CN101065526A - 含天然纤维的复合热塑性片材 - Google Patents

含天然纤维的复合热塑性片材 Download PDF

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CN101065526A
CN101065526A CNA2005800405219A CN200580040521A CN101065526A CN 101065526 A CN101065526 A CN 101065526A CN A2005800405219 A CNA2005800405219 A CN A2005800405219A CN 200580040521 A CN200580040521 A CN 200580040521A CN 101065526 A CN101065526 A CN 101065526A
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CN101065526B (zh
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D·S·伍德曼
V·拉盖文德兰
J·J·麦克休
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Abstract

在例举的实施方案中，复合片材材料包括多孔芯，所述多孔芯包括至少一种热塑性材料，和基于多孔芯的总重量，约20wt％－约80wt％的天然纤维。该天然纤维包括洋麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、纤维素纤维、剑麻纤维和椰纤维中的至少一种。

Description

含天然纤维的复合热塑性片材
技术领域
本发明一般地涉及多孔纤维增强的热塑性聚合物片材，和更特别地涉及含天然纤维的多孔纤维增强的热塑性聚合物片材。
背景技术
在美国专利Nos.4978489和4670331中公开了多孔纤维增强的热塑性片材，并在产品制造工业中在许多和各种应用中使用，这是因为纤维增强的热塑性片材容易模塑成制品。已知的技术，例如热冲压、压塑和热成形成功地用于由纤维增强的热塑性片材形成制品。
多孔纤维增强的热塑性片材有时形成为装饰性内部面板以供在机动车内部、公共交通车辆和建筑物，其中包括商业建筑物和私人建筑物中使用。一旦在其有效寿命终止时，这些装饰性面板的焚烧是不实际的，这是因为存在玻璃纤维增强。
发明内容
一方面，提供复合片材材料。该复合片材材料包括可渗透的芯，所述可渗透的芯包括用热塑性树脂粘结在一起的不连续的天然纤维。可渗透的芯的密度为约0.1gm/cc-约1.8gm/cc，且包括表面区域。
另一方面，提供含多孔芯的复合片材材料。多孔芯包括至少一种热塑性材料，和基于多孔芯的总重量，约20wt％-约80wt％的天然纤维。天然纤维包括至少一种洋麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、纤维素纤维、剑麻纤维和椰纤维。
