CN114589982B - 一种导热麻纤维地暖地板及其制作方法 - Google Patents

一种导热麻纤维地暖地板及其制作方法 Download PDF

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CN114589982B
CN114589982B CN202210077551.2A CN202210077551A CN114589982B CN 114589982 B CN114589982 B CN 114589982B CN 202210077551 A CN202210077551 A CN 202210077551A CN 114589982 B CN114589982 B CN 114589982B
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fibrilia
heat
layer
composite material
felt
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CN114589982A (zh
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庄理少
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JIANGYIN YANLI NEW MATERIAL TECHNOLOGY CO LTD
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JIANGYIN YANLI NEW MATERIAL TECHNOLOGY CO LTD
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Abstract

本发明公开了一种导热麻纤维地暖地板，包括依次设置的防水涂层、装饰漆层、麻纤维复合板层，所述麻纤维复合板层包括上无纺布层、麻纤维毡层和下无纺布层，所述麻纤维毡层包括导热填料改性的麻纤维树脂复合材料，按质量百分比计，所述麻纤维树脂复合材料的组分包括麻纤维60～70％、环氧树脂25～35％、导热填料3～8％。本发明还公开了一种导热麻纤维地暖地板的制作方法。先将麻纤维与环氧树脂进行复合，再在麻纤维树脂复合材料中添加导热填料，并使其均匀分散填充在麻纤维中，麻纤维树脂复合材料上的导热填料会在热流方向上形成导热网络，从而增强麻纤维在垂直于纤维方向的导热性。麻纤维板中碳纤维和芳纶纤维的加入对麻纤维板的强度起到一定的改善作用。

Description

一种导热麻纤维地暖地板及其制作方法
技术领域
本发明涉及地暖地板技术领域，具体涉及一种导热麻纤维地暖地板及其制作方法。
背景技术
近年来，传统取暖设施普遍存在的环境污染严重、能源浪费大、温度分布不均匀等缺点逐渐暴露，人们开始不满足于传统的采暖***，更符合人体舒适度的地暖逐渐映入眼帘。随着人们生活水平的提高，越来越多的家庭开始安装地暖，在地暖地板需求增加的同时，人们对地暖地板的质量也提出了更高的要求。目前，市场上应用较多的地暖地板主要是实木复合地板，其中，三层结构的实木复合地板，由三层实木交错层压形成，表层为优质硬木规格板条镶拼成，中间为软木板条，底层为旋切单板，排列呈纵横交错状。这样的结构组成使三层实木复合地板既有普通实木地板的优点，又有效地调整了木材之间的内应力，改进了木材随季节干湿度变化大的缺点。