Low-cost light-weight full-biodegradable dustproof net and production process thereof

Abstract

The invention relates to a low-cost light-weight full-biodegradable dustproof net and a production process thereof. The invention relates to a low-cost light-weight full-biodegradable dustproof net which is prepared from the following raw materials: resin, activation powder and an activation auxiliary agent, the resin comprises PBAT (poly (butylene adipate-co-terephthalate)) and PLA The activated powder comprises calcium carbonate, phthalocyanine green, zinc stearate, stearic acid and EBS; the activating auxiliary agent is prepared from an aluminate coupling agent, TGIC (triglycidyl isocyanurate), an antioxidant 1076, oxidized polyethlene wax and PPA-Si. According to the low-cost light-weight full-biodegradable dustproof net and the production process thereof, by optimizing the raw materials and the process, the problems that the thickness is too large, the gram weight is too high and sharpening is prone to occurring are solved, and meanwhile the mechanical property of a product is achieved.

Description

Technical Field

[0001] This invention belongs to the technical field of biodegradable dust control nets, specifically relating to a low-cost, lightweight, fully biodegradable dust control net and its production process. Background Technology

[0002] As a key material for controlling dust pollution, the production process of dust control netting has continuously evolved with environmental protection requirements and material technology iterations. Early production primarily used petroleum-based polymers such as polyethylene (PE) and polypropylene (PP), formed through casting, extrusion, filament drawing, winding, and warp knitting processes. While offering advantages such as low cost and high tensile strength, this process suffered from high energy consumption due to high temperatures, low recycling rates of scrap materials, and the difficulty in biodegrading the waste products, leading to "white pollution" from long-term accumulation, increasingly contradicting current ecological and environmental protection requirements. Addressing the resource waste issues of traditional processes, Shandong Binzhou Botao Chemical Fiber Co., Ltd. explored breakthroughs through technological innovation. Its independently developed technology for "producing safety netting using waste polyester bottle flakes" filled a domestic gap, resulting in multiple patents covering production process improvement and equipment optimization, becoming a typical attempt at green transformation in the traditional rope and netting industry. However, the inherent limitations of traditional dust control netting materials have not been fundamentally resolved. With increasingly stringent environmental regulations, deeper technological innovation is urgently needed to overcome development bottlenecks.

[0003] To address the environmental challenges posed by traditional dust control nets, fully biodegradable dust control nets have become a core research and development direction in the industry. Driven by both increasingly stringent environmental requirements and the urgent need for cost reduction and efficiency improvement, the development of lightweight, fully biodegradable dust control nets has become an inevitable trend. However, existing patents still face multiple challenges in achieving large-scale production: First, to ensure key mechanical properties such as wind erosion resistance and aging resistance, products often have excessive thickness and high basis weight, directly leading to increased material usage and higher production costs; second, some biodegradable materials have poor compatibility, easily causing problems such as tool sharpening during continuous production and processing. Furthermore, existing technologies have not fully overcome these challenges, thus restricting the large-scale implementation and market promotion of the products.

[0004] The existing technology CN 118756424A discloses "Modified Particles for Biodegradable Dust Control Nets and Their Preparation Method," which can avoid problems such as material strip precipitation during blown film production and severe blade wear during flat filament slitting in low-load semi-continuous production scenarios. However, when this modified particle is applied on a large scale, it reveals significant inadequacy in adaptability. For example, under full-load 24-hour continuous operation of the blown film machine, material strip precipitation occurs on average every 20 hours, affecting product quality stability; when the flat filament slitting machine is running at full load, a set of slitting blades needs to be replaced on average every 36 hours, which not only brings potential quality risks but also significantly reduces production capacity and increases overall production costs.

[0005] In view of this, the present invention proposes a new low-cost, lightweight, fully biodegradable dustproof net and its production process. By optimizing the raw materials and processes, the problems of excessive thickness, high basis weight, and easy sharpening are solved, while also ensuring the mechanical properties of the product. Summary of the Invention

[0006] The purpose of this invention is to provide a low-cost, lightweight, fully biodegradable dustproof net, which solves the problems of easy exudation of film strips and easy wear of flat wire slitting blades by optimizing the raw materials.

[0007] To achieve the above objectives, the technical solution adopted is as follows:

[0008] A low-cost, lightweight, fully biodegradable dustproof net is prepared from the following raw materials: resin, activated powder, and activation additives;

[0009] The resins mentioned include: PBAT and PLA;

[0010] The activated powder includes: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS;

[0011] The activating agents include: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, and PPA-Si.

