CN108248145A - 一种无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材及其制备方法 - Google Patents
一种无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材及其制备方法，属于汽车材料设计制造领域。无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材，首先对传统方法制备的天然纤维增强聚合物基复合板材进行加热，喷淋吸附剂，排风通风处理；然后进行负压吸附，排除和吸附释放的甲醛、乙醛；然后得到一种无甲醛、乙醛天然纤维增强聚合物基复合板材。本发明制得的天然纤维增强复合板材具有环保性能好、无甲醛、乙醛释放、质量轻、用途广泛。可广泛应用于汽车、轨道车辆、航空航天、建筑、装饰、包装等领域，具有良好的应用前景。
Description
技术领域
属于纤维增强复合材料制备领域。
背景技术
随着社会的进步，人们对环保、节能节材等需求不断提高，对汽车及汽车内饰件材料的要求也越来越高，市场竞争激烈。轻量化是汽车发展的趋势，因此轻量化材料在汽车上的应用也将越来越普遍。麻纤维作为有机质材料，具有良好的性能，且绿色环保。
而VOC问题是汽车内饰材料必须解决的问题，传统的处理方法很难完全除去复合材料中的甲醛、乙醛，生产出来的复合材料，仍然较难满足严格的汽车内饰件国家法规的VOC释放要求。因此，低成本去除麻纤维增强复合板材中的甲醛、乙醛，是产业发展中亟待解决的难题。
发明内容
为了解决上述问题，本发明公开了一种无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材，该板材由天然麻纤维和聚合物纤维相互混合、纤维交织并由聚合物纤维固化而成；所述的天然麻纤维的纤维束1之间空隙填充有吸附剂颗粒2，所述天然麻纤维为汉麻纤维、黄麻纤维、亚麻纤维、苎麻纤维或以上1～4种的混合物；聚合物纤维可以是PP、PE、PC、PA6、PA66或PLA。所述吸附剂为硅烷偶联剂改性的纳米黏土。
无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，具体步骤如下：
1)按天然麻纤维30wt％～70wt％，聚合物70wt％～30wt％的比例称取原料；
2)将天然麻纤维水洗除去杂质和烘干后，使用快速深冷脱胶处理方法对天然麻纤维进行脱胶处理；
3)将脱胶处理后的麻纤维在表面处理剂中浸渍30min～4h，取出后经多次水洗，置于80～100℃烘箱中干燥6～12h，得到表面改性麻纤维；
4)将干燥的聚合物纤维与改性麻纤维开松与混合均匀，通过梳理得到复合纤维单层薄网，交叉式铺叠6～10层，针刺成毡材；
5)将毡材充满模膛，用平板硫化机将毡材加热到软化后将其转移至脱模剂均匀涂抹上下表面的金属对模中，合模时先以10m/min的速度快速合模，待阴阳模相距8～10cm时，改为以3m/min的速度合模；合模后在50～80MPa压力和175～195℃温度下保持10～20min；脱模后得到天然纤维增强聚合物基复合板材；
6)对天然纤维增强聚合物基复合板材进行加热处理，加热温度为150～300℃，处理时间5～30分钟；
7)待毡材冷却后向其喷淋吸附剂溶液，至溶液完全浸润毡材；
8)对毡材进行排风干燥处理；
9)通过抽真空的方式对毡材进行负压吸附，真空度为1～10kPa，保压5～30分钟，去除天然纤维中可释放的甲醛和乙醛。
