A preformed breathable web and method of making the same

Abstract

The application relates to the technical field of composite materials, and discloses a prefabricated air-permeable coiled material and a preparation method thereof. From top to bottom, the prefabricated air-permeable coiled material comprises a surface layer and a bottom layer. The surface layer comprises the following raw materials in parts by weight: SEBS 30-40 parts, polypropylene 15-22 parts, a first filler 15-25 parts, a softening agent 25-30 parts, an antioxidant 1-3 parts and maleic anhydride grafted polypropylene 1-3 parts. The bottom layer comprises the following raw materials in parts by weight: SEBS 15-22 parts, polypropylene 30-40 parts, a second filler 20-30 parts, a softening agent 25-30 parts and maleic anhydride grafted polypropylene 1-3 parts. The first filler and the second filler are both calcium-containing compounds. Through the technical scheme, the problems of poor air permeability, wear resistance and mechanical properties of the prefabricated coiled material in the related art are solved.

Description

Technical Field

[0001] This invention relates to the field of composite material technology, specifically to a prefabricated breathable roll material and its preparation method. Background Technology

[0002] Precast roofing membranes, as an emerging high-performance material, are gradually becoming the preferred choice for sports facility construction. They not only enhance the safety and comfort of sports fields but also lead the innovation trend of sports field materials with their unique advantages. Precast roofing membranes are manufactured in factories using precise processes, possessing excellent elasticity and shock absorption properties. They effectively absorb the impact of sports activities, reducing the risk of athlete injury, and are especially suitable for high-intensity competitive sports, providing athletes with a safe sports environment. Precast roofing membranes are suitable for track and field competition venues and training grounds at all levels, as well as for various school competition and teaching venues. However, because the membranes are laid on the ground, groundwater evaporation can easily cause them to become damp and blister, affecting their use and lifespan. Therefore, it is necessary to develop a breathable membrane to prevent dampness and blistering caused by groundwater, thus extending the membrane's service life. Summary of the Invention

[0003] This invention proposes a prefabricated breathable roll material and its preparation method, which solves the problems of poor breathability, wear resistance and mechanical properties of prefabricated roll materials in related technologies.

[0004] The technical solution of the present invention is as follows: This invention proposes a prefabricated breathable roll material, which consists of a top layer and a bottom layer from top to bottom. The top layer comprises the following raw materials in parts by weight: 30-40 parts of SEBS, 15-22 parts of polypropylene, 15-25 parts of first filler, 25-30 parts of softener, 1-3 parts of antioxidant, and 1-3 parts of maleic anhydride-grafted polypropylene. The bottom layer comprises the following raw materials in parts by weight: 15-22 parts SEBS, 30-40 parts polypropylene, 20-30 parts second filler, 25-30 parts softener, and 1-3 parts maleic anhydride-grafted polypropylene. Both the first and second packing materials contain calcium compounds.

[0005] As a further technical solution, the first filler and the second filler are each independently one or more of calcium carbonate, calcium sulfate, and calcium oxide.

[0006] As a further technical solution, both the first packing material and the second packing material are calcium sulfate.

[0007] In this invention, the impact resistance, toughness and strength of the precast roll material are improved by adding calcium sulfate to the precast roll material.

[0008] As a further technical solution, the first filler and the second filler each independently include one or both of calcium sulfate whiskers and calcium sulfate powder.

[0009] As a further technical solution, the first filler is composed of calcium sulfate whiskers and calcium sulfate powder, and the second filler is calcium sulfate powder.

[0010] In this invention, by adding calcium sulfate whiskers and calcium sulfate powder to the surface layer, the wear resistance, elasticity and tensile properties of the surface layer are improved, and by adding calcium sulfate powder to the bottom layer, the density and wear resistance of the bottom layer are improved, thereby further improving the wear resistance and mechanical properties of the precast roll material.

[0011] As a further technical solution, the mass ratio of calcium sulfate whiskers to calcium sulfate powder in the first filler is 3~5:1.

[0012] In this invention, by limiting the mass ratio of calcium sulfate whiskers to calcium sulfate powder in the first filler to 3~5:1, the wear resistance and tensile strength of the precast roll material are further improved.

[0013] As a further technical solution, the mass ratio of calcium sulfate whiskers to calcium sulfate powder in the first filler is 4:1.

[0014] As a further technical solution, the diameter of the calcium sulfate whiskers is 25~37μm and the aspect ratio is 37.

[0015] As a further technical solution, the particle size of the calcium sulfate powder is 1250 mesh.

[0016] As a further technical solution, the softener includes one or more of naphthenic oil, polyethylene wax, and aromatic oil.

[0017] As a further technical solution, the antioxidant includes one or more of antioxidant 1010, antioxidant 168, and antioxidant 1330.

