Energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveying belt and manufacturing method thereof

Abstract

The invention discloses an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveying belt and a manufacturing method thereof. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveying belt comprises a polyarylate fabric whole belt core, a covering layer and a belt core dipping sizing material, the covering layer comprises the following components: solution polymerized styrene-butadiene rubber, a styrene-butadiene-styrene block copolymer, a thermoplastic polyurethane elastomer, zinc oxide, stearic acid, sulfur, an accelerant, an anti-aging agent, carbon black, a hybrid flame-retardant composite material, a phosphate flame retardant, paraffin oil and an antistatic agent; the covering layer of the energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveying belt prepared by the invention is compounded from white carbon black, expanded graphite, diethyl aluminum hypophosphite and dimethyl imidazole zinc, and is subjected to surface treatment through polyacrylamide; and then the styrene-butadiene-styrene block copolymer is used for carrying out macromolecular modification on the hybrid flame-retardant composite material, so that the prepared conveyor belt has excellent flame-retardant and antistatic properties, environment-friendly properties, low rolling resistance and mechanical properties.

Description

Technical Field

[0001] The invention belongs to the technical field of conveyor belts, and in particular relates to an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt and a manufacturing method thereof. Background Art

[0002] The whole core flame retardant conveyor belt for coal mines is the main tool for coal transportation in coal mines. The annual demand in my country is about 25 million meters. At present, the whole core flame retardant conveyor belt for coal mines in my country has the following outstanding problems: First, the product grade is low, mainly manifested in low strength, generally below 2500N / mm, thin covering layer, generally below 3mm, short service life, serious waste of resources. Under normal circumstances, the whole core flame retardant conveyor belt is selected for the full thickness tensile strength below 2500N / mm, the steel cord core flame retardant conveyor belt or aramid fabric core flame retardant conveyor belt is selected for 2500N / mm-4000N / mm, and the steel cord core flame retardant conveyor belt is selected for more than 4000N / mm; second, polyvinyl chloride and halogen- and antimony-containing flame retardants are used as the main raw materials. Not only is the production process seriously polluted, but also the smoke production and toxicity in the smoke are large when ignited, which will endanger the lives of personnel, corrode equipment, pollute the environment, and produce very serious secondary disasters, seriously threatening the lives of miners and safe production.

[0003] Patent CN107216560A discloses an aramid fabric whole core flame retardant conveyor belt and a manufacturing method thereof. The covering layer adopts PVC / CM / TPU blended thermoplastic elastomer, which has good flame retardant properties, high tensile strength, excellent elasticity, good wear resistance, and high bonding strength with the overall belt core after dipping and plasticization; the strength of the fabric core flame retardant belt is increased to 4500N / mm. Compared with the steel wire rope core flame retardant conveyor belt with the same strength, the belt body is thin and light, which can reduce the energy consumption of the conveyor; but due to the high price of aramid fiber and poor bending fatigue resistance, the strength decays quickly during use, and the melting point is higher than the ignition point of coal. It is used for transporting coal underground in coal mines, which has high cost, large strength loss, and certain safety risks. In addition, the aramid fabric core flame retardant conveyor belt of MT / T914 standard can only use vulcanized joints, which are complicated to operate and take a long time to construct. When used as a chute belt, frequent joints will affect production. Summary of the invention

[0004] The purpose of the present invention is to provide an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt to meet the needs of safe, economical and high-strength coal transportation in coal mines.

[0005] The second purpose of the present invention is to provide a method for manufacturing a conveyor belt with simple process, easy manufacturing, low energy consumption and high production efficiency, and to provide a method for manufacturing an energy-saving and environmentally friendly high-strength polyarylate fabric whole-core flame-retardant conveyor belt.

[0006] The purpose of the present invention can be achieved through the following technical solutions:

[0007] Energy-saving and environment-friendly polyarylate fabric integral core flame-retardant conveyor belt, comprising a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber material;

[0008] The covering layer comprises the following components by mass:

[0009] 40-60 parts of solution butadiene styrene rubber (SSBR), 20-30 parts of styrene-butadiene-styrene block copolymer (SBS), 20-30 parts of thermoplastic polyurethane elastomer (TPU), 2-4 parts of zinc oxide, 1-2 parts of stearic acid, 1.6-2 parts of sulfur, 1.6-2 parts of accelerator, 1.6-2 parts of antioxidant, 18-22 parts of carbon black, 60-70 parts of hybrid flame retardant composite material, 20-30 parts of phosphate flame retardant, 8-12 parts of paraffin oil and 2-4 parts of antistatic agent.

[0010] The phosphate flame retardant is any one of toluene diphenyl phosphate, diphenyl phosphate and trioctyl phosphate.

[0011] Further, the polyarylate fabric integral belt core is a 4-5 layer integral woven structure composed of liquid crystal polyarylate fibers, nylon fibers and cotton fibers, and the width is 104-106% of the belt width;

[0012] Furthermore, the warp force lines of the polyarylate fabric integral belt core are formed by plying 1000D or 1500D high-strength liquid crystal polyarylate fibers, and the tensile strength of a single fiber after plying is 1500-3500N, and the density is 184-279 fibers / 10cm.

