CN111559131A - 弹性体改性预交联聚乙烯复合膜层及其制备方法和应用 - Google Patents

弹性体改性预交联聚乙烯复合膜层及其制备方法和应用 Download PDF

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CN111559131A
CN111559131A CN202010240585.XA CN202010240585A CN111559131A CN 111559131 A CN111559131 A CN 111559131A CN 202010240585 A CN202010240585 A CN 202010240585A CN 111559131 A CN111559131 A CN 111559131A
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film layer
crosslinked polyethylene
elastomer
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polyethylene composite
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靳庆新
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Weft Solid Anticorrosion Resources Shanghai Co ltd
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Abstract

本发明公开了一种弹性体改性预交联聚乙烯复合膜层及其制备方法和其在自动测漏弹性体改性预交联聚乙烯防腐结构中的应用。所述弹性体改性预交联聚乙烯复合膜层包括依次复合的弹性PE膜层及纤维毡；所述弹性PE膜层的材质为包含有聚乙烯树脂的聚乙烯树脂组合物。制备方法为：将所述聚乙烯树脂组合物通过挤塑机采用T型模头挤出成型后得到的弹性PE膜层与纤维毡复合并经过挤塑机压辊，制得弹性体改性预交联聚乙烯复合膜层。本发明所涉及防腐结构层具有更加优良的防腐能力、更优良的抗热胀冷缩和机械冲击能力。

Description

弹性体改性预交联聚乙烯复合膜层及其制备方法和应用
技术领域
本发明涉及一种弹性体改性预交联聚乙烯复合膜层及其制备方法和应用，具体涉及一种自动测漏弹性体改性聚乙烯防腐防水结构，属于建筑防腐防水***技术领域。
背景技术
化工、石油、冶金、造纸、制药、环保等行业，大量的化学物质具有不同程度的腐蚀性，腐蚀会造成设备、建筑结构的破坏，以及对环境的污染。每年各种行业在防腐蚀方面的花费非常高昂，而混凝土化学池、地沟及地面等及钢结构的储槽、设备，通常采用的防腐形式为热固性树脂玻璃钢、各种涂料等。对于涂料防腐，由于刚性过大、热膨胀系数同基体差异大，容易开裂脱层，另外涂层施工时容易厚薄不均匀，容易产生针孔，且抗渗透性差，防腐能力有限，通常仅适用于轻防腐工况、且使用寿命较短；而热固性树脂玻璃钢耐腐蚀性能较好，但是由于其刚性大，固化收缩和热膨胀系数同基体差异等原因，容易同基体脱离和自身开裂，需要经常需要维修，寿命通常也只有几年。对于很多混凝土沟池、各种池漕，防腐层损坏后，不仅造成经济上的花费，很多化学介质的泄漏还会造成地下水的污染。
发明内容