[0018] As a further technical solution, the surface layer also includes 1 to 5 parts of polytetrahydrofuran ether diol.

[0019] As a further technical solution, the number-average molecular weight of the polytetrahydrofuran ether diol is 1000~1800.

[0020] As a further technical solution, the mass ratio of maleic anhydride-grafted polypropylene to polytetrahydrofuran ether diol in the surface layer is 1:2~4.

[0021] As a further technical solution, the mass ratio of maleic anhydride-grafted polypropylene to polytetrahydrofuran ether diol in the surface layer is 1:3.

[0022] In this invention, the tensile strength and abrasion resistance of the precast roll material are further improved by compounding polytetrahydrofuran ether diol and maleic anhydride-grafted polypropylene in the surface layer.

[0023] This invention also proposes a method for preparing prefabricated breathable roll material, comprising the following steps: After the raw materials for the top and bottom layers are mixed evenly, they are extruded and hot-pressed to obtain prefabricated breathable rolls.

[0024] As a further technical solution, the preparation method of the prefabricated breathable roll material is as follows: after the raw materials of the surface layer and the bottom layer are mixed evenly, the prefabricated breathable roll material is obtained by extrusion, hot pressing, embossing, cooling and perforation.

[0025] As a further technical solution, the thickness of the surface layer is 2~5mm, and the thickness of the bottom layer is 5~10mm.

[0026] As a further technical solution, the extrusion temperature is 180~220℃.

[0027] The present invention also provides an application of prefabricated breathable roll material, wherein the application involves applying adhesive to the bottom layer of the prefabricated breathable roll material and then attaching it to the ground. The specific method of applying adhesive is as follows: longitudinally: apply adhesive every 30 cm for 30 cm; transversely: leave a drainage hole every 1 meter, and the width of the drainage hole is 10 cm.

[0028] In this invention, by punching holes in the roll material and applying adhesive intermittently, the air permeability of the prefabricated roll material is improved, solving the problem of the roll material being prone to dampness and bubbling due to ground moisture.

[0029] The working principle and beneficial effects of this invention are as follows: In this invention, the precast roll material consists of a top layer and a bottom layer. The substrates of both the top and bottom layers are composed of SEBS and polypropylene, but the contents of SEBS and polypropylene in the top and bottom layers are different. This improves the wear resistance and mechanical properties of the precast roll material while reducing its cost. Furthermore, by adding calcium-containing compounds to the top and bottom layers, a physical entanglement is formed with SEBS and polypropylene, further improving the wear resistance and mechanical properties of the precast roll material and solving the problem of poor wear resistance and mechanical properties of precast roll materials. Detailed Implementation

[0030] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0031] In the following embodiments and comparative examples: SEBS, model: G1701; Polypropylene, model: K8303; Naphthenic oil, model: N4010; Polyethylene wax, model: Q-18PE; Aromatic oil, kinematic viscosity: 25~50; Maleic anhydride-grafted polypropylene, model: B1-1; Polytetrahydrofuran ether glycol, number average molecular weight 1000, 1400, 1800; Calcium sulfate whiskers, diameter 25~37μm, aspect ratio 37; Calcium sulfate powder, particle size 1250 mesh; Calcium carbonate, particle size 1250 mesh; Calcium oxide, particle size 1250 mesh.

[0032] Example 1 A method for preparing a prefabricated breathable roll material includes the following steps: The raw materials of the surface layer by weight are: 30 parts SEBS, 15 parts polypropylene, 15 parts calcium carbonate (1250 mesh), 25 parts naphthenic oil, 1 part antioxidant 1010, and 1 part maleic anhydride grafted polypropylene. The raw materials of the bottom weight components are: 15 parts SEBS, 30 parts polypropylene, 20 parts calcium carbonate (1250 mesh), 25 parts naphthenic oil, and 1 part maleic anhydride grafted polypropylene. After the raw materials of the top layer and the bottom layer are mixed evenly, they are extruded, hot-pressed, embossed, cooled and perforated at 180°C to obtain a prefabricated breathable roll material; the thickness of the top layer is 2mm and the thickness of the bottom layer is 5mm.

[0033] Example 2 A method for preparing a prefabricated breathable roll material includes the following steps: The raw materials of the surface layer by weight are: 35 parts SEBS, 18 parts polypropylene, 20 parts calcium oxide (1250 mesh), 27 parts polyethylene wax, 2 parts antioxidant 168, and 2 parts maleic anhydride grafted polypropylene. The raw materials of the bottom weight components are: 18 parts SEBS, 35 parts polypropylene, 25 parts calcium oxide (1250 mesh), 27 parts polyethylene wax, and 2 parts maleic anhydride grafted polypropylene. After the raw materials of the top layer and the bottom layer are mixed evenly, they are extruded, hot-pressed, embossed, cooled and perforated at 200℃ to obtain a prefabricated breathable roll material; the thickness of the top layer is 3mm and the thickness of the bottom layer is 8mm.

