CN1126658A - 具有卓越刚性的可加工片材及其制造方法 - Google Patents
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Abstract
廉价且具有良好刚性的可加工的片材不需要任何特殊设备而能被容易和安全地生产。片材包括纤维层和在纤维层的一面或两面上的多层膜。纤维层包括每个具有芯和壳结构的高度缠结的共轭纤维,芯是由高熔点热塑性树脂(B)制成的,而壳是由低熔点热塑性树脂(A)制成的。多层膜包括与低熔点热塑性树脂(A)高度相容的外层热塑性树脂(C)。通过热处理,纤维层和多层膜以及共轭纤维的接触点彼此被熔融粘接。
Description
本发明涉及可用作汽车、飞机等的内部材料的可加工片材和生产这种片材的方法。
迄今为止,人们已知多种汽车的内部材料及类似物,包括那些通过热处理由玻璃纤维和有机纤维制成的无纺织物而得到的(日本公开特许昭No.63—249754)和被固定到塑料片材上的含有粘结剂的缠结纤维体的复合片材(日本公开特许昭No.60—162628)。在应用时,这些无纺织物和复合片材经热压成型为天花板材料或门结构的内部材料。
由于在生产材料的过程中产生玻璃纤维的超细粉,含有玻璃纤维的材料涉及污染工作环境的危险。为了使纤维的所有接触点都粘结,含有粘结剂的材料也伴随着需要大量的重量上比纤维重的粘结剂的问题。另外,均匀地混合纤维和粘结剂是困难的,需要特殊的设备和费时的操作。
鉴于以上情况,本发明的目的是提供一种廉价的具有卓越刚性的可加工片材,并可在不引起任何危险或不需要任何特殊设备的情况下容易地生产出该片材。
本发明的发明人为实现本发明的目的进行了广泛研究,结果发现,通过热处理一种结构物获得可加工的片材,该结构物包括:
由具有芯和壳结构的高度缠结的共轭纤维形成的纤维层,共轭纤维的芯是由高熔点热塑性树脂(B)制成的,共轭纤维的壳是由低熔点热塑性树脂(A)制成,和
与低熔点热塑性树脂高度相容的具有外层热塑性树脂(C)的多层膜,
把多层膜放在纤维层的至少一个面上,以致共轭纤维的各接触点被熔融粘结,以及纤维层和多层膜之间彼此熔融粘结,而符合上述的指标。本发明是基于这个发现而完成的。
本发明的可加工片材包括:
纤维层和或在纤维层的一面或在纤维层的两面上的多层膜,其中
纤维层包括有芯和壳结构的高度缠结的共轭纤维,共轭纤维的芯是由高熔点热塑性树脂(B)制成的,共轭纤维的壳是由低熔点热塑性树脂(A)制成的,
多层膜包括具有与低熔点热塑性树脂高度相容的外层热塑性树脂(C),和
共轭纤维的接触点被熔融粘结,以及纤维层和多层膜之间彼此熔融粘结。
生产该片材的方法包括:
提供一个纤维层和一或两个多层膜,通过梳棉法或通过无定向成网法,首先形成具有壳/芯结构的共轭纤维的片材,然后通过针刺或射流喷网法(spun—lace method)使纤维缠结以制得纤维层,多层膜包括至少一层与作为共轭纤维的壳组分的低熔点热塑性树脂高度相容的第一热塑性树脂和至少一层熔点比第一热塑性树脂的熔点高的第二热塑性树脂;
把多层膜叠置在纤维层的一面或两面上;和
对所得的层进行热处理,热处理温度高于共轭纤维的壳组分或多层膜的第一热塑性树脂的任一熔点,但低于共轭纤维的芯组分或多层膜的第二热塑性树脂的任一熔点。
在本说明书中,所用的术语“可加工的片材”指被结合成一体的至少一种多层膜和至少一种纤维层的所有片材。
在本发明中,使用包括芯和壳的共轭纤维。各共轭纤维的壳是由低熔点热塑性树脂(A)形成的,而芯是由高熔点热塑性树脂(B)形成的。壳/芯组合的例子包括高密度聚乙烯/聚丙烯(在后面的每个实施例中,纤维组合物被解释为壳/芯材料),低密度聚乙烯/高密度聚乙烯,低熔点聚丙烯/聚丙烯,高密度聚乙烯/聚酯(PET),低熔点聚酯/聚酯,和尼龙6/尼龙66。
在本发明中,通过梳棉机或通过无定向成网法,首先形成具有壳/芯结构(A)/(B)的共轭纤维的片材而获得纤维层,然后通过针刺或射流喷网法使纤维充分地缠结。
在本发明中使用的多层膜包括两或三层薄膜。具体地讲,多层膜包括包括至少一层与作为共轭纤维的壳组分的低熔点热塑性树脂高度相容的第一热塑性树脂(C)和至少一层熔点比热塑性树脂(C)的熔点高的第二热塑性树脂(D)。当多层膜有三层薄膜时,放入的热塑性树脂(C)变成外层。
多层膜的层组合的例子包括低密度聚乙烯/高密度聚乙烯,低熔点聚丙烯/聚丙烯,低熔点聚酯/聚酯,和尼龙6/尼龙66。
通过把上述提到的多层膜叠置到上述提到的纤维层的一面或两面上,对所得的叠置的材料进行热处理而获得本发明的可加工的片材。在这个方法中,把多层膜的热塑性树脂(C)层放到纤维层上,使它们彼此接触,而热处理温度高于共轭纤维的壳组分或多层膜的热塑性树脂(C)的任一熔点,但低于共轭纤维的芯组分或多层膜的热塑性树脂(D)的任一熔点。
通过这种处理,在纤维充分缠结的纤维层的内部形成在它们的接触点熔融粘结的纤维的微细三维网络,并使纤维层与多层膜彼此熔融粘结以增强此三维网络。
通过本发明获得的可加工的片材,重量轻、刚性强,并容易进行热压加工。因此,作为汽车和飞机的内部材料是非常有用的。另外,由于本发明的可加工的片材是只由热塑性树脂制成的,因此,可以对薄片的碎片和边脚料通过切削、粉碎和熔融作为热塑性树脂原料而再次使用。
