Method for producing ultrathin highly breathable microporous membrane
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- WUJIANG HANTA TEXTILE FINISHING CO LTD
- Filing Date
- 2023-06-01
- Publication Date
- 2026-06-23
AI Technical Summary
Conventional methods for preventing feather protrusion in fabrics, such as applying polyurethane coatings, result in reduced moisture permeability and increased fabric weight, leading to discomfort and potential bacterial growth in humid environments.
A method involving the use of a micron-nano foaming machine to create bubbles with diameters of 5 μm or less, combined with a specific composition of aqueous foaming paste and high-precision micron gravure coating, to produce an ultra-thin and highly breathable microporous membrane with a thickness of 5 μm or less and pore diameters of 5 μm or less, enhancing breathability and preventing feather protrusion.
The method results in a lightweight, breathable, and comfortable fabric with excellent feather leakage prevention, maintaining air permeability and sound insulation while providing water resistance.
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Abstract
Description
Technical Field
[0001] The present invention belongs to the coating finishing technology of textiles and relates to a method for manufacturing an ultra-thin and highly breathable microporous membrane.
Background Art
[0002] In popular down jackets, duvets, and many outdoor fabrics with excellent heat retention, fillings such as duck down, goose down, and hollow fibers may protrude through the seams of the side fabric. Conventional measures against feather leakage involve applying a paste such as polyurethane to the surface of the side fabric to form a covering film that fills and covers the gaps between the fibers. However, while the coating that can prevent feather protrusion reduces the moisture permeability of the fabric and makes it less comfortable to wear, in a hot and humid environment, many bacteria are likely to breed in the down. Moreover, direct coating in the prior art generally produces a thick covering film, increasing the weight of the fabric.
[0003] In recent years, micron-nano foamers and micron-nano foam coating technologies have been widely applied in the industry, triggering environmental consideration technology innovation in foam coating. Under certain conditions, a micron-nano foamer can form micron-nano aerosol bubbles with diameters of about 10 microns to several hundred nanometers, having physical and scientific properties not possessed by conventional coating agents. The micron-nano foaming of aqueous paste has been increasingly widely applied as a new emerging environmentally friendly foam coating technology. However, ultra-micron (5 μm or less) foaming or ultra-thin (5 μm or less) coating of aqueous paste is still one of the problems in the industry. Solving this problem can obtain an ultra-thin and highly breathable microporous membrane with a network structure inside, and solve the problem of manufacturing a fabric with excellent feather leakage prevention effect, good air permeability, and small coating thickness (weight) in the prior art.
Summary of the Invention
Problems to be Solved by the Invention
[0004] The present invention provides a method for manufacturing a kind of ultra-thin and highly breathable microporous membrane, that is, treating an aqueous foaming paste with a micron-nano foaming machine and then coating it on a fabric by micron gravure technology (precisely measuring the coating liquid of gravure to control the thickness of the transferred thin film to achieve stable and high-precision coating), overcoming the problems in the prior art.
Means for Solving the Problems
[0005] Specifically, the present invention selects the following solutions. Regarding the method for manufacturing an ultra-thin and highly breathable microporous membrane, The aqueous foaming paste consists of 100 parts by weight of an aqueous paste (such as a polymer material like PU, PE, PP or PET), 0 - 15 parts by weight of a functional auxiliary agent, 0.1 - 5 parts by weight of an aqueous foam stabilizer (silicone-based aqueous foam stabilizer or non-silicone-based aqueous foam stabilizer), 0.1 - 5 parts by weight of a polyether-modified silicone-based aqueous foam stabilizer, and n parts by weight of water (the number of parts of water depends on the number of parts of other components and the viscosity of the mixture of the aqueous paste, functional auxiliary agent and water). The viscosity of the mixture formed by blending the aqueous paste, functional auxiliary agent and water is 500 CPS. The control parameters of the micron-nano foaming machine are a bubble specific gravity of 350 - 700 g / L, a mixing head rotation speed of 250 - 400 rpm, and a pump output of 100 - 500 L / hr. The diameter of the bubbles (the diameter of the bubbles in the present invention is all the outer diameter of the bubbles) is 5 μm or less. The thickness of the micron gravure coating is made to be 5 μm or less while being more than the diameter of the bubbles. The ultra-thin and highly breathable microporous membrane is a membrane containing micropores, with a membrane thickness of 5 μm or less and a pore diameter of 5 μm or less.
[0006] According to the prior art, the diameter of the bubbles obtained by treating an aqueous paste with a micron-nano foaming machine generally reaches 10 μm, but the diameter of the bubbles obtained by the present invention can reach 5 μm or less. The main reasons are as follows. The control parameters of the micron-nano foaming machine are reasonably set. Specifically, the bubble specific gravity is 350 - 700 g / L, the mixing head rotation speed is 250 - 400 rpm, and the pump output is 100 - 500 L / hr. The larger the bubble specific gravity, which reflects the proportion of gas and liquid in the foam, the smaller the bubbles. The higher the mixing head rotation speed, the larger the foaming amount. The pump output is set according to different aqueous pastes according to the coating requirements. In fact, the control parameters of the foaming machine in the present invention must be adjusted before mass production until the bubble diameter reaches 5 μm or less as confirmed by an electron microscope. 2. Add a certain amount of aqueous foam stabilizer to the aqueous foaming paste. The aqueous foam stabilizer makes the distribution of the bubble diameter narrower. However, if the dosage is too large, it will affect the formation of micropores as the bubble diameter becomes smaller, and if the dosage is too small, the bubble diameter will become larger. 3. Add a certain amount of polyether-modified silicone-based aqueous foam stabilizer to the aqueous foaming paste. The polyether-modified silicone-based aqueous foam stabilizer can control the structural stability of the bubble liquid film, make the surfactant molecules in it be orderly distributed, and give good elasticity and self-repair ability to the bubbles. The easy-to-use polyether-modified silicone-based aqueous foam stabilizer with excellent foam stabilizing effect extends the lifespan of small bubbles and reduces their coalescence, maintaining the bubble diameter at the micron-nano scale.