[0034] Example 3 A method for preparing a prefabricated breathable roll material includes the following steps: The raw materials of the surface layer by weight are: 40 parts SEBS, 22 parts polypropylene, 25 parts calcium sulfate powder (1250 mesh), 30 parts aromatic oil, 3 parts antioxidant 168, and 3 parts maleic anhydride grafted polypropylene. The raw materials of the bottom weight components are: 22 parts SEBS, 40 parts polypropylene, 30 parts calcium sulfate powder (1250 mesh), 30 parts aromatic oil, and 3 parts maleic anhydride grafted polypropylene. After the raw materials of the top layer and the bottom layer are mixed evenly, they are extruded, hot-pressed, embossed, cooled and perforated at 220℃ to obtain a prefabricated breathable roll material; the thickness of the top layer is 5mm and the thickness of the bottom layer is 10mm.

[0035] Example 4 The only difference between this embodiment and Embodiment 1 is that the calcium carbonate (1250 mesh) in the top and bottom layers is replaced with an equal amount of calcium sulfate powder (1250 mesh).

[0036] Example 5 Compared with Example 1, the only difference in this embodiment is that the calcium carbonate (1250 mesh) in the top and bottom layers is replaced with an equal amount of calcium sulfate whiskers (diameter of 25~37μm, aspect ratio of 37).

[0037] Example 6 The only difference between this embodiment and Example 4 is that the calcium sulfate powder (1250 mesh) in the surface layer is replaced with an equal amount of calcium sulfate powder (300 mesh) and calcium sulfate whiskers (diameter of 25~37μm and aspect ratio of 37) in a mass ratio of 1:3.

[0038] Example 7 The only difference between this embodiment and Example 4 is that the calcium sulfate powder (1250 mesh) in the surface layer is replaced with an equal amount of calcium sulfate powder (1250 mesh) and calcium sulfate whiskers (diameter of 25~37μm and aspect ratio of 37) in a mass ratio of 1:4.

[0039] Example 8 The only difference between this embodiment and embodiment 4 is that the calcium sulfate powder (1250 mesh) in the surface layer is replaced with an equal amount of calcium sulfate powder (1250 mesh) and calcium sulfate whiskers (diameter of 25~37μm and aspect ratio of 37) in a mass ratio of 1:5.

[0040] Example 9 The only difference between this embodiment and Example 7 is that 5 parts of polytetrahydrofuran ether diol (number average molecular weight of 1000) are added to the surface layer.

[0041] Example 10 The only difference between this embodiment and Example 7 is that 5 parts of polytetrahydrofuran ether diol (number average molecular weight of 1400) are added to the surface layer.

[0042] Example 11 The only difference between this embodiment and Example 7 is that 5 parts of polytetrahydrofuran ether diol (number average molecular weight of 1800) are added to the surface layer.

[0043] Example 12 The only difference between this embodiment and Example 9 is that 1 part of polytetrahydrofuran ether diol (number average molecular weight of 1400) is added to the surface layer.

[0044] Example 13 The only difference between this embodiment and Example 9 is that 2 parts of polytetrahydrofuran ether diol (number average molecular weight of 1400) are added to the surface layer.

[0045] Example 14 The only difference between this embodiment and Example 9 is that 3 parts of polytetrahydrofuran ether diol (number average molecular weight of 1400) are added to the surface layer.

[0046] Example 15 The only difference between this embodiment and Example 9 is that 4 parts of polytetrahydrofuran ether diol (number average molecular weight of 1400) are added to the surface layer.

[0047] Comparative Example 1 The only difference between this comparative example and Example 1 is that the calcium carbonate (1250 mesh) in both the top and bottom layers was replaced with an equal amount of silicon dioxide (1250 mesh).

[0048] The abrasion resistance and mechanical properties of the prefabricated breathable roll materials prepared in Examples 1-15 and Comparative Example 1 were tested respectively. The specific testing methods are as follows: Abrasion resistance: Abrasion resistance was tested according to GB / T 14833-2020 "Synthetic Materials for Sports Field Surfaces"; Mechanical properties: Tensile strength was tested according to EN 14810-2006 "Sports field surfaces - Determination of the resistance of cleats"; The test results are shown in Table 1.

[0049] Table 1 Performance test results of prefabricated breathable roll materials

[0050] Compared with Example 1, the filler in Comparative Example 1 was silicon dioxide. As a result, the wear of the prefabricated breathable roll material prepared in Comparative Example 1 was higher than that in Example 1, and the tensile strength was lower than that in Example 1. This indicates that calcium-containing compound fillers can improve the wear resistance and mechanical properties of prefabricated breathable roll materials.