虽然实木地板脚感好，纹理、色彩自然，但也存在以下几个问题：第一，由于该地板铺设于地暖之上，长时间使用会导致实木失水从而引起开裂；第二，木制品本是白蚁等蛀虫的喜爱之物，实木地板铺设在房间一段时间后，边缘和角落会遭白蚁等蛀虫的啃咬，导致地板报废；第三，实木复合地板多是由多层结构通过粘结剂粘结而成，在使用的过程中，粘结剂会挥发出有害气体，对人体健康和环境都会造成一定的负面影响；第四，木质地板在制作和铺装时需要消耗大量原木资源，原木资源的过度消耗也会对地球生态环境造成不利影响。
麻纤维板是近年来新兴起的一种板材，主要由麻纤维和少量的化学纤维混合后，经针刺、滚压而成，因其在生产过程中不加任何化学胶粘剂，具有质轻而韧性高、阻燃、无甲醛的优势而广泛应用于家庭装饰、列车地板、汽车饰件等各个领域。虽然麻纤维板制作过程简单，绿色环保，但其导热性较差，一般用做隔热保温材料使用。地暖地板一般铺设于地暖设备之上，通过热传导和热辐射的形式将地暖设备中产生的热量传递到地板表面并辐射于整个房间内，如果地暖地板不导热，热量则无法传递。因此，为了促进麻纤维板在地暖地板方面的应用，改善麻纤维板的导热性，尤其是改善麻纤维板垂直麻纤维方向的导热性势在必行。
发明内容
本发明的目的在于克服现有技术中存在的缺陷，采用麻纤维为主要原料，将其与环氧树脂复合，并对其进行导热改性，再将其与丙纶纤维、碳纤维、芳纶纤维一起混合制作麻纤维毡，在麻纤维毡的上下表面分别设置上下无纺布层，并采用针刺复合的方式将其连接。环氧树脂作为中间材料，一方面可以使导热填料能更好的与麻纤维复合，增加了麻纤维板的导热性，另一方面也增加了整个复合板的强度。由于在地暖地板制作的过程中不添加任何胶黏剂，不会产生大量的有害气体污染环境和威胁人类健康。使用针刺复合的方式将无纺布预先固定在麻纤维毡上，然后将整个复合毡滚压成型，可使得麻纤维复合板更加坚固，在使用的过程中不会出现分层的现象。
为实现上述目的，本发明的技术方案是提供了一种导热麻纤维地暖地板，其特征在于，包括依次设置的防水涂层、装饰漆层、麻纤维复合板层，所述麻纤维复合板层包括上无纺布层、麻纤维毡层和下无纺布层，所述麻纤维毡层包括导热填料改性的麻纤维树脂复合材料，按质量百分比计，所述麻纤维树脂复合材料的组分包括麻纤维 60~70%、环氧树脂25~35%、导热填料 3~8%。
进一步优选的技术方案为，所述导热填料为碳基导热填料，包括碳纳米管、石墨烯、纳米金刚石、石墨、碳化硅、碳纤维、碳化硼中的任意一种或几种。
进一步优选的技术方案为，按质量百分比计，所述麻纤维毡的成分包括麻纤维树脂复合材料 45~55%、丙纶纤维 20~35%、碳纤维 8~15%、芳纶纤维 5~12%。
本发明的技术方案还提供了一种导热麻纤维地暖地板的制作方法，其特征在于，包括以下步骤：
（1）麻纤维预处理：先将麻纤维放入NaOH溶液中浸泡30min，取出并清洗2~3次，将烘干后的麻纤维放入硅烷偶联剂中，在超声环境下处理40~60min，取出，并在100~120℃的条件下进行烘干处理；
（2）麻纤维与环氧树脂复合：将预处理后的麻纤维放入含有环氧树脂的浸润槽中，充分浸润后取出待用；
（3）麻纤维树脂复合材料改性：将麻纤维树脂复合材料、导热填和有机溶剂一起加入到高速混合机中，加热混合均匀，取出烘干；
（4）麻纤维毡的制备：将麻纤维树脂复合材料、丙纶纤维、碳纤维、芳纶纤维进行混合梳理，通过气流成网机成网，并经过预针刺、主针刺步骤制作成麻纤维毡；
