High-strength corrosion-resistant polyester base fabric

Abstract

The invention discloses a high-strength corrosion-resistant polyester tire base cloth, which belongs to the technical field of fiber product treatment, and is characterized in that the high-strength corrosion-resistant polyester tire base cloth comprises a fiber net subjected to needling consolidation and polyurethane impregnation treatment, the fiber net is composed of composite fibers, the composite fibers have a core-shell structure, and the core-shell structure is formed by interweaving of polyester fibers and polyester fibers. Wherein the shell layer is a polyurethane composite material, and the core layer is copolyester. The preparation method of the polyurethane composite material comprises the following steps: pretreatment, prepolymer synthesis, chain extension and granulation. The preparation method of the copolyester comprises the steps of esterification reaction, melt polycondensation, final polycondensation and granulation. The high-strength corrosion-resistant polyester tire base cloth prepared by the invention has relatively high strength performance, excellent thermal stability and excellent acid and alkali corrosion resistance.

Description

Technical Field

[0001] This invention belongs to the field of fiber product processing technology, specifically relating to a high-strength corrosion-resistant polyester base fabric. Background Technology

[0002] Polyester-based fabrics serve as the core reinforcing framework for waterproof membranes, geosynthetics, and other fields, directly impacting the mechanical strength, dimensional stability, and durability of composite materials. Traditional polyester-based fabrics primarily rely on the properties of the polyester fibers themselves. While they possess certain mechanical properties under normal conditions, their inherent molecular structure imposes numerous limitations on their performance. Firstly, the ester bonds in the polyester molecular chain are prone to hydrolysis under high temperature and humidity conditions, leading to chain breakage and a significant decrease in material strength. Particularly in alkaline environments, the hydrolysis reaction accelerates dramatically, severely restricting its long-term service life in concrete-related projects or specific industrial environments.

[0003] Secondly, the insufficient thermal stability of polyester materials is also a key technical challenge. During production and subsequent processing, the material is exposed to high temperatures, causing thermal shrinkage and deformation. This unstable thermomechanical property can lead to problems such as product dimensional changes and warping, directly affecting the quality of the final product and engineering safety.

[0004] To overcome these bottlenecks, the industry has made various attempts and improvements, mainly including the development of composite reinforcing materials such as glass fiber / basalt and the integration of functions through multi-layer composite structures and special coatings.

[0005] The development of composite reinforcing materials such as glass fiber / basalt mainly involves adding longitudinally uniformly distributed glass fiber filaments to the middle layer of traditional polyester base fabric. Utilizing the high modulus of glass fiber, the resulting glass fiber reinforced products significantly improve tensile strength, making the roll material less prone to shrinkage after construction. The invention application CN119613924A, "A High-Strength Basalt Fiber Composite Polyester Base and Its Preparation Method," uses basalt fiber to composite with a polyester matrix, and employs specific components such as epoxy silane coupling agents and maleic anhydride grafted polymers to form stable chemical bonds between the fibers and the matrix, thereby significantly improving interfacial bonding strength and preventing delamination.

[0006] The technology of achieving functional integration through multi-layered composite structures and specialized coatings mainly improves the comprehensive protective performance of materials through the synergistic effect of multiple material layers and the additional properties of functional coatings. The invention application CN119974690A, "A Corrosion-Inhibiting and Anti-Corrosion Flexible Protective Structure and Its Preparation Method," utilizes a multi-layered sealing structure including anti-corrosion tape, coated plain weave fabric, and fiber mesh fabric. This allows the protective structure to not only possess corrosion-inhibiting and anti-corrosion properties but also waterproof, erosion-resistant, and fire-resistant temperature-resistant characteristics. On the other hand, functional coatings such as superhydrophobic and high-efficiency infrared emitting coatings have also been developed and applied to fabrics to impart additional properties such as self-cleaning and radiative cooling to the substrate.

[0007] Although the above-mentioned technical solutions have improved one or more properties of polyester base fabric to varying degrees, they still have obvious limitations and technical problems.