[0051] Compared with Example 1, Examples 4-8 changed the composition of the fillers in the top and bottom layers. The prefabricated breathable roll material prepared in Example 5 had a lower abrasion rate and higher tensile strength than Examples 1 and 4, indicating that using calcium sulfate whiskers as fillers can further improve the abrasion resistance and mechanical properties of the prefabricated breathable roll material. Compared with Examples 6-8, the mass ratio of calcium sulfate whiskers to calcium sulfate powder in the top layer was changed. The prefabricated breathable roll material prepared in Examples 6-8 had a lower abrasion rate and higher tensile strength than Examples 4 and 5, indicating that when the mass ratio of calcium sulfate whiskers to calcium sulfate powder in the top layer is 3-5:1, the abrasion resistance and mechanical properties of the prefabricated breathable roll material can be further improved. The prefabricated breathable roll material prepared in Example 7 had a lower abrasion rate and higher tensile strength than Examples 6 and 8, indicating that when the mass ratio of calcium sulfate whiskers to calcium sulfate powder in the top layer is 4:1, the abrasion resistance and mechanical properties of the prefabricated breathable roll material can be further improved.

[0052] Compared with Example 7, Examples 9-11 added polytetrahydrofuran ether diol with different number average molecular weights to the surface layer. As a result, the abrasion of the prefabricated breathable roll material prepared in Example 10 was lower than that in Examples 9 and 11, and the tensile strength was higher than that in Examples 9 and 11. This indicates that when the number average molecular weight of polytetrahydrofuran ether diol is 1400, the abrasion resistance and mechanical properties of the prefabricated breathable roll material can be further improved.

[0053] Compared with Example 10, Examples 12-15 varied the amount of polytetrahydrofuran ether diol added. The results showed that the prefabricated breathable rolls prepared in Examples 13-15 had lower abrasion resistance and higher tensile strength than Examples 10 and 12. This indicates that when the mass ratio of maleic anhydride-grafted polypropylene to polytetrahydrofuran ether diol in the surface layer is 1:2-4, the abrasion resistance and mechanical properties of the prefabricated breathable rolls can be further improved. Comparing Examples 13-15, it was found that the prefabricated breathable rolls prepared in Example 14 had lower abrasion resistance and higher tensile strength than Examples 13 and 15. This indicates that when the mass ratio of maleic anhydride-grafted polypropylene to polytetrahydrofuran ether diol in the surface layer is 1:3, the prefabricated breathable rolls obtained have the highest abrasion resistance and mechanical properties.

[0054] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A prefabricated breathable roll material, characterized in that, From top to bottom, the layers are a top layer and a bottom layer. The top layer comprises the following raw materials in parts by weight: 30-40 parts of SEBS, 15-22 parts of polypropylene, 15-25 parts of first filler, 25-30 parts of softener, 1-3 parts of antioxidant, 1-3 parts of maleic anhydride-grafted polypropylene, and 1-5 parts of polytetrahydrofuran ether glycol. The bottom layer comprises the following raw materials in parts by weight: 15-22 parts SEBS, 30-40 parts polypropylene, 20-30 parts second filler, 25-30 parts softener, and 1-3 parts maleic anhydride-grafted polypropylene. Both the first and second fillers are calcium-containing compounds; The first filler is composed of calcium sulfate whiskers and calcium sulfate powder in a mass ratio of 3 to 5:1; The mass ratio of maleic anhydride-grafted polypropylene to polytetrahydrofuran ether diol in the surface layer is 1:2~4. The number-average molecular weight of the polytetrahydrofuran ether diol is 1400.

2. The prefabricated breathable roll material according to claim 1, characterized in that, The second filler is one or more of calcium carbonate, calcium sulfate, and calcium oxide.

3. The prefabricated breathable roll material according to claim 2, characterized in that, The second filler is calcium sulfate.

4. The prefabricated breathable roll material according to claim 3, characterized in that, The second filler includes one or both of calcium sulfate whiskers and calcium sulfate powder.

5. A prefabricated breathable roll material according to claim 1, characterized in that, The softener includes one or more of naphthenic oil, polyethylene wax, and aromatic oil.

6. A method for preparing a prefabricated breathable roll material according to any one of claims 1 to 5, characterized in that, Includes the following steps: After the raw materials for the top and bottom layers are mixed evenly, they are extruded and hot-pressed to obtain prefabricated breathable rolls.

7. The method for preparing a prefabricated breathable roll material according to claim 6, characterized in that, The extrusion temperature is 180~220℃.

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