Patent Application
20200165401
The disclosure relates to the field of preparation of macromolecular materials, and in particular to a thermoplastic polymer elastomer material with micro air holes and preparation thereof.
Thermoplastic polymer elastomer materials are widely applied to manufacture of production and living facilities, equipment, tools and consumables. More requirements are imposed on environmental protection, energy consumption and consumption reduction along with social development. Needs on light materials are also becoming ever more urgent. Weight-lightening of the thermoplastic polymer elastomer materials are also massively experimented and verified, and promotion and application of light materials proceed continuously, for example, polypropylene (PP) foam, polyethylene (PE) foam, polystyrene (PS) foam, polyester (PET) foam, polyamide (PA) foam and polyurethane (TPU) foam.
Currently, common expansion processes of thermoplastic polymer elastomer include expansion and foaming in a pouring mold, expansion and foaming by injection molding, expansion and foaming by extrusion molding, and expansion and foaming in a high-pressure reactor. In poor foaming uniformity and factor, foaming by injection molding is disadvantaged; materials produced by extrusion appear to have a melt breakage fault that can cause breakdown to bubble holes and collapse of the surface; and foaming in the high pressure reactor is relatively highly risky and weak in production capacity and performance. By foaming principle, foaming can be classified into physical foaming and chemical foaming. No matter which kind of polymer raw materials is used and which foaming method is adopted, the foaming process generally includes stages of foaming of bubble cores, foaming of bubble cores, and curing and finalization of foam.
After foaming and expansion, the thermoplastic polymer elastomer material still needs to maintain good physical properties, which requires design of the expanded material structure and bubble holes in the material. However, limited by various factors such as the structure and properties of the material itself and the understanding of the processing method and foaming principle, existing products like foam particles are generally prepared using a single polymer raw material and a foaming agent through an expansion process. In this way, the foam particles obtained with a solid structure that does not collapse have a pure, closed-hole structure with a continuous outer surface. The foam particles of such a bubble hole structure have a relatively high support power, but the inner air cannot be eliminated when the foam particles are pushed due to the continuous outer surface so that the foam particles have a relatively hard hand feeling. Moreover, the foam particles of such closed bubble hole structure basically fail to realize forward feedback when pressed, and therefore tend to slip when used in shoes. In addition, domestic and overseas approaches of control over the expanded thermoplastic polymer elastomer material are simple and unstable, so that stable and controllable expansion solutions for improving the properties and processing methods of materials, in particular, nylon, PET, PPT and thermoplastic polyurethane, are hardly available.
The objective of the disclosure is to provide a thermoplastic polymer elastomer material with micro air holes and a preparation method thereof to overcome defects in the prior art.
The objective of the disclosure can be achieved by the following technical solution:
One objective of the disclosure is to provide a thermoplastic polymer elastomer material with micro air holes, including the following ingredients in percentage by weight: 0.1-97% of support polymer material, 0.1-97% of pressure-resistant slow-rebound polymer material, 0.01-0.5% of nucleator and 0.1-10% of foaming agent.
As a preferable implementation solution, the support polymer material is a polymer material with a high molecular weight, high hardness, high crystallization or high polarity, and the pressure-resistant slow-rebound polymer material is a polymer material with a low molecular weight, low hardness, crystallization as low as to amorphous state and polarity as low as to no polarity, corresponding to the support polymer material.
As a more preferable option of the above preferable implementation solution, the support polymer material is macromolecular weight polyurethane, and the corresponding pressure-resistant slow-rebound polymer material is low-molecular weight polyurethane;
or the support polymer material is high-hardness thermoplastic polymer elastomer (TPU, TPE, or rubber, etc. selected upon actual situations), and the corresponding pressure-resistant slow-rebound polymer material is low-hardness thermoplastic polymer elastomer;
or the support polymer material is polyamide or polyester, and the corresponding pressure-resistant slow-rebound polymer material is thermoplastic polyurethane.
As a further preferable option of the above more preferable implementation solution, the molecular weight Mw of the macromolecular weight polyurethane is 8×104˜5 ×105, and the molecular weight Mw of the low-molecular weight polyurethane is 2×104˜2.5 ×105.
As a further preferable option of the above more preferable implementation solution, the shore hardness of the high-hardness thermoplastic polymer elastomer is in a range of 80A to 75D, and the shore hardness of the low-hardness thermoplastic polymer elastomer is in a range of 30A to 85D. In such circumstance, the high-hardness thermoplastic polymer elastomer and the low-hardness thermoplastic polymer elastomer are generally the same substance.
As a further preferable option of the above more preferable implementation solution, the polyester or polyamide is modified low-melting-point polyester or modified low-melting-point polyamide, and the difference between the melting points of the support polymer material and the pressure-resistant rebound polymer material is controlled to be within 20° C. More preferably, the modified low-melting-point polyester may be modified PET, PTT, or PBT, and the modified low-melting-point polyamide may be modified low-melting-point PA6, PA6I, PA11, PA12, or PA9. (A main reason of selecting the modified low-melting-point polyamide or the modified low-melting-point polyester is that the melting point of common polyester or polyamide is far higher than that of the polyurethane, which results in difficulties in adjustment to an appropriate processing temperature when the modified low-melting-point polyamide or the modified low-melting-point polyester and the polyurethane are used as raw materials to prepare foam products, and therefore problems such as over melting or insufficient mixing of some raw materials tend to arise.)
