CN113999455A - 一种具有隔离结构的导电epp泡沫的制备方法 - Google Patents
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Abstract
本发明公开了一种具有隔离结构的导电EPP泡沫的制备方法，属于导电和电磁屏蔽材料技术领域，该方法包括制备导电浆料和制备导电EPP泡沫。本发明将EPP表面构筑形成导电隔离结构，从而实现泡沫材料的导电功能化，通过万能表测试导电EPP泡沫成品电阻约为102～103欧姆，并且导电层的厚度能通过控制浆料的浓度、用量及共混方式进行控制，采用本发明方法制备的导电EPP泡沫延长了结构件使用寿命，具备耐温、耐候、防潮、防掉粉、良好的屏蔽效能等优良的特点；本发明方法采用现有的设备，工艺简单，制备方便，可实现连续性生产导电EPP泡沫制品的制备，适用于工业化大规模生产。
Description
技术领域
本发明涉及导电和电磁屏蔽材料技术领域，具体涉及一种具有隔离结构的导电EPP泡沫的制备方法。
背景技术
随着5G技术的应用，Sub 6 GHz、毫米波、太赫兹等频段不断地实际应用落地。对新场景频段的电磁屏蔽和电磁兼容问题亟待解决，具有功能性的导电泡沫需求也越来越大。目前常用导电泡沫基材主要为聚氨酯高分子基材，具有质轻、弹性好、易加工裁剪、价廉等优点，在电磁屏蔽和电磁兼容的应用场景使用的泡沫材料，最基本功能需求就是导电性能。通过传统合成的简单泡沫，利用浸润法使传统泡沫具有导电的效果。而这类导电泡沫存在易掉粉、易受潮等问题，再加上目前对环保的严格要求，对基材的选择和制备方法提出了更多的要求。
膨胀聚丙烯 (EPP) 是一种基于聚丙烯的超轻聚合物泡沫，具有广泛的积极特性：成本低、机械性能优异、成型性好、对环境友好、耐温耐候等，这是其他任何材料组合无法满足的，在上述新场景的应用将有极大的前景。但是，由于EPP珠粒无导电性能，受限于其发泡倍率和成型的工艺挑战，开发导电EPP泡沫的制备方法尚且处于探索阶段。
发明内容
本发明的目的在于克服现有技术的缺点，提供一种具有隔离结构的导电EPP泡沫的制备方法，本发明方法增加了EPP泡沫导电功能特点，延长了结构件使用寿命，具备耐温、耐候、防潮、防掉粉、良好的屏蔽效能等优良的特点。
本发明的目的通过以下技术方案来实现：一种具有隔离结构的导电EPP泡沫的制备方法，它包括以下步骤：
S1. 制备导电浆料：将导电剂、液态高分子聚合物和助剂加入高速分散机中进行分散，所述高速分散机的转速为400-600 r/min，分散1h后取出浆料，静置1h后进行脱泡，制得导电浆料；
其中，所述导电剂为石墨、鳞状石墨、炭黑、高导电炭黑、乙炔炭黑、纳米炭黑颗粒、碳纳米管、多壁碳纳米管、碳纤维、碳纳米纤维、石墨纳米片、石墨烯、单层石墨烯、少层石墨烯、多层石墨烯、镍包石墨粉、镍包碳纤维炭黑、金属粉、液态金属、片状铁基金属粉末、片状铁基合金粉末、片状铁硅铝合金粉末、片状铁硅合金粉末、片状铁硅铬合金粉末、片状钴基合金粉末、片状铁镍合金粉末中的一种或多种组成；
液态高分子聚合物为聚氨酯树脂、硅树脂、丙烯酸树脂、环氧树脂、聚酰亚胺、乙烯-醋酸乙烯共聚物、聚乙烯醇、聚乙烯吡咯烷酮、苯丙乳液、水溶性改性聚丙烯中的一种或多种组成；
所述助剂为分散剂、润湿剂、增稠剂、消泡剂中的一种或多种组成；
S2. 制备导电EPP泡沫：准备EPP预发泡珠粒，所述EPP预发泡珠粒的发泡倍率为5-45倍，将步骤S1制备的导电浆料以共混方式均匀包覆在EPP预发泡珠粒表面，过滤取出包覆有导电浆料的EPP泡沫粒珠，形成具有隔离结构导电EPP泡沫。
进一步地，步骤S1中所述导电浆料中，液态高分子聚合物固含量的质量分数占比为0.1-30%。
进一步地，步骤S1中所述导电浆料中，分散剂固含量的质量分数占比为0.01-10%，润湿剂固含量的质量分数占比为0.01-5%，增稠剂固含量的质量分数占比为0.01-5%，消泡剂固含量的质量分数占比为0.01-5%。
进一步地，步骤S2中所述共混方式为普通搅拌、高速混合、静置混合、超声混合方式中的一种或多种组合。
进一步地，步骤S2中所述过滤的方式为直接漏取、筛网过滤、超声过滤等方式中的一种或多种组合。
进一步地，步骤S2中所述具有隔离结构导电EPP泡沫的导电层厚度通过控制浆料的浓度、用量及共混方式进行控制，所述导电层厚度为0.01-1mm。
进一步地，它还包括后处理步骤，具体为：将具有隔离结构导电EPP泡沫在50-80℃的温度下烘8-12h，烘干后进行良品分选，将良品分选后的导电EPP泡沫导入载压罐，经过蒸汽熟化后，导电EPP泡沫导入蒸汽自动成型机成型，将成型的样品在50-80℃的温度下烘8-12h，得具有隔离结构的导电EPP泡沫制品。