[0008] First, the fiber-matrix interface compatibility and long-term durability are insufficient. Although coupling agents and other methods are used to improve the interfacial bonding between the fiber and resin, the stability of the interface still faces challenges under complex humid heat, chemical corrosion, and long-term stress. Any tiny defect at the interface can become a channel for corrosive media to penetrate or a starting point for damage under stress, leading to a decrease in reinforcement effect and affecting the reliability of the material in long-term use.

[0009] Secondly, the interfacial compatibility and performance balance of multilayer / multimaterial composite structures present challenges. When combining layered structures with different materials and functions, the interfacial compatibility between the layers is a key challenge. If the interfacial bonding is weak, delamination and peeling are likely to occur during service. Furthermore, achieving a balance of high performance without sacrificing the basic mechanical properties, flexibility, and ease of processing of materials when introducing multiple functions remains a current technological hurdle.

[0010] Finally, the ability to maintain overall performance under harsh environments is limited. Existing improvement solutions may perform well in single or mild environments, but under harsh conditions such as simultaneous acid and alkali corrosion, high temperature and humidity, and long-term mechanical loads, it is often difficult to maintain and sustain overall corrosion resistance, mechanical strength retention, and dimensional stability. For example, some coatings or modifiers may have a preference for protection against specific corrosive media, making it difficult to provide comprehensive, balanced, and durable protection.

[0011] Therefore, developing a new type of polyester base fabric that can fundamentally optimize the material interface structure and achieve a balance of high strength, excellent thermal stability, and superior resistance to acid and alkali corrosion to meet the increasingly demanding application environment requirements has become an urgent technical problem for those skilled in the art. Summary of the Invention

[0012] To address the shortcomings of existing technologies, this invention provides a high-strength, corrosion-resistant polyester base fabric with high strength, excellent thermal stability, and outstanding resistance to acid and alkali corrosion.

[0013] To solve the above technical problems, the technical solution adopted by the present invention is as follows: A high-strength, corrosion-resistant polyester base fabric comprises a fiber web treated with needle punching and polyurethane impregnation, the fiber web being composed of composite fibers having a core-shell structure, wherein: The outer shell is a polyurethane composite material, and the core layer is a copolyester. The mass ratio of the core layer to the shell layer of the composite fiber is 70-80:20-30.

[0014] The preparation method of the polyurethane composite material includes: pretreatment, prepolymer synthesis, chain extension and granulation; Pretreatment: Mica powder is surface-treated with a silane coupling agent to obtain modified mica powder, thereby improving compatibility; The polycarbonate diol has a molecular weight of 1500-2500 Da; The modified mica powder is prepared by mixing a silane coupling agent with a 70-90% ethanol-water solution, adjusting the pH to 4-5 with acetic acid (this acidic environment is conducive to silane hydrolysis), stirring continuously at room temperature for 30-40 minutes to fully hydrolyze it into silanol, adding the prepared silane hydrolysis solution dropwise to the mica powder slurry, heating to 60-80℃, and continuing the reaction at this temperature for 2-3 hours, filtering, washing, and drying to obtain silane coupling agent modified mica powder. The silane coupling agent is KH-550 or KH-560; The mica powder has a flake diameter of 0.1-0.3 μm; The mica powder slurry is prepared by dispersing mica powder in anhydrous ethanol, with the mass ratio of mica powder to anhydrous ethanol being 1:4-6.

[0015] The mass ratio of the silane coupling agent, ethanol-water solution, and mica powder slurry is 0.1-0.2:5-8:50-70.

[0016] Prepolymer synthesis: In a dry reactor, dehydrated polycarbonate diol is mixed with hexamethylene diisocyanate trimer and reacted at 75-85°C for 2-3 hours to generate a prepolymer with terminal -NCO groups.

[0017] Chain extension and granulation: Cool the system to 50-60℃, add dimethyl ethyl ketone oxime dissolved in anhydrous methyl ethyl ketone and organic bismuth catalyst, and simultaneously add mica powder modified with silane coupling agent. Stir at 1000-2000 rpm for 30-60 minutes to ensure uniform dispersion; then react at 75-85℃ for 3.2-3.8 hours. After the reaction is complete, transfer the material to a twin-screw extruder for devolatilization, melt extrusion and granulation to obtain polyurethane composite material.