As a preferable implementation solution, the nucleator is selected from at least any one of carbon nano-tube, silicon dioxide, talcum powder, modified calcium carbonate, carbon black and tetrafluoroethylene powder;
and the foaming agent is selected from at least any one of CO2, N2, normal butane, n-pentane and isopentane.
As a preferable solution, the particle size of the polymer elastomer material is in a range of 0.6 to 25 mm.
On the basis of the basic formula, the thermoplastic polymer elastomer material with micro air holes of the disclosure can be selectively added with other functional auxiliaries such as light stabilizers and antioxidants according to required material properties.
The thermoplastic polymer elastomer material with micro air holes, as one of the objectives, can be prepared with a conventional foaming process (for example, reactor foaming) based on the formula. The other objective of the disclosure is to provide a new method for preparing the thermoplastic polymer elastomer material with micro air holes, including the following steps:
(1) feeding the support polymer material, the pressure-resistant slow-rebound polymer material and the nucleator into a double-screw extruder via a feeding port at the front end, feeding the foaming agent into the double-screw extruder via a feeding port in the middle section, melting and well mixing all raw materials, sending the mixed materials into a static mixer for further homogenization to obtain a hot melt, and delivering the hot melt by a melt pump under a controlled pressure and at a fixed amount;
(2) guiding the hot melt that is delivered by the melt pump to pass a mold head and enter an underwater granulation chamber to obtain particles, delivering and separating the particles by process water, screening and drying the particles to obtain the target product.
As a preferable implementation solution, in step (1), the temperature of the double-screw extruder is in a range of 160 to 300° C., and the length-diameter ratio of the double-screw extruder is 32-56:1;
the temperature in the static mixer is set to be in a range of 120 to 280° C.; the inlet pressure of the melt pump is in a range of 50 to 200 bar; and the difference between the pressure of the hot melt extruded via the mold head and the pressure of the process water in the underwater granulation chamber is controlled to be in a range of 70 to 120 bar.
As a preferable implementation solution, in step (2), the process water in the underwater granulation chamber is at a temperature in a range of 10 to 90° C. and under a pressure in a range of 4 to 15 bar;
the particles are discharged out of the underwater granulation chamber and then delivered by the process water via a multi-stage pressure-release expansion process water pipeline of which the pressure gradually drops stage by stage.
As a further preferable option of the above preferable implementation solution, in step (2), the multi-stage pressure-release expansion process water pipeline is a four-stage process water pipeline, wherein the water pressure of a first-stage process water pipe keeps consistent with the process water pressure in the underwater granulation chamber. More preferably, the water pressure is 4-15 bar in the first-stage process water pipe, 3-10 bar in a second-stage process water pipe, 2-6 bar in a third-stage process water pipe, and 1-4 bar in a fourth-stage process water pipe.
According to a more specific preparation method, the double-screw extruder is driven by a motor to rotate at a speed in a range of 50 to 900 rpm; a screw barrel of the extruder is preferably set at a temperature in a range of 160 to 300° C. to ensure that the thermoplastic polymer can be fully melted; the polymer and the nucleator are added via a screw feeding port at the front end, and the foaming agent is added via a screw feeding port in the middle section. The mixed materials are heated by the extruder and sheared by screws, so that all materials are melted and well mixed by the screws to generate a melt which subsequently enters the static mixer. The melt is further homogenized and cooled in the static mixer to ensure that the melt temperature is in a range of 120 to 280° C. The temperature can be controlled upon requirements for physical properties of the finished product. Through the pressure control and fixed-amount delivery functions of the melt pump, the inlet pressure of the melt pump is set to be in a range of 50 to 200 bar to control the melt pressure in a screw cavity of the extruder to keep stable, so that the hot melt, the nucleator and the foaming agent can be well mixed and homogenized in a controllable high-pressure environment. The high-pressure hot melt is steadily pushed into the mold head of the extruder through the pressure control and fixed-amount delivery functions of the melt pump, wherein the mold heat is of a porous plate structure with a uniform heating facility inside to ensure that the hot melt can steadily pass the mold head. The hot melt delivered by the melt pump at a high pressure passes orifices of the mold head, and then is granulated into soybean-shaped particles by a granulation cutter which is rotating at a high speed in the underwater granulation chamber, wherein the granulation cutter of the underwater granulation chamber actually granulates hot melt under water. Preferably, the process water at a temperature in a range of 10 to 90° C. generates a pressure in a range of 4 to 15 bar by the effect of a process water pump, and enters the underwater granulation chamber via a process water inlet pipe of the underwater granulation chamber. In this way, the high-pressure hot melt is quickly cooled by the high-pressure process water and granulated into particles by the granulation cutter. The high-pressure hot melt and the high-pressure process water generate a differential pressure which can be regulated according to the inlet pressure of the melt pump and the pressure of a variable frequency process water