[0013] Furthermore, the weft force lines of the polyarylate fabric integral core are formed by plying 1000D or 1500D nylon fibers and cotton fibers, and the tensile strength of the single fibers after plying is 450-1250N / fiber, and the density is 124-160 fibers / 10cm.

[0014] Furthermore, the upper and lower warp threads of the overall polyarylate fabric core are cotton fibers, the middle 2-3 warp threads are liquid crystal polyarylate fibers, the warp content of the core is 15-25%, and the weft content of the core is 35-45%.

[0015] Furthermore, the accelerator is prepared by mixing accelerator M, accelerator DM and accelerator TMTD in any ratio; and the antioxidant is prepared by mixing antioxidant RD and 4020 in any ratio.

[0016] Furthermore, the core impregnated rubber material includes the following components in parts by mass:

[0017] 100-120 parts of polyvinyl chloride paste resin (EPVC), 40-60 parts of environmentally friendly plasticizer, 10-20 parts of epoxidized soybean oil, 8-12 parts of liquid nitrile rubber, 20-40 parts of phosphate flame retardant, 1-2 parts of imidazole phosphate ionic liquid flame retardant (PIL), 12-16 parts of intumescent flame retardant and 3-5 parts of calcium zinc composite stabilizer.

[0018] Further, the core impregnated rubber material is prepared by the following steps:

[0019] Polyvinyl chloride paste resin, environmentally friendly plasticizer, epoxy soybean oil, liquid nitrile rubber, phosphate flame retardant, imidazole phosphate ionic liquid flame retardant, intumescent flame retardant and calcium zinc composite stabilizer are sequentially added into a high-speed disperser for stirring, then ground by a three-roll grinder and degassed by a vacuum degassing machine to obtain a core impregnated rubber material.

[0020] Furthermore, the imidazole phosphate ionic liquid flame retardant is any one of 1-ethyl-3-methylimidazole dimethyl phosphate, 1-ethyl-3-methylimidazole diethyl phosphate and 1-butyl-3-methylimidazole dibutyl phosphate; the intumescent flame retardant is any one of ammonium polyphosphate, melamine polyphosphate and melamine cyanurate.

[0021] Further, the covering layer is prepared by the following steps:

[0022] The hybrid flame retardant masterbatch, solution polymerized styrene-butadiene rubber, thermoplastic polyurethane elastomer, zinc oxide, stearic acid, sulfur, accelerator, antioxidant, carbon black, phosphate flame retardant, paraffin oil and antistatic agent are added into an internal mixer and mixed at 40-60 rpm, dynamically vulcanized at 167-175° C. for 3-4 min, and then dynamically vulcanized at 175-180° C. for 5-6 min through a twin-screw extruder at 50-70 rpm, granulated and cooled to obtain a covering layer.

[0023] Further, the hybrid flame retardant masterbatch is prepared by the following steps:

[0024] The hybrid flame retardant composite material is added into an internal mixer at 20-40 rpm, heated to 70-80°C, and then styrene-butadiene-styrene block copolymer is added and blended for 180-200s, the discharge temperature is 165-175°C, the sheet is discharged, and the hybrid flame retardant masterbatch is obtained after cooling and parking for 8-10 hours.

[0025] Furthermore, the hybrid flame retardant composite material is prepared by the following steps:

[0026] Put white carbon black, expanded graphite, diethyl aluminum hypophosphite and dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 350-400rpm. Heat to 40-60°C, start spraying a 2-3wt% polyacrylamide aqueous solution, continue heating and stirring, stir at a temperature of 105-110°C for 10-15 minutes, and obtain a hybrid flame retardant composite material after cooling.

[0027] Furthermore, the mass ratio of white carbon black, expanded graphite, diethyl aluminum hypophosphite, dimethyl imidazole zinc and polyacrylamide aqueous solution is 30-35:30-35:20-25:1-2:4-5.

[0028] The manufacturing method of the energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt comprises the following steps:

[0029] Step 1: Impregnate the polyarylate fabric integral belt core through an impregnation tank filled with belt core impregnation rubber and a vacuum box, and plasticize the impregnated polyarylate fabric integral belt core in a plasticizing box at 160-175° C. at a plasticizing speed of 0.6-1.2 m / min to obtain a plasticized belt core.

[0030] Step 2: Dynamically vulcanize the covering layer granules through two extruders and a mold. The speed of the extruder is 30-50rpm, and the temperature of the extruder and the mold is 160-175°C. It is directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 145-165°C, and the thickness of the covering layer is 6-8mm, so as to obtain an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt.

[0031] Beneficial effects of the present invention:

[0032] (1) The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt covering layer prepared by the present invention is composited with white carbon black, expanded graphite, diethyl aluminum hypophosphite and dimethyl imidazole zinc, which is surface treated with polyacrylamide, and then the hybrid flame-retardant composite material is macromolecularly modified with styrene-butadiene-styrene block copolymer. The obtained conveyor belt has excellent flame-retardant and antistatic properties, environmental protection properties, low rolling resistance properties and mechanical properties.