本发明所要解决的技术问题是：建筑基体容易被腐蚀破坏，给地下水、地面造成污染等问题。
针对现有技术中存在的技术问题，本发明提供了一种弹性体改性预交联聚乙烯复合膜层，其特征在于，包括依次复合的弹性PE膜层及纤维毡；所述弹性PE 膜层的材质为包含有聚乙烯树脂的聚乙烯树脂组合物。
优选地，所述聚乙烯树脂组合物为乙烯均聚物与具有4～20个碳原子的α- 烯烃-乙烯共聚物。
更优选地，所述聚乙烯树脂组合物的原料包括以下以质量百分比计的组分：
聚乙烯树脂60％～95％，其熔融质量流量(MFR，ASTM D1238)优选为0.5～10g/10分钟(230℃/2.16kg)；
热塑性弹性体树脂2％～39.7％，其熔体质量流量(MFR，ASTMD1238)优选为 1～20g/10分钟(230℃/2.16kg)；
交联剂0.1％～5％，用以改善膜层抗拉伸强度；
过氧化物0～1.5％；
塑化剂0.1％～5％，用以改善树脂流动性；
紫外线保护剂0.1％～4％，用以改善功能性；
颜料0％～5％。
进一步地，所述交联剂为过氧化物交联剂、硅烷交联剂和偶氮交联剂中的任意一种或几种的组合。
优选地，所述弹性PE膜层的厚度为0.5～5mm。弹性体改性预交联聚乙烯复合膜层的厚度优选为1～3mm。
优选地，所述弹性体改性预交联聚乙烯复合膜层其中一条侧边的5～100mm部分仅包括弹性PE膜层，不包括纤维毡，以便后面的焊接施工。
优选地，所述纤维毡采用碳纤维毡，碳纤维毡由碳纤维发热线构成，且碳纤维毡内均布有PE膜层导线。该纤维毡具有导电功能。
优选地，所述纤维毡采用聚酯毡、涤纶毡或玻璃纤维毡。该纤维毡不具有导电功能。
本发明还提供了上述弹性体改性预交联聚乙烯复合膜层的制备方法，其特征在于，将所述聚乙烯树脂组合物通过挤塑机采用T型模头挤出成型后得到的弹性 PE膜层与纤维毡复合并经过挤塑机压辊，制得弹性体改性预交联聚乙烯复合膜层。
优选地，所述挤塑机的挤塑温度≤(聚乙烯树脂的熔点+35℃)，且聚乙烯树脂组合物在挤塑机中的停留时间控制在2～10min。通过上述方式对温度和时间加以控制，使其发生不充分的交联，使结构中包含了部分预交联单体，在采用热熔焊接时，高温诱导预交联单体在焊接面进一步发生交联，近而形成韧性更好，粘结更加牢固的焊接界面，从而提高了后热焊接的牢固性和可靠性。
优选地，当所述纤维毡为碳纤维毡时，复合前经过预浸液预浸处理；所述预浸液为聚乙烯醇、聚醋酸乙烯或丙烯酸。
本发明还提供了一种自动测漏弹性体改性预交联聚乙烯防腐结构，其特征在于，包括PE基层膜***，PE基层膜***采用权利要求7所述的弹性体改性预交联聚乙烯复合膜层，弹性体改性预交联聚乙烯复合膜层的碳纤维毡一侧通过粘结剂固定于基体内壁上，弹性体改性预交联聚乙烯复合膜层内的PE膜层导线，PE 膜层导线与电流交换器连接，电流交换器再依次连接电源、报警器、液体连接线、液体感应装置；使用时，所述液体感应装置置于基体内。
优选地，所述基体内壁上的凹陷处填充有修补材料。
更优选地，所述修补材料为砂浆和腻子中的至少一种。
优选地，所述粘结剂为环氧胶泥或聚氨酯沥青胶泥，优选防腐性能优异的聚氨酯沥青胶泥及具有弹性体改性后的有一定韧性的其它胶泥。
优选地，所述基体的内壁涂覆有底漆；底漆为环氧类底漆或聚氨酯底漆。
优选地，所有所述PE膜层导线并联后与电流交换器连接，此时可以实现当防腐内衬任何一处出现损坏后，渗入的液体将碳纤维层和液体连接线联通，电阻大幅度降低后，电流增强从而诱发报警器报警；或者每根PE膜层导线连接一电流交换器，每个电流交换器连接一报警器或所有电流交换器并联后连接一报警器。当采用后一种连接方式时，该***不仅具有渗漏后立即报警的功能，还有通过切换电路确认具体渗漏区位的功能。