pump, so that the initial expansion rate and factor of the polymer particles are under control and keep stable in the whole process. Since the cooling time of the just granulated polymer particles is short and the material crystallization speed varies a lot in different formulas, the disclosure specially preferably adopts a multi-stage pressure-release expansion process water pipeline. Based on the principle that the strength and the pressure bearing conditions increase as the outer surfaces of the polymer particles stay in process water for a longer time (the length of the retention time can be controlled by setting the length of the pipeline), the pressure is still maintained in a range of 4 to 15 bar in the first-stage process water pipe, and in such circumstance, the melt particles are partly cooled and initially expand under a differential pressure. In the second-stage process water pipe, the water pressure is lowered to 3-10 bar through increasing the pipeline diameter and shortening the pipeline. In such circumstance, the melt particles are further cooled, and the strength of the outer surfaces increases, but expansion occurs again after the differential pressure increases. In the third-stage process water pipe, the pipe resistance is lowered through increasing the pipe diameter and shortening the pipe to reduce the water pressure to 2-6 bar. In such circumstance, the melt particles are further cooled, and the strength of the outer surfaces increases, but expansion occurs again after the differential pressure increases. However, the expansion rate drops to a very low level because particle crystallization is about to be completed. In the fourth-stage process water pipe, the pipe resistance is lowered through regulating the pipe diameter and length to reduce the water pressure to 1-4 bar. In such circumstance, the melt particles are continuously cooled, and the strength of the outer surfaces further increases, but expansion occurs again after the differential pressure increases. However, due to sufficient cooling time, very high the strength of the outer surfaces of the particles, and basically completed particle crystallization, the outer diameters of the particles are firmly finalized. The expanded polymer particles and water jointly enter a centrifugal separator. The water and the expanded polymer particles are separated in the separator. The expanded particles enter a vibrating screen and then a post-treatment system, and the process water flows out of the centrifugal separator and then flows into a process water tank. The above procedures are repeated so that the process proceeds continuously. In the disclosure, the reason of adopting the multi-stage pressure-release expansion process water pipeline of which the pressure gradually drops stage by stage is to provide an appropriate, controllable and stable pressure-release expansion environment for particles which enter the underwater granulation chamber via the mold head, thus aiding the subsequent foaming and molding of the particles, ensuring controllable and stable foaming and expansion factor, and avoiding problems such as breakdown tendency of bubbles holes of particles, collapse of foam and molding failure or uncontrollable foaming factor in the conventional pressure-release expansion environment.
In the disclosure, the macromolecular weight, low molecular weight, etc. of combinations such as macromolecular weight polymer and low-molecular weight polymer, high-hardness polymer and low-hardness polymer, high-crystallization polymer and polymer with crystallization as low as to amorphous state, high-polarity polymer and low- or no-polarity polymer (preferably the combinations are the same kind or same type of polymer material) are distinguished through comparison, which means that between two kinds of polymer raw materials which are different in physical properties, the material with a higher molecular weight is defined as the macromolecular weight polymer, and the material with a lower molecular weight is defined as the low-molecular weight polymer. Likely, high hardness and low hardness as well as others are also defined in the similar way. More preferably, the molecular weight of the macromolecular weight polymer is at least one time greater than that of the low-molecular weight polymer; and the hardness of the high-hardness polymer is over 10A greater than that of the low-hardness polymer.
In the disclosure, the pressure-resistant rebound polymer material which mainly plays a rebound role should be selected from elastomer materials such as TPU, rubber and TPE; and the support polymer material which mainly plays a support role may be an elastomer type polymer material or a non-elastomer material, for example, PET, PTT, etc.
All raw materials and process steps involved in the disclosure, unless otherwise specified, may be any raw materials or process technologies known to those skilled in this field. The thermoplastic polyurethane, for example, can be selected directly from commercially available products or prepared by known process technologies. More preferably, the thermoplastic polyurethane can be polyether or polyester type thermoplastic polyurethane according to the product demands.
According to the disclosure, during preparation, the sizes, dimensions and density of inner micro air holes and the forms, dimensions and densities of the inner and surface bubble holes of expanded particles are designed and controlled through selection of raw materials and optimization of formulas; at the same time, the expansion of bubble cores is controlled through the pressure on the polymer hot melt in the screw cavity of the double-screw extruder and the pressure at the moment when the polymer hot melt is extruded out of the extruder; and finally, the expanded material is controlled be cured and finalized through the difference between the melt pressure and the process water pressure and by the method of slow pressure release of the process water.