[0033] (2) The radial force lines of the polyarylate fabric integral belt core of the energy-saving and environment-friendly polyarylate fabric integral flame-retardant conveyor belt prepared by the present invention are made of polyarylate fibers, which have high strength, a thin belt body, and a light weight. The weight of the finished belt is about 50% of that of a steel cord conveyor belt of the same strength, which can greatly reduce the energy consumption during the operation of the conveyor belt. Since polyarylate is cheaper than aramid, has better bending fatigue resistance, and has a melting point lower than the ignition point of coal, it has better safety and economic performance than aramid fabric flame-retardant conveyor belts of the same strength.

[0034] (3) The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt covering layer prepared by the present invention effectively improves the flame retardant properties of the covering layer by adding zinc dimethylimidazole. On the one hand, it effectively reduces the emission of toxic gases; on the other hand, it enables the covering layer to form a denser carbon layer, promotes carbonization to isolate heat and oxygen, and improves flame retardant safety; in addition, the addition of zinc dimethylimidazole can also prevent the agglomeration of white carbon black and other additives, improve the compatibility and dispersibility between the additives and the covering layer, and in addition to improving the flame retardant properties of the covering layer, it also improves the thermal stability, electrical conductivity, low rolling resistance and other mechanical properties of the covering layer.

[0035] (4) The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt prepared by the present invention uses polyacrylamide instead of silane coupling agent to modify the hybrid flame-retardant composite material, which can reduce the emission of VOCs during the modification and subsequent processing, which is beneficial to environmental protection. At the same time, the dispersion of the hybrid flame-retardant composite material is improved, the Payne effect is weakened, the processing temperature of the covering layer is reduced, the dynamic vulcanization time is shortened, and the flame retardant and antistatic properties, low rolling resistance and other mechanical properties are improved.

[0036] (5) The present invention combines a hybrid flame-retardant composite material with a phosphate flame retardant to form a halogen-free flame retardant system, which has a synergistic effect and can simultaneously improve the flame retardant and antistatic properties, low rolling resistance and other mechanical properties of the covering layer. At the same time, the hybrid flame-retardant composite material is macromolecularly modified by styrene-butadiene-styrene block copolymer, which can effectively coat the hybrid flame-retardant composite material, thereby improving the flame retardant and antistatic properties while improving the wear resistance of the covering layer and effectively reducing the rolling resistance of the covering layer.

[0037] (6) The belt core of the present invention is impregnated with rubber, and liquid nitrile rubber is used to partially replace PVC paste resin, thereby reducing the halogen content of the rubber, lowering the toxicity of the rubber, and increasing the bonding strength between the covering layer and the overall polyarylate fabric belt core and inside the belt core; environmentally friendly plasticizers and epoxy soybean oil are used to replace traditional dioctyl phthalate plasticizers, thereby reducing the amount of VOCs generated during the production process, which is beneficial to environmental protection.

[0038] (7) The present invention can be used with either vulcanized joints or mechanical joints. The mechanical joints can be used to quickly install or replace the conveyor belt, thereby reducing downtime. The vacuum impregnation of the integral belt core, hot oil carrier heating and plasticization, extruder veneer molding and dynamic vulcanization processes are used to achieve continuous conveyor belt production. Compared with the production processes of steel cord core flame retardant conveyor belts and aramid fabric core flame retardant conveyor belts, the present invention saves energy consumption, improves production efficiency, has a simple process and is easy to manufacture. DETAILED DESCRIPTION

[0039] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] Embodiment 1: An energy-saving and environment-friendly polyarylate fabric integral core flame-retardant conveyor belt, comprising a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber.

[0041] The polyarylate fabric integral belt core is a 4-layer integral woven structure composed of liquid crystal polyarylate (LCP) fiber, nylon fiber and cotton fiber, with a width of 1272mm; the warp force lines of the belt core are made of LCP fiber, which is made of 1000D high-strength LCP fiber, and the single tensile strength after plying is 1500N, and the density is 184 strands / 10cm; the upper and lower warp threads of the belt core are cotton fiber, and the middle two warp threads are LCP fiber, and the warp cotton content of the belt core is 25%; the weft force lines of the belt core are made of nylon fiber, and the weft threads are made of 1000D nylon fiber and cotton fiber, and the single tensile strength of the weft threads after plying is 450N / thread, and the density is 160 strands / 10cm; the weft threads of the belt core contain 45% cotton.

[0042] A method for manufacturing an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt comprises the following steps:

[0043] S1. Put 30kg of white carbon black, 30kg of expanded graphite, 20kg of diethyl aluminum hypophosphite and 1kg of dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 350rpm. Heat to 40°C, start spraying 4kg of 2wt% polyacrylamide aqueous solution, continue heating and stirring, stir at a temperature of 105°C for 10min, and obtain a hybrid flame-retardant composite material after cooling.

[0044] S2. Add 60 kg of hybrid flame-retardant composite material into an internal mixer at 20 rpm, heat to 70°C, then add 20 kg of styrene-butadiene-styrene block copolymer and blend for 180 seconds. The discharge temperature is 165°C, and the sheet is discharged. The hybrid flame-retardant masterbatch is obtained by cooling and standing for 8 hours.

