CN108859325B - 超轻量化pp玻纤板的生产方法 - Google Patents
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Abstract
本申请的超轻量化PP玻纤板，采用干法工艺，以玻璃纤维、PP粉末、发泡微球为原料。首先玻璃纤维形成稀疏玻璃纤维网；稀疏玻璃纤维网通过发泡微球和PP粉末的撒布过程以及堆叠过程形成发泡微球和PP粉末均匀分布的多层玻璃纤维网；多层玻璃纤维网不进行针刺加固，加热后压制成板材。与传统干法相比，采用PP粉末代替PP纤维，可提高PP利用率，提高玻璃纤维网的成网效率，不针刺加固直接加热压制板材，可避免PP粉末和发泡微球的脱落，还可增加PP玻纤板的膨胀高度。
Description
技术领域
本发明涉及一种PP玻纤板的生产方法。
背景技术
PP玻纤板，也叫轻质GMT（Glass Mat Reinforced Thermoplastics）材料，是一种轻量化的复合材料，广泛应用于汽车内饰顶棚、衣帽架等产品上。
PP玻纤板的主要成分是PP和玻璃纤维（简称玻纤），主要有两种生产方法，分别是干法和湿法。
干法采用PP纤维和玻璃纤维为原料，通过开松、梳理、铺网、层叠、针刺制成毡，然后加热后冷压制成板材。干法工艺设备简单，投资小，生产的板材均匀性较差，加热膨胀高度略小，目前顶棚用的基材一般在1000 g/m2左右。
湿法采用PP粉末和玻璃纤维为原料，原料和助剂加入水中，借助助剂和搅拌的作用，把玻璃纤维和PP粉末均匀地分散在介质中，再通过流浆箱和成型网，滤去液体，再经过加热和冷压制成板材。湿法工艺的设备投资较大，工艺复杂，但是板材均匀性较好，加热膨胀高度大，顶棚基材可以做到800 g/m2，甚至可以更低。
超轻量化的PP玻纤板，主要特征是其中含有发泡微球，发泡微球为核壳结构，表面的壳在高温下有一定的延伸性，里面的核在高温下体积急剧膨胀，所以在高温下发泡微球的体积会增加几十倍，从而增加板材的膨胀高度，改善成型特性，实现超轻量化，顶棚基材做到800 g/m2以下，甚至600 g/m2。
超轻量化的PP玻纤板生产工艺也分为干法和湿法。湿法工艺是在传统的湿法介质中加入了发泡微球，玻璃纤维与PP粉末、发泡微球一起成网。由于发泡微球的尺寸很小，在除水过程中容易流失，比传统的湿法更难以控制。
干法工艺中又包含浸渍法和撒粉法，可参见CN106427163A和CN108068424A。浸渍法是把PP玻纤针刺毡浸渍在含有发泡微球的液体中，使发泡微球渗透到PP玻璃针刺毡中去。这种工艺有两个问题，一是PP玻纤针刺毡浸渍后除去液体非常困难，相当一部分水分只能通过加热除去，需要大量的能耗；二是发泡微球的渗透力有限，而且在除去液体的过程中，会有大量的发泡微球流失和迁移，发泡微球在PP玻纤针刺毡中的分布均匀性较差，所以产品质量和经济效果较差。
撒粉法是通过撒粉方式在多层纤网形成之前让发泡微球在其中均匀分布，然后通过针刺加固形成带有发泡微球的PP玻纤针刺毡，再经过加热之后制成板材。这种工艺与浸渍法相比，发泡微球的分布均匀性有很大改善，而且不需要昂贵的除水工艺，产品质量和经济效益都大大提高。但是，针刺加固过程中，发泡微球很容易从PP玻纤针刺毡中脱落，影响发泡微球的分布均匀性。
而且，如同CN106427163A和CN108068424A中所述，由于浸渍法和撒粉法都是使用PP纤维为原料，玻璃纤维和PP纤维为点连接，树脂用量大，成本增加，难以进一步实现材料的轻量化。
发明内容
本发明的目的就是提供一种超轻量化的PP玻纤板的生产方法，解决干法工艺采用PP纤维为原料，PP利用率低以及发泡微球分布不理想的问题。
本发明的技术方案如下：
一种超轻量化PP玻纤板的生产方法，包括如下步骤，玻璃纤维形成稀疏玻璃纤维网；稀疏玻璃纤维网通过发泡微球和PP粉末的撒布过程以及堆叠过程形成发泡微球和PP粉末均匀分布的多层玻璃纤维网；多层玻璃纤维网不进行针刺加固，加热后压制成板材。
一种优选方案，发泡微球附着在PP粉末的表面，在稀疏玻璃纤维网堆叠成多层玻璃纤维网时撒布。
一种优选方案，发泡微球嵌合在PP粉末之中，在稀疏玻璃纤维网堆叠成多层玻璃纤维网时撒布。
一种优选方案，发泡微球在稀疏玻璃纤维网上撒布，PP粉末在稀疏玻璃纤维网堆叠成多层玻璃纤维网时撒布。