吸附剂悬浊液配置方法如下：将所述麻纤维总质量的0.5-2wt％的纳米粘土、0.25-1wt％的分散剂、1-2wt％的硅烷偶联剂加入水中，形成浓度为10-30wt％的纳米粘土-偶联剂悬浮液；将所述纳米粘土-偶联剂悬浮液在1000-1350rpm转速下搅拌0.5-2h；将所述纳米粘土-偶联剂悬浮液在1700-2000rpm转速下搅拌1.5-3h，形成纳米粘土的偶联剂混合液。
本发明的有益效果：
本发明制备的复合板材具有环保性能好、质量轻、无甲醛乙醛释放、用途广泛。可广泛应用于汽车、船体、飞行器、建筑、家具、装饰、包装、电池封装、高压容器等领域，具有良好的应用前景。该工艺是一种低成本、环保型复合板材除甲醛乙醛处理工艺。
附图说明
图1无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材结构示意图；
图1中1-麻纤维的纤维束，2-吸附剂颗粒，3-天然纤维增强聚合物基复合毡材。
具体实施方式
实施例1
1)按黄麻纤维30wt％～70wt％，聚合物70wt％～30wt％的比例称取原料；
2)将天然麻纤维水洗除去杂质和烘干后，使用快速深冷脱胶处理方法对黄麻纤维进行脱胶处理；
3)将脱胶处理后的麻纤维在表面处理剂中浸渍30min～4h，取出后经多次水洗，置于80～100℃烘箱中干燥6～12h，得到表面改性麻纤维；
4)将干燥的聚合物纤维与改性麻纤维开松与混合均匀，通过梳理得到复合纤维单层薄网，交叉式铺叠6～10层，针刺成毡材；
5)将毡材充满模膛，用平板硫化机将毡材加热到软化后将其转移至脱模剂均匀涂抹上下表面的金属对模中，合模时先以10m/min的速度快速合模，待阴阳模相距8～10cm时，改为以3m/min的速度合模；合模后在50～80MPa压力和175～195℃温度下保持10～20min；脱模后得到天然纤维增强聚合物基复合板材；
6)对天然纤维增强聚合物基复合板材进行加热处理，加热温度为170℃，处理时间10分钟；
7)待毡材冷却后向其喷淋吸附剂溶液，至溶液完全浸润毡材；
8)对毡材进行排风干燥处理；
9)通过抽真空的方式对毡材进行负压吸附，真空度为5kPa，保压20分钟，去除天然纤维中可释放的甲醛和乙醛。
采用袋式法VOC测试方法测试，甲醛和乙醛的释放量为甲醛为0.05mg/kg，乙醛为0.07mg/kg。符合国家标准要求。
实施例2
1)按汉麻纤维30wt％～70wt％，聚合物70wt％～30wt％的比例称取原料；
2)将天然麻纤维水洗除去杂质和烘干后，使用快速深冷脱胶处理方法对汉麻纤维进行脱胶处理；
3)将脱胶处理后的麻纤维在表面处理剂中浸渍30min～4h，取出后经多次水洗，置于80～100℃烘箱中干燥6～12h，得到表面改性麻纤维；
4)将干燥的聚合物纤维与改性麻纤维开松与混合均匀，通过梳理得到复合纤维单层薄网，交叉式铺叠6～10层，针刺成毡材；
5)将毡材充满模膛，用平板硫化机将毡材加热到软化后将其转移至脱模剂均匀涂抹上下表面的金属对模中，合模时先以10m/min的速度快速合模，待阴阳模相距8～10cm时，改为以3m/min的速度合模；合模后在50～80MPa压力和175～195℃温度下保持10～20min；脱模后得到天然纤维增强聚合物基复合板材；
6)对天然纤维增强聚合物基复合板材进行加热处理，加热温度为220℃，处理时间15分钟；
7)待毡材冷却后向其喷淋吸附剂溶液，至溶液完全浸润毡材；
8)对毡材进行排风干燥处理；
9)通过抽真空的方式对毡材进行负压吸附，真空度为10kPa，保压10分钟，去除天然纤维中可释放的甲醛和乙醛。
采用袋式法VOC测试方法测试，甲醛和乙醛的释放量为甲醛为0.08mg/kg，乙醛为0.05mg/kg。符合国家标准要求。
实施例3
1)按亚麻纤维30wt％～70wt％，聚合物70wt％～30wt％的比例称取原料；
2)将天然麻纤维水洗除去杂质和烘干后，使用快速深冷脱胶处理方法对亚麻纤维进行脱胶处理；
