Patent Application
20180119360
The invention belongs to the technical field of manufacturing of functional building decoration materials and specifically relates to bio-based environment-friendly flame retardant wallpaper and a preparation method thereof.
Wallpaper is special processed paper for decorating walls and is widely used in indoor decoration and the like of residences, offices, guesthouses and hotels. At present, the wallpaper has become popular to a considerable degree around the world. With the continuous improvement in production technical level, the manufacturing technology of the wallpaper is improved continuously. At present, the conventional wallpaper is prepared by using wood pulp paper as a base material, polyvinyl chloride (PVC) as a pattern layer and performing the process steps of printing, embossing, foaming and the like and has the characteristics of rich colors, diverse patterns, delicate texture, easy construction and the like.
However, as the wallpaper material uses a great quantity of PVC and other petrochemical raw materials, the wallpaper material is very prone to burning when a house catches fire and releases a lot of toxic smog, such as dioxins, hydrogen chloride and the like, thereby causing a great threat and hidden danger to life and property security of residents. At present, most of the common flame retardant wallpaper adopts a way of adding flame retardants into raw paper or a coating and a protecting layer to achieve the purpose of flame retardance. However, the wallpaper often has the following shortcomings: the using quantity of the flame retardants is large, and the flame retardants used by part of products are difficult to recover and not environment-friendly (such as halogen-containing and phosphorus-containing flame retardants); the flame retardants have poor durability, part of inorganic flame retardants are easy to remove, and part of organic flame retardants are prone to volatilization and failure after long-term use; the flame retardants are prone to moisture absorption, and the flame retardance and the physical performances of the paper after moisture absorption decline obviously; and the addition of the flame retardants has different degrees of adverse effects on the durability and the printability of the wallpaper.
The invention aims at providing bio-based environment-friendly flame retardant wallpaper and a preparation method thereof. According to the method, alginate fibre is selected to be mixed with wood pulp, beating is performed to prepare raw paper, the inherent flame retardant mechanism of metal ions in the alginate fibre is utilized to achieve the purpose of flame retardance of the wallpaper without adding flame retardants, and no toxic smog is produced during the process of being contact with a fire source.
A first task of the invention is to provide a preparation method of environment-friendly flame retardant wallpaper.
A preparation method of environment-friendly flame retardant wallpaper sequentially comprises the following steps:
a. preparing raw paper: selecting alginate fibre to be mixed with full wood pulp, beating to obtain mixed size, adding a dispersant into the mixed size and performing paper-making and drying to obtain the raw paper;
b. coating: sequentially uniformly coating the surface of the raw paper obtained in the step a with alginate colloid, PVC, calcium carbonate and DOP paste;
c. drying and cooling: drying and cooling a coating coated on the surface of the raw paper in the step b; and
d. printing: printing a required pattern on the surface of the raw paper coating after cooling, then softening the pattern, pressing the surface of the raw paper coating with an embossing wheel to obtain corresponding lines, and cutting into the required specification to obtain the wallpaper.
As a preferred solution of the invention, in the step a, the alginate fibre accounts for 20-80% of the mass of bone dry pulp in the mixed size; and the dispersant is an anion dispersant or a water-soluble polymer dispersant.
The anion dispersant is sodium fatty alcohol polyoxyethylene ether sulfate, sodium cellulose sulfate, sodium alkyl diphenyl ether sulfonate or alkyl phenyl polyoxy ethylene ether phosphate; and the water-soluble polymer dispersant is sodium alginate.
As another preferred solution of the invention, in the step b, the alginate colloid is sodium alginate, and the coating thickness after coating is 0.2-0.5 mm.
Preferably, in the step c, a hot air circulating system is selected to dry the coating on the surface of the raw paper, the drying temperature is 110-250° C., the drying time is 10-18 s, and the cooling time is 10-30 s.
Preferably, the alginate fibre is seaweed chopped fiber with the average length of 3-6 mm, and the wood pulp liquid is prepared by beating full wood pulp.
Preferably, the embossing depth of the embossing wheel is 0.2-1.0 mm.
Preferably, the preparation method of the seaweed chopped fiber comprises: filtering, defoaming and spinning a sodium alginate solution with the mass fraction of 2-12% under the condition that the temperature is 15-100° C. to obtain the alginate fibre, and chopping the obtained alginate fibre for preparation.
A second task of the invention is to provide environment-friendly flame retardant wallpaper prepared by any above-mentioned preparation method.