[0018] The mass ratio of polycarbonate diol, hexamethylene diisocyanate trimer, dimethyl ethyl ketone oxime, silane coupling agent modified mica powder, organobismuth catalyst, and anhydrous methyl ethyl ketone is 40-50:35-37:9-11:5-7:0.1-0.3:40-50. The polycarbonate diol is a polycarbonate diol that has been treated with vacuum dehydration at 100-110°C for 1-2 hours. The organic bismuth catalyst is bismuth neodecanoate.

[0019] The preparation method of the copolyester includes: esterification reaction, melt polycondensation, final polycondensation and granulation; Esterification reaction: Terephthalic acid, ethylene glycol, N-ethyldiethanolamine, diphenyl carbonate, 1,4-cyclohexanediethanol and catalyst Sb(Ac)3 are mixed evenly, and the mixture is heated to 240-250℃ under nitrogen protection, while the pressure is maintained at atmospheric pressure, and the reaction is carried out for 1.8-2.2 hours. Melt polycondensation: Raise the temperature to 270-285℃, increase the system vacuum to 80-120 Pa, and stir for 1.8-2.2 hours; Final polycondensation and granulation: Reduce the system vacuum to 80-100 Pa, continue the reaction at 260-275℃ for 30-45 minutes, cool and granulate to obtain copolyester; The mass ratio of terephthalic acid, ethylene glycol, N-ethyldiethanolamine, diphenyl carbonate, 1,4-cyclohexanediethanol, and catalyst Sb(Ac)3 is 100:40-50:8-12:40-50:10-12:0.03-0.05.

[0020] The method for preparing the composite fiber is as follows: Polyurethane composite material and copolyester are melted separately and fed into a core-shell composite spinning assembly. The shell melt is uniformly wrapped around the outer periphery of the core melt. The core-shell structured nascent fiber bundles extruded from the spinneret are cooled and solidified, and then stretched 4-4.5 times at 80-110℃ to obtain composite fibers. The mass ratio of the core layer to the shell layer of the composite fiber is 70-80:20-30.

[0021] The method for preparing the fiber web is as follows: Composite fibers are formed into a fiber web using an airflow web-forming process, with the areal density controlled at 180-220 g / m². 2 .

[0022] The method of acupuncture consolidation is as follows: The fiber web is needle-punched bidirectionally, 1-2 times on each side, with a needle-punching depth of 3-5 mm and a needle-punching density of 200-300 needles / cm. 2 After needle punching, the thickness of the fiber web is controlled at 1.3-1.5mm.

[0023] The method for polyurethane impregnation is as follows: The needle-punched fiber web is immersed in polyurethane emulsion for 30-60 seconds to ensure that the adhesive fully penetrates the fiber gaps. The amount of adhesive is controlled to be 160-180% of the fiber web mass by the extrusion roller. The impregnated base fabric is dried to obtain the finished polyester base fabric. The solid content of the polyurethane emulsion is 40-50%.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) Through the design of the core-shell composite spinning structure and the synergistic reinforcing effect of polycarbonate diol and modified mica powder in the shell, the polyester base fabric of the present invention exhibits high breaking strength and suitable breaking elongation, so that it has good tensile strength and deformation ability in application and meets the requirements of high strength use.

[0025] (2) The polyester base fabric prepared by the method of the present invention has significant thermal stability. Due to the physical barrier effect of modified mica powder in the shell and the rigid chain segment structure of polycarbonate diol, the deformation of the fiber under thermal conditions is effectively suppressed, which significantly improves the dimensional stability of the base fabric in the high temperature environment and avoids the performance decline caused by thermal shrinkage.

[0026] (3) The polyester base fabric prepared by the method of the present invention has excellent corrosion resistance and comprehensive performance balance, which is due to the construction of a multi-synergistic composite protection system. First, the shell layer uses polycarbonate diol, which is inherently resistant to hydrolysis, as the soft segment, and uses dimethylglyoxime chain extension to form stable oxime urethane bonds, which together construct a dense and corrosion-resistant bulk protective layer; second, the flake-modified mica powder uniformly dispersed in the shell layer can effectively extend the penetration path of the corrosive medium and provide excellent physical barrier effect; finally, the tertiary amino group introduced by the N-ethyldiethanolamine in the core layer reacts with the -NCO group at the end of the shell layer to form urea bonds, realizing a strong chemical bond at the shell-core interface, which fundamentally avoids failure caused by interface peeling in acidic and alkaline environments.