[0012] Furthermore, the resin comprises: 60-67 parts by weight of PBAT and 3-7 parts by weight of PLA;

[0013] The activated powder comprises: 22-28 parts by weight of calcium carbonate, 2-3 parts by weight of phthalocyanine green, 0.15-0.25 parts by weight of zinc stearate, 0.30-0.40 parts by weight of stearic acid, and 0.15-0.25 parts by weight of EBS;

[0014] The activating agent comprises: 0.3-0.5 parts by weight of aluminate coupling agent, 0.3-0.5 parts by weight of TGIC, 0.8-1.2 parts by weight of antioxidant 1076, 0.8-1.2 parts by weight of oxidized polyethylene wax, and 0.4-0.6 parts by weight of PPA-Si.

[0015] Furthermore, the resin comprises: 63.45 parts by weight of PBAT and 5 parts by weight of PLA;

[0016] The activated powder comprises: 25 parts by weight of calcium carbonate, 2.5 parts by weight of phthalocyanine green, 0.2 parts by weight of zinc stearate, 0.35 parts by weight of stearic acid, and 0.2 parts by weight of EBS.

[0017] The activating agent comprises: 0.4 parts by weight of aluminate coupling agent, 0.4 parts by weight of TGIC, 1 part by weight of antioxidant 1076, 1 part by weight of oxidized polyethylene wax, and 0.5 parts by weight of PPA-Si.

[0018] Furthermore, the activated powder processing procedure is as follows: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are made into a suspension, a dispersant is added, and the mixture is wet-milled, filtered, and dried to obtain dried powder; a surface treatment agent is heated to a liquid state and then atomized and sprayed onto the dried powder.

[0019] The process of the activation aid is as follows: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant are added to anhydrous ethanol and mixed evenly.

[0020] Another objective of this invention is to provide a production process for the aforementioned fully biodegradable dustproof net. By optimizing the process, the thickness and weight of the dustproof net can be reduced while maintaining mechanical properties and low cost.

[0021] To achieve the above objectives, the technical solution adopted is as follows:

[0022] The production process of the above-mentioned fully biodegradable dustproof net includes the following steps:

[0023] (1) After the resin, activated powder and activated additive are mixed evenly, they are extruded and granulated using a twin-screw extruder to obtain the modified material;

[0024] (2) The modified material is added to a blown film machine for blown film production to obtain a thin film;

[0025] (3) The film is placed in a flat filament production device, and as the rollers move, the film is cut into flat filaments by the blades;

[0026] (4) After the flat filaments are heated and stretched by a stretching plate, they are woven into a net to obtain the fully biodegradable dustproof net.

[0027] Furthermore, in step (2), the blowing temperature of the blown film machine is: 120-140℃ in zone 1, 140-160℃ in zone 2, 150-170℃ in zone 3, 140-160℃ in zone 4, and 140-150℃ in zone 5. The film blowing ratio is 2-4, the film width is 30-40mm, and the film thickness is 25-50um.

[0028] Furthermore, in step (3), the width of the flat filament is 2.5-4 mm;

[0029] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0030] Furthermore, in step (4), the heating and stretching temperature is 80-90℃ and the time is 25-35s.

[0031] Furthermore, in step (4), the heating and stretching time is 30 seconds.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] 1. In the technical solution of the present invention, while reducing the amount of lubricant zinc stearate, EBS and oxidized polyethylene wax, an organosilicon processing aid PPA-Si is introduced, thereby improving the smoothness of blown film and solving the problem of material strip precipitation.

[0034] 2. In the technical solution of the present invention, the coupling agent and epoxy chain extender are compounded and reinforced to further improve the compatibility of PBAT resin and calcium carbonate, ensure the processing stability of the modified material, thereby greatly reducing the replacement cycle of the cutting blade and solving the problem of easy wear of flat wire slitting blades.

[0035] 3. In the technical solution of the present invention, by optimizing the process and adding the process of "heating and stretching flat yarns twice by stretching plate", a number of advantages are generated, specifically: (1) the strength and elongation at break of flat yarns are improved, and the shrinkage problem after weaving of fully biodegradable dustproof nets is solved from the root; (2) the thickness and width of flat yarns are reduced, and the weight of dustproof nets is reduced significantly, up to 30g / ㎡; (3) at the same time, the shrinkage rate of the woven product is reduced, and the dimensional accuracy and reliability of use are significantly improved.