3)将脱胶处理后的麻纤维在表面处理剂中浸渍30min～4h，取出后经多次水洗，置于80～100℃烘箱中干燥6～12h，得到表面改性麻纤维；
4)将干燥的聚合物纤维与改性麻纤维开松与混合均匀，通过梳理得到复合纤维单层薄网，交叉式铺叠6～10层，针刺成毡材；
5)将毡材充满模膛，用平板硫化机将毡材加热到软化后将其转移至脱模剂均匀涂抹上下表面的金属对模中，合模时先以10m/min的速度快速合模，待阴阳模相距8～10cm时，改为以3m/min的速度合模；合模后在50～80MPa压力和175～195℃温度下保持10～20min；脱模后得到天然纤维增强聚合物基复合板材；
6)对天然纤维增强聚合物基复合板材进行加热处理，加热温度为190℃，处理时间20分钟；
7)待毡材冷却后向其喷淋吸附剂溶液，至溶液完全浸润毡材；
8)对毡材进行排风干燥处理；
9)通过抽真空的方式对毡材进行负压吸附，真空度为8kPa，保压30分钟，去除天然纤维中可释放的甲醛和乙醛。
采用袋式法VOC测试方法测试，甲醛和乙醛的释放量为甲醛为0.05mg/kg，乙醛为0.08mg/kg。符合国家标准要求。
吸附剂悬浊液的配置方法可采用以下方式：
1、取混合纤维总质量的0.5wt％纳米蒙脱土，0.25wt％聚乙烯吡咯烷酮作为分散剂，1wt％硅烷偶联剂加入水中，制成浓度20wt％悬浮液，先用机械搅拌器在1350rpm下搅拌1h，随后在1700rpm搅拌2h，制备均匀分散的纳米粘土悬浮液。
2、取混合纤维总质量的1wt％纳米蒙脱土，0.25wt％聚乙烯吡咯烷酮作为分散剂，1.5wt％硅烷偶联剂加入水中，制成浓度20wt％的悬浮液，先用机械搅拌器在1350rpm下搅拌1h，随后在1700rpm搅拌2h，制备均匀分散的纳米粘土悬浮液。
3、取混合纤维总质量的2wt％纳米蒙脱土，1wt％聚乙烯吡咯烷酮作为分散剂，2wt％硅烷偶联剂加入水中，制成浓度20wt％的悬浮液，先用机械搅拌器在1350rpm下搅拌1h，随后在1700rpm搅拌2h，制备均匀分散的纳米粘土悬浮液。
上述实施例中的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的结构如图1所示，该板材由天然麻纤维和聚合物纤维相互混合、纤维交织并由聚合物纤维固化而成；所述的天然麻纤维的纤维束1之间空隙填充有吸附剂颗粒2。
Claims (9)
1.一种无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材，其特征在于，该板材由天然麻纤维和聚合物纤维相互混合、纤维交织并由聚合物纤维固化而成；所述的天然麻纤维的纤维束(1)之间空隙填充有吸附剂颗粒(2)，所述天然麻纤维为汉麻纤维、黄麻纤维、亚麻纤维、苎麻纤维或以上2～4种的混合物；聚合物纤维是PP、PE、PC、PA6、PA66或PLA；所述吸附剂为硅烷偶联剂改性的纳米黏土。
2.一种如权利要求1所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，具体步骤如下：
1)按天然麻纤维30wt％～70wt％，聚合物70wt％～30wt％的比例称取原料；
2)将天然麻纤维水洗除去杂质和烘干后，使用快速深冷脱胶处理方法对天然麻纤维进行脱胶处理；
3)将脱胶处理后的麻纤维在表面处理剂中浸渍30min～4h，取出后经多次水洗，置于80～100℃烘箱中干燥6～12h，得到表面改性麻纤维；
4)将干燥的聚合物纤维与改性麻纤维开松与混合均匀，通过梳理得到复合纤维单层薄网，交叉式铺叠6～10层，针刺成毡材；
