A polyester material and its preparation process

Abstract

This invention relates to E04B1, and more specifically, to a polyester material and its preparation process. The raw materials of the polyester material include polyester fibers, modified polyester fibers, and natural fibers. Modification of the polyester fibers via ultraviolet radiation reduces their molecular weight, leading to changes in their mechanical properties, typically resulting in a decrease in elongation at break. However, this invention mitigates this effect through radiation under alkaline conditions. Furthermore, by combining first and second polyester fibers, the mechanical properties are actually improved, as is the sound absorption coefficient. Through the synergistic effect of the polyester material system, the polyester material obtained by this invention, when used to produce sound-absorbing panels, significantly reduces the release of harmful gases, and the sound-absorbing panels exhibit good stain and oil resistance.

Description

Technical Field

[0001] This invention relates to E04B1, and more specifically, to a polyester material and its preparation process. Background Technology

[0002] Polyester fiber sound-absorbing material is a porous fiber material with excellent sound absorption properties, making it an environmentally friendly new material. The material contains numerous micropores, allowing sound waves to enter the material through these pores and convert sound energy into other forms of energy, thus achieving sound absorption.

[0003] Patent CN103964750B discloses a novel fire-resistant, non-toxic sound-absorbing panel material and its preparation method. It incorporates self-prepared additives to increase the fiber content, giving the material advantages such as light weight, large porosity, and flexibility. Patent CN106968042B discloses a sound-absorbing and noise-reducing curtain fabric. It uses sodium hydroxide to etch micropores onto the surface of polyester fibers and introduces natural diatomaceous earth and shellac to effectively absorb noise.

[0004] The sound absorption coefficient of traditional polyester fiber is generally 0.4-0.7, while the sound absorption coefficient of the material obtained by patent CN103964750B is 0.78-0.91. It can be seen that the sound absorption coefficient of this type of material is difficult to break through 1. In addition, the anti-fouling and cleanliness performance of polyester when used as sound-absorbing material has become an increasingly important focus. Summary of the Invention

[0005] To address the aforementioned problems, the first aspect of this invention provides a polyester material, wherein the raw materials of the polyester material include polyester fibers, modified polyester fibers, and natural fibers.

[0006] As a preferred embodiment of the present invention, the polyester fiber comprises a first polyester fiber with a diameter of 6-10D and a second polyester fiber with a diameter of 1-5D.

[0007] D stands for denier, a unit of measurement for the fineness of yarn. It can also be used as a unit of diameter, referring to the weight in grams of 9000m of fiber at standard moisture regain. For example, if 9000m of fiber weighs 600 grams, the fiber is called 600D fiber. The larger the number, the thicker the fiber.

[0008] As a preferred embodiment of the present invention, the fiber length of the first polyester fiber is 50-70 mm.

[0009] As a preferred embodiment of the present invention, the fiber length of the second polyester fiber is 45-60 mm.

[0010] As a preferred technical solution of the present invention, the weight ratio of the first polyester fiber and the second polyester fiber is (25-30):(8-12).

[0011] The applicant unexpectedly discovered in their experiments that by using a specific blend of polyester fibers, not only could the fiber's toughness, elasticity, and other mechanical properties be guaranteed, but the material's sound absorption coefficient could also be improved. The applicant speculates that this may be because the mixing of fibers with different lengths and diameters causes molecular entanglement, which affects the pore distribution of the entire material system, thus influencing the material's sound absorption effect; simultaneously, the synergistic effect with modified polyester fibers affects the molecular crystallinity of the polyester material, thereby affecting the molecular structure and altering its mechanical properties.

[0012] As a preferred technical solution of the present invention, the natural fiber is selected from one or more of bamboo fiber, soybean fiber, and leaf fiber.

[0013] As a preferred embodiment of the present invention, the modified polyester fiber is obtained by ultraviolet radiation modification.

[0014] Preferably, the specific steps of the ultraviolet radiation modification method are as follows: 2g of the third polyester fiber is soaked in 400mL of 0.4mol / L NaOH aqueous solution at 47℃ for 15min, irradiated with an ultraviolet spectrometer at a wavelength of 340nm or 365nm for 40min, and then washed with 500mL of deionized water and dried to obtain the modified polyester fiber.

