A tear-resistant PVC composite vehicle tarpaulin, its equipment, preparation method, and applications.

Abstract

This invention belongs to the technical field of polymer composite tarpaulins, specifically relating to a tear-resistant PVC composite automotive tarpaulin, its equipment, preparation method, and applications. The automotive tarpaulin consists of a base fabric and PVC films bonded to both sides by a PVC paste. The PVC paste comprises 100 parts PVC paste resin, 90-120 parts plasticizer, 4-8 parts adhesive, 11-12 parts viscosity reducer, and 25-35 parts PVC calcium powder; the thickness of the PVC paste penetrating the base fabric is less than or equal to 1 / 3 of the base fabric thickness. This invention improves the automotive tarpaulin manufacturing equipment by adding a bottom film pressing roller and a top film pressing roller to enhance the bonding of the PVC film to the main cylinder. Furthermore, by using a modified transfer sizing roller assembly, the original impregnation process is replaced with a transfer sizing method, which reduces the sizing weight and penetration into the mesh fabric, increases the tarpaulin's tear resistance, and provides excellent peel resistance.

Description

Technical Field

[0001] This invention belongs to the field of polymer composite tarpaulin technology, specifically relating to a tear-resistant PVC composite vehicle tarpaulin, its equipment, preparation method, and applications. Background Technology

[0002] Tarpaulin is a high-strength, waterproof material with good toughness and flexibility. It is used in trucks, outdoor cargo, outdoor tents / campuses, and outdoor awnings. Commonly used tarpaulins are coated tarpaulins, using polyester mesh as the base fabric and PVC film bonded to the surface with PVC adhesive. The PVC film, located on the surface of the tarpaulin, provides excellent protection against dirt, maintains airtightness, prevents rainwater leakage, and is also printable, absorbing inks effectively to produce vibrant colors. The polyester mesh, as the support layer for coated automotive tarpaulins, is typically made of high-strength polyester fibers or other synthetic fibers, providing the necessary strength and stability to ensure long-term use in outdoor environments. The PVC adhesive, located between or below the polyester mesh and PVC film, provides excellent adhesion, connecting the two polar polymers of polyester and PVC film to form a stable structure, allowing the PVC film to adhere firmly to the polyester mesh without easily detaching. Current tarpaulins generally meet market demands in terms of sunshade and waterproofing, but their tear resistance needs improvement. This is especially true for customers in the European and American markets, who have higher requirements for the tear resistance of tarpaulins.

[0003] Existing technologies mostly rely on special tear-resistant agents, increased adhesive usage, the use of special fiber base fabrics, or changes in the weaving density of the base fabric to improve the tear resistance of tarpaulins. However, this leads to increased costs and higher weight of the tarpaulins. Chinese patent document CN114561814A provides a tear-resistant tarpaulin that uses polyethersulfone and plasticizers, but requires additional polymethylvinylsiloxane silanolate potassium to improve tear resistance. Chinese patent document CN110356080A provides a tear-resistant tarpaulin, but requires additional tear-resistant agents and tear-resistant layers, and does not disclose which tear-resistant agent is used. Chinese patent documents CN113863003A and CN116084176A provide various tear-resistant tarpaulins, but require modification of the warp and weft threads of the base fabric, the addition of polymer-modified fibers, glass fibers, or additional current treatment. These tarpaulins have high tear resistance, but the production cost is high and the process is more complex.

[0004] Improving the tear resistance of tarpaulins without increasing the complexity of the process or the cost of materials is an urgent problem to be solved in the tarpaulin industry. Summary of the Invention

[0005] To address the aforementioned problems, the purpose of this invention is to provide a tear-resistant PVC composite automotive tarpaulin, its equipment, preparation method, and applications. This invention improves the tear resistance of automotive tarpaulins without increasing material costs or process complexity, thus meeting the performance requirements of automotive tarpaulins in the United States and other countries.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] First: This invention provides a tear-resistant PVC composite vehicle tarpaulin, comprising a base fabric, a PVC film, and a PVC slurry, wherein the PVC film is bonded to the bottom and top sides of the base fabric by the PVC slurry; characterized in that the raw materials of the PVC slurry, by weight, include the following materials: 100 parts of PVC paste resin, 90-120 parts of plasticizer, 4-8 parts of adhesive, 11-12 parts of viscosity reducer, and 25-35 parts of PVC calcium powder; the thickness of the PVC slurry penetrating into the base fabric is less than or equal to 1 / 3 of the thickness of the base fabric.