[0007] Generally, since the coating film thickness is larger than the bubble diameter, the conventional foaming technology that usually produces bubbles with a diameter of 10 μm or more is only suitable for thick coating (for example, knife coating with a film thickness of 20 - 50 μm). However, in the present invention, the bubble diameter is set to 5 μm or less, and an ultra-thin microporous film with a thickness of 5 μm or less can be manufactured by micron gravure coating.
[0008] Conventional direct coating results in a large film thickness. On the other hand, a paste such as polyurethane that prevents the protrusion of feathers may penetrate into the gaps between the filaments of the fabric. Therefore, the coated fabric becomes hard and makes a rattling sound when vibrated. The micron gravure coating of the present invention can not only form a thin film, but also the aqueous paste does not penetrate too much into the yarn, so the coated fabric is soft and has good sound insulation.
[0009] Preferred embodiments according to the present invention are shown below.
[0010] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, the film thickness is 0.5 to 5 μm, and the pore diameter of the micropores is 0.1 to 5 μm. The air permeability of the membrane is measured according to "Measurement of the air permeability of textiles" in the national standard GB / T 5453 of China. The performance of preventing the protrusion of feathers of the membrane is measured according to "Down jackets" in the national standard GB / T 14272-2011 of China and meets the requirements. In addition, the membrane has excellent sound insulation and no frictional noise. The down used as the filling of the down jacket can be said to be the feathers growing on the chest of ducks or geese. Since the average diameter of the barbs contained in the feathers exceeds 5 μm, the ultra-thin and highly breathable microporous membrane with micropores of 5 μm or less of the present invention has an excellent effect in preventing the protrusion of feathers.
[0011] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, a high-precision micron gravure coating device that can form a uniform film thickness of 1 to 5 μm without coating leakage is adopted.
[0012] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, the substrate for high-precision micron gravure coating is a base fabric or a base film. Generally, the fabric to be coated on the surface is called a "base fabric", and the release film to be coated is called a "base film".
[0013] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, in order to improve the adhesion strength of the base fabric or base film to the aqueous paste before high-precision micron gravure coating, the base fabric or base film is subjected to electron beam irradiation treatment. Thus, smooth transfer from the gravure roll of the micron coating liquid film to the base fabric or base film and the stability of the micron coating liquid film are maintained. In the present invention, although the bubbles generated by the foaming machine are transferred to the surface of the base fabric or base film by the micron gravure coating device, since the bubbles have time-dependent attenuation, the uniform distribution of the bubbles along the lateral direction of the base fabric or base film determines the uniformity of the sandwiched coating liquid. The present invention enhances the adhesion strength of the base fabric or base film to the bubbles by electron beam irradiation treatment, improves the stability of the bubbles, and maintains the uniformity of the bubble coating liquid film.
[0014] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, the base fabric is a fabric made of calendared ultra-fine fibers (such as ultra-thin polyester sponge or nylon taffeta). Since the surface of a normal fabric has irregularities reflecting the intersection of warp and weft threads, when the irregularities are severe, there is more paste in the concave part and less paste in the convex part. Therefore, the present invention uses an ultra-fine fiber fabric with a gentle surface height difference as the base fabric and further subjects the base fabric to calendaring treatment to improve the flatness of the coating.
[0015] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, it is preferable that the calender machine for treating the base fabric has a mirror-finish alloy roll in contact with the base fabric and a high flatness rubber roll as the squeezing roll, and is equipped with high-precision intelligent temperature control and pressure control. At the same time, a photoelectric sensor is used to detect the linear velocity of each roll and control the synchronization of the linear velocities of each roll, so as to realize that the base fabric to be calendared is only subjected to normal direction pressure.
[0016] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, after high-precision micron gravure coating, thermal pressing or cold pressing may be applied to the coated layer of the base fabric or base film. Among them, the thermal pressing temperature is lower than the melting point of the aqueous paste (i.e., the material for forming the film), higher than room temperature, and at the same time does not exceed the maximum heat resistance temperature of the base fabric or base film. The cold pressing temperature is room temperature. The pressure of thermal pressing or cold pressing is 0.5 - 1 MPa (the value displayed on the pressure gauge), and the speed is 15 - 50 m / min. When the coated layer solidified from the foam is exposed to heat, the micropores to be isolated in the film become huge, and furthermore, they collapse due to pressure or penetrate the walls and connect with each other, and an ultra-thin and highly breathable microporous membrane that is thin, flexible, and has a slow recovery force can be formed. In addition, multiple cold pressings are also effective instead of thermal pressing. That is, although the microporous membrane of the present invention has a small pore diameter, many micropores communicate with each other, so it has good air permeability.