[0015] Modifying polyester fibers using ultraviolet radiation reduces their molecular weight, altering their mechanical properties, typically leading to a decrease in elongation at break. However, this invention mitigates this effect through radiation under alkaline conditions. Furthermore, by combining first and second polyester fibers, the mechanical properties are actually improved, as is the sound absorption coefficient. The applicant hypothesizes that under alkaline conditions, radiation causes the intertwined fiber chains in the polyester fibers to break, resulting in chain shortening and molecular rearrangement at the chain ends, thus affecting molecular crystallinity. Under specific alkaline environments and with specific polyester fiber molecular conditions, this effect on crystallinity is weakened. Especially in a 0.4 mol / L NaOH aqueous solution, this effect positively influences molecular crystallinity, not only increasing the fiber's elongation at break but also improving the sound absorption coefficient.

[0016] As a preferred technical solution of the present invention, the polyester material comprises 30-50 parts polyester fiber, 1-10 parts natural fiber and 1-10 parts modified polyester fiber by weight.

[0017] As a preferred embodiment of the present invention, the polyester material comprises, by weight, 33-42 parts polyester fiber, 4-7 parts natural fiber and 3-6 parts modified polyester fiber.

[0018] A second aspect of the present invention provides a process for preparing a polyester material, characterized in that the polyester material is obtained through a blending process.

[0019] The blending process is as follows: (1) The raw materials of polyester material are mixed according to the weight ratio to obtain mixture 1; (2) Mixture 1 is added to water, the weight ratio of water to the first mixture is (2.2-5.7):1, and an antistatic agent is added to the water, the weight of the antistatic agent is 0.6% of the total weight of water and the first mixture, and the reaction is carried out at 65-70℃ for 2-4 hours to obtain mixture 2; (3) Washing and drying: Mixture 2 is washed with water for 8-15 minutes and dried at 40℃ for 2-4 hours to obtain mixture 3; (4) Spinning: Add to a blending machine and blend to obtain polyester material.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] (1) A polyester fiber mixture using a first polyester fiber with a diameter of 6-10D and a second polyester fiber with a diameter of 1-5D can not only ensure the toughness, elasticity and other mechanical properties of the fiber, but also improve the sound absorption coefficient of the material.

[0022] (2) A specific ratio of polyester fiber is mixed, especially when the weight ratio of the first polyester fiber and the second polyester fiber is (25-30): (8-12), which improves the stability of the polyester material and extends its service life. When the polyester material is used to make sound-absorbing panels, it can maintain a good sound absorption effect for a long time.

[0023] (3) The polyester fiber is modified by ultraviolet radiation. The radiation effect causes the molecular weight of the polyester fiber to decrease, which leads to changes in its mechanical properties. Generally, this will cause a decrease in the elongation at break. However, this invention weakens this effect by irradiating under alkaline conditions. At the same time, the mechanical properties are improved and the sound absorption coefficient is also improved when combined with the first polyester fiber and the second polyester fiber.

[0024] (4) Through the combined action of the system substances of polyester material, the release of harmful gases from the sound-absorbing panel is significantly reduced after the polyester material obtained by the present invention is used to produce the sound-absorbing panel.

[0025] (5) Through the combined action of the polyester material system, the polyester material obtained by the present invention produces sound-absorbing panels with good anti-fouling and anti-oil capabilities. Detailed Implementation

[0026] Example

[0027] The raw materials used in the preparation of the compositions in the examples were all commercially available. The first polyester fiber was purchased from Guangzhou Zhongcheng New Material Technology Co., Ltd., with a diameter of 7D and a fiber length of 60mm. The second polyester fiber was purchased from Longfeng Chemical Fiber, with a diameter of 2.5D and a fiber length of 51mm. The third polyester fiber was purchased from Taicang Fangke Textile Co., Ltd., and the bamboo fiber was purchased from Shandong Jiumian Textile Co., Ltd. The antistatic agent was purchased from Weihai Huaen Rubber & Plastic New Material Co., Ltd., model 7101.

[0028] Example 1

[0029] This example provides a polyester material comprising, by weight, 37 parts polyester fiber, 6 parts natural fiber, and 5 parts modified polyester fiber. The polyester fiber comprises a first polyester fiber and a second polyester fiber. The weight ratio of the first polyester fiber to the second polyester fiber is 27:10. The natural fiber is bamboo fiber.

[0030] Modified polyester fibers are obtained by ultraviolet radiation modification.

[0031] The specific steps of the ultraviolet radiation modification method are as follows: 2g of the third polyester fiber is immersed in 400mL of 0.4mol / L NaOH aqueous solution at 47℃ for 15min, and then irradiated with an ultraviolet spectrometer at a wavelength of 340nm for 40min. After removal, it is washed with 500mL of deionized water and dried to obtain the modified polyester fiber.