[0008] Obviously, the set value for the thickness of PVC slurry penetrating the base fabric here is the upper limit. The lower limit for its penetration into the base fabric should be 0, that is, the thickness X of PVC slurry penetrating the base fabric is greater than 0 and less than or equal to 1 / 3 of the thickness of the base fabric.

[0009] Preferably, the PVC paste resin is selected from one or more of PB-50, P80, PSM-31, and C65V.

[0010] Preferably, the PVC paste resin is made by mixing PB-50 and PSM-31, and the weight ratio of PB-50 to PSM-31 is 4:1.

[0011] Preferably, the PVC paste resin is PSM-31.

[0012] Preferably, the PVC paste resin is made by mixing P80 and C65V, and the weight ratio of PB-50 and PSM-31 is 4:1.

[0013] Preferably, the plasticizer is selected from one or more of dimethyl phthalate (DMP), di-n-butyl phthalate (DBP), di(α-ethylhexyl) phthalate (DEHP), dioctyl phthalate (DOP), diisononyl phthalate (DINP), and Mesamoll alkyl sulfonate plasticizers.

[0014] Preferably, the adhesive is selected from one or more of TP-53-552, N3300, TP-300, NP001, NP002, RG-901, and NP4042.

[0015] Preferably, the viscosity reducer is one or both of D-80 and D-60.

[0016] Preferably, the PVC calcium powder is selected from one or more of heavy calcium carbonate, light calcium carbonate, and ultra-white nano calcium.

[0017] Second: This invention provides an apparatus for preparing the aforementioned tear-resistant PVC composite automotive tarpaulin, which is arranged in sequence according to the steps of base fabric traction, sizing, and PVC film lamination, including a base fabric frame, a base fabric traction wheel, a base fabric guide wheel, a PVC sizing tank A, a PVC sizing tank B, an oven, a bottom film frame, a large cylinder A, a top film frame, and a large cylinder B; the apparatus also includes a transfer sizing wheel group A, a transfer sizing wheel group B, a bottom film pressing wheel, and a top film pressing wheel; the transfer sizing wheel group A and the transfer sizing wheel group B are each composed of a sizing wheel a disposed in the PVC sizing tank A or the PVC sizing tank B and a sizing wheel b that is in linear contact with the surface of the sizing wheel a; the bottom film pressing wheel and the top film pressing wheel are respectively disposed between the bottom film and the top film and the large cylinder A or the large cylinder B.

[0018] The sizing wheel a is used to pick up PVC slurry from PVC slurry tank A or PVC slurry tank B and apply it to the wheel surface by means of rotation. The sizing wheel b is used to transfer the PVC slurry carried on the surface of the sizing wheel a to the surface of the base fabric by means of linear contact with the surface of the sizing wheel a and by means of rotation.

[0019] Preferably, both the sizing wheel a and the sizing wheel b are 30-mesh screen wheels.

[0020] Preferably, cylinder A and cylinder B are 1500 and 2000 cylinders respectively.

[0021] Third: This invention provides a method for preparing tear-resistant PVC composite automotive tarpaulin using the aforementioned equipment, comprising the following steps:

[0022] S1 PVC slurry preparation: Take PVC paste resin, plasticizer, viscosity reducer and PVC calcium powder and stir in a high-speed mixer to obtain PVC raw slurry. Cool for 24 hours, pull it to the machine, add adhesive and mix to obtain PVC slurry.

[0023] S2 vehicle tarpaulin preparation: The base fabric is placed on the base fabric frame, PVC film is placed on the bottom film frame and the top film frame, and PVC slurry is placed in PVC slurry tank A and PVC slurry tank B. The unit is started, causing the sizing roller a to rotate, carrying the PVC slurry from PVC slurry tank A and PVC slurry tank B, and then transferring the PVC slurry to the surface of the sizing roller b through linear surface contact. The base fabric is rotated and bonded to the upper surface of the sizing roller b to achieve sizing transfer. The sizing base fabric is dried in an oven. The bottom film and the top film are pressed and bonded to the surfaces of large cylinders A and B respectively by the bottom film pressing roller and the top film pressing roller, and then, by rotation, the bottom film and the top film are bonded to the bottom or top side of the base fabric through the surfaces of large cylinders A and B respectively. Roller pressing yields the vehicle tarpaulin.

[0024] Fourth: This invention provides the use of the aforementioned tear-resistant PVC composite vehicle tarpaulin in the preparation of vehicle covering products. The vehicle covering product refers to a cover used temporarily or for a certain period of time to cover the surface of a vehicle or its cargo. The vehicle includes cargo trucks, generally referred to as freight trucks or lorries, including dump trucks, tractor-trailers, off-road trucks, etc., belonging to the commercial vehicle category, and can be divided into heavy-duty and light-duty types according to the vehicle's weight. Of course, the vehicle covering product can also be used as a cargo tarpaulin for covering and protecting goods outdoors, such as at docks.