According to the disclosure, raw materials including combinations of macromolecular weight polymer and low-molecular weight polymer, high-hardness polymer and low-hardness polymer, high-crystallization polymer and polymer with crystallization as low as to amorphous state, high-polarity polymer and low- or no-polarity polymer are designed first; then, the raw materials are mixed and melted and then added with the foaming agent; next, the obtained mixture is treated by an expansion process (preferably by the uncontrollable expansion process designed in this disclosure). The foaming agent has different foaming capabilities in polymer raw materials of different physical properties. The polymer raw material that serves as the support is quickly molded and is low in foaming strength, so that the foaming agent operates in the supporting polymer raw material in a short time and creates a closed hole structure that is shaped to shape the support by extremely micro-closed air holes. The polymer raw material which serves the pressure-resistant slow-rebound elastomer is slowly molded and is high in foaming capability, so that the foaming agent works in a long time in the pressure-resistant slow-rebound polymer raw material and can generate an open hole structure and form the pressure-resistant slow-rebound elastomer. The two different structures, namely the support and the pressure-resistant slow-rebound elastomer, are mixed in the foaming particles to jointly form an open-and-closed hole compound expanded material with a coiled, network-like and cross-linking air channel structure. In the disclosure, the polymer material with a macromolecular weight or high hardness or high crystallization or high polarity and the foaming agent form numerous 0.01-20 μm closed micro air holes by the effect of the nucleator, and the closed micro air holes serve as the support component in the expanded material; the polymer with a low molecular weight or low hardness or low crystallization or low polarity/no polarity and the foaming agent form extremely micro open bubble holes (non-closed holes), which together with some expanded particles form a pressure-resistant slow rebound component; the open bubble holes form air channels that coil the closed micro air holes in the expanded material, and the air channels partly communicate with one another and extend to the surfaces of the expanded particles. In this way, when the expanded material is extruded, the closed micro air holes which serve as the support component are extruded to play the supporting role, while the air in the open bubble holes in the pressure-resistant slow rebound component is quickly discharged out, which endows the expanded material with a good extrusion flexible feeling and higher support stability; when the extrusion force disappears, the closed micro air holes support the expanded material to reset, and outside air is then absorbed into the open bubble holes. The whole material can obtain a better cushion feedback.
Besides, according to the disclosure, in the preparation process, the dimensions and number of micro air holes and the dimensions, shapes and number of the open bubble holes in the expanded material can be controlled to adjust the physical properties of the material to meet various downstream purposes and customer requirements according to the permeability difference of different foaming agents in different polymer materials, the melt strength difference of different materials caused by differential pressures and melt crystallization speed, and the difference of different polymers in changes and retention of physical properties.
According to the disclosure, in the preparation process, when large open holes are required or when the ratio of the open bubble holes is small, the inlet pressure of the melt booster pump can be increased at a constant process water temperature to improve the inlet pressure of the mold head, and the pressure release can be accelerated using the process water pressure. When small open holes are required or when the ratio of the open bubble holes needs to be reduced, the inlet pressure of the melt booster pump can be reduced at a constant process water temperature to indirectly reduce the inlet pressure of the mold head, and pressure release can be slowed down by the pressure of the process water.
Compared with the prior art, the disclosure has the following beneficial effects:
(1) Compared with common expanded materials with closed micro holes that are made from a polymer raw material with a single physical property, the disclosure actually adopts two kinds of polymer raw materials with different physical properties, so that a coiled, network-like and cross-linking air channel structure including proper micro air holes and appropriate open bubble holes is formed in the expansion and foaming process of the two kinds of polymer raw materials. In this way, the micro air hole structure can endow the material with excellent physical properties such as strength, elastic modulus and rebound force, and the open bubble hole structure can enhance the energy absorption and storage properties, contact feeling and comfort feeling of the material. The whole material can provide a better cushion feedback.
(2) Adjustment in the formulas and process conditions can help effectively regulate the structures, densities and dimensions of the micro air holes and the open bubble holes and the opening forms of the open bubble holes, and control the micro air holes and the open bubble holes to respectively account for 20-99.5% and 0.5-80% of the material by volume.
(3) According to the disclosure, in the preparation process, the speed and factor of expansion caused by pressure release can be stabilized by control over the back pressure of the hot melt in the double-screw extruder and the back pressure of the underground granulation chamber, thus meeting the requirement of accurately controlling the expansion factor of the material.
(4) Multi-stage gradual pressure release is adopted to allow flexible control over the bubble breaking rate of different polymers in the expansion process, so that an appropriate expanded compound material can be manufactured.
(5) The particle sizes of the expanded particles are controlled to be in a range of 0.6 to 25 mm by control over the inlet pressure of the melt pump and the dimensions of orifices of the porous plate.
(6) The polymer elastomer material prepared by the disclosure is applicable to fields of expanded materials such as shoe products, packing materials, shock absorption materials, heat insulating materials, tracks, and solid tyres.
In the drawings, 1—motor; 2—double-screw extruder; 3—feeding port I; 4—feeding port II; 5—static mixer; 6—melt pump; 7—mold head; 8—underwater granulation chamber; 9—process water inlet pipe; 10—first-stage process water pressure release pipe; 11—second-stage process water pressure release pipe; 12—third-stage process water pressure release pipe; 13—fourth-stage process water pressure release pipe; 14—centrifugal separator; 15—vibrating screen; 16—process water pump.