优选地，所述PE基层膜***为整体结构的弹性体改性预交联聚乙烯复合膜层或由多片弹性体改性预交联聚乙烯复合膜层拼接而成的拼接结构，当采用拼接结构时，相邻弹性体改性预交联聚乙烯复合膜层的边缘处重叠，重叠部分的宽度 d为5～100mm。
更优选地，所述重叠部分中靠近基体一侧的弹性体改性预交联聚乙烯复合膜层仅包括弹性PE膜层。
更优选地，所述弹性体改性预交联聚乙烯复合膜层通过粘结剂固定于基体后，再采用热熔焊接机对重叠部分进行热熔焊接，然后根据需要相邻弹性体改性预交联聚乙烯复合膜层的拼接处采用热熔焊条进行补焊，将拼缝完全密封。
进一步地，所述热熔焊接的具体工艺为：将重叠部分预热5～120s后再进行热熔焊接，预热温度为聚乙烯树脂熔点至(聚乙烯树脂熔点+55℃)之间，热熔焊接的温度不小于480℃。
本发明提供了一种安全可靠的防腐结构，该防腐结构具有优秀的防腐蚀性能，能够耐受大部分酸、碱、盐及其他化学介质的腐蚀，该防腐结构还具有厚度均一、具有高韧性且具有优异的粘结性能永远不会因为温度膨胀原因而脱层，该防腐结构层还具有良好的可焊接性，接缝部位采用热焊接方式连接，形成连续整体的防腐结构。本发明能够很好的解决目前常用防腐涂层或玻璃钢内衬所存在的问题，大幅度降低维修费用及环境污染风险。传统的热熔焊接需要在焊缝外进行补焊才能保证焊接质量，而本发明可以实现一次性热熔焊即可得到高的焊接质量，省工省时。
本发明所涉及防腐结构层具有更加优良的防腐能力、更优良的抗热胀冷缩和机械冲击能力。由于改性聚乙烯防腐结构在交联过程中通过温度和时间控制，发生不充分的交联，使结构中包含了部分预交联单体，在采用热熔焊接时，高温诱导预交联单体在焊接面进一步发生交联，近而形成韧性更好，粘结更加牢固的焊接界面，从而提高了后热焊接的牢固性和可靠性。该技术解决了热塑性片材焊接面不稳定的问题，另外，本发明还通过预复合导电层解决了渗漏监控难题，是一种安全可靠、长效且可控的防腐蚀解决方案，大大降低了使用单位的防腐内衬维修改造成本，避免了因腐蚀造成地意外停机停产问题。
本发明与现有技术相比，其有益效果在于：
1)本发明主要配方的PE材料组合物采用挤塑工艺制作的PE膜层，具有极佳的抗冲击性能，柔软且延伸率极高，具有良好的抗腐蚀能力，再热焊接性能优良，极好的贴附性、易施工。
2)通过整体结构的优化，自动测漏弹性改性聚乙烯防腐结构中的PE组合物采用板材或片材挤出后同经过表面预处理的无纺布或碳纤维毡(布)一同进入压辊使两者界面融合粘结，而复合的无纺布或碳纤维毡(布)起到良好接着作用和导电监测功能。
3)由于PE材料组合物采用挤塑工艺制作时，通过温度和时间控制，时树脂发生不充分的交联，使结构中包含了部分预交联单体，在采用热熔焊接时，高温诱导预交联单体在焊接面进一步发生交联，近而形成韧性更好，粘结更加牢固的焊接界面，从而提高了后热焊接的牢固性和可靠性。
附图说明
图1为本发明提供的自动测漏弹性体改性聚乙烯防腐结构的示意图；
图2为图1中Ⅰ部分的局部放大图；
图3为图1中A-A面的剖视图；
图4为图3中Ⅱ部分的局部放大图；
图5为弹性体改性预交联聚乙烯复合膜层与其它部件的连接示意图；
图6为图5中B-B面的剖视图。
具体实施方式
为使本发明更明显易懂，兹以优选实施例，并配合附图作详细说明如下。
实施例