另一方面，提供制造多孔天然纤维增强的热塑性片材的方法。该方法包括添加平均长度为约5mm-约50mm的天然纤维，和热塑性树脂粉末颗粒到搅拌的含水泡沫体中，形成分散的混合物，将天然纤维和热塑性树脂颗粒的分散混合物层铺在线网上，抽空水，形成网幅(web)，加热网幅到高于热塑性树脂的玻璃化转变温度，并压制该网幅成预定的厚度，形成孔隙含量为复合片材体积的约1％-约95％的多孔热塑性复合片材。
附图说明
图1是根据本发明实施方案的复合塑料片材的截面示意图。
具体实施方式
以下详细地描述含有天然纤维作为增强的多孔复合热塑性片材。天然纤维选自在含水泡沫体中提供良好分散和排放特性的各种变体。与具有例如玻璃纤维增强的复合片材相比，天然纤维增强提供环境保护优势，例如在有效寿命终止时清洁的焚烧，和再循环的可能性。与玻璃纤维相比，天然纤维增强还提供重量减少。
参考附图，图1是例举的复合热塑性片材10的截面示意图，它包括具有第一表面14和第二表面16的多孔芯12。装饰性表层18粘结到第一表面14上。在替代的实施方案中，表层和/或阻挡层粘结到第二表面16上。
芯12由开孔结构组成的网幅形成，所述开孔结构通过无规交叉由一种或更多种热塑性树脂至少部分保持在一起的增强的天然纤维形成，其中多孔芯12的孔隙含量范围一般地介于芯12的总体积的约1％至约95％，和尤其介于约30％至约80％。在另一实施方案中，多孔芯12由开孔结构制成，所述开孔结构通过无规交叉由一种或更多种热塑性树脂至少部分保持在一起的增强纤维形成，其中孔结构中约40％-约100％是开孔并允许空气和气体流过其中。在一个实施方案中，芯12的密度为约0.1gm/cc-约1.8gm/cc，和在另一实施方案中，为约0.3gm/cc-约1.0gm/cc。使用已知的制造工艺，例如湿法成网工艺、气流成网工艺、干混工艺、精梳和针织工艺，和制造非织造产品所使用的其它已知工艺，形成芯12。这些制造工艺的结合也是有用的。
芯12包括约20％-约80wt％平均长度为约5mm至约50mm的天然纤维，和约20％-约80wt％全部或者基本上未凝固的纤维或者粒状热塑性材料，其中重量百分数以芯12的总重量为基础。在另一实施方案中，芯12包括约30％-约55wt％的天然纤维。在另一实施方案中，芯12包括平均长度为约5mm至约25mm的天然纤维。合适的天然纤维包括，但不限于，洋麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、纤维素纤维、剑麻纤维、椰纤维及其混合物。
在例举的实施方案中，平均长度为约5mm-约50mm的天然纤维与热塑性粉末颗粒，例如聚丙烯粉末一起添加到可含有表面活性剂的搅拌的含水泡沫体中。搅拌各组分充足的时间，形成天然纤维和热塑性粉末在含水泡沫体中的分散混合物。然后在任何合适的载体结构，例如线网上层铺分散的混合物，然后通过形成网幅的线网抽空水。干燥网幅，并加热到高于热塑性粉末的软化温度。然后冷却网幅并挤压成预定厚度，产生孔隙含量为约1％-约95％的复合片材。在替代的实施方案中，含水泡沫体还包括粘合剂材料。