[0036] 4. In the technical solution of the present invention, after process optimization, cost reduction and efficiency improvement are achieved by simplifying redundant winding processes. After the flat yarn is stretched twice, it is directly fed into the warp knitting machine for weaving, without the need for additional winding-related equipment. This not only reduces the cost of fixed asset purchase, but also reduces the operation and management manpower of the winding process by simplifying the production process. At the same time, it shortens the process connection time, avoids potential losses in the winding and unwinding process, optimizes the production cycle, and further improves the overall production efficiency. Attached Figure Description

[0037] Figure 1 The production process before optimization;

[0038] Figure 2 This is the technical solution of the present invention. Detailed Implementation

[0039] To further illustrate the low-cost, lightweight, fully biodegradable dustproof net and its manufacturing process according to the present invention, and to achieve the intended purpose of the invention, the following detailed description, in conjunction with preferred embodiments, details the specific implementation methods, structures, features, and effects of the low-cost, lightweight, fully biodegradable dustproof net and its manufacturing process proposed according to the present invention. In the following description, different "embodiments" or "embodiments" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable manner.

[0040] The following will provide a detailed description of the low-cost, lightweight, fully biodegradable dustproof net and its manufacturing process according to specific embodiments of the present invention:

[0041] This invention provides a low-cost, lightweight, fully biodegradable dustproof net and its production process. Through: (1) optimization and upgrading of the modified material formula, effectively solving the problems of blown film strip exudation and flat yarn slitting and grinding, thus reducing processing costs; (2) adding a secondary heating and stretching process to reduce product weight, achieving product lightweighting while reducing product shrinkage, increasing the actual effective coverage area, and reducing production costs; (3) streamlining redundant winding processes, reducing equipment investment and labor, shortening process time, and further reducing production costs. This solves the problems of excessive thickness, high weight, and easy grinding, while also maintaining the product's mechanical properties. The technical solution adopted in this invention is as follows:

[0042] A low-cost, lightweight, fully biodegradable dustproof net is prepared from the following raw materials: resin, activated powder, and activation additives;

[0043] The resins mentioned include: PBAT and PLA;

[0044] The activated powder includes: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS;

[0045] The activating agents include: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, and PPA-Si.

[0046] Preferably, the resin comprises: 60-67 parts by weight of PBAT and 3-7 parts by weight of PLA;

[0047] The activated powder comprises: 22-28 parts by weight of calcium carbonate, 2-3 parts by weight of phthalocyanine green, 0.15-0.25 parts by weight of zinc stearate, 0.30-0.40 parts by weight of stearic acid, and 0.15-0.25 parts by weight of EBS;

[0048] The activating agent comprises: 0.3-0.5 parts by weight of aluminate coupling agent, 0.3-0.5 parts by weight of TGIC, 0.8-1.2 parts by weight of antioxidant 1076, 0.8-1.2 parts by weight of oxidized polyethylene wax, and 0.4-0.6 parts by weight of PPA-Si.

[0049] In the above technical solution, based on the existing patented technology, the amount of lubricant zinc stearate, EBS and oxidized polyethylene wax added is reduced. At the same time, in order to improve the die opening of the blown film machine, the silicone-based processing aid PPA-Si is introduced to effectively suppress material accumulation at the die opening and improve the smoothness of the blown film. Through fine adjustment, the problem of material strip precipitation is effectively solved.

[0050] More preferably, the resin comprises: 63.45 parts by weight of PBAT and 5 parts by weight of PLA;

[0051] The activated powder comprises: 25 parts by weight of calcium carbonate, 2.5 parts by weight of phthalocyanine green, 0.2 parts by weight of zinc stearate, 0.35 parts by weight of stearic acid, and 0.2 parts by weight of EBS.

[0052] The activating agent comprises: 0.4 parts by weight of aluminate coupling agent, 0.4 parts by weight of TGIC, 1 part by weight of antioxidant 1076, 1 part by weight of oxidized polyethylene wax, and 0.5 parts by weight of PPA-Si.

[0053] Preferably, the activated powder processing procedure is as follows: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are made into a suspension, a dispersant is added, and the mixture is wet-milled, filtered, and dried to obtain dried powder; a surface treatment agent is heated to a liquid state and then atomized and sprayed onto the dried powder.

[0054] The process of the activation aid is as follows: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant are added to anhydrous ethanol and mixed evenly.

[0055] In the above technical solution, during the powder activation process, zinc stearate, stearic acid, EBS are activated together with calcium carbonate and phthalocyanine green, so that zinc stearate, stearic acid, and EBS can be better dispersed in calcium carbonate and phthalocyanine green, enhancing the fluidity of calcium carbonate and phthalocyanine green, and thus can be better distributed in the material system.

