊的速度为18m/min。
黑浆调制和第二涂层:黑浆按重量份包括聚氨酯19份,丙烯酸32份;二氧化钛分散体15份;稳泡剂15份;发泡剂1.5份;氨水1份;黑色色浆6份;硬挺全遮光帘的制作方法胶25份;黑浆pH值10,粘度2500cps;然后采用涂刀压辊将黑浆碾压在带有第一涂层上获得全遮光帘的制作方法第二涂层;
其中,第二涂层时的涂刀角度为95°、刀距为0.65mm、发泡浆料密度为49g/cm3、发全遮光帘的制作方法泡倍率为4倍、压辊气压在0.4MPa;坯布经过压辊的速度为18m/min。
灰浆调制和第三涂层:黑浆按重量份包括聚氨酯19份,丙烯酸32份;二氧化钛分散15份;稳泡剂15份;发泡剂1.5份;氨水1份;黑色色浆2份;硬 挺胶全遮光帘的制作方法25份;灰浆pH值10,粘度2500cps;然后采用涂刀压辊将灰浆碾压在带有第二涂层上获得第全遮光帘的制作方法三涂层;
其中,第三涂层时的涂刀角度为95°、刀距为0.6mm、发泡浆料密度为40g/cm3、发泡全遮光帘的制作方法倍率为5倍、压辊气压在0.4MPa;坯布经过压辊的速度为22m/min。
黑浆或灰浆中的硬挺胶为丙烯酸与丙烯酸酯共聚而成的阴离子乳液。
面浆调制和第四涂层:面浆按重量份包括聚氨酯60份;全遮光帘的制作方法二氧化钛分散体15份;稳泡剂15份;发泡剂2.2份;氨水1.2份;面浆pH值10,粘度2400cps;然全遮光帘的制作方法后采用涂刀压辊将面浆碾压在带有第三涂层上获得第四涂层;
其中,第四涂层时的涂刀角度为95°、刀距为0.75mm、发泡浆料密度为48g/cm3、发全遮光帘的制作方法泡倍率为3.5倍、压辊气压在0.4MPa;坯布经过压辊的速度为22m/min。
白浆、黑浆、灰浆或面浆中的黑色色浆包含钛白粉分散体和水性黑色颜料;钛白粉全遮光帘的制作方法分散体是将钛白粉、水、分散剂按照重量份65∶45∶1混合分散而成。
刮色浆调制和布面刮色:刮色浆按重量份包括水基丙烯酸乳液28份;聚氨酯8份;消泡剂0.27份;渗透剂5份;pH值稳定剂1.9份;粘度30000cps;然全遮光帘的制作方法后采用尖刀在坯布的另一面用刮色浆进行布面刮色。
布面刮色时的涂刀角度为95°、刀距为42mm、发泡浆料密度为48g/cm3、发泡倍率为全遮光帘的制作方法4倍、压辊气压在0.4MPa;刀头为尖刀;坯布经过压辊的速度为16m/min。
上述各层浆液中的发泡剂为1∶1质量混合的正丁烷和5%的碳酸氢钠溶液;渗透剂全遮光帘的制作方法为顺丁烯二酸二仲辛酯磺酸钠;稳泡剂为十二烷基二甲基氧化胺。
通过对比实施例一至实施例三、以及对比例二的生产过程,可以看出,实施例一至实施例三采用经过挤出吹塑所生产的TPU黑遮光膜与基布面料进行复合,而对比例是采用多次涂层的方式进行生产制备遮光帘。使得实施例一至实施例三整个生产过程中,没有废气废水的产生。即便是采用去油剂对面料进行清洗,其所产生废水也可以在企业内部经废水处理完成,可以较为方便的进行处理。
对实施例一至实施例三、及对比例一、对比例二所制备全遮光帘进行遮光性、防紫外性能、隔音和隔热性测试。
遮光率的测试是采用符合国际照明委员会要求的美国AATCC-148-79《窗帘材料遮光效应评定方法》,采取光透射的“箱法”来判断窗帘织物的遮光性能。
采用测试纺织品紫外线防护指数UPF来评价纺织品、以及经过10次洗涤和25次洗涤后的紫外线防护效果。经测试,实施例一至实施例三、对比例一、对比例二的UPF值分别为42.6、41.3、43.5、33.6、19.4,洗涤10次后实施例一至实施例三、对比例一、对比例二的UPF值分别为39.7、38.4、40.6、30.4、18.3,洗涤25次后实施例一至实施例三、对比例一及对比例二的UPF值分别为37.2、36.1、38.7、29.5、13.4。由此可知,实施例一至实施例三所涉及的窗帘与对比例相比较,其具有较好的防紫外效果,并且在经过10次和25次洗涤后,其防紫外效果下降不多。
实施例一至实施例三的透光率为0%,即遮光率均为100%。对比例一的透 光率为2%,即遮光率为98%。对比例二的透光率为10%,即遮光率为90%。