[0025] The beneficial effects of this invention are as follows:

[0026] The PVC slurry of this invention reduces the amount of adhesive used. Combined with improvements in the production process and equipment for vehicle tarpaulins, it can significantly improve the tear resistance and durability of vehicle tarpaulins.

[0027] This invention improves the production process and equipment for vehicle tarpaulins by adding pressing rollers to the surface of the large cylinder, allowing the PVC film to better cover the cylinder and increasing the pressing area. At the same time, a transfer sizing roller set is added, changing the original impregnation process to a transfer sizing process, which reduces the penetration of PVC sizing into the base fabric and structural damage, allowing the base fabric fibers to slide better and significantly improving its tear resistance.

[0028] Overall, this invention, through adjustments to the PVC slurry and improvements to the production process of automotive tarpaulins, has yielded an automotive tarpaulin with good tear resistance and durability, which can meet the performance requirements of automotive tarpaulin products in the European and American markets. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the layered structure of a vehicle tarpaulin in the prior art;

[0030] Figure 2 This is a schematic diagram of the layered structure of the vehicle tarpaulin of the present invention;

[0031] Figure 3 The manufacturing process of the vehicle tarpaulin of the present invention is shown according to the manufacturing component relationship;

[0032] In the diagram, 1 is the PVC face film layer, 2 is the PVC base film layer, 3 is the base fabric layer, 4 is the PVC slurry layer, 5 is the base fabric traction wheel, 6 is the base fabric guide wheel, 7 is the PVC slurry tank A, 8 is the transfer slurry roller group A, 9 is the PVC slurry tank B, 10 is the transfer slurry roller group B, 11 is the base film pressing wheel, 12 is the face film pressing wheel, 13 is the slurry roller a, 14 is the slurry roller b, 15 is the base fabric frame, 16 is the drying oven, 17 is the base film frame, 18 is the face film frame, 19 is the large cylinder A, 20 is the large cylinder B, and 21 is the finished vehicle tarpaulin. Detailed Implementation

[0033] The following detailed embodiments illustrate and explain the solutions and effects of the present invention. These embodiments are illustrative examples and should not be considered as limiting the scope of protection of the present invention.

[0034] In the following examples, the terms "bottom" and "surface" are relative concepts, equivalent to the conventional terms "top," "bottom," "left," and "right," describing the position of the layered surface. Similarly, the terms PVC slurry tank A, PVC slurry tank B, and transfer sizing roller group A and transfer sizing roller group B in the following examples are relative concepts, indicating the existence of two corresponding devices. This description is adapted to sizing both sides of the base fabric separately and does not imply any structural difference between PVC slurry tank A and PVC slurry tank B. As an example, the base fabric used in the following embodiments is model 1000D20*20C18403. All materials used in the following embodiments are commercially available.

[0035] Example 1: PVC Slurry and its Preparation

[0036] This embodiment provides six types of PVC slurry, including one prior art slurry as a comparative slurry 1; and five slurries of the present invention as experimental slurries 1-5. The ingredient list of the PVC slurry is shown in Table 1.

[0037] Table 1. PVC Slurry Batching Table (parts by weight)

[0038]

[0039]

[0040] PVC slurry preparation method: According to the weight parts and materials in Table 1, take PVC paste resin, plasticizer, viscosity reducer and PVC calcium powder and stir in a high-speed mixer to obtain PVC raw slurry. Cool for 24 hours, pull it to the machine, add adhesive and mix to obtain PVC slurry.

[0041] Example 2 PVC film and its preparation

[0042] Since the main improvement of the vehicle tarpaulin of this invention does not lie in the PVC film, this embodiment only provides a PVC film for testing and its preparation method. The PVC film used below serves as the base fabric covering layer of the vehicle tarpaulin. This PVC film and its preparation method belong to the prior art in terms of ingredient formulation and preparation methods, and all materials used are commercially available. Commercially available PVC film can be used directly.

[0043] Table 2. PVC Film Ingredients (parts by weight)

[0044] PVC resin 100 copies plasticizer 58 copies (DOP) stabilizer 2 portions (132 stabilizer) PVC calcium powder 30 servings (PVC-specific calcium) White pigment 5 copies (ATR-316)

[0045] PVC film preparation method: According to the weight parts and materials in Table 2, PVC resin, plasticizer, stabilizer, PVC calcium powder and white pigment are mixed and stirred. The mixture is then plasticized by conventional extrusion, mixed in a rolling mill, filtered to remove impurities in a filter, mixed again in a rolling mill, fed into a swaying machine and calender, calendered, drawn, embossed and cooled to obtain PVC film.