[0027] (4) The polyester base fabric prepared by the method of the present invention has the following comprehensive performance range: longitudinal breaking strength: 800-840 N / 50mm, transverse breaking strength: 730-770 N / 50mm; longitudinal breaking elongation: 30-35%, transverse breaking elongation: 35-40%; thermal stability: longitudinal thermal elongation 1.3-1.7%, transverse thermal shrinkage 1.1-1.4%; corrosion resistance breaking strength retention rate: 82.5-83.3% in 5% hydrochloric acid solution, and 83.6-84.4% in 5% sodium hydroxide solution. Detailed Implementation

[0028] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention are now described.

[0029] Example 1 Preparation of a high-strength, corrosion-resistant polyester base fabric: (1) Preparation of polyurethane composite materials Pretreatment: Mix 0.09g of silane coupling agent KH-550 with 3.9g of 75% ethanol-water solution, adjust the pH to 4.5 with acetic acid, and stir at room temperature for 35 minutes. Add this mixture dropwise to the prepared mica powder slurry. Heat to 70℃ and react for 2.5 hours, then filter, wash, and dry for later use.

[0030] The mica powder slurry was prepared by dispersing 6g of mica powder with a flake diameter of 0.2μm in 30g of anhydrous ethanol. Prepolymer synthesis: 45g of dehydrated polycarbonate diol and 36g of hexamethylene diisocyanate trimer were reacted at 80°C for 2.5 hours.

[0031] The polycarbonate diol is a polycarbonate diol that has been vacuum dehydrated at 105°C for 1.5 hours, with a molecular weight of 2000 Da.

[0032] Chain extension and granulation: Cool to 55℃, add 10g of dimethylglyoxime and 0.2g of bismuth neodecanoate catalyst dissolved in 45g of anhydrous methyl ethyl ketone, and simultaneously add 6g of the above-mentioned modified mica powder. Stir at 1500 rpm for 35 minutes.

[0033] The reaction was then carried out at 80°C for 3.5 hours. After the reaction was complete, the product was devolatilized, melt-extruded, and granulated using a twin-screw extruder to obtain a polyurethane composite material.

[0034] (2) Preparation of copolyester Esterification reaction: 100g terephthalic acid, 45g ethylene glycol, 10g N-ethyldiethanolamine, 45g diphenyl carbonate, 11g 1,4-cyclohexanediethanol and 0.04g catalyst Sb(Ac)3 were mixed and heated to 245℃ under nitrogen protection and reacted at atmospheric pressure for 2 hours.

[0035] Melt polycondensation: Heat to 277°C, increase the system vacuum to 100 Pa, and react for 2 hours.

[0036] Final polycondensation and granulation: Maintaining the system vacuum, continue the reaction at 267°C for 37 minutes. Cool and granulate to obtain the copolyester.

[0037] (3) Preparation of composite fibers Polyurethane composite material and copolyester were melted separately at a mass ratio of 25:75 and then subjected to core-sheath composite spinning. The nascent fiber bundles were extruded from the spinneret, cooled, and then drawn 4.2 times at 95°C to obtain composite fibers.

[0038] (4) Fiber web formation Composite fibers are formed with an areal density of 200 g / m² using an airflow web-forming process. 2 Fiber web.

[0039] (5) Acupuncture consolidation The fiber web is needle-punched bidirectionally, once on each side, with a needle depth of 4 mm and a needle density of 250 needles / cm. 2 The thickness of the fiber web after needle punching is controlled at 1.4 mm.

[0040] (6) Polyurethane impregnation treatment The fiber web is immersed in a polyurethane emulsion with a solid content of 45% for 45 seconds. The amount of resin impregnation is controlled to be 170% of the mass of the fiber web by the extrusion roller, and then dried to obtain the finished product.

[0041] Example 2 Preparation of a high-strength, corrosion-resistant polyester base fabric: (1) Preparation of polyurethane composite materials Pretreatment: Mix 0.05g of silane coupling agent KH-560 with 2.5g of 70% ethanol-water solution, adjust the pH to 4 with acetic acid, and stir at room temperature for 40 minutes. Add this mixture dropwise to the prepared mica powder slurry. Heat to 60℃ and react for 3 hours, then filter, wash, and dry for later use.