5)将毡材充满模膛，用平板硫化机将毡材加热到软化后将其转移至脱模剂均匀涂抹上下表面的金属对模中，合模时先以10m/min的速度快速合模，待阴阳模相距8～10cm时，改为以3m/min的速度合模；合模后在50～80MPa压力和175～195℃温度下保持10～20min；脱模后得到天然纤维增强聚合物基复合板材；
6)对天然纤维增强聚合物基复合板材进行加热处理，加热温度为150～300℃，处理时间5～30分钟；
7)待毡材冷却后向其喷淋吸附剂溶液，至溶液完全浸润毡材；
8)对毡材进行排风干燥处理；
9)通过抽真空的方式对毡材进行负压吸附，真空度为1～10kPa，保压5～30分钟，去除天然纤维中可释放的甲醛和乙醛。
3.根据权利要求2所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，其特征在于，所述吸附剂悬浊液按照如下步骤配置：将所述麻纤维总质量的0.5-2wt％的纳米粘土、0.25-1wt％的分散剂、1-2wt％的硅烷偶联剂加入水中，形成浓度为10-30wt％的纳米粘土-偶联剂悬浮液；将所述纳米粘土-偶联剂悬浮液在1000-1350rpm转速下搅拌0.5-2h；将所述纳米粘土-偶联剂悬浮液在1700-2000rpm转速下搅拌1.5-3h，形成纳米粘土的偶联剂混合液。
4.根据权利要求3所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，其特征在于，取混合纤维总质量的0.5wt％纳米蒙脱土，0.25wt％聚乙烯吡咯烷酮作为分散剂，1wt％硅烷偶联剂加入水中，制成浓度20wt％悬浮液，先用机械搅拌器在1350rpm下搅拌1h，随后在1700rpm搅拌2h，制备均匀分散的纳米粘土悬浮液。
5.根据权利要求3所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，取混合纤维总质量的1wt％纳米蒙脱土，0.25wt％聚乙烯吡咯烷酮作为分散剂，1.5wt％硅烷偶联剂加入水中，制成浓度20wt％的悬浮液，先用机械搅拌器在1350rpm下搅拌1h，随后在1700rpm搅拌2h，制备均匀分散的纳米粘土悬浮液。
6.根据权利要求3所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，其特征在于，取混合纤维总质量的2wt％纳米蒙脱土，1wt％聚乙烯吡咯烷酮作为分散剂，2wt％硅烷偶联剂加入水中，制成浓度20wt％的悬浮液，先用机械搅拌器在1350rpm下搅拌1h，随后在1700rpm搅拌2h，制备均匀分散的纳米粘土悬浮液。
7.根据权利要求2～6中任意一项所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，其特征在于，
步骤6)对黄麻纤维增强聚合物基复合板材进行加热处理，加热温度为170℃，处理时间10分钟；以及步骤9)通过抽真空的方式对毡材进行负压吸附，真空度为5kPa，保压20分钟。
8.根据权利要求2～6中任意一项所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，其特征在于，
步骤6)对汉麻纤维增强聚合物基复合板材进行加热处理，加热温度为220℃，处理时间15分钟；以及步骤9)通过抽真空的方式对毡材进行负压吸附，真空度为10kPa，保压10分钟。
9.根据权利要求2～6中任意一项所述的无甲醛和乙醛释放的天然麻纤维增强聚合物基复合板材的制备方法，其特征在于，
步骤6)对亚麻纤维增强聚合物基复合板材进行加热处理，加热温度为190℃，处理时间20分钟；以及步骤9)通过抽真空的方式对毡材进行负压吸附，真空度为8kPa，保压30分钟。
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