The disclosure is further described in detail in conjunction with the attached drawings and specific embodiment.
It is necessary to point out that the following embodiment is intended only for further describing the disclosure and cannot be understood as limitations to the protective scope of the disclosure. Those skilled in this field can make some non-essential improvements and adjustments according to the content of the disclosure, which shall still fall within the protective scope of the disclosure.
Besides, unless otherwise specified, all raw materials are commercially available.
The contents of the disclosure can be more easily understood by referring to the detailed description of the preferable implementation methods and inclusive embodiment of the disclosure below. Unless otherwise specified, all technologies and scientific terms used in this text have meanings that can be generally understood by the ordinarily skilled in the field. If contradictions arise, the definition in the Description shall prevail.
For example, terms “is prepared by” and “comprising” used in this text are synonymous. Terms “including”, “comprising”, “having” and “containing” or any other modifications used in this text are intended for non-exclusive inclusion. For example, compositions, procedures, methods, products or devices including listed factors are not necessarily limited to the factors, but can include all other unlisted factors, or their inherent factors.
When values, concentrations, or other values or parameters are expressed by a scope, a preferable scope, or a scope defined by a series of upper preferred values and lower preferred values, this should be understood as that all scopes defined by any match of an upper limit in any scope or a preferred value and a lower limit in any scope or a preferred value are specifically disclosed, regardless of whether or not the scopes are individually disclosed. For example, when a scope of 1 to 5 is disclosed, the described scope should be understood to include a scope of “1 to 4”, a scope of “1 to 3”, a scope of “1 to 2”, a scope of “1 to 2 and 4 to 5”, a scope of “1 to 3 and 5”, etc. When the scope of a numerical value is described in this text, unless otherwise specified, the scope is intended for including end values and all integers and fractions in this scope.
Approximate words used in the Description and the Claims are adjuncts of the quantifier, indicating that the disclosure is not limited to the specific quantity, but also includes acceptable revision portions which approach the quantity, but do not cause changes in the relevant basic functions. Correspondingly, “approximate” and “about” are adjuncts of a numerical value, meaning that the disclosure is not limited to the accurate numerical value. In some cases, approximation words may be corresponding to the accuracy of instruments for measuring the numerical values. In the Description and Claims of the present application, scope definitions can be combined and/or exchanged. Unless otherwise specified, each of those scopes includes all sub-scopes there-between.
In addition, indefinite articles “a” and “an” in front of the factors or ingredients in the disclosure do not limit the quantity of the factors or ingredients. Therefore, “a” and “an” should be understood to include “one” or “at least one”, and a singular factor or ingredient also includes the plural form, unless the described number obviously indicates the singular form.
“Polymer” refers to a polymer compound prepared by polymerizing identical or different types of monomers. The general term “polymer” contains terms “homopolymer”, “co-polymer”, “terpolymer” and “interpolymer”.
The disclosure provides a thermoplastic polymer elastomer material with micro air holes, including the following ingredients in percentage by weight: 0.1-97% of support polymer material, 0.1-97% of pressure-resistant slow-rebound polymer material, 0.01-0.5% of nucleator and 0.1-10% of foaming agent.
As a preferable implementation solution, the support polymer material is a polymer material with a high molecular weight, high hardness, high crystallization or high polarity, and the pressure-resistant slow-rebound polymer material is a polymer material with a low molecular weight, low hardness, crystallization as low as to amorphous state and low polarity/no polarity, corresponding to the support polymer material.
As a more preferable option of the above preferable implementation solution, the support polymer material is macromolecular weight polyurethane, and the corresponding pressure-resistant slow-rebound polymer material is low-molecular weight polyurethane;
or the support polymer material is high-hardness thermoplastic polymer elastomer (TPU, TPE, or rubber, etc. selected upon actual situations), and the corresponding pressure-resistant slow-rebound polymer material is low-hardness thermoplastic polymer elastomer;
or the support polymer material is polyamide or polyester, and the corresponding pressure-resistant slow-rebound polymer material is thermoplastic polyurethane.
As a further preferable option of the above more preferable implementation solution, the molecular weight Mw of the macromolecular weight polyurethane is 8×104˜5×105, and the molecular weight Mw of the low-molecular weight polyurethane is 2×104˜2.5×105;
the shore hardness of the high-hardness thermoplastic polymer elastomer is in a range of 80A to 75 D; the shore hardness of the low-hardness thermoplastic polymer elastomer is in a range of 30 to 85A;
the polyester or polyamide is modified low-melting-point polyester or modified low-melting-point polyamide, and the difference between the melting points of the support polymer material and the pressure-resistant rebound polymer material is controlled to be within 20° C. More preferably, the modified low-melting-point polyester may be modified PET, PTT, or PBT, and the modified low-melting-point polyamide may be modified low-melting-point PA6, PA6I, PA11, PA12, or PA9.
As a preferable implementation solution, the nucleator is selected from at least any one of carbon nano-tube, silicon dioxide, talcum powder, modified calcium carbonate, carbon black and tetrafluoroethylene powder;
and the foaming agent is selected from at least any one of CO2, N2, normal butane, n-pentane and isopentane.