[0017] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, after high-precision micron gravure coating, a hydrophobization treatment may be applied to the coated layer of the base fabric or base film. The hydrophobization treatment is to put the base fabric or base film into a hydrophobizing agent for immersion treatment, or spray and coat the hydrophobizing agent on the base fabric or base film, and then dry it. The hydrophobizing agent is a water-repellent agent such as fluorine-based or carbon-based, and preferably an environmentally friendly water-repellent agent is adopted. The purpose of the hydrophobization treatment is to endow the microporous membrane with excellent water resistance. In fact, after applying 1 - 5 wt% of the hydrophobizing agent to the ultra-thin and highly breathable microporous membrane, the water repellency of the membrane (by GB / T 4745-2012 "Textiles - Measurement and evaluation of water repellency - Spray test") is above grade 4, and the water resistance (by GB / T 4744-2013 "Textiles - Measurement and evaluation of water repellency - Hydrostatic pressure method") is above 5 KPa.
[0018] Both thermal pressing (or cold pressing) and hydrophobization treatment are carried out after high-precision micron gravure coating, but there is no priority order, that is, either thermal pressing or hydrophobization treatment can be carried out first.
[0019] In the method for manufacturing the ultra-thin and highly breathable microporous membrane, after the ultra-thin and highly breathable microporous membrane is made, it should be wound up. Winding may be performed after separating the ultra-thin and highly breathable microporous membrane from the base fabric or base film, or winding may be performed without separation. Regarding the winding device, the roll that contacts the ultra-thin and highly breathable microporous membrane is a super mirror surface roll to prevent surface damage of the microporous membrane, while having winding tension control, preferably zero-tension winding to reduce the influence on the microporous membrane.
Advantages of the Invention
[0020] The advantages of the present invention are as follows: (1) It is a novel technology that optimizes the control parameters of the foaming machine and the composition of the aqueous paste to produce bubbles with a diameter of 5 μm or less, and further manufactures an ultra-thin and highly breathable microporous membrane with a thickness of 5 μm or less and a pore diameter of 5 μm or less by high-precision micron gravure coating. (2) By applying thermal pressure or cold pressure to the coating layer of the base fabric or base film, the isolated micropores in the film are collapsed and connected to each other, and slow springback is performed to form an ultra-thin, soft and slow-recovery ultra-thin film, so that an ultra-thin, highly breathable and silent micron-nano thin film can be manufactured. (3) By applying a hydrophobization treatment to the coating layer of the base fabric or base film, the microporous membrane is given excellent water resistance. (4) The microporous membrane has a small thickness, improves the lightweight of clothing, has good breathability, is not stuffy even when sweating, can be worn comfortably, has an improved comfort in preventing the protrusion of feathers, and can also achieve a protective effect in bad weather with excellent water resistance. (5) Utilizes technologies such as high breathability, countermeasures against feather protrusion, and high water resistance related to down jackets and outdoor fabrics.
Brief Description of the Drawings
[0021]
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Embodiments for Carrying Out the Invention
[0022] Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the following examples as long as the gist thereof is not exceeded. Even if those skilled in the art who have read the content of the present invention are allowed to modify various aspects of the present invention, it is still limited within the scope of the claims of the present invention as an equivalent form of the present invention.
[0023] The order of steps (2) and (3) in the following examples is not limited. Exchanging them or performing them simultaneously will not affect the structure and performance of the final product. Steps (3) and (4) can be performed simultaneously. Whether the electron beam irradiation treatment or the calendar treatment on the base fabric in step (3) is performed first will not affect the structure and performance of the final product. The order of steps (6) and (7) is not limited. Exchanging them or performing them simultaneously will not affect the structure and performance of the final product.