[0045] S3. The hybrid flame retardant masterbatch prepared in S2, 40 kg of solution-polymerized styrene-butadiene rubber, 20 kg of thermoplastic polyurethane elastomer, 2 kg of zinc oxide, 1 kg of stearic acid, 1.6 kg of sulfur, 0.48 kg of accelerator M, 0.48 kg of accelerator DM, 0.64 kg of accelerator TMTD, 0.6 kg of antioxidant RD, 1 kg of antioxidant 4020, 18 kg of carbon black, 20 kg of toluene diphenyl phosphate, 8 kg of paraffin oil and 2 kg of antistatic agent are added into an internal mixer and mixed at 40 rpm, dynamically vulcanized at 167 ° C for 3 min, and then dynamically vulcanized at 175 ° C for 5 min through a twin-screw extruder at 50 rpm, granulated and cooled to obtain a covering layer.

[0046] S4. 100kg of polyvinyl chloride paste resin, 40kg of environmentally friendly plasticizer, 10kg of epoxy soybean oil, 8kg of liquid nitrile rubber, 20kg of toluene diphenyl phosphate, 1kg of 1-butyl-3-methylimidazole dibutyl phosphate, 12kg of ammonium polyphosphate and 3kg of calcium-zinc composite stabilizer are sequentially added into a high-speed disperser and stirred at 2500rpm for 20min. A paste is obtained after the viscosity reaches 4000Pa.s. The paste is ground three times with a three-roll grinder, with a grinder roller spacing of 0.15mm and a rotation speed of 500rpm. The paste is then degassed in a vacuum degasser, and degassed at room temperature for 20min under a vacuum degree of -0.05Mpa to obtain a core impregnated rubber compound.

[0047] S5. Driven by a traction machine, the polyarylate fabric integral belt core is impregnated through an impregnation tank and a vacuum box filled with belt core impregnation rubber at a speed of 0.6 m / min, with a vacuum degree of -0.05 MPa. The impregnated polyarylate fabric integral belt core is plasticized in a plasticizing box at 160°C, with a plasticizing speed of 0.6 m / min, to obtain a plasticized belt core.

[0048] S6. The covering layer granules are dynamically vulcanized through two extruders and a mold. The speed of the extruder is 30 rpm, and the temperatures of the extruder and the mold are 160°C. The covering layer is directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 145°C. The covering layer thickness is 6 mm, and an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt is obtained.

[0049] Embodiment 2: An energy-saving and environment-friendly polyarylate fabric integral core flame-retardant conveyor belt, comprising a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber.

[0050] The integral belt core of polyarylate fabric is a 4-layer integral woven structure composed of liquid crystal polyarylate (LCP) fiber, nylon fiber and cotton fiber, with a width of 1272mm; the warp force lines of the belt core are made of LCP fiber, which is made of 1000D high-strength LCP fiber, and the single tensile strength after plying is 1500N, and the density is 187 strands / 10cm; the upper and lower warp threads of the belt core are cotton fiber, and the middle two warp threads are LCP fiber, and the warp cotton content of the belt core is 23%; the weft force lines of the belt core are made of nylon fiber, and the weft threads are made of 1000D nylon fiber and cotton fiber, and the single tensile strength of the weft threads after plying is 600N / thread, and the density is 150 strands / 10cm; the weft threads of the belt core have a cotton content of 43%.

[0051] A method for manufacturing an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt comprises the following steps:

[0052] S1. Put 31kg of white carbon black, 31kg of expanded graphite, 21kg of diethyl aluminum hypophosphite and 1.2kg of dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 350rpm. Heat to 40°C, start spraying 4.2kg of 2.2wt% polyacrylamide aqueous solution, continue heating and stirring, stir at a temperature of 105°C for 10min, and obtain a hybrid flame-retardant composite material after cooling.

[0053] S2. Add 68 kg of hybrid flame-retardant composite material into an internal mixer at 20 rpm, heat to 70°C, then add 28 kg of styrene-butadiene-styrene block copolymer and blend for 180 seconds. The discharge temperature is 165°C, and the sheet is discharged. The hybrid flame-retardant masterbatch is obtained by cooling and standing for 8 hours.

[0054] S3. Add the hybrid flame retardant masterbatch prepared in S2, 45kg solution polystyrene butadiene rubber, 27kg thermoplastic polyurethane elastomer, 2.5kg zinc oxide, 1.3kg stearic acid, 1.7kg sulfur, 0.6kg accelerator M, 0.6kg accelerator DM, 0.5kg accelerator TMTD, 0.8kg antioxidant RD, 1kg antioxidant 4020, 19kg carbon black, 22kg diphenyl phosphate, 11kg paraffin oil and 3.5kg antistatic agent into an internal mixer and mix at 40rpm, dynamically vulcanize at 167°C for 3min, and then dynamically vulcanize at 175°C for 5min through a twin-screw extruder at 50rpm, granulate, and cool to obtain a covering layer.