[0042] The mica powder slurry was prepared by dispersing 5g of mica powder with a flake diameter of 0.1μm in 20g of anhydrous ethanol. Prepolymer synthesis: 40g of dehydrated polycarbonate diol was reacted with 35g of hexamethylene diisocyanate trimer at 75°C for 3 hours.

[0043] The polycarbonate diol is a polycarbonate diol that has been vacuum dehydrated at 100°C for 2 hours, and has a molecular weight of 1500 Da.

[0044] Chain extension and granulation: Cool to 50℃, add 10g of dimethylglyoxime and 0.1g of bismuth neodecanoate catalyst dissolved in 40g of anhydrous methyl ethyl ketone, and simultaneously add 5g of the above-mentioned modified mica powder. Stir at 1000 rpm for 40 minutes.

[0045] The reaction was then carried out at 75°C for 3.8 hours. After the reaction was complete, the product was devolatilized, melt-extruded, and granulated using a twin-screw extruder to obtain a polyurethane composite material.

[0046] (2) Preparation of copolyester Esterification reaction: 100g terephthalic acid, 40g ethylene glycol, 8g N-ethyldiethanolamine, 40g diphenyl carbonate, 10g 1,4-cyclohexanediethanol and 0.04g catalyst Sb(Ac)3 were mixed and heated to 240℃ under nitrogen protection and reacted at atmospheric pressure for 2.2 hours.

[0047] Melt polycondensation: Heat to 270℃, increase system vacuum to 120 Pa, and react for 2.2 hours.

[0048] Final polycondensation and granulation: Maintaining the system vacuum, continue the reaction at 260°C for 45 minutes. Cool and granulate to obtain the copolyester.

[0049] (3) Preparation of composite fibers Polyurethane composite material and copolyester were melted separately at a mass ratio of 20:80 and then subjected to core-sheath composite spinning. The nascent fiber bundles were extruded from the spinneret, cooled, and then drawn four times at 80°C to obtain composite fibers.

[0050] (4) Fiber web formation Composite fibers are formed with an areal density of 180 g / m² using an airflow web-forming process. 2 Fiber web.

[0051] (5) Acupuncture consolidation The fiber web is needle-punched bidirectionally, once on each side, with a needle depth of 3 mm and a needle density of 200 needles / cm². 2 The thickness of the fiber web after needle punching is controlled at 1.3 mm.

[0052] (6) Polyurethane impregnation treatment The fiber web is immersed in a polyurethane emulsion with a solid content of 40% for 60 seconds. The amount of resin impregnation is controlled to be 160% of the mass of the fiber web by extrusion rollers, and then dried to obtain the finished product.

[0053] Example 3 Preparation of a high-strength, corrosion-resistant polyester base fabric: (1) Preparation of polyurethane composite materials Pretreatment: Mix 0.14g of silane coupling agent KH-560 with 5.6g of 90% ethanol-water solution, adjust the pH to 5 with acetic acid, and stir at room temperature for 30 minutes. Add this mixture dropwise to the prepared mica powder slurry. Heat to 80℃ and react for 3 hours, then filter, wash, and dry for later use.

[0054] The mica powder slurry was prepared by dispersing 7g of mica powder with a flake diameter of 0.3μm in 42g of anhydrous ethanol. Prepolymer synthesis: 50g of dehydrated polycarbonate diol was reacted with 37g of hexamethylene diisocyanate trimer at 85°C for 2 hours.

[0055] The polycarbonate diol is a polycarbonate diol that has been vacuum dehydrated at 110°C for 1 hour, with a molecular weight of 2500 Da.

[0056] Chain extension and granulation: Cool to 60℃, add 11g of dimethylglyoxime and 0.3g of bismuth neodecanoate catalyst dissolved in 50g of anhydrous methyl ethyl ketone, and simultaneously add 7g of the above-mentioned modified mica powder. Stir at 2000 rpm for 30 minutes.

[0057] The reaction was then carried out at 85°C for 3.2 hours. After the reaction was complete, the product was devolatilized, melt-extruded, and granulated using a twin-screw extruder to obtain a polyurethane composite material.