[0024] Example 1 A method for manufacturing an ultra-thin and highly breathable microporous membrane. As shown in FIG. 1, the specific process is as follows. (1) Reagents and samples Aqueous paste: PU Functional auxiliary agent: Colorless and transparent nano-silver solution AGS-WM1000A / B / C (manufactured by Shanghai Hu Zheng Co., Ltd.) Aqueous foam stabilizer: Silicone foam stabilizer GSYPU G-595 for polyurethane foam (manufactured by Shenzhen Guang Siyuan Co., Ltd.) Aqueous foam stabilizer: Polyether-modified silicone-based foam stabilizer FM-550 (manufactured by Shandong Yousu Chemical Industry Co., Ltd.) Water Base fabric: Ultra-fine fiber fabric Hydrophobic treatment agent: Colorless and transparent hydrophobic auxiliary agent SSJ-FG3 / SSJ-F181 (manufactured by Shanghai Hu Zheng Co., Ltd.) (2) Preparation of foaming paste 100 parts by weight of aqueous paste, 2 parts by weight of functional auxiliary agent and water are mixed to form a mixture with a viscosity of 500 CPS, and 0.1 part by weight of aqueous foam stabilizer and 0.5 part by weight of polyether-modified silicone-based aqueous foam stabilizer are added to the mixture to obtain an aqueous foaming paste. (3) Treatment of base fabric The base fabric is subjected to electron beam irradiation treatment and calendar treatment. Among them, the calendar treatment device has a mirror-finished alloy roll in contact with the base fabric and a high flatness rubber roll as the squeezing roll. (4) Micron-nano foaming The aqueous paste is foamed by a micron-nano foaming machine. Among them, the control parameters are a bubble specific gravity of 500 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 150 L / hr. The diameter of the obtained bubbles is 5 μm or less, and the average diameter is 3 μm. (5) High-precision micron gravure coating High-precision micron gravure coating adopts a high-precision micron gravure coating device that can form a uniform film thickness of 5 μm without coating leakage. Specifically, it includes the following steps. (5.1) Cleaning of paint receiving pan and installation of gravure roll: The paint receiving pan is cleaned, and a gravure roll with 150 lines per inch adjusted to the target film thickness of 5 μm is installed. (5.2) Installation of base material: The base fabric is installed according to the guide direction of the coating device, and the coated product (i.e., ultra-thin and highly breathable microporous membrane) is wound by a winding device. Among them, the roll in contact with the ultra-thin and highly breathable microporous membrane is a mirror-finished roll. (5.3) Coating: The foam produced in step (4) is transferred to the paint receiving pan, and the gravure roll is immersed to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating according to the dosage of auxiliary agent). (5.4) Drying: The coated base fabric is put into a four-stage oven at 50 m / min for drying. Among them, the temperature and wind speed of the four-stage oven are 100 °C, 130 °C, 155 °C, 155 °C and 3 m / s, 4 m / s, 5 m / s, 5 m / s in the order of the base fabric entering. (6) Hot pressing Apply hot pressing to the coating layer of the base fabric after step (5), among which the temperature of hot pressing is 155 °C, the pressure is 1 MPa, and the speed is 35 m / min. (7) Hydrophobic treatment Apply hydrophobic treatment to the coating layer of the base fabric after step (5) to apply an 8 wt% hydrophobic treatment agent to the ultra-thin and highly breathable microporous membrane. Finally obtained ultra-thin and highly breathable microporous membrane has a film thickness of 4.5 μm, the pore diameter of micropores is 1 - 4 μm, and the average pore diameter is 2.5 μm. The air permeability of the membrane complies with "Textiles - Determination of air permeability of fabrics" in Chinese national standard GB / T 5453. The performance of preventing feathers from protruding of the membrane complies with "Down jackets" in Chinese national standard GB / T 14272-2011. The water repellency of the membrane is above grade 4, and the water resistance of the membrane exceeds 5 KPa.
[0025] Example 2 A method for manufacturing an ultra-thin and highly breathable microporous membrane. Compared with Example 1, the difference is only that step (6) is omitted. Finally obtained ultra-thin and highly breathable microporous membrane has a film thickness of 5 μm, the pore diameter of micropores is 1 - 5 μm, and the average pore diameter is 3 μm. The air permeability of the membrane complies with "Textiles - Determination of air permeability of fabrics" in Chinese national standard GB / T 5453. The performance of preventing feathers from protruding of the membrane complies with "Down jackets" in Chinese national standard GB / T 14272-2011. The water repellency of the membrane is above grade 4, and the water resistance of the membrane exceeds 5 KPa. When comparing Example 1 and Example 2, the ultra-thin and highly permeable microporous membrane in Example 1 has a slightly smaller film thickness and a softer touch than the ultra-thin and highly permeable microporous membrane in Example 2 because the micropores isolated in the membrane collapse due to hot pressing and obtain a slow recovery force.
[0026] Example 3 A method for manufacturing an ultra-thin and highly breathable microporous membrane, and the specific process is as follows. (1) Reagents and samples Aqueous paste: PU Functional auxiliary agent: Colorless and transparent nano-silver solution AGS-WM1000A / B / C (manufactured by Shanghai Hu Zheng Co., Ltd.) Water-based foam stabilizer: Silicone foam stabilizer GSYPU G-595 for polyurethane foam (manufactured by Shenzhen Guangsiyuan Co., Ltd.) Water-based foam stabilizer: Polyether-modified silicone-based foam stabilizer FM-550 (manufactured by Shandong Yousu Chemical Co., Ltd.) Water Base film: OPP film (biaxially oriented polypropylene) Hydrophobizing agent: Colorless and transparent hydrophobizing aid SSJ-FG3 / SSJ-F181 (manufactured by Shanghai Huzheng Co., Ltd.) (2) Preparation of foaming paste Mix 100 parts by weight of water-based paste, 2 parts by weight of functional auxiliary agent and water to form a mixture with a viscosity of 500 CPS, and then add 0.1 part by weight of water-based foam stabilizer and 0.5 part by weight of polyether-modified silicone-based water-based foam stabilizer to the mixture to obtain a water-based foaming paste. (3) Treatment of base film Irradiate the base film with electron beam. (4) Micron-nano foaming The water-based paste is foamed by a micron-nano foaming machine, and the control parameters are a bubble specific gravity of 500 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 150 L / hr. The