（5）麻纤维复合板的制作：分别制作上下无纺布半成品，并将其与麻纤维毡的上表面和下表面贴合，再分别对上无纺布面和下无纺布面进行单向针刺，将针刺固定的复合毡依次输送到烘烤设备和滚压机中进行烘烤和滚压成型；
（6）涂层制作：用滚涂机在麻纤维复合板上依次涂布装饰漆层和防水涂层，并对每一涂层进行烘干处理。
进一步优选的技术方案为，所述麻纤维树脂复合材料改性步骤还包括对导热填料进行预处理的步骤，所述预处理剂为质量分数为2%的硅烷偶联剂。
进一步优选的技术方案为，在所述麻纤维预处理步骤中，所述NaOH的质量分数为3~5%，所述硅烷偶联剂的质量分数为1.5~3%。
进一步优选的技术方案为，在所述麻纤维树脂复合材料改性步骤中，混合时加热温度为60~80℃，搅拌转速为220~350r/min，搅拌时间为120~150s
进一步优选的技术方案为，在所述麻纤维复合板的制作步骤中，所述单向针刺的针刺深度大于无纺布的厚度并小于无纺布和麻纤维毡的厚度之和。
进一步优选的技术方案为，在所述麻纤维复合板的滚压成型步骤中，烘烤温度为180~200℃，烘烤时间为5~8min。
地暖地板一般用于铺设在地暖设备之上作为房间的地板使用，传统的实木地板因长时间使用后会出现开裂、白蚁啃食等现象，使用寿命较短，另一方面，实木地板多是由不同板材通过粘结剂粘结形成的多层结构，在使用的过程中，粘结剂会挥发出有害气体，对人体健康和环境都会造成一定的负面影响，木质地板在制作和铺装时对原木资源的过度消耗也会对地球生态环境造成不利影响。麻纤维板是近年来新兴起的一种板材，主要由麻纤维和少量的化学纤维混合后，经针刺、热烘、滚压而成，因其在生产过程中不加任何化学胶粘剂，具有质轻而韧性高、阻燃、无甲醛的优势。然而，麻纤维是一种不导热的材料，一般用于隔热和保温要求较高的场所，如汽车内车厢饰件等。而对于地暖地板来说，一般要求地板的导热性较好，尤其是在垂直于地板的方向，以保证地暖设备产生的热量能够通过地板导出并向房间内部辐射。
为了改善麻纤维板的导热性，使其能成功应用于地暖地板领域，本发明的技术方案是对麻纤维进行导热改性，并与其他纤维一起混合制作麻纤维板。在对麻纤维进行导热改性时，由于麻纤维表面较为光滑，麻纤维本身非粘性，不容易与一些导热材料进行复合，因此，本发明的技术方案是先将麻纤维与环氧树脂进行复合，再在麻纤维树脂复合材料中添加导热填料，使其均匀分散填充在麻纤维中，以增强麻纤维在垂直于纤维方向上的导热性。改性后的麻纤维在与丙纶纤维、芳纶纤维、碳纤维进行混合并被制作成麻纤维板后，麻纤维树脂复合材料上的导热填料会在热流方向上形成导热网络，导热网络***可简单的视为“并联电路”，麻纤维和导热填料可以看作为两个电阻，当填料较多时，由于填料具有更好的导热性，麻纤维树脂复合材料的导热性能也随即有了长足的提升。
本发明的麻纤维地暖地板中，麻纤维毡中除了常用的麻纤维、丙纶纤维之外，还有碳纤维和芳纶纤维，由于碳纤维自身含有导热性能，碳纤维的加入对整个纤维板的导热性能的提升起到积极的作用，碳纤维和芳纶纤维的加入也有助于整个纤维板的强度和机械性能的提升。
本发明的技术方案在制作麻纤维树脂复合材料之前，先对麻纤维进行预处理，采用NaOH溶液对其预处理的主要目的是去除纤维表面的杂质以及部分多余的木质素组织，之后用硅烷偶联剂对麻纤维表面进行改性处理，修复纤维表面缺陷，增强麻纤维的界面强度，以便于麻纤维与树脂之间的紧密结合。将麻纤维进行表面处理后，将其放入环氧树脂处理液中进行浸润，使得环氧树脂能均匀涂覆于麻纤维的表面，再将其与导热填料进行混合，最后将混合均匀的麻纤维进行烘干处理即得麻纤维树脂复合材料。在进一步的技术方案中，在导热填料与麻纤维复合材料进行混合之前，先对导热填料进行预处理，以除去填料表面的杂质，并促进填料与麻纤维复合材料的均匀混合。