[0055] S4, 105kg polyvinyl chloride paste resin, 45kg environmentally friendly plasticizer, 12.5kg epoxy soybean oil, 9kg liquid nitrile rubber, 25kg toluene diphenyl phosphate, 1.25kg 1-ethyl-3-methylimidazole dimethyl phosphate, 13kg melamine polyphosphate and 3.5kg calcium zinc composite stabilizer are sequentially added into a high-speed disperser and stirred at 2500rpm for 20min, and a paste is obtained after the viscosity reaches 4000Pa.s. The paste is ground three times by a three-roll grinder with a roller spacing of 0.15mm and a rotation speed of 500rpm, and then degassed by a vacuum degassing machine, and degassed at room temperature for 20min under a vacuum degree of -0.05Mpa to obtain a core impregnated rubber material.

[0056] S5. Driven by a traction machine, the polyarylate fabric integral belt core is impregnated through an impregnation tank and a vacuum box filled with belt core impregnation rubber at a speed of 0.6 m / min, with a vacuum degree of -0.05 MPa. The impregnated polyarylate fabric integral belt core is plasticized in a plasticizing box at 160°C, with a plasticizing speed of 0.6 m / min, to obtain a plasticized belt core.

[0057] S6. The covering layer granules are dynamically vulcanized through two extruders and a mold. The speed of the extruder is 30 rpm, and the temperatures of the extruder and the mold are 160°C. The covering layer is directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 145°C. The covering layer thickness is 6 mm, and an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt is obtained.

[0058] Embodiment 3: An energy-saving and environment-friendly polyarylate fabric integral core flame-retardant conveyor belt, comprising a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber.

[0059] The polyarylate fabric integral belt core is a 5-layer integral woven structure composed of LCP fiber, nylon fiber and cotton fiber, with a width of 1400mm; the warp force line of the belt core adopts LCP fiber, which is formed by plying 1500D high-strength LCP fiber. The single tensile strength after plying is 2500N, and the density is 220 strands / 10cm; the upper and lower warp threads of the belt core are cotton fiber, and the middle 3 warp threads are LCP fiber, and the warp cotton content of the belt core is 20%; the weft force line of the belt core adopts nylon fiber, and the weft threads are formed by plying 1500D nylon fiber and cotton fiber. The single tensile strength of the weft threads after plying is 850N / thread, and the density is 142 strands / 10cm; the weft threads of the belt core contain 38% cotton.

[0060] A method for manufacturing an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt comprises the following steps:

[0061] S1. Put 32.5 kg of white carbon black, 32.5 kg of expanded graphite, 22.5 kg of diethyl aluminum hypophosphite and 1.5 kg of dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 370 rpm. Heat to 50° C. and start spraying 4.5 kg of a 2.5 wt% polyacrylamide aqueous solution. Continue heating and stirring. Stir at a temperature of 107° C. for 12.5 min. After cooling, obtain a hybrid flame-retardant composite material.

[0062] S2. Add 65 kg of hybrid flame-retardant composite material into a 30 rpm internal mixer, heat to 75°C, then add 25 kg of styrene-butadiene-styrene block copolymer and blend for 190 seconds. The discharge temperature is 170°C, and the sheet is discharged. The hybrid flame-retardant masterbatch is obtained by cooling and parking for 9 hours.

[0063] S3. Add the hybrid flame retardant masterbatch prepared in S2, 50kg solution polymerized styrene-butadiene rubber, 25kg thermoplastic polyurethane elastomer, 3kg zinc oxide, 1.5kg stearic acid, 1.8kg sulfur, 0.5kg accelerator M, 0.6kg accelerator DM, 0.7kg accelerator TMTD, 0.9kg antioxidant RD, 0.9kg antioxidant 4020, 20kg carbon black, 25kg trioctyl phosphate, 10kg paraffin oil and 3kg antistatic agent into an internal mixer and mix at 50rpm, dynamically vulcanize at 170°C for 3.5min, and then dynamically vulcanize at 177°C for 5.5min through a twin-screw extruder at 60rpm, granulate, and cool to obtain a covering layer.

[0064] S4. 110kg of polyvinyl chloride paste resin, 50kg of environmentally friendly plasticizer, 15kg of epoxy soybean oil, 10kg of liquid nitrile rubber, 30kg of diphenyl phosphate, 1.5kg of 1-ethyl-3-methylimidazole dimethyl phosphate, 14kg of melamine polyphosphate and 4kg of calcium-zinc composite stabilizer are sequentially added into a high-speed disperser and stirred at 2700rpm for 25min. After the viscosity reaches 5000Pa.s, a paste is obtained. The paste is ground three times with a three-roll grinder, with a grinder roller spacing of 0.2mm and a rotation speed of 650rpm. The paste is then degassed in a vacuum degasser, and degassed at room temperature for 25min under a vacuum degree of -0.07Mpa to obtain a core impregnated rubber material.

[0065] S5. Driven by a traction machine, the polyarylate fabric integral belt core is impregnated through an impregnation tank and a vacuum box filled with belt core impregnation rubber at a speed of 0.9 m / min, with a vacuum degree of -0.07 MPa. The impregnated polyarylate fabric integral belt core is plasticized in a plasticizing box at 170°C, with a plasticizing speed of 0.9 m / min, to obtain a plasticized belt core.