diameter of the obtained bubbles is 5 μm or less, and the average diameter is 3 μm. (5) High-precision micron gravure coating For high-precision micron gravure coating, a high-precision micron gravure coating device that can form a uniform film thickness of 5 μm without coating leakage is adopted. Specifically, it includes the following steps. (5.1) Cleaning of paint receiving pan and installation of gravure roll: Clean the paint receiving pan and install a gravure roll with 150 lines per inch corresponding to the target film thickness of 5 μm. (5.2) Installation of base material: Install the base film according to the guide direction of the coating device, and wind the coated product (i.e., ultra-thin and highly breathable microporous film) with a winding device. Among them, the roll in contact with the ultra-thin and highly breathable microporous film is a super mirror roll. (5.3) Coating: Transfer the foam made in step (4) to the paint receiving pan and immerse the gravure roll to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating according to the dosage of auxiliary agent). (5.4) Drying: The applied base film is placed in a four-stage oven and dried at 25 m / min. Among them, the temperature and wind speed of the four-stage oven are 100 °C, 105 °C, 110 °C, 110 °C and 3 m / s, 4 m / s, 5 m / s, 5 m / s respectively in the order in which the base film enters. (6) Thermal pressing Apply thermal pressing to the coating layer of the base film after step (5), among which the temperature of thermal pressing is 100 °C, the pressure is 0.8 MPa, and the speed is 25 m / min. The SEM image of a local area of the microporous membrane after 24 hours of slow springback after thermal pressing is shown in Figure 5. From it, the collapse and mutual connection of the isolated micropores are found. Therefore, the touch and sound insulation of the microporous membrane can be improved. (7) Hydrophobic treatment Apply hydrophobic treatment to the coating layer of the base fabric after step (5) and apply 8 wt% of the hydrophobic treatment agent to the ultra-thin and highly breathable microporous membrane. Finally, the obtained ultra-thin and highly breathable microporous membrane is found to contain many micropores according to both the SEM image of the membrane surface shown in Figures 2 - 3 and the SEM image of the membrane cross-section shown in Figure 4. Specifically, the membrane thickness is 4 μm, the pore diameter of the micropores is 1 - 4 μm, the average pore diameter is 2 μm, the air permeability of the membrane conforms to "Measurement of the Air Permeability of Textiles" of the Chinese national standard GB / T 5453, the performance of preventing the feathers from protruding of the membrane conforms to "Down Jackets" of the Chinese national standard GB / T 14272-2011, the water repellency of the membrane is above grade 4, and the water resistance of the membrane exceeds 5 KPa.
[0027] Example 4 A method for manufacturing an ultra-thin and highly breathable microporous membrane, and the specific process is as follows. (1) Reagents and samples Aqueous paste: PE Functional auxiliary agent: Colorless and transparent nano-zinc ion solution ZNS-WP20 (manufactured by Shanghai Huzheng Co., Ltd.) Aqueous foam stabilizer: Silicone-based foam stabilizer F-8805 (manufactured by Jinan Guolan New Materials Co., Ltd.) Aqueous foam stabilizer: Polyether-modified silicone-based foam stabilizer FM-550 (manufactured by Shandong Mobel Chemical Industry Co., Ltd.) Water Base film: PE film Hydrophobic treatment agent: Colorless and transparent anti-scratch aid FTY-FG3 (manufactured by Shanghai Hu Zheng Co., Ltd.) (2) Preparation of foaming paste Mix 100 parts by weight of an aqueous paste, 2 parts by weight of a functional aid, and water to form a mixture with a viscosity of 500 CPS. Then, add 0.1 part by weight of an aqueous foam stabilizer and 0.5 part by weight of a polyether-modified silicone-based aqueous foam stabilizer to the mixture to obtain an aqueous foaming paste. (3) Treatment of the base film Irradiate the base film with electron beams. (4) Micron-nano foaming The aqueous paste is foamed by a micron-nano foaming machine, and the control parameters are a bubble specific gravity of 550 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 100 L / hr. The diameter of the obtained bubbles is 5 μm or less, and the average diameter is 3 μm. (5) High-precision micron gravure coating For high-precision micron gravure coating, a high-precision micron gravure coating device that can form a uniform film thickness of 5 μm without coating leakage is adopted. Specifically, it includes the following steps. (5.1) Cleaning of the paint receiving pan and installation of the gravure roll: Clean the paint receiving pan and install a gravure roll with 150 lines per inch corresponding to the target film thickness of 5 μm. (5.2) Installation of the substrate: Install the base film according to the guide direction of the coating device, and wind the coated product (i.e., the ultra-thin and highly breathable microporous membrane) with a winding device. Among them, the roll in contact with the ultra-thin and highly breathable microporous membrane is a super mirror roll. (5.3) Coating: Transfer the foam produced in step (4) to the paint receiving pan and immerse the gravure roll to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating according to the dosage of the aid). (5.4) Drying: Put the coated base film into a four-stage oven at 25 m / min for drying. Among them, the temperature and wind speed of the four-stage oven are 100 °C, 105 °C, 110 °C, 110 °C and 3 m / s, 4 m / s, 5 m / s, 5 m / s in the order of the base film entering. (6) Cold pressing Apply cold pressing to the coating layer of the base fabric after step (5), where the temperature of the cold pressing is 25°C, the pressure is 0.8 MPa, and the speed is 30 m / min. (7) Hydrophobic treatment Apply hydrophobic treatment to the coating layer of the base fabric after step (5) to apply an 8 wt% hydrophobic treatment agent to the ultra-thin and highly breathable microporous membrane. Finally, the obtained ultra-thin and highly breathable microporous membrane has a membrane thickness of 4 μm, the pore diameter of the micropores is 1 - 4 μm, the average pore diameter is 2 μm, the air permeability of the membrane complies with "Textiles - Determination of air permeability of fabrics" in Chinese national standard GB / T 5453, the performance of preventing feathers from protruding from the membrane complies with "Down jackets" in Chinese national standard GB / T 14272-2011, the water repellency of the membrane is above grade 4, and the water resistance of the membrane exceeds 5 KPa.