为了验证该织物的隔音效果,还进行了简单的隔音性能测试。将一台木工用的微型空气压缩机放在一空房间门口正前方1.6米处,用声级计在房间内,离门0.5米,高为0.4米处测量。然后分别测试开门,用实施例一至实施例三以及对比例一、对比例二所涉及的遮光帘封闭门框,测试这种状态下的噪声。具体结果如下:背景噪声为30.3dB;开门为72.5dB;用实施例一封闭门框:40.6dB;用实施例二封闭门框:40.2dB;用实施例三封闭门框:39.5dB;用对比例一封闭门框:56.2dB,用对比例二封闭门框:61.7dB。这表明该实施例一至实施例三所制备的窗帘具有明显的隔音效果。
通过测试实施例一至实施例三、以及对比例一、对比例二所涉及的复合面料的克罗值,来对面料的隔热性能进行测试。克罗值是描述服装或织物隔热保暖性能即“热阻”的工程单位。在室温20℃或21℃时,相对湿度不超过50%,空气流速不超过10cm/s(相当于有通风设备的室内正常气流速度)的环境中,一个人静坐或从事轻度脑力劳动保持舒适状态时所穿服装的隔热值为1clo,用法定计量单位定义为1clo=4.30×10 -2K·m 2·h/J=155m 2·K/W。克罗值的大小表示了织物保暖隔热程度的高低。克罗值越大,面料的导热性越差,其隔热性越好。经测试,实施例一至实施例三、对比例的克罗值分别为0.85、0.83、0.89、0.69、0.42。
以上详细描述了本发明的较佳具体实施例。应当理解,本领域的普通技术人员无需创造性劳动就可以根据本发明的构思做出诸多修改和变化。因此,凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案,皆应在由权利要求书所确定的保护范 围内。

Claims (6)

  1. 一种全遮光帘复合面料的生产方法,其特征在于,所述全遮光帘复合面料包括第一基布层(1)、TPU黑遮光膜(2)和第二基布层(3);所述第一基布层(1)与遮光膜(2)通过第一胶粘层(4)相复合;所述第二基布层(3)与TPU黑遮光膜(2)通过第二胶粘层(5)相复合;第一基布层(1)和第二基布层(2)表面均具有压花所形成的花纹;
    按如下步骤生产:
    (一)、基布的处理:对第一基布层(1)和第二基布层(3)所选择的面料进行预处理;
    (二)、TPU黑遮光膜的制备:所述TPU黑遮光膜含有30-50份的聚氨酯、8-12份的低密度聚乙烯,20质量份的炭黑、30-50质量份的乳白剂、8质量份的二氧化钛、10-20份的纳米明胶微珠、5-8份的水杨酸苯酯;所述的份为质量份;
    (三)、第一步热压复合:采用热压复合设备在第一基布层(1)的一侧涂覆丙烯酸树脂作为第一粘合层(4),再在130-180℃条件下,进行热压将TPU黑遮光膜与第一基布层(1)热压复合;在热压复合的同时进行压花处理,在第一基布层(1)的表面形成设定的图案;
    (四)、第二步热压复合:采用热压复合设备在第二基布层(3)的表面涂覆丙烯酸树脂作为第二粘合层,再在130-180℃条件下,进行热压将上一步骤所制备的复合面料的TPU黑遮光膜一侧与第二基布层(3)热压复合;在热压复合的同时进行压花处理,在第二基布层(3)的表面形成设定的图案。
  2. 根据权利要求1所述的全遮光帘复合面料的生产方法,其特征在于,对于基布的处理是对基布进行去油去污。
  3. 根据权利要求1所述的全遮光帘复合面料的生产方法,其特征在于,所 形成的TPU黑遮光膜的面密度为40-50克每平方米。
  4. 根据权利要求1所述的全遮光帘复合面料的生产方法,其特征在于,步骤(三)和步骤(四)中,丙烯酸树脂的涂覆量为7-10克每平方米。
  5. 根据权利要求1所述的全遮光帘复合面料的生产方法,其特征在于,步骤(三)和步骤(四)中,热压复合的压力为6kg。
  6. 根据权利要求1所述的全遮光帘复合面料的生产方法,其特征在于,步骤(三)和步骤(四)中,复合速度为1800-2200米每小时。
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