一种优选方案，在PP粉末中，还含有熔点比PP粉末更低的热塑性聚合物成分。
一种优选方案，多层玻璃纤维网的加热在两层特氟龙网的夹持下进行。
一种优选方案，多层玻璃纤维网的加热在两层特氟龙带的夹持下进行。
一种优选方案，多层玻璃纤维网加热后，压制成板材前，上下表面分别加上胶膜和无纺布。
在本申请的方案中，采用干法工艺，使用PP粉末作为原料，可以减少PP材料的用量，提高PP材料的利用率，实现更好的轻量化效果。
由于PP粉末颗粒粗大，如提前撒布在稀疏玻璃纤维网上，在稀疏玻璃纤维网的运行过程中，容易脱落，所以PP粉末在稀疏玻璃纤维网堆叠成多层玻璃纤维网时进行撒布。发泡微球的颗粒直径很小，不太容易脱落，可以在稀疏玻璃纤维网形成之后的直线运行过程中进行撒布。
正常的干法工艺，一般需要通过针刺工艺来加固纤网，形成针刺毡，借助针刺毡中纤维的缠绕来实现较好的拉伸强度。加热过程中针刺毡可以不用特氟龙带或特氟龙网承托，直接借助辊子的驱动来运行。
本申请的方案中，有了PP粉末和发泡微球两种颗粒材料，在针刺过程中非常容易脱落，不适合进行针刺加固，所以多层玻璃纤维网不能形成针刺毡，就没有拉伸强度，加热过程必须在两层特氟龙带或特氟龙网的加持下进行加热。
发泡微球与PP粉末提前混合成含有发泡微球的PP粉末，可以两种粉末的撒布可以一次完成，简化生产工艺和设备。发泡微球附着在PP粉末的表面，可以通过简单的混合实现，操作起来非常简单，也可一定程度上减少发泡微球的飞散；发泡微球嵌合在PP粉末之中，需要在PP粉末的生产过程中加入发泡微球，可以更有效地解决发泡微球飞散的问题。
在PP粉末中加入比PP熔点更低的聚合物成分，可以在低于PP熔点的温度下使低熔点的聚合物先熔化，实现玻璃纤维和PP粉末、发泡微球的粘接。
特氟龙网是以玻纤或其他耐高温纤维编织成网状结构，再进行特氟龙涂覆，得到的表面带有特氟龙的耐高温网状材料。采用特氟龙网夹持，热空气可以透过特氟龙网上的孔洞进入玻璃纤维网中，加热效率高。
特氟龙带是以玻纤或其他耐高温纤维编织成比较密实的织物，再进行特氟龙涂覆，得到的表面带有特氟龙的耐高温带状材料。采用特氟龙带夹持，可避免PP粉末和发泡微球的撒落。发泡微球和PP粉末为可燃物质，撒落后有燃烧的危险。
具体实施方式
实施例1
玻璃纤维，长度38-51mm，开松后，铺成克重50-80g/m2的稀疏玻璃纤维网；在稀疏玻璃纤维网上按照玻纤克重2-10%的比例撒布发泡微球；稀疏玻璃纤维网在特氟龙网上往复堆叠成多层玻璃纤维网；PP粉末按照PP 45%、玻纤55%的比例撒布在堆叠中的稀疏玻璃纤维网上，边堆叠，边撒粉，这样每一层稀疏玻璃纤维网上都有发泡微球和PP粉末分布，在多层玻璃纤维网中均匀地混合PP粉末和发泡微球；多层玻璃纤维网随着特氟龙网按照一定的速度连续向前运行，上面被特氟龙网压住后，进入加热工序，PP粉末熔化后，上下表面分别加上50-120 g/m2的热熔胶膜和35-50 g/m2的无纺布，压制到厚度1.2-2mm，冷却后切成片材。
上述方法生产的600 g/m2片材，在195-205℃加热，可膨胀到8-12mm高度，用于生产汽车内饰顶棚。相对于1000 g/m2的不含发泡微球的干法PP玻纤板和800 g/m2的普通湿法PP玻纤板，这种克重600 g/m2左右的超轻量化的PP玻纤板，发泡微球的分布更均匀，利用效率更高，膨胀高度更大，成型性能更好，表面更平整，特别适用于轻量化要求迫切的新能源汽车。
由于PP采用粉末材料，所以玻璃纤维的成网工序中不含有PP纤维，成网效率更高。相对于PP纤维来说，PP粉末可形成更结实的连接点，可提高PP的利用效率，实现更高的玻纤含量，取得更好的轻量化效果。
在干法的超轻量化PP玻纤板中，由于经过针刺过程，形成了一些纵向穿插的玻璃纤维，板材在膨胀过程中，这些纵向穿插的玻璃纤维限制了板材的膨胀高度。采用本申请的方案，没有经过针刺过程，板材的膨胀没有纵向纤维的束缚，可以达到更大的高度，具有更好的成型特性。
实施例2
含有发泡微球的PP粉末这样准备，把发泡微球按照2-10%的比例加入到已经研磨好的PP粉末中，充分混合后，发泡微球均匀地吸附到PP粉末的表面，可以减少撒粉过程中的发泡微球的飞散，改善作业环境，也提高发泡微球的利用效率。