[0058] (2) Preparation of copolyester Esterification reaction: 100g terephthalic acid, 50g ethylene glycol, 12g N-ethyldiethanolamine, 50g diphenyl carbonate, 12g 1,4-cyclohexanediethanol and 0.05g catalyst Sb(Ac)3 were mixed and heated to 250℃ under nitrogen protection and reacted at atmospheric pressure for 1.8 hours.

[0059] Melt polycondensation: Heat to 285℃, increase the system vacuum to 80 Pa, and react for 1.8 hours.

[0060] Final polycondensation and granulation: Maintaining the system vacuum, continue the reaction at 275°C for 30 minutes. Cool and granulate to obtain the copolyester.

[0061] (3) Preparation of composite fibers Polyurethane composite material and copolyester were melted separately at a mass ratio of 30:70 and then subjected to core-sheath composite spinning. The nascent fiber bundles were extruded from the spinneret, cooled, and then drawn 4.5 times at 110°C to obtain composite fibers.

[0062] (4) Fiber web formation Composite fibers are formed with an areal density of 220 g / m² using an airflow web-forming process. 2 Fiber web.

[0063] (5) Acupuncture consolidation The fiber web was needle-punched bidirectionally, twice on each side, with a needle depth of 5 mm and a needle density of 300 needles / cm². 2 The thickness of the fiber web after needle punching is controlled at 1.5mm.

[0064] (6) Polyurethane impregnation treatment The fiber web is immersed in a polyurethane emulsion with a solid content of 50% for 30 seconds. The amount of resin impregnation is controlled to be 180% of the mass of the fiber web by the extrusion roller, and then dried to obtain the finished product.

[0065] Example 4 The preparation method of the high-strength corrosion-resistant polyester base fabric in Example 1 is adopted, except that 1,4-butanediol is used instead of dimethylglyoxime as a chain extender in the preparation of polyurethane composite material, while other process parameters are the same.

[0066] Example 5 The preparation method of the high-strength corrosion-resistant polyester base fabric in Example 1 is adopted, except that: no modified mica powder is added to the shell layer formulation during the preparation of the polyurethane composite material, while other process parameters are the same.

[0067] Example 6 The preparation method of the high-strength corrosion-resistant polyester base fabric in Example 1 is adopted, except that ethylene glycol is used instead of N-ethyldiethanolamine in the preparation process of copolyester, while other process parameters are the same.

[0068] Example 7 The preparation method of the high-strength corrosion-resistant polyester base fabric in Example 1 is adopted, except that polybutylene adipate diol is used instead of polycarbonate diol in the preparation process of polyurethane composite material, with a molecular weight of 2000 Da, while other process parameters are the same.

[0069] Experimental Example 1 The high-strength corrosion-resistant polyester base fabrics prepared in Examples 1-7 were tested for breaking strength, elongation at break, and thermal stability. The testing methods were in accordance with the methods described in GB / T 17987—2000. The test results are shown in Table 1.

[0070] Table 1. Breaking strength, elongation at break, and thermal stability

[0071] Experimental Example 2 The corrosion resistance of the high-strength corrosion-resistant polyester base fabrics prepared in Examples 1-7 was tested. The specific testing method was as follows: the base fabrics were immersed in 5% hydrochloric acid solution and 5% sodium hydroxide solution for 24 hours respectively. After being taken out, they were dried at 110°C for 2 hours. The breaking strength was measured and the breaking strength retention rate was calculated. The breaking strength retention rate = breaking strength before immersion in acid or alkali solution / breaking strength after immersion in acid or alkali solution. The test results are shown in Table 2.

[0072] Table 2 Corrosion Resistance

[0073] Analysis of Experimental Results in Examples 1-3 Mechanical properties: The breaking strength reaches 700N / 50mm or more, and the elongation is increased to 30% or more.

[0074] Excellent thermal stability: Due to the reinforcing effect of mica powder and the rigidity of the polycarbonate diol shell, thermal deformation is strictly controlled at an extremely low level, with longitudinal deformation ≤1.7% and transverse deformation ≤1.4%.