[0056] The production process of the above-mentioned fully biodegradable dustproof net includes the following steps:

[0057] (1) After the resin, activated powder and activated additive are mixed evenly, they are extruded and granulated using a twin-screw extruder to obtain the modified material;

[0058] (2) The modified material is added to a blown film machine for blown film production to obtain a thin film;

[0059] (3) The film is placed in a flat filament production device, and as the rollers move, the film is cut into flat filaments by the blades;

[0060] (4) After the flat filaments are heated and stretched by a stretching plate, they are woven into a net to obtain the fully biodegradable dustproof net.

[0061] In the above technical solution, the film is cut into filaments while being heated and stretched. That is, after being cut into filaments, it is directly heated and stretched.

[0062] Preferably, in step (2), the blowing temperature of the blown film machine is: 120-140℃ in zone 1, 140-160℃ in zone 2, 150-170℃ in zone 3, 140-160℃ in zone 4, and 140-150℃ in zone 5. The film blowing ratio is 2-4, the film width is 30-40mm, and the film thickness is 25-50um.

[0063] Preferably, in step (3), the width of the flat filament is 2.5-4 mm;

[0064] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0065] Preferably, in step (4), the heating and stretching temperature is 80-90℃ and the time is 25-35s, so that the flat filament is in full contact with the stretching plate.

[0066] In existing technologies, the inherent properties of biodegradable materials make them unsuitable for heat stretching processes. This invention controls the heat stretching parameters and the width and thickness of the flat filaments to achieve a stretching effect before damage occurs.

[0067] More preferably, in step (4), the heating and stretching time is 30s.

[0068] All raw materials used in the examples are commercially available.

[0069] TGIC, triglycidyl isocyanurate, is a white crystalline solid and a heterocyclic polycyclic epoxy compound. PPA-Si is an organosilicon processing aid.

[0070] Example 1.

[0071] 1. Raw materials (total mass 15kg)

[0072] The resin comprises: 60 parts by weight of PBAT and 3 parts by weight of PLA.

[0073] The activated powder comprises: 22 parts by weight of calcium carbonate, 2 parts by weight of phthalocyanine green, 0.15 parts by weight of zinc stearate, 0.30 parts by weight of stearic acid, and 0.15 parts by weight of EBS.

[0074] The activating agents include: 0.3 parts by weight of aluminate coupling agent, 0.3 parts by weight of TGIC, 0.8 parts by weight of antioxidant 1076, 0.8 parts by weight of oxidized polyethylene wax, and 0.4 parts by weight of PPA-Si.

[0075] The activated powder treatment process is as follows: Calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are blended and then prepared into a 30% (w / w) suspension using deionized water. A dispersant is added, and the mixture is wet-milled until the average particle size is 2.0 μm. The mixture is then filtered to obtain a powder filter. The powder filter is dried at 100°C to obtain a powder with a moisture content ≤500 ppm. The surface treatment agent, stearic acid, is heated to 80°C, atomized, and sprayed onto the dried powder placed in a high-speed dispersion reactor (1300 rpm). Simultaneously, the mixture is stirred at high speed for 10 minutes to obtain the activated powder for later use. The stirring device has a constant temperature function to ensure that the powder does not agglomerate due to heating during stirring.

[0076] The process of activating aids is as follows: After uniformly mixing aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant, anhydrous ethanol is added for dilution, and then the mixture is further mixed evenly for later use.

[0077] 2. Combining Figure 2 The specific operating steps are as follows:

[0078] (1) After the resin, activated powder and activated additive are mixed evenly, they are added to a twin-screw extruder for extrusion granulation to obtain modified material.

[0079] (2) Add the modified material to the blown film machine to blow film and obtain a film.

[0080] The blowing temperature of the blown film machine is: Zone 1 120-140℃, Zone 2 140-160℃, Zone 3 150-170℃, Zone 4 140-160℃, Zone 5 140-150℃. The film blow-up ratio is 2-4, the film width is 30-40mm, and the film thickness is 25-50um. The film is then wound up for later use.

[0081] (3) Place the film in the flat filament production device, start the equipment, and as the rollers move, the film is gradually cut into flat filaments with a width of 2.5-4mm by the blades.

[0082] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0083] (4) The cut flat wires are directly heated and stretched through a stretching plate. The heating and stretching temperature is 80℃ and the time is 35s, so that the flat wires are in full contact.