如图1-6所示，为本发明提供的一种自动测漏弹性体改性聚乙烯防腐结构，其包括PE基层膜***30，PE基层膜***30采用弹性体改性预交联聚乙烯复合膜层，弹性体改性预交联聚乙烯复合膜层的碳纤维毡31一侧通过粘结剂20固定于基体10内壁上，弹性体改性预交联聚乙烯复合膜层内的PE膜层导线38，PE 膜层导线38与电流交换器37连接，电流交换器37再依次连接电源36、报警器 35、液体连接线34、液体感应装置39；使用时，所述液体感应装置39置于基体 10内。
上述弹性体改性预交联聚乙烯复合膜层包括依次复合的弹性PE膜层32及碳纤维毡31，碳纤维毡31由碳纤维发热线33构成，且碳纤维毡31内均布有PE 膜层导线38；所述弹性PE膜层32的材质为包含有聚乙烯树脂的聚乙烯树脂组合物。弹性PE膜层32的厚度为2mm。弹性体改性预交联聚乙烯复合膜层的厚度为3mm。所述聚乙烯树脂组合物的原料包括以下以质量百分比计的组分：
线性低密度聚乙烯树脂80％，其熔融质量流量(MFR，ASTM D1238)为1.5g/10 分钟(230℃/2.16kg)；
聚烯烃热塑性弹性体树脂13％，其熔体质量流量(MFR，ASTMD1238)为1g/10 分钟(230℃/2.16kg)；
硅烷交联剂2％；
过氧化物0.5％；
塑化剂2％；
紫外线保护剂0.5％；
颜料(PE基色母粒)2％；
碳纤维毡克重500g/m2。
所述弹性体改性预交联聚乙烯复合膜层其中一条侧边的100mm部分仅包括弹性PE膜层32，不包括纤维毡。
上述弹性体改性预交联聚乙烯复合膜层的制备方法：
将聚乙烯树脂组合物通过挤塑机采用T型模头挤出成型后得到的弹性PE膜层32与碳纤维毡31(碳纤维毡31复合前经过预浸液预浸处理；预浸液为聚乙烯醇)复合并经过挤塑机压辊，制得弹性体改性预交联聚乙烯复合膜层。挤塑机的塑化段温度为160℃，且聚乙烯树脂组合物在挤塑机中的停留时间控制在 5min。
所述粘结剂20采用柔性聚氨酯沥青胶泥，将PE基层膜***30粘贴在基体 10，原基体11表面需要进行喷砂或打磨处理，并保证清洁干燥，对于基体凹孔较深可采用修补材料12进行修补平整，所述修补材料12为砂浆和腻子。此类砂浆产品包括纬宝水泥基基层纤维增强修补砂浆Winproof BFRM,德昊化工DH型烟囱专用修补砂浆MO-60，奥迪美RM702砂浆、RM770砂浆，粘接剂包括纬固Winff Adhensive/Membrane,Winff Adhensive/Membrane-E。所述基体10的内壁涂覆有底漆；底漆为环氧类底漆或聚氨酯底漆，此类环氧类底漆产品包括Winff EX Primer Winff CS primer,JOTUN Penguard Clear Sealer纯环氧封闭清漆,ARDEX亚地斯R3E环氧耐潮底漆，汉恭化工MIL-2001-APU。
所述PE基层膜***30为整体结构的弹性体改性预交联聚乙烯复合膜层或由多片弹性体改性预交联聚乙烯复合膜层拼接而成的拼接结构。当采用整体式结构，可根据所需用部位尺寸进行定制整体式，减少大面拼接现象。当采用拼接结构，生产不同形状、尺寸的PE基层膜，在施工中进行拼接热焊接成一整体。该 PE膜层由于复合了表面处理过的无纺布，具有同胶粘剂非常好的粘接性，无纺布可以采用聚酯、聚丙烯、玻璃纤维等结构层，当采用碳纤维毡31作为粘结层时，在碳纤维毡31内放置碳纤维发热线33，并于导线组和测漏***相连接，粘结层就具备均匀的导电功能，可作为渗漏的导电通路，并于导线组和测漏***接入实现在线监测，可通过电流变化、温度变化设置报警***。
当采用拼接结构时，相邻弹性体改性预交联聚乙烯复合膜层的边缘处重叠，重叠部分的宽度d为100mm。重叠部分中靠近基体10一侧的弹性体改性预交联聚乙烯复合膜层仅包括弹性PE膜层32。