The invention has the following beneficial technical effects:
The invention provides environment-friendly flame retardant wallpaper and a preparation method thereof. In the aspect of selecting raw materials, in the prior art, the raw paper is prepared by beating the wood pulp, and various flame retardants are added separately onto the raw paper layer during coating to obtain the flame retardant wallpaper; whereas in the preparation process of the raw paper of the invention, the alginate fibre is selected to be mixed with the wood pulp, the beating is performed to obtain the mixed size, the dispersant is added into the mixed size, paper-making and drying are performed to obtain the raw paper. According to the invention, on the premise of not adding any flame retardant, the raw paper with flame retardance and durability is prepared by simple production process steps, the alginate fibre is used as paper pulp fiber, and the catalytic cracking effect is realized by the metal ions in the seaweed chopped fiber, so as to reduce the production of flammable gases, form an alkaline environment, produce incombustible CO2, dilute the flammable gases and produce a precipitate of metal oxides and metal carbonates to cover the surface of the fiber in the paper to form a solid-state barrier; and meanwhile, the cracking temperature of the fiber is improved by the dense chelated structure in the alginate fiber, so as to finally achieve the flame retardant effects of no addition of the flame retardants, no smoke and no melt drops.
According to the invention, the alginate colloid, the PVC, the calcium carbonate and the DOP paste are used as a coating layer, and the process improves the shape stability, the flame retardance and the processing performance of the alginate fibre paper, improves the production speed and saves the production energy consumption of a single piece of wallpaper. The coated surface has higher smoothness, and the non-coated surface has prominent natural lines of the fiber, with strong three-dimensional sense and convenience in secondary construction.
According to the invention, the alginate fibre with natural inherent flame retardance is selected to be blended with the wood pulp for flame retardant modification, and then beating, paper-making, squeezing, drying, curling and other process steps are performed to manufacture the raw paper of the environment-friendly flame retardant wallpaper. Compared with the ordinary wallpaper, the invention has the advantages of simple production process steps and simple structure of overlapped layers of the wallpaper, and the wallpaper has the excellent functions of flame retardance, no toxicity, no smoke, environment friendliness, biodegradability and the like; and the flame retardant wallpaper prepared by the invention has the flame retardant oxygen index of more than 30%.
The invention provides bio-based environment-friendly flame retardant wallpaper and a preparation method thereof In order to enable the advantages and the technical solutions of the invention to be clearer and more definite, the invention will be further clearly and fully illustrated below in conjunction with the specific embodiments.
The raw materials selected by the invention are commercially available.
According to the invention, a preparation method of bio-based environment-friendly flame retardant wallpaper specifically comprises the following steps:
(1) preparing raw paper: preparing seaweed chopped fiber with the length of 3 mm and 6 mm (with the mass ratio of 1:1) by wet spinning, mixing with 6 wt % of wood pulp with the beating degree of 30° SR and beating, wherein the mass of the seaweed chopped fiber accounts for 20% of the mass of bone dry paper pulp; and performing paper-making and drying after adding a dispersant, namely sodium cellulose sulfate with the concentration of 0.04 wt % after dilution and 0.3 wt % of a sodium alginate polymer solution dispersant to prepare the raw paper of the wallpaper;
(2) coating: firstly coating the 2 wt % of the sodium alginate solution by a coating machine, performing gelation treatment by 5 wt % of a calcium chloride solution, and then uniformly coating PVA, calcium carbonate and DOP paste on the surface of the raw paper, wherein the coating thickness is 0.25 mm;
(3) drying: drying a coating on the surface of the raw paper through a hot air circulating system, wherein the ambient temperature for drying is 150° C. and the drying time is 15 s;
(4) cooling: cooling and hardening the surface material by circulating cooling water through two cooling rings, wherein the cooling process is performed at normal temperature, and the cooling time is 10 s;
(5) printing: using different printing patterns to print the required patterns on the surface of the wallpaper by using corresponding printing wheels;
(6) softening: heating the wallpaper by utilizing a heating cover to soften the wallpaper to facilitate embossing;
(7) embossing: pressing the surface of the wallpaper by using an embossing wheel to produce corresponding line effects, wherein the embossing depth is 0.6 mm; and
(8) cutting and packaging: cutting the wallpaper into the required specification and curling the product into a finished product by a curling machine according to the required size and packaging.
The flame retardant oxygen index of the flame retardant wallpaper prepared by the embodiment is tested to be 31%.
According to the invention, bio-based environment-friendly flame retardant wallpaper, and the preparation thereof specifically comprises the following steps:
(1) preparing raw paper: preparing seaweed chopped fiber with the length of 3 mm, 4 mm, 5 mm and 6 mm(with the mass ratio of 2:2:3:3) by wet spinning, mixing with 5 wt % of wood pulp with the beating degree of 40° SR and beating, wherein the mass of the seaweed chopped fiber accounts for 50% of the mass of bone dry paper pulp; and performing paper-making and drying after adding a dispersant, namely sodium alkyl diphenyl ether sulfonate with the concentration of 0.02 wt % after dilution and 0.4 wt % of a sodium alginate polymer solution dispersant to prepare the raw paper of the wallpaper;
(2) coating: firstly coating the 1 wt % of the sodium alginate solution by a coating machine, performing gelation treatment by 4 wt % of a calcium chloride solution, and then uniformly coating PVA, calcium carbonate and DOP paste on the surface of the raw paper, wherein the coating thickness is 0.3 mm;
(3) drying: drying a coating on the surface of the raw paper through a hot air circulating system, wherein the ambient temperature for drying is 190° C. and the drying time is 18 s;
(4) cooling: cooling and hardening the surface material by circulating cooling water through two cooling rings, wherein the cooling process is performed at normal temperature, and the cooling time is 20 s;
(5) printing: using different printing patterns to print the required patterns on the surface of the wallpaper by using corresponding printing wheels;
(6) softening: heating the wallpaper by utilizing a heating cover to soften the wallpaper to facilitate embossing;
(7) embossing: pressing the surface of the wallpaper by using an embossing wheel to produce corresponding line effects, wherein the embossing depth is 0.5 mm; and
(8) cutting and packaging: cutting the wallpaper into the required specification and curling the product into a finished product by a curling machine according to the required size and packaging.