[0084] (5) Then the stretched flat filaments are woven into a net to obtain the fully biodegradable dustproof net. The weaving process is as follows: the flat filaments are placed on both sides of the frame of the weaving machine according to the warp and weft distribution for later use. The frame can hold 18*15*4 rolls of flat filaments. Then, the weft flat filaments are threaded one by one into the customized fixed needle holes, and the warp flat filaments are threaded one by one into the customized hook needle holes. During production, the biodegradable flat filaments are transmitted to the hook needles through the tension device, so that the left and right swing of the hook needles completes the weaving of the dustproof net, thus obtaining the biodegradable dustproof net.

[0085] Example 2.

[0086] 1. Raw materials (total mass 15kg)

[0087] The resin comprises 67 parts by weight of PBAT and 7 parts by weight of PLA.

[0088] The activated powder comprises: 28 parts by weight of calcium carbonate, 3 parts by weight of phthalocyanine green, 0.25 parts by weight of zinc stearate, 0.40 parts by weight of stearic acid, and 0.25 parts by weight of EBS.

[0089] The activating agents include: 0.5 parts by weight of aluminate coupling agent, 0.5 parts by weight of TGIC, 1.2 parts by weight of antioxidant 1076, 1.2 parts by weight of oxidized polyethylene wax, and 0.6 parts by weight of PPA-Si.

[0090] The activated powder treatment process is as follows: Calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are blended and then prepared into a 30% (w / w) suspension using deionized water. A dispersant is added, and the mixture is wet-milled until the average particle size is 2.0 μm. The mixture is then filtered to obtain a powder filter. The powder filter is dried at 100°C to obtain a powder with a moisture content ≤500 ppm. The surface treatment agent, stearic acid, is heated to 80°C, atomized, and sprayed onto the dried powder placed in a high-speed dispersion reactor (1300 rpm). Simultaneously, the mixture is stirred at high speed for 10 minutes to obtain the activated powder for later use. The stirring device has a constant temperature function to ensure that the powder does not agglomerate due to heating during stirring.

[0091] The process of activating aids is as follows: After uniformly mixing aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant, anhydrous ethanol is added for dilution, and then the mixture is further mixed evenly for later use.

[0092] 2. Combining Figure 2 The specific operating steps are as follows:

[0093] (1) After the resin, activated powder and activated additive are mixed evenly, they are added to a twin-screw extruder for extrusion granulation to obtain modified material.

[0094] (2) Add the modified material to the blown film machine to blow film and obtain a film.

[0095] The blowing temperature of the blown film machine is: Zone 1 120-130℃, Zone 2 140-150℃, Zone 3 150-160℃, Zone 4 140-150℃, Zone 5 140-150℃. The film blowing ratio is 2-3, the film width is 30-40mm, and the film thickness is 25-50um. The film is then wound up for later use.

[0096] (3) Place the film in the flat filament production device, start the equipment, and as the rollers move, the film is gradually cut into flat filaments with a width of 2.5-4mm by the blades.

[0097] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0098] (4) The cut flat wires are directly heated and stretched through a stretching plate. The heating and stretching temperature is 90℃ and the time is 25s, so that the flat wires are in full contact.

[0099] (5) Then the stretched flat filaments are woven into a net to obtain the fully biodegradable dustproof net.

[0100] Example 3.

[0101] 1. Raw materials (total mass 15kg)

[0102] The resin comprises 64 parts by weight of PBAT and 4.5 parts by weight of PLA.

[0103] The activated powder comprises: 26 parts by weight of calcium carbonate, 2.3 parts by weight of phthalocyanine green, 0.18 parts by weight of zinc stearate, 0.36 parts by weight of stearic acid, and 0.18 parts by weight of EBS.

[0104] The activating agents include: 0.4 parts by weight of aluminate coupling agent, 0.4 parts by weight of TGIC, 0.9 parts by weight of antioxidant 1076, 0.9 parts by weight of oxidized polyethylene wax, and 0.5 parts by weight of PPA-Si.

[0105] The activated powder treatment process is as follows: Calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are blended and then prepared into a 30% (w / w) suspension using deionized water. A dispersant is added, and the mixture is wet-milled until the average particle size is 2.0 μm. The mixture is then filtered to obtain a powder filter. The powder filter is dried at 100°C to obtain a powder with a moisture content ≤500 ppm. The surface treatment agent, stearic acid, is heated to 80°C, atomized, and sprayed onto the dried powder placed in a high-speed dispersion reactor (1300 rpm). Simultaneously, the mixture is stirred at high speed for 10 minutes to obtain the activated powder for later use. The stirring device has a constant temperature function to ensure that the powder does not agglomerate due to heating during stirring.