加热网幅到高于芯12上的热塑性树脂的软化温度，基本上软化塑料材料，并穿过一个或更多个凝固装置，例如压延辊、复带式层压器(double belt laminator)、转位压机(indexing press)、multipledaylight press、热压罐，和层压并凝固片材与织物，以便塑料材料可流动并润湿纤维所使用的其它这种装置。设定凝固装置内凝固元件之间的间隙为小于未凝固网幅的尺寸并大于若它充分凝固时的网幅的尺寸，从而允许网幅膨胀并在穿过辊之后保持基本上可渗透。在一个实施方案中，设定间隙为比若它充分凝固时网幅的尺寸大约5％-约10％的尺寸。充分凝固的网幅是指充分压缩且基本上不含孔隙的网幅。充分凝固的网幅具有小于5％的孔隙含量，且具有可忽略不计的开孔结构。
在另一实施方案中，芯12也可包括最多约10％的无机纤维以供增加的硬挺度和或改进的蓬松度。无机纤维可包括例如金属纤维、金属化的无机纤维、金属化的合成纤维、玻璃纤维、石墨纤维、碳纤维、陶瓷纤维、矿物纤维、玄武岩纤维、无机纤维、芳族聚酰胺纤维及其混合物。
粒状塑料材料包括为在制造过程中提高网幅结构的内聚性而可以包括的短塑料纤维。通过利用网幅结构内塑料材料的热特性，进行粘结。充分地加热网幅结构，引起热塑性组分在其与相邻颗粒和纤维的表面处熔融。
在一个实施方案中，单独的增强纤维不应当平均短于约5mm，这是因为较短的纤维在最终的模塑制品内通常没有提供充足的增强。此外，纤维不应当平均长于约50mm，这是因为这种纤维难以在制造工艺中处理。
在一个实施方案中，为了赋予结构强度，天然纤维的平均直径为约7至约22微米。直径小于约7微米的纤维可容易地变为气载，且可引起环境健康和安全问题。直径大于约22微米的纤维难以在制造工艺中处理，且在模塑之后，没有有效地增强塑性基体。
在一个实施方案中，热塑性材料至少部分为粒状形式。合适的热塑性材料包括，但不限于，聚烯烃，其中包括聚亚甲基、聚乙烯和聚丙烯、聚苯乙烯、丙烯腈基苯乙烯、丁二烯、聚酯，其中包括聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯和聚对苯二甲酸丙二酯、polybutyleneterachlorate和聚氯乙烯(增塑和未增塑的)、丙烯酸类，其中包括聚甲基丙烯酸甲酯，和这些材料彼此或者与其它聚合物材料的共混物。其它合适的热塑性材料包括，但不限于，聚芳醚、丙烯腈-丙烯酸丁酯-苯乙烯聚合物、无定形尼龙，以及这些材料彼此或者与其它聚合物材料的合金和共混物。认为可使用没有受到水化学进攻且可通过加热充分地软化，以提供熔融和/或模塑且没有化学或者热分解的任何热塑性树脂。
热塑性颗粒不需要过细，但糙于约1.5mm的颗粒是令人不满意的，因为它们在模塑工艺过程中没有充分地流动，以产生均匀结构。使用较大颗粒可导致当凝固时材料的弯曲模量下降。
含有如上所述的天然纤维作为增强的多孔复合热塑性片材可用于，但不限于，建筑结构、机动车headliner、门的模件、侧壁面板、天花板面板、货物衬里、办公室隔档，和目前用聚氨酯泡沫体、聚酯纤维填充的多层复合材料和热塑性片材制造的其它这种器具。可使用本领域已知的方法，例如压力成形、热成形、热冲压、真空成形、压缩成形和热压罐，模塑含有天然纤维作为增强的多孔复合热塑性片材。与具有例如玻璃纤维增强剂的复合片材相比，天然纤维增强具有环境优势，例如在有效寿命终止时清洁的焚烧，和再循环的可能性。与玻璃纤维相比，天然纤维增强还提供重量下降。
尽管用各种具体的实施方案描述了本发明，但本领域的技术人员要意识到可在权利要求的精神和范围内，对本发明进行改变。