[0075] Excellent corrosion resistance: The synergistic effect of polycarbonate diol and N-ethyldiethanolamine results in acid and alkali retention rates of over 82%.

[0076] Example 4: Analysis of Experimental Results Mechanical and thermal properties: Elongation increased slightly because 1,4-butanediol may form more flexible segments. Thermal stability decreased slightly but remained close to the critical point of 2% because the reinforcing effect of mica powder was still present.

[0077] Corrosion resistance: The retention rate was significantly lower than in Example 1, and the corrosion resistance decreased significantly after using the common chain extender 1,4-butanediol. This demonstrates that the oxime ester bonds formed in the shell material directly contribute to the corrosion resistance.

[0078] Example 5: Analysis of Experimental Results Mechanical and Thermal Properties: Thermal Stability - Longitudinal elongation reached 3.5%, and transverse shrinkage reached 2.8%, far exceeding Example 1. This directly demonstrates that mica powder is crucial for improving thermal stability. Simultaneously, strength decreased, while elongation increased.

[0079] Corrosion resistance: The retention rate decreased slightly. When corrosive media attempted to penetrate the coating vertically, the flake-like mica powder dispersed in the backing polymer became an impenetrable physical barrier. The media had to constantly bypass these flakes, which greatly extended the time required for the media to penetrate the substrate. This meant that the corrosion process was effectively slowed down, and the durability of the material was significantly improved.

[0080] Example 6: Analysis of Experimental Results Mechanical and thermal properties: The strength performance is reduced, which also proves that N-ethyldiethanolamine plays a role in improving the strength performance in this invention. It may be because the N-ethyldiethanolamine added in the preparation of the core material introduces tertiary amino groups to react with the terminal -NCO groups of the shell material to form urea bonds, thereby improving the interfacial bonding force and improving the strength performance.

[0081] Corrosion resistance: Corrosion resistance, especially acid resistance, decreases significantly. This indicates that a strong interfacial bond is crucial for ensuring long-term corrosion resistance. In acidic environments, weaker interfaces may be the first to break down, leading to localized peeling of the outer shell and allowing corrosive media to directly attack the core fibers.

[0082] Example 7: Analysis of Experimental Results Mechanical and thermal properties: Strength decreases, elongation is the highest, indicating the flexibility of polybutylene adipate diol. However, thermal stability is poor.

[0083] Corrosion resistance: Due to the easy hydrolysis of the ester bonds in polybutylene adipate diol, its alkali resistance is severely reduced, and its thermal stability is poor. This highlights that the excellent alkali hydrolysis resistance and bulk heat resistance of polycarbonate diol are the foundation for the durable function of the shell.

[0084] Unless otherwise specified, all percentages (%) mentioned in this invention are mass percentages.

[0085] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-strength corrosion-resistant polyester carcass fabric, characterized by, It comprises a fiber web consolidated by needle punching and polyurethane impregnation, the fiber web is composed of composite fibers, the composite fibers have a core-shell structure, wherein: The shell layer is a polyurethane composite material, and the core layer is a copolyester.

2. A high strength corrosion resistant polyester carcass fabric according to claim 1, characterized in that, The preparation method of the polyurethane composite material comprises pretreatment, prepolymer synthesis, chain extension and granulation; The pretreatment is surface treatment of mica powder with a silane coupling agent to obtain modified mica powder to improve compatibility; Prepolymer synthesis: in a dry reactor, after dehydration, polycarbonate diol is mixed with hexamethylene diisocyanate trimer, and reacted at 75-85 DEG C for 2-3 hours to form a prepolymer; Chain extension and granulation: the system is cooled to 50-60 DEG C, and butanedione oxime and organic bismuth catalyst dissolved in anhydrous butanone are added, and the modified mica powder is added at the same time, stirring at 1000-2000 rpm for 30-60 minutes; then reacted at 75-85 DEG C for 3.2-3.8 hours, after the reaction is completed, the material is transferred to a twin-screw extruder for devolatilization, melt extrusion and granulation to obtain a polyurethane composite material.