在制作麻纤维复合板时，本发明的技术方案是，先制作上下无纺布半成品和麻纤维毡，然后将上下无纺布半成品分别与麻纤维毡的上下表面贴合，采用针刺机对其进行单面针刺，使得无纺布和麻纤维预先复合在一起，然后再放进烘烤设备和滚压设备中滚压成型，麻纤维毡中的丙纶纤维在受热后融化，冷却后又凝固，可使得麻纤维和其他纤维紧紧粘合在一起，界面处的丙纶纤维受热后也可将无纺布与麻纤维紧密粘结，在针刺预固定后，无纺布层与麻纤维层之间结合紧密，即使地板长时间在较热的条件下使用，也不容易出现分层的现象。
本发明的优点和有益效果在于：
1、先将麻纤维与环氧树脂进行复合，再在麻纤维树脂复合材料中添加导热填料，并使其均匀分散填充在麻纤维中，麻纤维树脂复合材料上的导热填料会在热流方向上形成导热网络，从而增强麻纤维在垂直于纤维方向的导热性。
2、麻纤维板中碳纤维和芳纶纤维的加入对麻纤维板的强度和力学性能起到一定的改善作用，碳纤维的加入也能增加整个麻纤维板的导热性能。
3、麻纤维的预处理可除去麻纤维表面的杂质，活化麻纤维表面，使得麻纤维与树脂材料以及导热填料之间的结合更为紧密。
4、在制作麻纤维复合板时，先制作麻纤维毡和无纺布半成品，将无纺布半成品和麻纤维毡通过针刺预固定，然后再进行热烘滚压复合，上下无纺布的存在可使得麻纤维板在滚压复合时形变量小，针刺预固定可进一步加强无纺布层与麻纤维层之间的粘结，使得麻纤维板在作为地暖地板使用时不容易出现层与层分离的现象。
具体实施方式
下面结合实施例，对本发明的具体实施方式作进一步描述。以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。
实施例1
一种导热麻纤维地暖地板，包括依次设置的防水涂层、装饰漆层、麻纤维复合板层，麻纤维复合板层包括上无纺布层、麻纤维毡层和下无纺布层，上下无纺布层与麻纤维毡层之间通过针刺固定连接在一起，按质量百分比计，麻纤维毡层包括麻纤维树脂复合材料45%、丙纶纤维 35%、碳纤维 8%、芳纶纤维 12%，麻纤维树脂复合材料包括麻纤维 60%、环氧树脂 32%、石墨 8%。
一种导热麻纤维地暖地板的制作方法，包括以下步骤：
（1）麻纤维预处理：先将麻纤维放入质量分数为3%的NaOH溶液中浸泡30min，取出并清洗2次，将烘干后的麻纤维放入质量分数为1.5%的硅烷偶联剂中，在超声环境下处理40min，取出，并在100℃的条件下进行烘干处理；
（2）麻纤维与环氧树脂复合：将预处理后的麻纤维放入含有环氧树脂的浸润槽中，充分浸润后取出待用；
（3）麻纤维树脂复合材料改性：将麻纤维树脂复合材料、导热填和有机溶剂一起加入到高速混合机中，加热混合均匀，取出烘干，混合时加热温度为60℃，搅拌转速为350r/min，搅拌时间为120s；
（4）麻纤维毡的制备：将麻纤维树脂复合材料、丙纶纤维、碳纤维、芳纶纤维进行混合梳理，通过气流成网机成网，并经过预针刺、主针刺步骤制作成麻纤维毡；
（5）麻纤维复合板的制作：分别制作上下无纺布半成品，并将其与麻纤维毡的上表面和下表面贴合，再分别对上无纺布面和下无纺布面进行单向针刺，将针刺固定的复合毡依次输送到烘烤设备和滚压机中进行烘烤和滚压成型，烘烤温度为180℃，烘烤时间为8min；
（6）涂层制作：用滚涂机在麻纤维复合板上依次涂布装饰漆层和防水涂层，并对每一涂层进行烘干处理。