Claims (26)

1.一种复合片材材料，包括：
可渗透的芯，所述可渗透的芯包括用热塑性树脂粘结在一起的不连续的天然纤维，所述可渗透的芯的密度为约0.1gm/cc-约1.8gm/cc，所述可渗透的芯包括表面区域。
2.权利要求1的复合片材材料，其中所述天然纤维包括洋麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、纤维素纤维、剑麻纤维和椰纤维中的至少一种。
3.权利要求1的复合片材材料，其中所述可渗透的芯具有孔隙含量为所述可渗透的芯的总体积的约1％-约95％的开孔结构。
4.权利要求1的复合片材材料，其中所述可渗透的芯包括选自聚烯烃、聚苯乙烯、丙烯腈基苯乙烯、丁二烯、聚酯、polybutyleneterachlorate、聚氯乙烯、聚苯醚、聚碳酸酯、聚酯碳酸酯、丙烯腈-丙烯酸丁酯-苯乙烯聚合物、无定形尼龙及其混合物中的热塑性树脂。
5.权利要求1的复合片材材料，其中所述芯包括约20-约80wt％的所述天然纤维和约20-约80wt％的所述热塑性树脂。
6.权利要求1的复合片材材料，其中所述芯包括约35-约55wt％的所述天然纤维和约45-约65wt％的所述热塑性树脂。
7.权利要求1的复合片材材料，其厚度为约0.5mm-约50mm。
8.权利要求1的复合片材材料，进一步包括与所述表面区域相邻的粘合层。
9.权利要求8的复合片材材料，其中所述粘合层的厚度为约25微米-约2.5mm。
10.权利要求8的复合片材材料，其中所述相邻的粘合层包括热塑性膜、弹性膜、金属箔、热固性涂层、无机涂层、纤维基稀松布、非织造织物和织造织物中的至少一种。
11.权利要求2的复合片材材料，其中所述可渗透的芯进一步包括金属纤维、金属化的无机纤维、金属化的合成纤维、玻璃纤维、石墨纤维、碳纤维、陶瓷纤维、玄武岩纤维、无机纤维和芳族聚酰胺纤维中的至少一种。
12.一种复合片材材料，包括：
含至少一种热塑性材料和天然纤维的多孔芯，所述天然纤维基于所述多孔芯层的总重量计为约20wt％-约80wt％，所述天然纤维包括洋麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、纤维素纤维、剑麻纤维和椰纤维中的至少一种。
13.权利要求12的复合片材材料，其中所述多孔芯具有孔隙含量为所述多孔芯的总体积的约1％-约95％的开孔结构。
14.权利要求12的复合片材材料，其中所述多孔芯包括选自聚烯烃、聚苯乙烯、丙烯腈基苯乙烯、丁二烯、聚酯、polybutyleneterachlorate、聚氯乙烯、聚苯醚、聚碳酸酯、聚酯碳酸酯、丙烯腈-丙烯酸丁酯-苯乙烯聚合物、无定形尼龙及其混合物中的热塑性树脂。
15.权利要求12的复合片材材料，其中所述多孔芯包括约35-约55wt％的所述天然纤维和约45-约65wt％的所述热塑性树脂。
16.权利要求12的复合片材材料，其厚度为约0.5mm-约50mm。
17.权利要求12的复合片材材料，进一步包括至少一层表层，每一所述表层覆盖所述多孔芯层的至少一部分表面，所述表层包括热塑性膜、弹性膜、金属箔、热固性涂层、无机涂层、纤维基稀松布、非织造织物和织造织物中的至少一种。
18.权利要求12的复合片材材料，其中所述多孔芯进一步包括金属纤维、金属化的无机纤维、金属化的合成纤维、玻璃纤维、石墨纤维、碳纤维、陶瓷纤维、玄武岩纤维、无机纤维和芳族聚酰胺纤维中的至少一种。
19.制造多孔的经天然纤维增强的热塑性片材的方法，所述方法包括：
添加平均长度为约5mm-约50mm的天然纤维，和热塑性树脂粉末颗粒到搅拌的含水泡沫体中，形成分散的混合物；
在线网上层铺天然纤维和热塑性树脂颗粒的所述分散的混合物；
抽空水，形成网幅；
加热网幅到高于热塑性树脂的玻璃化转变温度；和
挤压该网幅成预定厚度，形成孔隙含量为约1％-约95％的多孔热塑性复合片材。
20.权利要求19的方法，其中天然纤维包括洋麻纤维、黄麻纤维、亚麻纤维、苎麻纤维、纤维素纤维、剑麻纤维和椰纤维中的至少一种。
21.权利要求19的方法，其中热塑性树脂包括聚烯烃、聚苯乙烯、丙烯腈基苯乙烯、丁二烯、聚酯、polybutyleneterachlorate、聚氯乙烯、聚苯醚、聚碳酸酯、聚酯碳酸酯、丙烯腈-丙烯酸丁酯-苯乙烯聚合物、无定形尼龙及其混合物中的至少一种。
22.权利要求19的方法，其中多孔热塑性复合片材包括约20-约80wt％的天然纤维和约20-约80wt％的热塑性树脂。
23.权利要求19的方法，其中多孔热塑性复合片材包括约35-约55wt％的天然纤维和约45-约65wt％的热塑性树脂。
24.权利要求19的方法，进一步包括将表层粘合到多孔热塑性复合片材的至少一部分表面上。
25.权利要求24的方法，其中表层包括热塑性膜、弹性膜、金属箔、热固性涂层、无机涂层、纤维基稀松布、非织造织物和织造织物中的至少一种。
26.权利要求19的方法，进一步包括添加金属纤维、金属化的无机纤维、金属化的合成纤维、玻璃纤维、石墨纤维、碳纤维、陶瓷纤维和芳族聚酰胺纤维中的至少一种到搅拌的含水泡沫体中。
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