[0046] Example 3: Vehicle Tarpaulin and its Preparation

[0047] Six types of PVC slurry were prepared according to the ingredients and methods of Example 1; PVC film was prepared according to the ingredients and methods of PVC film in Example 2, and PET mesh was used as the base fabric to prepare six types of vehicle tarpaulins.

[0048] Part 1: Comparative Example 1 - Structure and Preparation of Vehicle Tarpaulin

[0049] Compared to the vehicle tarpaulin in Example 1, the structure has layers as follows: Figure 1 As shown, 1 is the PVC face film layer; 2 is the PVC base film layer; 3 is the base fabric layer; and 4 is the PVC slurry layer. That is, the thickness of the PVC slurry layer penetrating into the base fabric layer exceeds 2 / 3 of the thickness of the base fabric layer, or even penetrates the entire base fabric layer.

[0050] This vehicle tarpaulin is representative of commercially available vehicle tarpaulins and can be used as a substitute for comparative testing. Specifically, in the preparation of the vehicle tarpaulin in Comparative Example 1, the PVC slurry uses a traditional impregnation process; when the PVC face film layer 1 and PVC base film layer 2 are introduced onto the surface of the large cylinder, no additional corresponding PVC film pressing structure is set. The structure of the impregnation process device of this equipment can be found in CN216825733U.

[0051] Part Two: The Structure, Preparation Equipment, and Methods of Vehicle Tarpaulins in Examples 1 to 5

[0052] The vehicle tarpaulins in Experiments 1 to 5 have layered structures as follows: Figure 2 As shown, 1 is the PVC face film layer; 2 is the PVC base film layer; 3 is the base fabric layer; and 4 is the PVC slurry layer. That is, the PVC slurry layer penetrates the base fabric layer relatively shallowly, with a penetration thickness of less than or equal to 1 / 3 of the base fabric layer thickness.

[0053] The vehicle tarpaulins in Examples 1 to 5 were prepared using the following method:

[0054] 1. Manufacturing equipment: Modified from existing equipment, such as... Figure 3As shown, in this equipment, 5 is the base fabric traction wheel, 6 is the base fabric guide wheel, 7 is the PVC slurry tank A, 8 is the transfer sizing wheel group A, 9 is the PVC slurry tank B, 10 is the transfer sizing wheel group B, 11 is the bottom film pressing wheel, 12 is the top film pressing wheel, 13 is the sizing wheel a, 14 is the sizing wheel b, 15 is the base fabric frame, 16 is the drying oven, 17 is the bottom film frame, 18 is the top film frame, 19 is the large cylinder A, 20 is the large cylinder B, and 21 is the finished vehicle tarpaulin.

[0055] Transfer sizing roller group A, transfer sizing roller group B, bottom film pressing roller, and top film pressing roller are devices added through structural modification; the others are the original structure of commercially available equipment. Sizing roller a is used to pick up PVC sizing material from the sizing tank by rotating. Sizing roller b is in linear contact with sizing roller a (i.e., the surfaces of the two rollers contact to form a contact line), thereby transferring the PVC sizing material carried by sizing roller a to the surface of the base fabric through rotation. The bottom film pressing roller and the top film pressing roller are used to better cover the PVC film on both sides of the base fabric onto the large cylinder, increasing the pressing area and thus improving the pressing effect. Sizing rollers a and b are both 30-mesh rollers.

[0056] Obviously, the width and spacing of the sizing rollers a, b, bottom film pressing roller, and top film pressing roller should meet the requirements of the base fabric or PVC film specifications. In this embodiment, the sizing rollers a, b, bottom film pressing roller, and top film pressing roller are cylindrical with a fixed rotating shaft in the middle. The diameter of the rotating shaft is smaller than the main body of the roller, which is common knowledge in the field. The sizing rollers a, b, bottom film pressing roller, and top film pressing roller can be manufactured using stainless steel or seamless steel pipes, and the surface of the rollers can be covered with an electroplated layer. Large cylinders A and B can be selected as 1500mm and 2000mm respectively.

[0057] Obviously, for those skilled in the art, the manufacturing equipment described is a device that pulls the base fabric sequentially through the upper surface of the sizing wheel b, the drying oven, the upper surface or side of the large cylinder A, and the lower surface or side of the large cylinder B, thereby achieving the processes of sizing, drying, and film application. The diameter and speed settings of each wheel structure are not beyond common sense and are adjustable.