[0032] This example also provides a preparation process for polyester material, the blending process specifically being: (1) mixing the raw materials of polyester material according to the weight parts to obtain mixture 1; (2) adding mixture 1 to water, the weight ratio of water to the first mixture being 4.5:1, and adding an antistatic agent to the water, the weight of the antistatic agent being 0.6% of the total weight of water and the first mixture, reacting at 67°C for 3 hours to obtain mixture 2; (3) washing and drying: washing mixture 2 with water for 10 minutes, drying at 40°C for 3.5 hours to obtain mixture 3; (4) spinning: adding to a blending machine, blending to obtain polyester material.

[0033] Example 2

[0034] This example provides a polyester material and its preparation process. Unlike Example 1, the polyester material includes 41 parts polyester fiber, 6 parts natural fiber and 5 parts modified polyester fiber.

[0035] This example also provides a preparation process for a polyester material, which is the same as in Example 1.

[0036] Example 3

[0037] This example provides a polyester material and its preparation process. Unlike Example 1, the polyester material includes 35 parts polyester fiber, 5 parts natural fiber and 3 parts modified polyester fiber.

[0038] This example also provides a preparation process for a polyester material, which is the same as in Example 1.

[0039] Example 4

[0040] This example provides a polyester material and its preparation process. Unlike Example 1, the polyester material includes 40 parts polyester fiber, 7 parts natural fiber and 6 parts modified polyester fiber, and the weight ratio of the first polyester fiber and the second polyester fiber is 15:12.

[0041] This example also provides a preparation process for a polyester material, which is the same as in Example 1.

[0042] Example 5

[0043] This example provides a polyester material and its preparation process. Unlike Example 1, the polyester material includes 39 parts polyester fiber, 6 parts natural fiber and 8 parts modified polyester fiber, and the weight ratio of the first polyester fiber and the second polyester fiber is 27:10.

[0044] This example also provides a preparation process for a polyester material, which is the same as in Example 1.

[0045] Performance testing:

[0046] 1. Hazardous gas test: The polyester material obtained in Example 1 was opened and hot-pressed to form a sound-absorbing board according to conventional methods in the art. The formaldehyde emission was tested according to GB18580-2001. The formaldehyde emission was 0.29mg / L, which reached the E1 level and is safe and environmentally friendly.

[0047] 2. Performance Testing: The polyester materials obtained in Examples 1-5 were opened and hot-pressed to obtain sound-absorbing panels according to conventional methods in the art. The sound absorption coefficient was tested according to JT / T 646.4-2016. After being placed at 3°C ​​and 50% humidity for 30 days, the sound absorption coefficient was tested again. The results are shown in Table 1.

[0048] Table 1

[0049] Example Sound absorption coefficient Sound absorption coefficient after 30 days 1 1.05 1.05 2 0.97 0.96 3 1.00 0.97 4 0.90 0.85 5 0.95 0.95

Claims

1. A polyester material, characterized in that, By weight, the polyester material comprises 33-42 parts polyester fiber, 4-7 parts natural fiber and 3-6 parts modified polyester fiber; The natural fiber mentioned is bamboo fiber; The polyester fiber includes a first polyester fiber with a diameter of 6-10D and a second polyester fiber with a diameter of 1-5D; The first polyester fiber has a fiber length of 50-70 mm; The second polyester fiber has a fiber length of 45-60 mm; The weight ratio of the first polyester fiber to the second polyester fiber is (25-30):(8-12); The modified polyester fiber was obtained by ultraviolet radiation modification. The specific steps of the ultraviolet radiation modification method are as follows: 2g of the third polyester fiber is soaked in 400mL of 0.4mol / L NaOH aqueous solution at 47℃ for 15min, and then irradiated with an ultraviolet spectrometer at a wavelength of 340nm or 365nm for 40min. After taking it out, it is washed with 500mL of deionized water and dried to obtain the modified polyester fiber. The polyester material is obtained by blending raw materials using a blending machine. The specific blending process is as follows: (1) The raw materials of polyester material are mixed according to the weight parts to obtain the first mixture; (2) Add the first mixture to water, with the weight ratio of water to the first mixture being (2.2-5.7):1, and add an antistatic agent to the water, with the weight of the antistatic agent being 0.6% of the total weight of water and the first mixture. React at 65-70℃ for 2-4 hours to obtain the second mixture. (3) Washing and drying: The second mixture is washed with water for 8-15 min and dried at 40℃ for 2-4 h to obtain the third mixture; (4) Spinning: The third mixture is added to the blending machine and blended to obtain polyester material.