[0106] The process of activating aids is as follows: After uniformly mixing aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant, anhydrous ethanol is added for dilution, and then the mixture is further mixed evenly for later use.

[0107] 2. Combining Figure 2 The specific operating steps are as follows:

[0108] (1) After the resin, activated powder and activated additive are mixed evenly, they are added to a twin-screw extruder for extrusion granulation to obtain modified material.

[0109] (2) Add the modified material to the blown film machine to blow film and obtain a film.

[0110] The blowing temperature of the blown film machine is: Zone 1 130-140℃, Zone 2 150-160℃, Zone 3 160-170℃, Zone 4 150-160℃, Zone 5 140-150℃. The film blow-up ratio is 3-4, the film width is 30-40mm, and the film thickness is 25-50um. The film is then wound up for later use.

[0111] (3) Place the film in the flat filament production device, start the equipment, and as the rollers move, the film is gradually cut into flat filaments with a width of 2.5-4mm by the blades.

[0112] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0113] (4) The cut flat wires are directly heated and stretched through a stretching plate. The heating and stretching temperature is 80-90℃ and the time is 30s, so that the flat wires are in full contact.

[0114] (5) Then the stretched flat filaments are woven into a net to obtain the fully biodegradable dustproof net.

[0115] Comparative Example 1.

[0116] 1. The specific amount of raw materials (total mass of 15kg) is shown in Table 1.

[0117] 2. Combining Figure 1 The specific operating steps are as follows:

[0118] (1) After the resin, activated powder and activated additive are mixed evenly, they are added to a twin-screw extruder for extrusion granulation to obtain modified material.

[0119] (2) Add the modified material to the blown film machine to blow film and obtain a film.

[0120] The blowing temperature of the blown film machine is: Zone 1 120-140℃, Zone 2 140-160℃, Zone 3 150-170℃, Zone 4 140-160℃, Zone 5 140-150℃. The film blow-up ratio is 2-4, the film width is 30-40mm, and the film thickness is 25-50um. The film is then wound up for later use.

[0121] (3) Place the film in the flat filament production device, start the equipment, and as the rollers move, the film is gradually cut into flat filaments with a width of 3-6mm by the blades.

[0122] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0123] (4) After the flat filaments are torn and drawn by the blades, they are combed into individual strands by the filament splitting device and laid flat on the conveyor belt. Then, each flat filament is gradually wound into the filament winding machine for winding.

[0124] The take-up machine is an automatic variable frequency high-speed take-up machine, equipped with a servo motor and tension adjustment device, which can synchronously drive the flat yarn to complete the take-up of the flat yarn according to the cutting speed of the flat yarn. The take-up device in this embodiment is a four-row, five-section take-up machine.

[0125] (5) After the flat yarn is wound up, it is placed on both sides of the frame of the braiding machine according to the warp and weft distribution. The frame can hold 18*15*4 rolls of flat yarn. Then, the weft flat yarn is inserted one by one into the customized fixed needle hole, and the warp flat yarn is inserted one by one into the customized hook needle hole. During production, the biodegradable flat yarn is transmitted to the hook needle through the tension device, so that the left and right swing of the hook needle can complete the weaving of the dustproof net, and the biodegradable dustproof net is obtained.

[0126] Example 4.

[0127] 1. Raw materials (total mass 15kg)

[0128] Resins include: PBAT and PLA.

[0129] The activated powders include: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS.

[0130] Activating agents include: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, and PPA-Si.

[0131] The activated powder treatment process is as follows: Calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are blended and then prepared into a 30% (w / w) suspension using deionized water. A dispersant is added, and the mixture is wet-milled until the average particle size is 2.0 μm. The mixture is then filtered to obtain a powder filter. The powder filter is dried at 100°C to obtain a powder with a moisture content ≤500 ppm. The surface treatment agent, stearic acid, is heated to 80°C, atomized, and sprayed onto the dried powder placed in a high-speed dispersion reactor (1300 rpm). Simultaneously, the mixture is stirred at high speed for 10 minutes to obtain the activated powder for later use. The stirring device has a constant temperature function to ensure that the powder does not agglomerate due to heating during stirring.