实施例2
一种导热麻纤维地暖地板，包括依次设置的防水涂层、装饰漆层、麻纤维复合板层，麻纤维复合板层包括上无纺布层、麻纤维毡层和下无纺布层，上下无纺布层与麻纤维毡层之间通过针刺固定连接在一起，按质量百分比计，麻纤维毡层包括麻纤维树脂复合材料50%、丙纶纤维 30%、碳纤维 15%、芳纶纤维 5%，麻纤维树脂复合材料包括麻纤维 62%、环氧树脂 35%、碳纳米管 3%。
一种导热麻纤维地暖地板的制作方法，包括以下步骤：
（1）麻纤维预处理：先将麻纤维放入质量分数为4%的NaOH溶液中浸泡30min，取出并清洗3次，将烘干后的麻纤维放入质量分数为2%的硅烷偶联剂中，在超声环境下处理50min，取出，并在110℃的条件下进行烘干处理；
（2）麻纤维与环氧树脂复合：将预处理后的麻纤维放入含有环氧树脂的浸润槽中，充分浸润后取出待用；
（3）麻纤维树脂复合材料改性：将导热填料放入质量分数为2%的硅烷偶联剂中混合搅拌10min后取出，将麻纤维树脂复合材料、导热填料和有机溶剂一起加入到高速混合机中，加热混合均匀，取出烘干，混合时加热温度为80℃，搅拌转速为280r/min，搅拌时间为150s；
（4）麻纤维毡的制备：将麻纤维树脂复合材料、丙纶纤维、碳纤维、芳纶纤维进行混合梳理，通过气流成网机成网，并经过预针刺、主针刺步骤制作成麻纤维毡；
（5）麻纤维复合板的制作：分别制作上下无纺布半成品，并将其与麻纤维毡的上表面和下表面贴合，再分别对上无纺布面和下无纺布面进行单向针刺，将针刺固定的复合毡依次输送到烘烤设备和滚压机中进行烘烤和滚压成型，烘烤温度为180℃，烘烤时间为6min；
（6）涂层制作：用滚涂机在麻纤维复合板上依次涂布装饰漆层和防水涂层，并对每一涂层进行烘干处理。
实施例3
一种导热麻纤维地暖地板，包括依次设置的防水涂层、装饰漆层、麻纤维复合板层，麻纤维复合板层包括上无纺布层、麻纤维毡层和下无纺布层，上下无纺布层与麻纤维毡层之间通过针刺固定连接在一起，按质量百分比计，麻纤维毡层包括麻纤维树脂复合材料55%、丙纶纤维 20%、碳纤维 15%、芳纶纤维 10%，麻纤维树脂复合材料包括麻纤维 70%、环氧树脂 25%、石墨烯 5%。
一种导热麻纤维地暖地板的制作方法，包括以下步骤：
（1）麻纤维预处理：先将麻纤维放入质量分数为5%的NaOH溶液中浸泡30min，取出并清洗3次，将烘干后的麻纤维放入质量分数为3%的硅烷偶联剂中，在超声环境下处理60min，取出，并在100℃的条件下进行烘干处理；
（2）麻纤维与环氧树脂复合：将预处理后的麻纤维放入含有环氧树脂的浸润槽中，充分浸润后取出待用；
（3）麻纤维树脂复合材料改性：将导热填料放入质量分数为2%的硅烷偶联剂中混合搅拌15min后取出，将麻纤维树脂复合材料、导热填料和有机溶剂一起加入到高速混合机中，加热混合均匀，取出烘干，混合时加热温度为80℃，搅拌转速为220r/min，搅拌时间为150s；
（4）麻纤维毡的制备：将麻纤维树脂复合材料、丙纶纤维、碳纤维、芳纶纤维进行混合梳理，通过气流成网机成网，并经过预针刺、主针刺步骤制作成麻纤维毡；
（5）麻纤维复合板的制作：分别制作上下无纺布半成品，并将其与麻纤维毡的上表面和下表面贴合，再分别对上无纺布面和下无纺布面进行单向针刺，将针刺固定的复合毡依次输送到烘烤设备和滚压机中进行烘烤和滚压成型，烘烤温度为200℃，烘烤时间为5min；
（6）涂层制作：用滚涂机在麻纤维复合板上依次涂布装饰漆层和防水涂层，并对每一涂层进行烘干处理。