[0028] Example 5 A method for manufacturing an ultra-thin and highly breathable microporous membrane, and the specific process is as follows. (1) Reagents and samples Aqueous paste: PP Functional aid: Nano titanium dioxide aqueous dispersion TIO-WPR010 (manufactured by Shanghai Hu Zheng Co., Ltd.) Aqueous foam suppressant: Silicone-based foam suppressant F-8805 (manufactured by Jinan Guolan New Materials Co., Ltd.) Aqueous foam stabilizer: Polyether-modified silicone-based foam stabilizer FM-550 (manufactured by Shandong Mobel Chemical Co., Ltd.) Water Base film: PE film Hydrophobic treatment agent: Colorless and transparent writing prevention aid FTY-FG3 (manufactured by Shanghai Hu Zheng Co., Ltd.) (2) Preparation of foamed paste Mix 100 parts by weight of the aqueous paste, 1 part by weight of the functional aid, and water to form a mixture with a viscosity of 500 CPS, and then add 0.1 part by weight of the aqueous foam suppressant and 0.5 part by weight of the polyether-modified silicone-based aqueous foam stabilizer to the mixture to obtain an aqueous foamed paste. (3) Micron-nano foaming The aqueous paste is foamed by a micron-nano foaming machine, and the control parameters are a bubble specific gravity of 550 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 200 L / hr. The obtained bubbles have a diameter of 5 μm or less and an average diameter of 3 μm. (4) High-precision micron gravure coating For high-precision micron gravure coating, a high-precision micron gravure coating apparatus that can form a 5-μm film thickness uniformly without coating leakage is adopted. Specifically, it includes the following steps. (4.1) Cleaning of the paint receiving pan and attachment of the gravure roll: Clean the paint receiving pan and attach a gravure roll with 150 line numbers according to the target film thickness of 5 μm. (4.2) Attachment of the substrate: Attach the base film according to the guide direction of the coating apparatus, wind up the coated product (i.e., the ultra-thin and highly breathable microporous membrane) with a winding device, and among them, the roll in contact with the ultra-thin and highly breathable microporous membrane is a super mirror surface roll. (4.3) Coating: Transfer the foam made in step (3) to the paint receiving pan and immerse the gravure roll to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating depending on the dosage of the auxiliary agent). (4.4) Drying: Put the coated base film into a four-stage oven at 25 m / min for drying. Among them, the temperature and wind speed of the four-stage oven are 100 °C, 105 °C, 110 °C, 110 °C and 3 m / s, 4 m / s, 5 m / s, 5 m / s respectively in the order of the base film entering. (5) Hydrophobic treatment Apply a hydrophobic treatment to the coating layer of the base fabric after step (4) to apply an 8 wt% hydrophobic treatment agent to the ultra-thin and highly breathable microporous membrane. Finally, the obtained ultra-thin and highly breathable microporous membrane has a film thickness of 5 μm, the pore diameter of the micropores is 1 to 4 μm and the average pore diameter is 2 μm. The air permeability of the membrane complies with the "Measurement of Air Permeability of Textiles" of the Chinese national standard GB / T 5453. The performance of preventing the protrusion of feathers of the membrane complies with the "Down Jackets" of the Chinese national standard GB / T 14272-2011. The water repellency of the membrane is above grade 4, and the water resistance of the membrane exceeds 5 KPa.
[0029] Example 6 A method for manufacturing an ultra-thin and highly breathable microporous membrane, and the specific process is as follows. (1) Reagents and samples Aqueous paste: PET Functional auxiliary agent: Aqueous nano-copper dispersion CUS-WM1000 (manufactured by Shanghai Hu Zheng Co., Ltd.) Aqueous foam stabilizer: Foam stabilizer 9002-84-0 for synthetic leather (manufactured by Shenzhen Dudao United Chemical Industry Co., Ltd.) Aqueous foam stabilizer: Polyether-modified silicone-based foam stabilizer FM-550 (manufactured by Shandong Yousu Chemical Industry Co., Ltd.) Water Base fabric: Ultra-fine fiber fabric (2) Preparation of foamed paste Mix 100 parts by weight of the aqueous paste, 10 parts by weight of the functional auxiliary agent, and water to form a mixture with a viscosity of 500 CPS, and then add 0.1 part by weight of the aqueous foam stabilizer and 0.5 part by weight of the polyether-modified silicone-based aqueous foam stabilizer to the mixture to obtain an aqueous foamed paste. (3) Micron-nano foaming The aqueous paste is foamed by a micron-nano foaming machine, and the control parameters are a bubble specific gravity of 500 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 200 L / hr. The diameter of the obtained bubbles is 5 μm or less, and the average diameter is 3 μm. (4) High-precision micron gravure coating For high-precision micron gravure coating, a high-precision micron gravure coating device that can form a 5-μm film thickness uniformly without coating leakage is adopted. Specifically, it includes the following steps. (4.1) Cleaning of the paint receiving pan and installation of the gravure roll: Clean the paint receiving pan and install a gravure roll with 150 line numbers according to the target film thickness of 5 μm. (4.2) Installation of the base material: Install the base fabric according to the guide direction of the coating device, and wind the coated product (i.e., the ultra-thin and highly breathable microporous membrane) with a winding device. Among them, the roll in contact with the ultra-thin and highly breathable microporous membrane is a super mirror surface roll. (4.3) Coating: Transfer the foam made in step (3) to the paint receiving pan and immerse the gravure roll to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating according to the dosage of the auxiliary agent). (4.4) Drying: The coated base fabric is put into a four-stage oven and dried at 40 m / min. Among them, the temperature and wind speed of the four-stage oven are 100 °C, 130 °C, 155 °C, 155 °C and 3 m / s, 4 m / s, 5 m / s, 5 m / s respectively in the order of the base fabric entering. The finally obtained ultra-thin and highly breathable microporous membrane has a film thickness of 5 μm, the pore diameter of the micropores is 1 - 4 μm, and the average pore diameter is 2 μm. The air permeability of the membrane complies with the "Measurement of the Air Permeability of Textiles" in the Chinese national standard GB / T 5453. The performance of preventing the protrusion of feathers of the membrane complies with the "Down Jackets" in the Chinese national standard GB / T 14272 - 2011. The water repellency of the membrane is above grade 4, and the water resistance of the membrane exceeds 5 KPa.