The extreme oxygen index of the flame retardant wallpaper prepared by the embodiment is tested to be 36%.
According to the invention, bio-based environment-friendly flame retardant wallpaper, and the preparation thereof specifically comprises the following steps:
(1) preparing raw paper: preparing seaweed chopped fiber with the length of 3 mm and 6 mm(with the mass ratio of 1:1) by wet spinning, mixing with 6 wt % of wood pulp with the beating degree of 50° SR and beating, wherein the mass of the seaweed chopped fiber accounts for 60% of the mass of bone dry paper pulp; and performing paper-making and drying after adding a dispersant, namely sodium fatty alcohol polyoxyethylene ether sulfate with the concentration of 0.04 wt % after dilution and 0.3 wt % of a sodium alginate polymer solution dispersant to prepare the raw paper of the wallpaper;
(2) coating: firstly coating the 2 wt % of the sodium alginate solution by a coating machine, performing gelation treatment by 5 wt % of a calcium chloride solution, and then uniformly coating PVA, calcium carbonate and DOP paste on the surface of the raw paper, wherein the coating thickness is 0.4 mm;
(3) drying: drying a coating on the surface of the raw paper through a hot air circulating system, wherein the ambient temperature for drying is 150° C. and the drying time is 18 s;
(4) cooling: cooling and hardening the surface material by circulating cooling water through two cooling rings, wherein the cooling process is performed at normal temperature, and the cooling time is 15 s;
(5) printing: using different printing patterns to print the required patterns on the surface of the wallpaper by using corresponding printing wheels;
(6) softening: heating the wallpaper by utilizing a heating cover to soften the wallpaper to facilitate embossing;
(7) embossing: pressing the surface of the wallpaper by using an embossing wheel to produce corresponding line effects, wherein the embossing depth is 0.6 mm; and
(8) cutting and packaging: cutting the wallpaper into the required specification and curling the product into a finished product by a curling machine according to the required size and packaging.
The extreme oxygen index of the flame retardant wallpaper prepared by the embodiment is tested to be 38%.
According to the invention, bio-based environment-friendly flame retardant wallpaper, and the preparation thereof specifically comprises the following steps:
(1) preparing raw paper: preparing seaweed chopped fiber with the length of 3 mm and 6 mm (with the mass ratio of 1:1) by wet spinning, mixing with 6 wt % of wood pulp with the beating degree of 60° SR and beating, wherein the mass of the seaweed chopped fiber accounts for 80% of the mass of bone dry paper pulp; and performing paper-making and drying after adding a dispersant, namely alkyl phenyl polyoxy ethylene ether phosphate with the concentration of 0.04 wt % after dilution and 0.3 wt % of a sodium alginate polymer solution dispersant to prepare the raw paper of the wallpaper;
(2) coating: firstly coating the 2 wt % of the sodium alginate solution by a coating machine, performing gelation treatment by 5 wt % of a calcium chloride solution, and then uniformly coating PVA, calcium carbonate and DOP paste on the surface of the raw paper, wherein the coating thickness is 0.5 mm;
(3) drying: drying a coating on the surface of the raw paper through a hot air circulating system, wherein the ambient temperature for drying is 250° C. and the drying time is 18s ;
(4) cooling: cooling and hardening the surface material by circulating cooling water through two cooling rings, wherein the cooling process is performed at normal temperature, and the cooling time is 30 s;
(5) printing: using different printing patterns to print the required patterns on the surface of the wallpaper by using corresponding printing wheels;
(6) softening: heating the wallpaper by utilizing a heating cover to soften the wallpaper to facilitate embossing;
(7) embossing: pressing the surface of the wallpaper by using an embossing wheel to produce corresponding line effects, wherein the embossing depth is 0.5 mm; and
(8) cutting and packaging: cutting the wallpaper into the required specification and curling the product into a finished product by a curling machine according to the required size and packaging.
The extreme oxygen index of the flame retardant wallpaper prepared by the embodiment is tested to be 41%.
It should be understood that the above description of the preferred embodiments is relatively detailed, but it cannot be considered to limit the protection scope of the inventive patent. Those of ordinary skill in the art can make substitutions, simple combinations and other various modifications without departing from the scope protected by the claims of the invention under the inspiration of the invention, and the protection scope claimed by the invention should be defined by the appended claims.