As a preferable solution, the particle size of the polymer elastomer material is in a range of 0.6 to 25 mm.
Besides, it needs to be noted that the formula disclosed above is merely a basic formula of the disclosure. On the basis of the basic formula disclosed by the disclosure, those skilled in this field can add other conventional auxiliaries into the formula, for example, antioxidants and anti-aging agents which can improve the anti-aging performance of the product.
The disclosure also provides a method for preparing a thermoplastic elastomer material with micro air holes, including the following steps:
(1) feeding the support polymer material, the pressure-resistant slow-rebound polymer material and the nucleator into a double-screw extruder via a feeding port at the front end, feeding the foaming agent into the double-screw extruder via a feeding port in the middle section, melting and well mixing all raw materials, sending the mixed materials into a static mixer for further homogenization to obtain a hot melt, and delivering the hot melt by a melt pump under a controlled pressure and at a fixed amount;
(2) guiding the hot melt that is delivered by the melt pump to pass a mold head and enter an underwater granulation chamber to obtain particles, delivering and separating the particles by process water, screening and drying the particles to obtain the target product.
As a preferable implementation solution, in step (1), the temperature of the double-screw extruder is in a range of 160 to 300° C., and the length-diameter ratio of the double-screw extruder is 32:56;
the temperature in the static mixer is set to be in a range of 120 to 280° C.; the inlet pressure of the melt pump meets the following requirement: the pressure of the hot melt extruded via the mold head and the pressure of the process water in the underwater granulation chamber is in a range of 70 to 120 bar.
As a preferable implementation solution, the process water in the underwater granulation chamber in step (2) is at a temperature in a range of 10 to 90° C. and under a pressure in a range of 4 to 15 bar.
The particles are brought out of the underwater granulation chamber and delivered by the process water via a multi-stage pressure-release expansion process water pipeline of which the pressure gradually drops.
As a further preferable option of the above preferable implementation solution, in step (2), the multi-stage pressure-release expansion process water pipeline is a four-stage process water pipeline, wherein the water pressure is 4-15 bar in the first-stage process water pipe, 3-10 bar in the second-stage process water pipe, 2-6 bar in the third-stage process water pipe, and 1-4 bar in the fourth-stage process water pipe.
Further preferably, the details of the above preparation process can be seen in
In addition, it needs to be pointed out that, the above preparation method is a preferable process of the disclosure for preparing the compound bubble hole structure with open and closed holes. Besides the above-mentioned preferable process which adopts screws for continuous foaming, the disclosure can also adopt other conventional foaming preparation processes such as reactor foaming on the basis of a basic formula which can generate multiple bubble hole structures, and the finally obtained products also have the compound bubble hole structure with open and closed holes.
In the following embodiment, raw materials used include: polyether type and polyester type thermoplastic polyurethane from Bayer and Huntsman, modified low-melting-point PET and PBT from Sinopec Shanghai Petrochemical Company Limited, and modified low-melting-point polyamide from DuPont and Evonik.
According to the process flow as shown in
In this embodiment, the raw materials added in percentage by weight included: 75% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 150K to 300K (K means the unit “thousand” here, the same below), 20% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 50K to 100K, 4.5% of foaming agent which was CO2, and 0.5% of nucleator which was calcium carbonate. The length-diameter ratio L/D of the double-screw extruder was 40; the heating temperature of the screws was in a range of 160 to 220° C.; the temperature of the static mixer was in a range of 140-180° C.; the inlet pressure of the melt pump was in a range of 100 to 120 bar; the process water pressure was about 12 bar; and the difference pressure during pressure release (namely the differential pressure between the high-pressure hot melt at the exit of the mold head and the process water in the underwater granulation chamber) was controlled to be in a range of 90 to 120 bar. In the multi-stage pressure-release expansion process water pipeline, the water pressure was controlled to be about 12 bar in the first-stage process water pipe, about 8 bar in the second-stage process water pipe, about 5 bar in the third-stage process water pipe, and about 2 bar in the fourth-stage process water pipe.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen had a particle size in a range of about 1 to 3 mm. In the material, the formed micro air hole structure accounted for about 60-80% and the open bubble hole structure accounted for about 10-35% by volume.
According to the process flow as shown in
In this embodiment, the raw materials added in percentage by weight included: 60% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 300K to 500K (K means the unit “thousand” here, the same below), 35% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 150K to 250K, 4.95% of foaming agent which was N2, and 0.05% of nucleator which was carbon black. The length-diameter ratio L/D of the double-screw extruder was 56; the heating temperature of the screws was in a range of 160 to 220° C.; the temperature of the static mixer was in a range of 140-180° C.; the inlet pressure of the melt pump was in a range of 100 to 150 bar; the process water pressure was about 6 bar; and the differential pressure during pressure release (namely the differential pressure between the high-pressure hot melt at the exit of the mold head and the process water in the underwater granulation chamber) was controlled to be in a range of 90 to 140 bar. In the multi-stage pressure-release expansion process water pipeline, the water pressure was controlled to be about 6 bar in the first-stage process water pipe, about 5 bar in the second-stage process water pipe, about 3 bar in the third-stage process water pipe, and about 1 bar in the fourth-stage process water pipe.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen had a particle size in a range of about 8 to 12 mm. In the material, the formed micro air hole structure accounted for about 30-50% and the open bubble hole structure accounted for about 40-60% by volume.