[0030] Example 7 A method for manufacturing an ultra-thin and highly breathable microporous membrane, and the specific process is as follows. (1) Reagents and Samples Aqueous paste: PE Aqueous foam stabilizer: Foam stabilizer 9002 - 84 - 0 for synthetic leather (manufactured by Shenzhen Dudao United Chemical Industry Co., Ltd.) Aqueous foam stabilizer: Polyether-modified silicone-based foam stabilizer FM - 550 (manufactured by Shandong Yousu Chemical Industry Co., Ltd.) Water Base fabric: Ultra-fine fiber fabric (2) Preparation of Foaming Paste 100 parts by weight of aqueous paste is mixed with water to form a mixture with a viscosity of 500 CPS, and 0.1 part by weight of aqueous foam stabilizer and 0.5 part by weight of polyether-modified silicone-based aqueous foam stabilizer are added to the mixture to obtain an aqueous foaming paste. (3) Treatment of Base Fabric The base fabric is given electron beam irradiation treatment and calendering treatment. Among them, in the calendering treatment device, the brightening roll in contact with the base fabric is an ultra-mirror surface alloy roll, and the squeezing roll is a high flatness rubber roll. (4) Micron-Nano Foaming The aqueous paste is foamed by a micron-nano foaming machine. Among them, the control parameters are a bubble specific gravity of 500 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 300 L / hr. The diameter of the obtained bubbles is 5 μm or less, and the average diameter is 3 μm. (5) High-precision micron gravure coating For high-precision micron gravure coating, a high-precision micron gravure coating device that can form a 5μm film thickness uniformly without coating leakage is adopted. Specifically, it includes the following steps. (5.1) Cleaning of the paint receiving pan and attachment of the gravure roll: Clean the paint receiving pan and attach a gravure roll with 150 line numbers according to the target film thickness of 5μm. (5.2) Attachment of the substrate: Attach the base fabric according to the guiding direction of the coating device, wind up the coated product (i.e., the ultra-thin and highly breathable microporous membrane) with a winding device, and among them, the roll that contacts the ultra-thin and highly breathable microporous membrane is a super mirror surface roll. (5.3) Coating: Transfer the foam made in step (4) to the paint receiving pan and immerse the gravure roll to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating according to the dosage of the auxiliary agent). (5.4) Drying: Put the coated base fabric into a four-stage oven at 45m / min for drying. Among them, the temperature and wind speed of the four-stage oven are 100°C, 130°C, 155°C, 155°C and 3m / s, 4m / s, 5m / s, 5m / s respectively in the order of the base fabric entering. (6) Cold pressing Apply cold pressing to the coating layer of the base fabric after step (5). Among them, the temperature of the cold pressing is 27°C, the pressure is 1MPa, and the speed is 30m / min. Finally obtained ultra-thin and highly breathable microporous membrane has a film thickness of 5μm, the pore diameter of the micropores is 1 - 5μm, the average pore diameter is 3μm, the air permeability of the membrane conforms to the "Measurement of air permeability of textiles" of the Chinese national standard GB / T 5453, the performance of preventing the protrusion of feathers of the membrane conforms to the "Down jacket" of the Chinese national standard GB / T 14272 - 2011, the water repellency of the membrane is 4 levels, and the water resistance of the membrane is 5KPa.