3. The high-strength corrosion-resistant polyester base fabric according to claim 2, characterized in that, The preparation of the modified mica powder is that the silane coupling agent is mixed with an ethanol-water solution with a concentration of 70-90%, the pH value is adjusted to 4-5 with acetic acid, and stirring is continued at room temperature for 30-40 minutes to hydrolyze the silane coupling agent to generate silanol, the prepared silane hydrolysis solution is added dropwise into the mica powder slurry, heated to 60-80 DEG C, and the reaction is continued at this temperature for 2-3 hours, and the silane coupling agent modified mica powder is obtained by filtration, washing and drying; The mass ratio of the silane coupling agent, the ethanol-water solution and the mica powder slurry is 0.1-0.2:5-8:50-70.

4. The high-strength corrosion-resistant polyester base fabric according to claim 2, characterized in that, The molecular weight of the polycarbonate diol is 1500-2500 Da; The organic bismuth catalyst is bismuth neodecanoate.

5. A high strength corrosion resistant polyester carcass fabric according to claim 2, wherein, The mass ratio of the polycarbonate diol, the hexamethylene diisocyanate trimer, the butanedione oxime, the modified mica powder, the organic bismuth catalyst and the anhydrous butanone is 40-50:35-37:9-11:5-7:0.1-0.3:40-50.

6. A high strength corrosion resistant polyester carcass fabric according to claim 1, wherein, The preparation method of the copolyester comprises esterification reaction, melt polycondensation, final polycondensation and granulation; The esterification reaction: the terephthalic acid, the ethylene glycol, the N-ethyldiethanolamine, the diphenyl carbonate, the 1,4-cyclohexanedimethanol and the catalyst Sb(Ac)3 are mixed uniformly, heated to 240-250 DEG C under nitrogen protection, the pressure is maintained at atmospheric pressure, and the reaction is carried out for 1.8-2.2 hours; The melt polycondensation: the temperature is raised to 270-285 DEG C, the system vacuum degree is increased to 80-120 Pa, and stirring is carried out for 1.8-2.2 hours; The final polycondensation and granulation: the system vacuum degree is reduced to 80-100 Pa, the reaction is continued at 260-275 DEG C for 30-45 minutes, and the copolyester is obtained by cooling and granulation.

7. A high strength corrosion resistant polyester carcass fabric according to claim 6, wherein, The mass ratio of the terephthalic acid, ethylene glycol, N-ethyldiethanolamine, diphenyl carbonate, 1,4-cyclohexane dimethanol, catalyst Sb(Ac)3 is 100:40-50:8-12:40-50:10-12:0.03-0.

05.

8. A high strength corrosion resistant polyester carcass fabric according to claim 1, wherein, The preparation method of the composite fiber is that the polyurethane composite material and the copolyester are respectively melted, and then are sent into a sheath-core type composite spinning assembly, the shell melt uniformly wraps the periphery of the core melt, the nascent fiber tows with core-shell structure are extruded from the spinneret, and after cooling and solidification, the nascent fiber tows are drawn at 80-110 DEG C for 4-4.5 times to obtain the composite fiber. The mass ratio of the core layer and the shell layer of the composite fiber is 70-80:20-30.

9. A high strength corrosion resistant polyester carcass fabric according to claim 1, characterized in that, The method for producing the fiber web is to form a fiber web by air-laying the conjugated fibers, and the areal density is controlled to 180-220 g / m 2 ; The method for needle-punching is to needle punch the fiber web in two directions, 1-2 times on the front and back sides, with a needle punching depth of 3-5 mm and a needle punching density of 200-300 needles / cm 2 The thickness of the fiber web after needle punching is controlled at 1.3-1.5 mm; The method of the polyurethane impregnation treatment is that the fiber web after needling is immersed in the polyurethane emulsion, the impregnation time is 30-60 seconds, the glue is ensured to fully penetrate the fiber gap, the impregnation amount is controlled by the extrusion roller to be 160-180% of the mass of the fiber web, and the tire base cloth after impregnation is dried to obtain the polyester tire base cloth product. 10.The high-strength corrosion-resistant polyester tire base cloth according to claim 3, characterized in that, The silane coupling agent is KH-550 or KH-560. The flake diameter of the mica powder is 0.1-0.3 μm. The mica powder slurry is prepared by dispersing the mica powder in anhydrous ethanol, and the mass ratio of the mica powder to the anhydrous ethanol is 1:4-6.

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