According to the process flow as shown in
In this embodiment, the raw materials added in percentage by weight included: 97% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 80K to 120K (K indicates the unit “thousand” here, the same below), 0.1% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 20K to 50K, 2.4% of foaming agent which was N2, and 0.5% of nucleator which was the mixture of talcum powder and modified calcium carbonate in a mass ratio of 1:1. The length-diameter ratio L/D of the double-screw extruder was 46; the heating temperature of the screws was in a range of 160 to 220° C.; the temperature of the static mixer was in a range of 130-170° C.; the inlet pressure of the melt pump was in a range of 120 to 180 bar; the process water pressure was about 15 bar; and the pressure difference of pressure release (namely the differential pressure between the high-pressure hot melt at the exit of the mold head and the process water in the underwater granulation chamber) was controlled to be in a range of 120 to 150 bar. In the multi-stage pressure-release expansion process water pipeline, the water pressure was controlled to be about 15 bar in the first-stage process water pipe, about 10 bar in the second-stage process water pipe, about 6 bar in the third-stage process water pipe, and about 4 bar in the fourth-stage process water pipe.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen had a particle size of about 0.6-2 mm. In the material, the formed micro air hole structure accounted for about 30-45% and the open bubble hole structure accounted for about 0.5-10% by volume.
According to the process flow as shown in
In this embodiment, the raw materials added in percentage by weight included: 0.1% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 300K to 500K (K means the unit “thousand” here, the same below), 97% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 20K to 50K, 2.8% of foaming agent which was N2, and 0.1% of nucleator which was carbon nano-tube. The length-diameter ratio L/D of the double-screw extruder was 48; the heating temperature of the screws was in a range of 160 to 220° C.; the temperature of the static mixer was in a range of 130-180° C.; the inlet pressure of the melt pump was in a range of 90 to 120 bar; the process water pressure was about 10 bar; and the pressure difference of pressure release (namely the differential pressure between the high-pressure hot melt at the exit of the mold head and the process water in the underwater granulation chamber) was controlled to be in a range of 80 to 120 bar. In the multi-stage pressure-release expansion process water pipeline, the water pressure was controlled to be about 10 bar in the first-stage process water pipe, about 7 bar in the second-stage process water pipe, about 4 bar in the third-stage process water pipe, and about 2 bar in the fourth-stage process water pipe.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen had a particle size in a range of about 12 to 25 mm. In the material, the formed micro air hole structure accounted for about 20% and the open bubble hole structure accounted for about 60-70% by volume.
According to the process flow as shown in
In this embodiment, the raw materials added in percentage by weight included: 70% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 120K to 180K (K indicates the unit “thousand” here, the same below), 19.7% of polyether type thermoplastic polyurethane with a molecular weight Mw in a range of 20K to 50K, 10% of foaming agent which was the mixture of CO2 and N2 in a volume ratio of 1:1, and 0.3% of nucleator which was the mixture of calcium carbonate and tetrafluoroethylene powder in a mass ratio of 1:1. The length-diameter ratio L/D of the double-screw extruder was 40; the heating temperature of the screws was in a range of 180 to 240° C.; the temperature of the static mixer was in a range of 140-190° C.; the inlet pressure of the melt pump was in a range of 100 to 120 bar; the process water pressure was about 10 bar; and the differential pressure during pressure release (namely the differential pressure between the high-pressure hot melt at the exit of the mold head and the process water in the underwater granulation chamber) was controlled to be in a range of 90 to 120 bar. In the multi-stage pressure-release expansion process water pipeline, the water pressure was controlled to be about 10 bar in the first-stage process water pipe, about 7 bar in the second-stage process water pipe, about 4 bar in the third-stage process water pipe, and about 2 bar in the fourth-stage process water pipe.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen had a particle size in a range of about 3 to 6 mm. In the material, the formed micro air hole structure accounted for about 60% and the open bubble hole structure accounted for about 10% by volume.