[0132] The process of activating aids is as follows: After uniformly mixing aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant, anhydrous ethanol is added for dilution, and then the mixture is further mixed evenly for later use.

[0133] 2. Combining Figure 2 The specific operating steps are as follows:

[0134] (1) After the resin, activated powder and activated additive are mixed evenly, they are added to a twin-screw extruder for extrusion granulation to obtain modified material.

[0135] (2) Add the modified material to the blown film machine to blow film and obtain a film.

[0136] The blowing temperature of the blown film machine is: Zone 1 120-140℃, Zone 2 140-160℃, Zone 3 150-170℃, Zone 4 140-160℃, Zone 5 140-150℃. The film blow-up ratio is 2-4, the film width is 30-40mm, and the film thickness is 25-50um. The film is then wound up for later use.

[0137] (3) Place the film in the flat filament production device, start the equipment, and as the rollers move, the film is gradually cut into flat filaments with a width of 2.5-4mm by the blades.

[0138] The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

[0139] (4) The cut flat wires are directly heated and stretched through a stretching plate. The heating and stretching temperature is 80-90℃ and the time is 30s, so that the flat wires are in full contact.

[0140] (5) The stretched flat filaments are then woven into a net to obtain the fully biodegradable dustproof net. The specific amounts of each raw material used in this embodiment are shown in Table 1.

[0141] Table 1

[0142]

[0143] 3. Performance Testing

[0144] (1) Mechanical properties of thin films

[0145] The thin film performance of the products obtained in this embodiment (1-4) and Comparative Example 1 was tested, that is, the performance of the thin film obtained by blown film in step (2) was tested.

[0146] The testing method adopted is a conventional method in this field. The test was conducted according to the method specified in GB / T 1040.3-2006, Determination of Tensile Properties of Plastics Part 3: Test Conditions for Films and Sheets. The specimens used were long strip-shaped specimens with a test length of 15±0.5 mm and a width of 10±0.2 mm, with a minimum of 5 valid specimen sets. The testing instrument was an INSTRON 5966 series universal testing system.

[0147] The test results are shown in Table 2-3.

[0148] Table 2 Mechanical properties of thin films

[0149] Comparative Example 1 1 2 3 4 Tensile strength (MPa) 18.95 18.75 19.23 18.66 19.25 Elongation at break (%) 676.8 655.4 662.5 689.5 646.5

[0150] Table 3 Production Failure Frequency

[0151] Comparative Example 1 1 2 3 4 Precipitation frequency of material strips 20 hours / time 10 days / time 30 days / time 50 days / time 0 Blade replacement cycle 36h / time 10 days / time 15 days / time 30 days / time 1.5 months / time

[0152] Based on Table 2-3, the following points can be observed:

[0153] ① The optimization of raw materials and their dosage has no significant impact on mechanical properties.

[0154] ② With the reduction of the amount of lubricants zinc stearate, EBS and oxidized polyethylene wax, and the introduction of organosilicon-based processing aid PPA-Si, the precipitation frequency of the material strips decreased significantly.

[0155] ③ The coupling agent and epoxy chain extender are compounded and reinforced to further improve the compatibility between PBAT resin and calcium carbonate, ensuring the processing stability of the modified material. This allows the flat wire slitting to operate at full load, with an average of one set of slitting blades to be replaced every 1.5 months, effectively solving the problem of equipment downtime caused by wear of some blades during the flat wire slitting process.

[0156] (2) Flat yarn performance

[0157] The performance of the dustproof net in Comparative Example 1 and the dustproof net No. 4 in this embodiment was tested.

[0158] The testing method was conducted in accordance with GB / T 1040.3-2006, Determination of Tensile Properties of Plastics Part 3: Test Conditions for Films and Sheets. The sample length was initially set at 15±0.5 mm. However, due to the narrow width of the flat wire, which could not meet the national standard requirements, a long strip sample with an actual measured width of 1.2 mm was selected. The minimum number of samples was ensured to be at least 5 sets of valid samples. The testing instrument was an INSTRON 5966 series universal testing system.

[0159] The test results are shown in Table 4.

[0160] Table 4

[0161]

[0162]

[0163] Referring to Table 4, the optimized process of this invention, through the core adjustment of "adding key processes + streamlining redundant processes," achieves product performance upgrades and lightweight breakthroughs while ensuring the dustproof net coverage remains consistent with the original process. The newly added "flat yarn heated and stretched twice by a stretching plate" process is remarkably effective. It not only increases the strength of the flat yarn by nearly 2 times compared to before optimization and reduces the breaking elongation to 2 / 3 of the original, fundamentally solving the shrinkage problem after weaving the fully biodegradable dustproof net, but also reduces the thickness of the flat yarn by 3 times and the width by 1.8 times, directly driving the weight of the dustproof net down from 160g / ㎡ to 30g / ㎡. At the same time, it reduces the shrinkage rate of the woven product from 35% to 10%, significantly improving dimensional accuracy and reliability.