实施例1:
以1∶1的比例对含有6%乙烯和94%丙烯的无规共聚物(低熔点热塑性树脂)形成的壳组分和丙烯均聚物(高熔点热塑性树脂)形成的芯组分纺纱,制备具有15旦细度的共轭纤维(单丝)。梳理纤维并形成具有基重(每单位面积的重量)300克/平方米的片材,接着在40针/平方厘米的条件下,针刺片材以获得纤维层。
分别地,用上述提到的丙烯均聚物作为具有厚度250μm的中间层和用上述提到的无规共聚物作为具有厚度75μm的夹住中间层的上层和下层而制备具有三层结构的多层膜。把所得的多层膜叠置到纤维层的两个面上并在炉温150℃的炉中加热5分钟。然后,将热处理的材料加压并在2mm间隙的压机中冷却,获得本发明的可加工的片材。
按照JIS(K7203)测得的最大弯曲承重是1.0千克/平方厘米。因此,发现该片材具有卓越的可加工性。
数据被示于表1中。实施例2—4和比较例1—3:
用表1的纤维和膜并以与实施例1相似的方式制备各种多层片材。在比较实施例3中,没有对纤维层进行针刺。各多层片材的最大弯曲承重也被列于表1中。
表1
纤维层 多层膜
单根单丝 基重 壳组份 芯组分 厚度 外层 内层 热处理 最大弯曲承重 附注
的细度 (克/平方米) (μm) 温度
(旦) (℃) (千克/平方厘米)实施例1 15 300 LMPP PP 300 LMPP PP 150 1.0实施例2 15 500 LMPP PP 100 LMPP PP 150 0.9实施例3 15 300 LDPE PP 150 LDPE HDPE 125 0.5实施例4 15 300 LMPET PET 150 LMPET PET 140 0.6比较例1 15 300 HDPE PP 100 LMPP PP 150 0.1 A)比较例2 15 300 LMPP PP 300 PP PP 170 - B)比较例3*15 500 LMPP PP 300 LMPP PP 150 0.2 C)*):在比较例3中,没有针刺纤维层LMPP:低熔点聚丙烯 PP:聚丙烯LDPE:低密度聚乙烯 HDPE:高密度聚乙烯LMPET:低熔点聚酯 PET:聚对苯二甲酸乙二(醇)酯A):脱层B):成膜C):脱层实施例5
从实施例1获得的每一可加工的片材中切取测试样品(50厘米长×30厘米宽)。在150℃下预热测试样品,接着在压机中冲压和冷却测试样品,形成在纵向上长度为5厘米的两个头,向下弯曲60°,获得可加工材料。容易完成弯曲加工,所得的材料具有良好的形状保持性能。比较例4
使用梳棉机以与实施例1中所述的相似方式将含50%的厚度为12μm的玻璃纤维和50%的细度为6旦(单丝)的高密度聚乙烯纤维的掺混料加工成片材。在片材的上面和下面叠置具有100μm厚的高密度聚乙烯膜。如实施例1那样对所得的层状材料进行热处理和加压冷却而获得多层片材。由于玻璃纤维的突出使片材的表面粗糙,因此,它不宜接触皮肤。实施例6
在实施例1的纤维层的两个面上,叠置包括具有75μm厚的丙烯均聚物层和具有75μm厚的低熔点聚丙烯层的多层膜,为此,使低熔点聚丙烯层与纤维层相接触。按实施例1所述对所得的材料进行热处理,而获得可加工的片材。这种片材的最大弯曲承重是0.9千克/平方厘米,发现它具有卓越的可加工性。实施例7
把实施例6所用的多层膜叠置到实施例1的纤维层的一个表面上,使低熔点聚丙烯层与纤维层接触。按实施例1所述的类似方法对所得的材料进行热处理以获得可加工的片材。这种片材的最大弯曲承重为0.6千克/平方厘米,发现它具有良好的可加工性。
如上所述,本发明的可加工的片材价廉且具有良好的刚性。它可方便和安全地使用普通设备和机器如梳棉机和加热炉来制造。
Claims (2)
1.一种可加工的片材,包括纤维层和或在纤维层的一面或在纤维层的两面上的多层膜,其中:
纤维层包括每个具有芯和壳结构的高度缠结的共轭纤维,芯是由高熔点热塑性树脂(B)制成的,而壳是由低熔点热塑性树脂(A)制成的,
多层膜包括具有与低熔点热塑性树脂高度相容的外层热塑性树脂(C),和
共轭纤维的接触点熔融粘接,且纤维层和多层膜彼此间熔融粘接。
2.一种生产可加工的片材的方法,包括:
提供一个纤维层和一或两个多层膜,所述的纤维层是通过梳棉法或通过无定向成网法首先形成具有壳/芯结构的共轭纤维的片材然后通过针刺或射流喷网法使纤维缠结而制得的,而所述的多层膜包括至少一层与作为共轭纤维的壳组分的低熔点热塑性树脂高度相容的第一热塑性树脂和至少一层熔点比第一热塑性树脂的熔点高的第二热塑性树脂;
把所述的多层膜叠置在所述的纤维层的一面或两面上;和
对所得的层进行热处理,热处理温度高于共轭纤维的壳组分或多层膜的第一热塑性树脂的任一熔点,但低于共轭纤维的芯组分或多层膜的第二热塑性树脂的任一熔点。