[0031] Example 8 A method for manufacturing an ultra-thin and highly breathable microporous membrane, and the specific process is as follows. (1) Reagents and samples Aqueous paste: PP Aqueous foam stabilizer: Foam stabilizer for synthetic leather 9002 - 84 - 0 (manufactured by Shenzhen Dudao United Chemical Industry Co., Ltd.) Aqueous foam stabilizer: Polyether-modified silicone-based foam stabilizer FM-550 (manufactured by Shandong Yousu Chemical Co., Ltd.) Water Base film: OPP film Hydrophobic treatment agent: Colorless and transparent anti-scratch aid FTY-FG3 (manufactured by Shanghai Hu Zheng Co., Ltd.) (2) Preparation of foaming paste 100 parts by weight of an aqueous paste and water are mixed to form a mixture with a viscosity of 500 CPS, and 0.1 part by weight of an aqueous foam regulator and 0.5 part by weight of a polyether-modified silicone-based aqueous foam stabilizer are added to the mixture to obtain an aqueous foaming paste. (3) Treatment of the base film The base film is subjected to electron beam irradiation treatment. (4) Micron-nano foaming The aqueous paste is foamed by a micron-nano foaming machine, and the control parameters thereof are a bubble specific gravity of 500 g / L, a mixing head rotation speed of 330 rpm, and a pump output of 250 L / hr. The diameter of the obtained bubbles is 5 μm or less, and the average diameter is 3 μm. (5) High-precision micron gravure coating For high-precision micron gravure coating, a high-precision micron gravure coating device that can form a 5-μm film thickness uniformly without coating leakage is adopted. Specifically, it includes the following steps. (5.1) Cleaning of the paint receiving pan and installation of the gravure roll: The paint receiving pan is cleaned, and a gravure roll with 150 line numbers adjusted to a target film thickness of 5 μm is installed. (5.2) Installation of the base material: The base film is installed according to the guide direction of the coating device, and the coated product (i.e., an ultra-thin and highly breathable microporous membrane) is wound by a winding device, and the roll in contact with the ultra-thin and highly breathable microporous membrane is a super mirror surface roll. (5.3) Coating: The foam produced in step (4) is transferred to the paint receiving pan, and the gravure roll is immersed to a depth of 1 / 4 to 1 / 2 of the gravure roll diameter (floating depending on the dosage of the auxiliary agent). (5.4) Drying: The applied base film is placed in a four-stage oven and dried at 25 m / min. Among them, the temperature and wind speed of the four-stage oven are 100 °C, 105 °C, 110 °C, 110 °C and 3 m / s, 4 m / s, 5 m / s, 5 m / s respectively in the order in which the base film enters. (6) Hot pressing Apply hot pressing to the coated layer of the base fabric after step (5), where the temperature of the hot pressing is 100 °C, the pressure is 0.8 MPa, and the speed is 35 m / min. (7) Hydrophobic treatment Apply hydrophobic treatment to the coated layer of the base fabric after step (5) to apply an 8 wt% hydrophobic treatment agent to the ultra-thin and highly breathable microporous membrane. Finally, the obtained ultra-thin and highly breathable microporous membrane has a film thickness of 4.5 μm, the pore diameter of the micropores is 1 - 4 μm, the average pore diameter is 2 μm, the air permeability of the membrane conforms to "Measurement of the Air Permeability of Textiles" in the Chinese national standard GB / T 5453, the performance of preventing the protrusion of feathers of the membrane conforms to "Down Jackets" in the Chinese national standard GB / T 14272-2011, the water repellency of the membrane is 4, and the water resistance of the membrane is 5 KPa.
Claims
1. An aqueous foaming paste is made comprising 100 parts by weight of an aqueous paste containing a polymer material such as PU, PE, PP, or PET, 0 to 15 parts by weight of a functional additive, 0.1 to 5 parts by weight of a silicone oil-based aqueous foam stabilizer, 0.1 to 5 parts by weight of a silicone resin polyether emulsion-based aqueous foam stabilizer, and n parts by weight of water, wherein the viscosity of the mixture of the aqueous paste, functional additive, and water is 500 cps. The foaming process is performed using a micron-nano foaming machine with control parameters set to a mixing head rotation speed of 250-400 rpm and a pump output of 100-500 L / hr. A method for producing an ultrathin, ultrapermeable, microporous film, characterized by obtaining an ultrathin, ultrapermeable, microporous film with a thickness of 5 μm or less and having micropores with a pore diameter of 5 μm or less, by high-precision micron gravure coating to create a coated layer with a thickness of 5 μm or less and a thickness of 5 μm or less.
2. The method for producing an ultrathin, ultra-permeable microporous film according to claim 1, characterized in that the target of high-precision micron gravure coating is a base fabric or base film.
3. A method for producing an ultrathin, ultra-permeable microporous film according to claim 2, characterized in that the base fabric or base film is subjected to electron beam irradiation treatment before high-precision micron gravure coating.
4. The method for producing an ultrathin, ultra-permeable microporous membrane according to claim 2, characterized in that the base fabric is a calendered ultrafine filament fabric.
5. A method for producing an ultrathin, ultra-permeable microporous film according to claim 4, characterized in that the roll in contact with the base fabric in the calendering apparatus is a super-mirror alloy roll and the receiving roll is a high-flatness rubber roll.
6. A method for producing an ultrathin, ultrapermeable microporous film according to claim 2, characterized in that, after high-precision micron gravure coating, hot pressure or cold pressure is applied to the coated layer of the base fabric or base film, the hot pressure temperature is lower than the melting point of the aqueous paste, higher than room temperature, and does not exceed the maximum heat resistance temperature of the base fabric or base film, the cold pressure temperature is room temperature, the hot pressure or cold pressure is 0.5 to 1 MPa, and the speed is 15 to 50 m / min.
7. A method for producing an ultrathin, ultra-permeable microporous film according to claim 2, characterized in that the coated layer of the base fabric or base film is hydrophobicized after high-precision micron gravure coating.