[0164] At the same time, process optimization has reduced costs and increased efficiency by streamlining redundant winding processes. Flat yarns are directly fed into the warp knitting machine after secondary stretching, eliminating the need for additional winding-related equipment. This reduces fixed asset purchase costs and simplifies the production process by reducing the manpower required for operation and management in the winding stage. It also shortens the process connection time, avoids potential losses during winding and unwinding, optimizes the production cycle, and further improves overall production efficiency.

[0165] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A low-cost, lightweight, fully biodegradable dustproof net, characterized in that, It is prepared from the following raw materials: resin, activated powder, and activation additives; The resins mentioned include: PBAT and PLA; The activated powder includes: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS; The activating agents include: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, and PPA-Si.

2. The fully biodegradable dustproof net according to claim 1, characterized in that, The resin comprises: 60-67 parts by weight of PBAT and 3-7 parts by weight of PLA; The activated powder comprises: 22-28 parts by weight of calcium carbonate, 2-3 parts by weight of phthalocyanine green, 0.15-0.25 parts by weight of zinc stearate, 0.30-0.40 parts by weight of stearic acid, and 0.15-0.25 parts by weight of EBS; The activating agent comprises: 0.3-0.5 parts by weight of aluminate coupling agent, 0.3-0.5 parts by weight of TGIC, 0.8-1.2 parts by weight of antioxidant 1076, 0.8-1.2 parts by weight of oxidized polyethylene wax, and 0.4-0.6 parts by weight of PPA-Si.

3. The fully biodegradable dustproof net according to claim 2, characterized in that, The resin comprises: 63.45 parts by weight of PBAT and 5 parts by weight of PLA; The activated powder comprises: 25 parts by weight of calcium carbonate, 2.5 parts by weight of phthalocyanine green, 0.2 parts by weight of zinc stearate, 0.35 parts by weight of stearic acid, and 0.2 parts by weight of EBS. The activating agent comprises: 0.4 parts by weight of aluminate coupling agent, 0.4 parts by weight of TGIC, 1 part by weight of antioxidant 1076, 1 part by weight of oxidized polyethylene wax, and 0.5 parts by weight of PPA-Si.

4. The fully biodegradable dustproof net according to claim 1, characterized in that, The activated powder processing procedure is as follows: calcium carbonate, phthalocyanine green, zinc stearate, stearic acid, and EBS are made into a suspension, a dispersant is added, and the mixture is wet-milled, filtered, and dried to obtain the dried powder; a surface treatment agent is heated to a liquid state and then atomized and sprayed onto the dried powder. The process of the activation aid is as follows: aluminate coupling agent, TGIC, antioxidant 1076, oxidized polyethylene wax, PPA-Si and lubricant are added to anhydrous ethanol and mixed evenly.

5. The production process of the fully biodegradable dustproof net according to any one of claims 1-4, characterized in that, Includes the following steps: (1) After the resin, activated powder and activated additive are mixed evenly, they are extruded and granulated using a twin-screw extruder to obtain the modified material; (2) The modified material is added to a blown film machine for blown film production to obtain a thin film; (3) The film is placed in a flat filament production device, and as the rollers move, the film is cut into flat filaments by the blades; (4) After the flat filaments are heated and stretched by a stretching plate, they are woven into a net to obtain the fully biodegradable dustproof net.

6. The production process according to claim 5, characterized in that, In step (2), the blowing temperature of the blown film machine is: 120-140℃ in zone 1, 140-160℃ in zone 2, 150-170℃ in zone 3, 140-160℃ in zone 4, and 140-150℃ in zone 5. The film blowing ratio is 2-4, the film width is 30-40mm, and the film thickness is 25-50um.

7. The production process according to claim 5, characterized in that, In step (3), the width of the flat filament is 2.5-4 mm; The blades are ultra-thin ceramic tungsten carbide three-hole blades or round blades.

8. The production process according to claim 5, characterized in that, In step (4), the heating and stretching temperature is 80-90℃ and the time is 25-35s.

9. The production process according to claim 8, characterized in that, In step (4), the heating and stretching time is 30 seconds.

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