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WO2014183233A1 (zh) * | 2013-05-17 | 2014-11-20 | Zhang Yan | 一种制作塑料托盘的方法和塑料托盘 |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US20030143366A1 (en) * | 2002-01-17 | 2003-07-31 | Jerry Foley | Polymeric and fibrous laminate and methods of forming and using same |
US6863970B2 (en) * | 2002-01-17 | 2005-03-08 | Penske Composites | Fastener retention foam sheet and associated method |
US6902694B2 (en) * | 2002-01-17 | 2005-06-07 | Penske Composites Inc. | Fastener retention foam sheet and associated methods |
ES2908846T3 (es) * | 2015-11-17 | 2022-05-04 | Marhaygue Llc | Composición estructural y método |
US20180229407A1 (en) | 2017-02-03 | 2018-08-16 | Marhaygue, Llc | Structural Composition and Method |
CN106702112A (zh) * | 2016-12-26 | 2017-05-24 | 安徽雷萨重工机械有限公司 | 一种钢坯的处理方法 |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
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US4375532A (en) * | 1980-11-03 | 1983-03-01 | Monsanto Company | Multiphase core/shell polymers |
US4950541A (en) * | 1984-08-15 | 1990-08-21 | The Dow Chemical Company | Maleic anhydride grafts of olefin polymers |
US4737404A (en) * | 1984-08-16 | 1988-04-12 | Chicopee | Fused laminated fabric |
JPH0712367B2 (ja) * | 1986-05-22 | 1995-02-15 | 花王株式会社 | 吸収性物品 |
JP2522601B2 (ja) * | 1990-11-19 | 1996-08-07 | 大和紡績株式会社 | イオン交換性ポリマ、イオン交換繊維およびその製造方法並びにイオン交換不織布 |
DE4129188A1 (de) * | 1991-09-03 | 1993-03-04 | Spinnstoffabrik Zehlendorf Ag | Schmelzfaserverklebter schichtstoff, verfahren und zwischenprodukt zu dessen herstellung und dessen verwendung |
US5466513A (en) * | 1992-12-18 | 1995-11-14 | Kimberly-Clark Corporation | Multi-layer absorbent composite |
-
1994
- 1994-08-12 JP JP21176394A patent/JP3379559B2/ja not_active Expired - Fee Related
-
1995
- 1995-08-11 CN CN95115877A patent/CN1126658A/zh active Pending
-
1997
- 1997-06-06 US US08/870,605 patent/US5804312A/en not_active Expired - Fee Related
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014183233A1 (zh) * | 2013-05-17 | 2014-11-20 | Zhang Yan | 一种制作塑料托盘的方法和塑料托盘 |
Also Published As
Publication number | Publication date |
---|---|
JPH0852830A (ja) | 1996-02-27 |
JP3379559B2 (ja) | 2003-02-24 |
US5804312A (en) | 1998-09-08 |
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