[0066] S6. The covering layer granules are dynamically vulcanized through two extruders and a mold. The speed of the extruder is 40 rpm, and the temperatures of the extruder and the mold are 170°C. The covering layer granules are directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 155°C, and the thickness of the covering layer is 7 mm, thereby obtaining an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt.

[0067] Embodiment 4: An energy-saving and environment-friendly polyarylate fabric integral core flame-retardant conveyor belt, comprising a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber.

[0068] The polyarylate fabric integral belt core is a 5-layer integral woven structure composed of LCP fiber, nylon fiber and cotton fiber, with a width of 1462mm; the warp force lines of the belt core are made of LCP fiber, which is formed by plying 1500D high-strength LCP fiber. The tensile strength of a single strand after plying is 3000N, and the density is 231 strands / 10cm; the upper and lower warp threads of the belt core are cotton fiber, and the middle three warp threads are LCP fiber, and the cotton content of the belt core in the warp direction is 17%; the weft force lines of the belt core are made of nylon fiber, and the weft threads are formed by plying 1500D nylon fiber and cotton fiber. The tensile strength of a single strand after plying is 1050N / strand, and the density is 133 strands / 10cm; the cotton content of the weft threads of the belt core is 36%.

[0069] A method for manufacturing an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt comprises the following steps:

[0070] S1. Put 35kg of white carbon black, 35kg of expanded graphite, 25kg of diethyl aluminum hypophosphite and 2kg of dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 400rpm. Heat to 60°C, start spraying 5kg of 3wt% polyacrylamide aqueous solution, continue heating and stirring, stir at a temperature of 110°C for 15min, and obtain a hybrid flame-retardant composite material after cooling.

[0071] S2. Add 70 kg of hybrid flame-retardant composite material into an internal mixer at 40 rpm, heat to 80°C, then add 23 kg of styrene-butadiene-styrene block copolymer and blend for 200 seconds. The discharge temperature is 175°C, and the sheet is discharged. The hybrid flame-retardant masterbatch is obtained by cooling and parking for 10 hours.

[0072] S3. Add the hybrid flame retardant masterbatch prepared in S2, 55kg solution polymerized styrene-butadiene rubber, 22kg thermoplastic polyurethane elastomer, 3.5kg zinc oxide, 1.8kg stearic acid, 1.9kg sulfur, 0.5kg accelerator M, 0.5kg accelerator DM, 0.9kg accelerator TMTD, 0.9kg antioxidant RD, 1kg antioxidant 4020, 21kg carbon black, 28kg trioctyl phosphate, 9kg paraffin oil and 2.5kg antistatic agent into an internal mixer and mix at 60rpm, dynamically vulcanize at 175°C for 4min, and then dynamically vulcanize at 180°C for 6min through a twin-screw extruder at 70rpm, granulate, and cool to obtain a covering layer.

[0073] S4. 115kg of polyvinyl chloride paste resin, 55kg of environmentally friendly plasticizer, 17.5kg of epoxy soybean oil, 11kg of liquid nitrile rubber, 35kg of diphenyl phosphate, 1.75kg of 1-ethyl-3-methylimidazole diethyl phosphate, 15kg of melamine cyanurate and 4.5kg of calcium zinc composite stabilizer are sequentially added into a high-speed disperser and stirred at 2900rpm for 30min. A paste is obtained after the viscosity reaches 5500Pa.s. The paste is ground three times with a three-roll grinder, with a roller spacing of 0.25mm and a rotation speed of 750rpm. The paste is then degassed in a vacuum degasser, and degassed at room temperature for 30min under a vacuum degree of -0.085MPa to obtain a core impregnated rubber material.

[0074] S5. Driven by a traction machine, the polyarylate fabric integral belt core is impregnated through an impregnation tank and a vacuum box filled with belt core impregnation rubber at a speed of 1.2 m / min, with a vacuum degree of -0.085 MPa. The impregnated polyarylate fabric integral belt core is plasticized in a plasticizing box at 175°C at a plasticizing speed of 1.2 m / min to obtain a plasticized belt core.

[0075] S6. The covering layer granules are dynamically vulcanized through two extruders and a mold. The speed of the extruder is 50 rpm, and the temperatures of the extruder and the mold are 175°C. The covering layer is directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 165°C. The covering layer thickness is 8 mm, and an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt is obtained.

[0076] Embodiment 5: An energy-saving and environment-friendly polyarylate fabric integral core flame-retardant conveyor belt, comprising a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber.

[0077] The polyarylate fabric integral belt core is a 5-layer integral woven structure composed of LCP fiber, nylon fiber and cotton fiber, with a width of 1456mm; the warp force lines of the belt core are made of LCP fiber, which is formed by plying 1500D high-strength LCP fiber. The tensile strength of a single strand after plying is 3500N, and the density is 236 strands / 10cm; the upper and lower warp threads of the belt core are cotton fiber, and the middle three warp threads are LCP fiber, and the cotton content of the belt core in the warp direction is 15%; the weft force lines of the belt core are made of nylon fiber, and the weft threads are formed by plying 1500D nylon fiber and cotton fiber. The tensile strength of a single strand after plying is 1250N / strand, and the density is 124 strands / 10cm; the cotton content of the weft threads of the belt core is 35%.