Compared with embodiment 1, all were identical, except the raw material formula replaced by the following ingredients in percentage by weight:
80% of polyester type thermoplastic polyurethane with a molecular weight Mw in a range of 200K to 300K (K indicates the unit “thousand” here, the same below), 18.9% of polyester type thermoplastic polyurethane with a molecular weight Mw in a range of 50K to 100K, 1% of foaming agent which was the mixture of CO2 and N2 in a volume ratio of 1:1, and 0.1% of nucleator which was the mixture of calcium carbonate and tetrafluoroethylene powder in a mass ratio of 1:1.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 1, all were identical, except the raw material formula replaced by the following ingredients in percentage by weight:
80% of polyester type thermoplastic polyurethane with 80A shore hardness, 19.5% of polyester type thermoplastic polyurethane with 30A shore hardness, 0.4% of the foaming agent which was the mixture of CO2 and N2 in weight ratio of 1:1, and 0.1% of nucleator which was the mixture of carbon nano-tube, talcum powder and calcium carbonate.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 7, all were identical, except the raw material formula replaced by the following ingredients in percentage by weight:
70% of polyester type thermoplastic polyurethane with 75D shore hardness, 27.5% of polyester type thermoplastic polyurethane with 85A shore hardness, 2% of the foaming agent which was the mixture of CO2 and N2 in weight ratio of 1:1, and 0.5% of nucleator which was the mixture of carbon nano-tube, talcum powder and calcium carbonate.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 7, all were identical, except the high-hardness polyester type thermoplastic polyurethane with 90A shore hardness and low-hardness polyester type thermoplastic polyurethane with 50A shore hardness as replacements in the raw material formula.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
According to the process flow as shown in
In this embodiment, the raw materials added in percentage by weight included: 60% of modified low-melting-point PET, 37% of polyester type polyurethane (the difference between the melting points of the modified low-melting point PET and the polyester type polyurethane was 20° C.), 0.5% of nucleator which was carbon black, and 2.5% of foaming agent which was the mixture of CO2 and N2.
The length-diameter ratio L/D of the double-screw extruder was 52; the heating temperature of the screws was in a range of 220 to 280° C.; the temperature of the static mixer was in a range of 160-200° C.; the inlet pressure of the melt pump was in a range of 100 to 150 bar; the process water pressure was about 15 bar; and the differential pressure during pressure release (namely the differential pressure between the high-pressure hot melt at the exit of the mold head and the process water in the underwater granulation chamber) was controlled to be in a range of 130 to 180 bar. In the multi-stage pressure-release expansion process water pipeline, the water pressure was controlled to be about 15 bar in the first-stage process water pipe, about 12 bar in the second-stage process water pipe, about 8 bar in the third-stage process water pipe, and about 4 bar in the fourth-stage process water pipe.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 10, all were identical, except the modified low-melting-point polyaminde (PA) which replaced the modified low-melting-point PET.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 10, all were identical, except the PBT which replaced the modified low-melting-point PET.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 1, all were identical, except the n-butane, n-pentane and iso-pentane, which respectively served as the foaming agent.
In embodiment 13-15, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 1, all were identical in this embodiment, except the procedure of directly bringing out the particles in the underwater granulation chamber by the process water at a basically stable pressure in a range 40 to 50° C. of and under a basically stable pressure in a range of 4 to 8 bar, and the procedures of pressure release, cooling and molding.
Finally, the thermoplastic polymer elastomer material with micro air holes obtained using the vibrating screen also had a compound bubble hole structure formed by micro air holes (closed holes) and open bubble holes. Refer to the bubble hole structure as shown in
Compared with embodiment 1, a conventional reactor foaming process at a foaming temperature of about 150° C. and under a pressure of about 15 Mpa was adopted in this embodiment.
Finally, the prepared foam particles also had the compound bubble hole structure formed by micro air holes (closed hole) and open bubble holes, like the foam particles as shown in
Compared with embodiment 1, all were identical in this example, except that all the polymer raw material was polyether type thermoplastic polyurethane with a molecular weight in a range of 150K to 300K .
Compared with embodiment 7, all were identical in this example, except that all the polymer raw material was polyester type thermoplastic polyurethane with 80A shore hardness.
Compared with embodiment 10, all were identical in this example, except that all the polymer raw material was modified low-melting-point PET (which means that no polyester type polyurethane was added).
Finally, the foaming materials prepared in comparison examples 1-3 were tested to analyze the bubble holes thereof. Results showed that all foaming materials obtained in the three comparison examples were foam particles with continuous surfaces, and the inner scanning pictures of the cut particles showed that all bubble holes were closed holes, without the open holes which extended to the surfaces, like the foam particles obtained in embodiment 1 as shown in
From the above embodiment and comparison examples it can be known that, in comparison with the comparison examples which used a single polymer as the raw material to prepare foam particles with pure closed holes, the disclosure, through improving the formula of the foam particles, adopts two kinds of polymers of different physical conditions as the raw materials to prepare the foam particles with a compound bubble hole structure which is formed by open and closed holes, in conjunction with the principle that the foaming agent has different foaming capabilities in two kinds of polymers during the foaming process.
The above embodiment is illustrative, intended for explaining some characteristics of the method of the disclosure. The attached claims are aimed to define a protective scope as wide as possible, and the embodiment described in this text merely illustrates combinational preferable implementation solutions according to all possible embodiment. Therefore, the attached claims cannot be limited by the above embodiment options of the characteristics of the disclosure. Some scopes of the numerical values in the claims also include their sub-scopes, and changes in such scopes shall also fall within the protective scope of the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201710660205.6 | Aug 2017 | CN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2018/098024 | 8/1/2018 | WO | 00 |