玻璃纤维，长度12-38mm，开松后，铺成克重30-50g/m2的单层玻璃纤维网；并在特氟龙网上往复堆叠成多层玻璃纤维网；然后含有发泡微球的PP粉末按照PP 50%玻纤50%的比例撒布在折叠中的玻璃纤维网上，使多层玻璃纤维网中均匀地混合PP粉末和发泡微球；多层玻璃纤维网随着特氟龙网向前运行，上面也被特氟龙网压住，进入加热工序，PP粉末熔化后，上下表面分别加上35-50 g/m2的无纺布和50-80 g/m2的热熔胶膜，压制到厚度1.2-2mm，冷却后切成片。
实施例3
含有发泡微球的PP粉末这样准备，把发泡微球按照2-5%的比例加入到PP颗粒中，在低温下研磨成PP粉末，这样有相当一部分发泡微球在研磨的过程中嵌合到PP粉末中，可以进一步减少撒粉过程中的粉尘，改善作业环境，也提高发泡微球的利用效率。
玻璃纤维，长度25-38mm，开松后，铺成克重30-50g/m2的单层玻璃纤维网；并在特氟龙带上往复堆叠成多层玻璃纤维网；然后按照PP 55%玻纤45%的比例撒布在折叠中的玻璃纤维网上，使多层玻璃纤维网中均匀地混合PP粉末和发泡微球；多层玻璃纤维网随着特氟龙带向前运行，上面也被特氟龙带压住，进入加热工序，PP粉末熔化后，上下表面分别加上35-50 g/m2的无纺布和50-80 g/m2的热熔胶膜，压制到厚度1.2-2mm，冷却后切成片材。
实施例4
含有2-5%发泡微球的PP粉末中，按照5-25%的比例加入PE成分，这样在PP粉末熔化之前，已经有一定的热塑性成分熔化，实现玻璃纤维和PP粉末、发泡微球的粘接。
玻璃纤维，长度50-75mm，开松后，铺成克重50-100g/m2的单层玻璃纤维网；并在特氟龙带上往复堆叠成多层玻璃纤维网；然后按照PP 50%玻纤50%的比例撒布在折叠中的玻璃纤维网上，使多层玻璃纤维网中均匀地混合PP粉末和发泡微球以及其中的PE成分；多层玻璃纤维网随着特氟龙带向前运行，上面也被特氟龙带压住，进入加热工序，首先低熔点的热塑性聚合物熔化，继续加热到PP粉末部分熔化后，上下表面分别加上35-50 g/m2的无纺布和50-80 g/m2的热熔胶膜，压制到厚度1.2-2mm，冷却后切成片材。
这里的低熔点的热塑性聚合物，除了PE，还可以是EVA、EAA等其他成分。这里的玻璃纤维，可以毫无悬念地替换成玄武岩纤维。
上述案例中，PP粉末的粒径一般在50-200um，发泡微球的粒径一般在5-15um，起发温度一般在150-210℃，玻璃纤维的直径一般在8-18um。
Claims (8)
1.一种超轻量化PP玻纤板的生产方法，其特征在于包含如下步骤，玻璃纤维形成稀疏玻璃纤维网；稀疏玻璃纤维网通过发泡微球和PP粉末的撒布过程以及堆叠过程形成发泡微球和PP粉末均匀分布的多层玻璃纤维网；多层玻璃纤维网不进行针刺加固，加热后压制成板材。
2.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，发泡微球附着在PP粉末的表面，在稀疏玻璃纤维网堆叠成多层玻璃纤维网时撒布。
3.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，发泡微球嵌合在PP粉末之中，在稀疏玻璃纤维网堆叠成多层玻璃纤维网时撒布。
4.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，发泡微球在稀疏玻璃纤维网上撒布，PP粉末在稀疏玻璃纤维网堆叠成多层玻璃纤维网时撒布。
5.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，PP粉末中还含有比PP粉末熔点更低的热塑性聚合物成分。
6.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，多层玻璃纤维网的加热在两层特氟龙网的夹持下进行。
7.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，多层玻璃纤维网的加热在两层特氟龙带的夹持下进行。
8.如权利要求1所述的超轻量化PP玻纤板的生产方法，其特征在于，多层玻璃纤维网加热后压制成板材前，上下表面分别加上胶膜和无纺布。
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