[0078] A method for manufacturing an energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt comprises the following steps:

[0079] S1. Put 35kg of white carbon black, 35kg of expanded graphite, 25kg of diethyl aluminum hypophosphite and 2kg of dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 400rpm. Heat to 60°C, start spraying 5kg of 3wt% polyacrylamide aqueous solution, continue heating and stirring, stir at a temperature of 110°C for 15min, and obtain a hybrid flame-retardant composite material after cooling.

[0080] S2. Add 70 kg of hybrid flame-retardant composite material into an internal mixer at 40 rpm, heat to 80°C, then add 30 kg of styrene-butadiene-styrene block copolymer and blend for 200 seconds. The discharge temperature is 175°C, and the sheet is discharged. The hybrid flame-retardant masterbatch is obtained by cooling and parking for 10 hours.

[0081] S3. Add the hybrid flame retardant masterbatch prepared in S2, 60kg solution polymerized styrene-butadiene rubber, 30kg thermoplastic polyurethane elastomer, 4kg zinc oxide, 2kg stearic acid, 2kg sulfur, 0.5kg accelerator M, 0.5kg accelerator DM, 1kg accelerator TMTD, 1kg antioxidant RD, 1kg antioxidant 4020, 22kg carbon black, 30kg toluene diphenyl phosphate, 12kg paraffin oil and 4kg antistatic agent into an internal mixer and mix at 60rpm, dynamically vulcanize at 175°C for 4min, and then dynamically vulcanize at 180°C for 6min through a twin-screw extruder at 70rpm, granulate, and cool to obtain a covering layer.

[0082] S4. 120kg of polyvinyl chloride paste resin, 60kg of environmentally friendly plasticizer, 20kg of epoxy soybean oil, 12kg of liquid nitrile rubber, 40kg of trioctyl phosphate, 2kg of 1-butyl-3-methylimidazole dibutyl phosphate, 16kg of melamine cyanurate and 5kg of calcium zinc composite stabilizer are sequentially added into a high-speed disperser and stirred at 2900rpm for 30min. After the viscosity reaches 5500Pa.s, a paste is obtained. The paste is ground three times with a three-roll grinder, with a grinder roller spacing of 0.25mm and a rotation speed of 750rpm. Then, the paste is degassed in a vacuum degasser, and degassed at room temperature for 30min under a vacuum degree of -0.085MPa to obtain a core impregnated rubber material.

[0083] S5. Driven by a traction machine, the polyarylate fabric integral belt core is impregnated through an impregnation tank and a vacuum box filled with belt core impregnation rubber at a speed of 1.2 m / min, with a vacuum degree of -0.085 MPa. The impregnated polyarylate fabric integral belt core is plasticized in a plasticizing box at 175°C at a plasticizing speed of 1.2 m / min to obtain a plasticized belt core.

[0084] S6. The covering layer granules are dynamically vulcanized through two extruders and a mold. The speed of the extruder is 50 rpm, and the temperatures of the extruder and the mold are 175°C. The covering layer is directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 165°C. The covering layer thickness is 8 mm, and an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt is obtained.

[0085] The polyarylate fabric whole core flame retardant conveyor belts prepared in Examples 1 to 5 were tested according to the standard MT / T 914-2019 to test the physical properties and flame retardant properties of the samples. The results are as follows:

[0086] As shown in Table 1:

[0087]

[0088]

[0089]

[0090]

[0091] As can be seen from Table 1, the energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt prepared by the present invention has excellent tensile strength, can meet the requirements of high strength, has good flame retardant properties, good antistatic properties, high bonding strength between the cover layer and the core layer, is not easy to fall off, and is convenient for mechanical joints. At the same time, the hydrochloric acid release is low, it is environmentally friendly and economical, has high strength and long service life.

[0092] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. Energy-saving and environmentally friendly polyarylate fabric whole core flame retardant conveyor belt, characterized in that: It includes a polyarylate fabric integral belt core, a covering layer and a belt core impregnated with rubber material; The covering layer comprises the following components in parts by mass: 40-60 parts of solution-polymerized styrene-butadiene rubber, 20-30 parts of styrene-butadiene-styrene block copolymer, 20-30 parts of thermoplastic polyurethane elastomer, 2-4 parts of zinc oxide, 1-2 parts of stearic acid, 1.6-2 parts of sulfur, 1.6-2 parts of accelerator, 1.6-2 parts of antioxidant, 18-22 parts of carbon black, 60-70 parts of hybrid flame retardant composite material, 20-30 parts of phosphate flame retardant, 8-12 parts of paraffin oil and 2-4 parts of antistatic agent; The phosphate flame retardant is any one of toluene diphenyl phosphate, diphenyl phosphate and trioctyl phosphate; The polyarylate fabric integral belt core is a 4-5-layer integral woven structure composed of liquid crystal polyarylate fibers, nylon fibers and cotton fibers, and the width is 104-106% of the bandwidth; The warp force lines of the polyarylate fabric integral belt core are formed by plying 1000D or 1500D high-strength liquid crystal polyarylate fibers, and the tensile strength of a single fiber after plying is 1500-3500N, and the density is 184-279 fibers / 10cm; The polyarylate fabric integral belt core weft force line is formed by plying 1000D or 1500D nylon fiber and cotton fiber, and the tensile strength of a single fiber after plying is 450-1250N / fiber, and the density is 124-160 fibers / 10cm; The upper and lower warp threads of the polyarylate fabric integral belt core are cotton fibers, the middle 2-3 warp threads are liquid crystal polyarylate fibers, the warp content of the belt core is 15-25%, and the weft content of the belt core is 35-45%.