弹性体改性预交联聚乙烯复合膜层通过粘结剂20固定于基体10后，再采用热熔焊接机对重叠部分进行热熔焊接，然后根据需要相邻弹性体改性预交联聚乙烯复合膜层的拼接处采用热熔焊条进行补焊，将拼缝完全密封。热熔焊接的具体工艺为：将重叠部分预热60s后再进行热熔焊接，预热温度为180℃，热熔焊接的温度500℃。
当采用渗漏检测***时，导线组的连接方式包含两种：
第一种连接方式为：所有PE膜层导线38并联后与电流交换器37连接。此时可以实现当防腐内衬任何一处出现损坏后，渗入的液体将碳纤维毡31和防腐槽(池)内的液体中引出的液体连接线34联通，电阻大幅度降低后，电流增强从而诱发报警器35报警。
第二种连接方式为：每根PE膜层导线38连接一电流交换器37，每个电流交换器37连接一报警器35或所有电流交换器37并联后连接一报警器35。当采用第二种连接方式时，该***不仅具有渗漏后立即报警的功能，还有通过切换电路确认具体渗漏区位的功能。
当不采用报警***，该PE基层膜***30可以作为常规防腐涂层或玻璃钢衬里的替代防腐衬里。

Claims (14)

1.一种弹性体改性预交联聚乙烯复合膜层，其特征在于，包括依次复合的弹性PE膜层(32)及纤维毡；所述弹性PE膜层(32)的材质为包含有聚乙烯树脂的聚乙烯树脂组合物。
2.如权利要求1所述的弹性体改性预交联聚乙烯复合膜层，其特征在于，所述聚乙烯树脂组合物为乙烯均聚物与具有4～20个碳原子的α-烯烃-乙烯共聚物。
3.如权利要求2所述的弹性体改性预交联聚乙烯复合膜层，其特征在于，所述聚乙烯树脂组合物的原料包括以下以质量百分比计的组分：
聚乙烯树脂60％～95％；
热塑性弹性体树脂2％～39.7％；
交联剂0.1％～5％；
过氧化物0～1.5％；
塑化剂0.1％～5％；
紫外线保护剂0.1％～4％；
颜料0％～5％。
4.如权利要求3所述的弹性体改性预交联聚乙烯复合膜层，其特征在于，所述交联剂为过氧化物交联剂、硅烷交联剂和偶氮交联剂中的任意一种或几种的组合。
5.如权利要求1所述的弹性体改性预交联聚乙烯复合膜层，其特征在于，所述弹性PE膜层(32)的厚度为0.5～5mm；所述弹性体改性预交联聚乙烯复合膜层其中一条侧边的5～100mm部分仅包括弹性PE膜层(32)，不包括纤维毡。
6.如权利要求1-5任意一项所述的弹性体改性预交联聚乙烯复合膜层，其特征在于，所述纤维毡采用碳纤维毡(31)，碳纤维毡(31)由碳纤维发热线(33)构成，且碳纤维毡(31)内均布有PE膜层导线(38)；或者所述纤维毡采用聚酯毡、涤纶毡或玻璃纤维毡。
7.权利要求1-6任意一项所述的弹性体改性预交联聚乙烯复合膜层的制备方法，其特征在于，将所述聚乙烯树脂组合物通过挤塑机采用T型模头挤出成型后得到的弹性PE膜层(32)与纤维毡复合并经过挤塑机压辊，制得弹性体改性预交联聚乙烯复合膜层。
8.如权利要求7所述的弹性体改性预交联聚乙烯复合膜层的制备方法，其特征在于，所述挤塑机的挤塑温度≤(聚乙烯树脂的熔点+35℃)，且聚乙烯树脂组合物在挤塑机中的停留时间控制在2～10min。
9.如权利要求7所述的弹性体改性预交联聚乙烯复合膜层的制备方法，其特征在于，当所述纤维毡为碳纤维毡(31)时，复合前经过预浸液预浸处理；所述预浸液为聚乙烯醇、聚醋酸乙烯或丙烯酸。