对比例
取常规工艺制作的含麻纤维 65%和丙纶纤维 35%的麻纤维板，麻纤维板的上下表面设置有无纺布层，并在上无纺布层表面制作装饰漆层和防水涂层。
取实施例1-3和对比例中的麻纤维地暖地板，并对其进行拉伸强度、弯曲强度以及导热系数的测试，测试结果见下表。
从上表结果可以看出，采用本发明的技术方案制作出的麻纤维地暖地板具有较好的导热性能，树脂与麻纤维的复合有助于增强麻纤维板的强度，然而，导热填料的加入会导致麻纤维板在受力时应力集中，导致最终的麻纤维板的强度较常规麻纤维板的强度变化不大。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (8)

1.一种导热麻纤维地暖地板，其特征在于，包括依次设置的防水涂层、装饰漆层、麻纤维复合板层，所述麻纤维复合板层包括上无纺布层、麻纤维毡层和下无纺布层，按质量百分比计，所述麻纤维毡的成分包括麻纤维树脂复合材料45~55%、丙纶纤维20~35%、碳纤维8~15%、芳纶纤维5~12%，所述麻纤维树脂复合材料的组分包括麻纤维60~70%、环氧树脂25~35%、导热填料3~8%。
2.根据权利要求1所述的地暖地板，其特征在于，所述导热填料为碳基导热填料，包括碳纳米管、石墨烯、纳米金刚石、石墨、碳化硅、碳纤维、碳化硼中的任意一种或几种。
3.一种根据权利要求2所述的地暖地板的制作方法，其特征在于，包括以下步骤：
（1）麻纤维预处理：先将麻纤维放入NaOH溶液中浸泡30min，取出并清洗2~3次，将烘干后的麻纤维放入硅烷偶联剂中，在超声环境下处理40~60min，取出，并在100~120℃的条件下进行烘干处理；
（2）麻纤维与环氧树脂复合：将预处理后的麻纤维放入含有环氧树脂的浸润槽中，充分浸润后取出待用；
（3）麻纤维树脂复合材料改性：将麻纤维树脂复合材料、导热填和有机溶剂一起加入到高速混合机中，加热混合均匀，取出烘干；
（4）麻纤维毡的制备：将麻纤维树脂复合材料、丙纶纤维、碳纤维、芳纶纤维进行混合梳理，通过气流成网机成网，并经过预针刺、主针刺步骤制作成麻纤维毡；
（5）麻纤维复合板的制作：分别制作上下无纺布半成品，并将其与麻纤维毡的上表面和下表面贴合，再分别对上无纺布面和下无纺布面进行单向针刺，将针刺固定的复合毡依次输送到烘烤设备和滚压机中进行烘烤和滚压成型；
（6）涂层制作：用滚涂机在麻纤维复合板上依次涂布装饰漆层和防水涂层，并对每一涂层进行烘干处理。
4.根据权利要求3所述的制作方法，其特征在于，所述麻纤维树脂复合材料改性步骤还包括对导热填料进行预处理的步骤，所述预处理剂为质量分数为2%的硅烷偶联剂。
5.根据权利要求3或4所述的制作方法，其特征在于，在所述麻纤维预处理步骤中，所述NaOH的质量分数为3~5%，所述硅烷偶联剂的质量分数为1.5~3%。
6.根据权利要求3或4所述的制作方法，其特征在于，在所述麻纤维树脂复合材料改性步骤中，混合时加热温度为60~80℃，搅拌转速为220~350r/min，搅拌时间为120~150s。
7.根据权利要求3或4所述的制作方法，其特征在于，在所述麻纤维复合板的制作步骤中，所述单向针刺的针刺深度大于无纺布的厚度并小于无纺布和麻纤维毡的厚度之和。
8.根据权利要求3或4所述的制作方法，其特征在于，在所述麻纤维复合板的滚压成型步骤中，烘烤温度为180~200℃，烘烤时间为5~8min。
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