[0058] 2. Preparation method: Please refer to... Figure 3 Of these, 21 are finished vehicle tarpaulins, and the preparation method and process are as follows: Figure 3 The process is from left to right.

[0059] The base fabric is placed on the base fabric frame. The PVC film of Example 2 is placed on the PVC face film frame and the PVC bottom film frame, respectively. The PVC slurry prepared in Example 1 is introduced into the PVC slurry tank A and the PVC slurry tank B.

[0060] Start the unit so that the transfer sizing roller group A and transfer sizing roller group B carry PVC sizing material. The PVC sizing material is transferred and sizing onto both sides of the base fabric through the sizing roller b. After drying in the oven, the contact surface between the PVC base film layer and the PVC surface film layer and the large cylinder A and large cylinder B is increased with the help of the bottom film pressing roller and the top film pressing roller. The PVC base film layer and the PVC surface film layer are then bonded to the base fabric with the help of the large cylinder A and large cylinder B. Roller pressing is then performed to obtain the vehicle tarpaulin.

[0061] Example 4: Performance Test of Vehicle Tarpaulin

[0062] The performance of the vehicle tarpaulin prepared in Comparative Example 1 (Example 3) and the vehicle tarpaulins prepared in Examples 1 to 5 was tested.

[0063] The tear strength of six types of automotive tarpaulins was tested under the same conditions according to DIN 53363 test method; the peel strength of the six types of automotive tarpaulins was tested under the same conditions according to FZ / T 60039 test method; all tarpaulins were placed in the same normal temperature and humidity environment for 30 days as samples for durability testing. The results are shown in Tables 3 and 4.

[0064] Table 3. Tear resistance (radial / weft tear strength, N) of 6 types of vehicle tarpaulins

[0065]

[0066] As shown in Table 3, among the five types of vehicle tarpaulins, the tear strength of the tarpaulins in Experiments 1-5 is higher than that of the tarpaulin in Comparative Example 1. Specifically, the tarpaulins prepared with PVC slurry in Experiments 3-5 have higher tear strength than those in Experiments 1 and 2.

[0067] Table 4. Peel strength (radial / weft tear strength, N) of six types of automotive tarpaulins

[0068]

[0069]

[0070] As shown in Table 4, among the six types of vehicle tarpaulins, the anti-peeling effect of the vehicle tarpaulins in Experiments 1-5 is close to that of the vehicle tarpaulin in Comparative Example 1, and no reduction in anti-peeling effect was observed.

Claims

1. A tear-resistant PVC composite vehicle tarpaulin, comprising a base fabric, a PVC film, and a PVC paste, wherein the PVC film is bonded to the bottom and top sides of the base fabric using the PVC paste; characterized in that, The raw materials of the PVC slurry, by weight, include the following materials: 100 parts PVC paste resin, 90-120 parts plasticizer, 4-8 parts adhesive, 11-12 parts viscosity reducer, and 25-35 parts PVC calcium powder; the thickness of the PVC slurry penetrating the base fabric is less than or equal to 1 / 3 of the base fabric thickness; the PVC paste resin is selected from one or more of PB-50, P80, PSM-31, and C65V; the plasticizer is selected from one or more of DMP, DBP, DEHP, DOP, DINP, and Mesamoll alkyl sulfonate plasticizer; the adhesive is selected from one or more of TP-53-552, N3300, TP-300, NP001, NP002, RG-901, and NP4042; the viscosity reducer is one or both of D-80 and D-60; the PVC slurry is dipped from the slurry tank by the rotation of the transfer slurry roller assembly and transferred to the surface of the base fabric located above the transfer slurry roller.

2. The tear-resistant PVC composite vehicle tarpaulin according to claim 1, characterized in that, The PVC paste resin is made by mixing PB-50 and PSM-31, with a weight ratio of PB-50 to PSM-31 of 4:

1.

3. The tear-resistant PVC composite vehicle tarpaulin according to claim 1, characterized in that, The PVC paste resin is PSM-31.

4. The tear-resistant PVC composite vehicle tarpaulin according to claim 1, characterized in that, The PVC paste resin is made by mixing P80 and C65V, with a weight ratio of P80 to C65V of 4:

1.

5. The tear-resistant PVC composite vehicle tarpaulin according to claim 1, characterized in that, The PVC calcium powder is selected from one or more of heavy calcium carbonate, light calcium carbonate, and ultra-white nano calcium.

6. Use of the tear-resistant PVC composite vehicle tarpaulin according to any one of claims 1-5 in the preparation of vehicle covering articles.

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