10.一种自动测漏弹性体改性预交联聚乙烯防腐结构，其特征在于，包括PE基层膜***(30)，PE基层膜***(30)采用权利要求1-6任意一项所述的弹性体改性预交联聚乙烯复合膜层，弹性体改性预交联聚乙烯复合膜层的纤维毡采用碳纤维毡(31)，碳纤维毡(31)一侧通过粘结剂(20)固定于基体(10)内壁上，弹性体改性预交联聚乙烯复合膜层内的PE膜层导线(38)，PE膜层导线(38)与电流交换器(37)连接，电流交换器(37)再依次连接电源(36)、报警器(35)、液体连接线(34)、液体感应装置(39)；使用时，所述液体感应装置(39)置于基体(10)内。
11.如权利要求10所述的自动测漏弹性体改性预交联聚乙烯防腐结构，其特征在于，所述基体(10)内壁上的凹陷处填充有修补材料(12)；所述修补材料(12)为砂浆和腻子中的至少一种；所述粘结剂(20)为环氧胶泥或聚氨酯沥青胶泥。
12.如权利要求10所述的自动测漏弹性体改性预交联聚乙烯防腐结构，其特征在于，所述基体(10)的内壁涂覆有底漆；底漆为环氧类底漆或聚氨酯底漆。
13.如权利要求10所述的自动测漏弹性体改性预交联聚乙烯防腐结构，其特征在于，所有所述PE膜层导线(38)并联后与电流交换器(37)连接；或者每根PE膜层导线(38)连接一电流交换器(37)，每个电流交换器(37)连接一报警器(35)或所有电流交换器(37)并联后连接一报警器(35)。
14.如权利要求10所述的自动测漏弹性体改性预交联聚乙烯防腐结构，其特征在于，所述PE基层膜***(30)为整体结构的弹性体改性预交联聚乙烯复合膜层或由多片弹性体改性预交联聚乙烯复合膜层拼接而成的拼接结构，当采用拼接结构时，相邻弹性体改性预交联聚乙烯复合膜层的边缘处重叠，重叠部分的宽度d为5～100mm；所述重叠部分中靠近基体(10)一侧的弹性体改性预交联聚乙烯复合膜层仅包括弹性PE膜层(32)；所述弹性体改性预交联聚乙烯复合膜层通过粘结剂(20)固定于基体(10)后，再采用热熔焊接机对重叠部分进行热熔焊接，然后根据需要相邻弹性体改性预交联聚乙烯复合膜层的拼接处采用热熔焊条进行补焊，将拼缝完全密封，所述热熔焊接的具体工艺为：将重叠部分预热5～120s后再进行热熔焊接，预热温度为聚乙烯树脂熔点至(聚乙烯树脂熔点+55℃)之间，热熔焊接的温度不小于480℃。
CN202010240585.XA 2020-03-31 2020-03-31 弹性体改性预交联聚乙烯复合膜层及其制备方法和应用 Pending CN111559131A (zh)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112265342A (zh) * 2020-09-18 2021-01-26 纬固防腐资源(上海)有限公司 一种改性阻燃热塑性复合板及其制备方法和应用
CN112477342A (zh) * 2020-11-11 2021-03-12 纬固防腐资源(上海)有限公司 一种增强导电聚合物膜层结构及其制作方法和防腐应用

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112265342A (zh) * 2020-09-18 2021-01-26 纬固防腐资源(上海)有限公司 一种改性阻燃热塑性复合板及其制备方法和应用
CN112477342A (zh) * 2020-11-11 2021-03-12 纬固防腐资源(上海)有限公司 一种增强导电聚合物膜层结构及其制作方法和防腐应用

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