2. The energy-saving and environment-friendly polyarylate fabric whole core flame-retardant conveyor belt according to claim 1 is characterized in that: The accelerator is prepared by mixing accelerator M, accelerator DM and accelerator TMTD in any ratio; and the antioxidant is prepared by mixing antioxidant RD and 4020 in any ratio.

3. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 1 is characterized in that: The core impregnated rubber material comprises the following components in parts by mass: 100-120 parts of polyvinyl chloride paste resin, 40-60 parts of environmentally friendly plasticizer, 10-20 parts of epoxy soybean oil, 8-12 parts of liquid nitrile rubber, 20-40 parts of phosphate flame retardant, 1-2 parts of imidazole phosphate ionic liquid flame retardant, 12-16 parts of intumescent flame retardant and 3-5 parts of calcium zinc composite stabilizer.

4. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 3 is characterized in that: The core impregnated rubber material is prepared by the following steps: Polyvinyl chloride paste resin, environmentally friendly plasticizer, epoxy soybean oil, liquid nitrile rubber, phosphate flame retardant, imidazole phosphate ionic liquid flame retardant, intumescent flame retardant and calcium zinc composite stabilizer are sequentially added into a high-speed disperser for stirring, then ground by a three-roll grinder and degassed by a vacuum degassing machine to obtain a core impregnated rubber material.

5. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 4 is characterized in that: The imidazole phosphate ionic liquid flame retardant is any one of 1-ethyl-3-methylimidazole dimethyl phosphate, 1-ethyl-3-methylimidazole diethyl phosphate and 1-butyl-3-methylimidazole dibutyl phosphate; the intumescent flame retardant is any one of ammonium polyphosphate, melamine polyphosphate and melamine cyanurate.

6. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 1, characterized in that: The covering layer is prepared by the following steps: The hybrid flame retardant masterbatch, solution polymerized styrene-butadiene rubber, thermoplastic polyurethane elastomer, zinc oxide, stearic acid, sulfur, accelerator, antioxidant, carbon black, phosphate flame retardant, paraffin oil and antistatic agent are added into an internal mixer and mixed at 40-60 rpm, dynamically vulcanized at 167-175° C. for 3-4 min, and then dynamically vulcanized at 175-180° C. for 5-6 min through a twin-screw extruder at 50-70 rpm, granulated and cooled to obtain a covering layer.

7. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 6, characterized in that: The hybrid flame retardant masterbatch is prepared by the following steps: The hybrid flame retardant composite material is added into an internal mixer at 20-40 rpm, heated to 70-80°C, and then styrene-butadiene-styrene block copolymer is added and blended for 180-200s, the discharge temperature is 165-175°C, the sheet is discharged, and the hybrid flame retardant masterbatch is obtained after cooling and parking for 8-10 hours.

8. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 7, characterized in that: The hybrid flame retardant composite material is prepared by the following steps: Put white carbon black, expanded graphite, diethyl aluminum hypophosphite and dimethyl imidazole zinc into a kneader and heat and stir at a stirring speed of 350-400rpm. Heat to 40-60°C, start spraying a 2-3wt% polyacrylamide aqueous solution, continue heating and stirring, stir at a temperature of 105-110°C for 10-15 minutes, and obtain a hybrid flame retardant composite material after cooling.

9. The energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 8, characterized in that: The mass ratio of the white carbon black, expanded graphite, diethyl aluminum hypophosphite, dimethyl imidazole zinc and polyacrylamide aqueous solution is 30-35:30-35:20-25:1-2:4-5.

10. The method for manufacturing the energy-saving and environment-friendly polyarylate fabric whole-core flame-retardant conveyor belt according to claim 1, characterized in that: The steps include: Step 1: Impregnate the polyarylate fabric integral belt core through an impregnation tank filled with belt core impregnation rubber and a vacuum box, and put the impregnated polyarylate fabric integral belt core into a plasticizing box at 160-175° C. for plasticization at a plasticizing speed of 0.6-1.2 m / min to obtain a plasticized belt core; Step 2: Dynamically vulcanize the covering layer granules through two extruders and a mold. The speed of the extruder is 30-50rpm, and the temperature of the extruder and the mold is 160-175°C. It is directly bonded to the plasticized belt core in a hot state. The surface temperature of the plasticized belt core is 145-165°C, and the thickness of the covering layer is 6-8mm, so as to obtain an energy-saving and environmentally friendly polyarylate fabric whole-core flame-retardant conveyor belt.

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