进一步地，所述载压罐的级别有50kg、60kg、70kg或80kg级，载压罐的蒸汽压力为0.2-0.8MPa。
进一步地，所述蒸汽自动成型机的温度范围为120-180℃，蒸汽压力为0.5-1.2Mpa。
本发明具有以下优点：
（1）本发明将EPP表面构筑形成导电隔离结构，导电层在隔离结构的表面，由于隔离结构的存在，只需低含量的导电填料即可到达阈值，从而实现泡沫材料的导电功能化，通过万能表测试导电EPP泡沫成品电阻约为102～103欧姆，并且导电层的厚度能通过控制浆料的浓度、用量及共混方式进行控制，采用本发明方法制备的导电EPP泡沫延长了结构件使用寿命，具备耐温、耐候、防潮、防掉粉、良好的屏蔽效能等优良的特点。
（2）本发明方法采用现有的设备，工艺简单，制备方便，可实现连续性生产导电EPP泡沫制品的制备，适用于工业化大规模生产。
附图说明
图1为本发明方法制备的导电EPP泡沫的隔离结构示意图。
具体实施方式
下面结合附图及实施例对本发明做进一步的描述，本发明的保护范围不局限于以下所述：
实施例1：一种具有隔离结构的导电EPP泡沫的制备方法，它包括以下步骤：
S1. 制备导电浆料：将导电剂、液态高分子聚合物和助剂加入高速分散机中进行分散，所述高速分散机的转速为400 r/min，分散1h后取出浆料，静置1h后进行脱泡，制得导电浆料；
其中，所述导电剂为石墨、镍包碳纤维炭黑、铁粉和片状铁镍合金粉末以任意比例的混合；液态高分子聚合物为聚氨酯树脂、乙烯-醋酸乙烯共聚物和水溶性改性聚丙烯以任意比例的混合；所述助剂为分散剂、润湿剂、增稠剂和消泡剂的混合；
所述导电浆料中，液态高分子聚合物固含量的质量分数占比为0.1%；分散剂固含量的质量分数占比为0.01%，润湿剂固含量的质量分数占比为0.01%，增稠剂固含量的质量分数占比为0.01%，消泡剂固含量的质量分数占比为0.01%；
S2. 制备导电EPP泡沫：准备EPP预发泡珠粒，所述EPP预发泡珠粒的发泡倍率为10倍，将步骤S1制备的导电浆料以普通搅拌方式均匀包覆在EPP预发泡珠粒表面，直接漏取出包覆有导电浆料的EPP泡沫粒珠，形成具有隔离结构导电EPP泡沫，如图1所示；
S3. 后处理步骤：将具有隔离结构导电EPP泡沫在50℃的温度下烘8h，烘干后进行良品分选，将良品分选后的导电EPP泡沫导入载压罐，所述载压罐的级别为70kg，载压罐的蒸汽压力为0.2MPa，经过蒸汽熟化后，导电EPP泡沫导入蒸汽自动成型机成型，蒸汽自动成型机的温度范围为120℃，蒸汽压力为0.8MPa，将成型的样品在50℃的温度下烘8h，得具有隔离结构的导电EPP泡沫制品。
实施例2：一种具有隔离结构的导电EPP泡沫的制备方法，它包括以下步骤：
S1. 制备导电浆料：将导电剂、液态高分子聚合物和助剂加入高速分散机中进行分散，所述高速分散机的转速为600 r/min，分散1h后取出浆料，静置1h后进行脱泡，制得导电浆料；
其中，所述导电剂为碳纳米纤维、石墨纳米片、石墨烯和片状铁基金属粉末以任意比例的混合；液态高分子聚合物为丙烯酸树脂、环氧树脂和苯丙乳液以任意比例的混合；所述助剂为分散剂、润湿剂、增稠剂和消泡剂；
所述导电浆料中，液态高分子聚合物固含量的质量分数占比为30%；分散剂固含量的质量分数占比为10%，润湿剂固含量的质量分数占比为5%，增稠剂固含量质量分数占比为5%，消泡剂固含量的质量分数占比为5%；
S2. 制备导电EPP泡沫：准备EPP预发泡珠粒，所述EPP预发泡珠粒的发泡倍率为45倍，将步骤S1制备的导电浆料以共混方式均匀包覆在EPP预发泡珠粒表面，所述共混方式为静置混合和超声混合，筛网过滤出包覆有导电浆料的EPP泡沫粒珠，形成具有隔离结构导电EPP泡沫，如图1所示；
S3. 后处理：将具有隔离结构导电EPP泡沫在50-80℃的温度下烘12h，烘干后进行良品分选，将良品分选后的导电EPP泡沫导入载压罐，所述载压罐的级别为80kg，载压罐的蒸汽压力为0.8MPa，经过蒸汽熟化后，导电EPP泡沫导入蒸汽自动成型机成型，蒸汽自动成型机的温度范围为180℃，蒸汽压力为1MPa，将成型的样品在80℃的温度下烘12h，得具有隔离结构的导电EPP泡沫制品。
实施例3：一种具有隔离结构的导电EPP泡沫的制备方法，它包括以下步骤：
S1. 制备导电浆料：将导电剂、液态高分子聚合物和助剂加入高速分散机中进行分散，所述高速分散机的转速为500 r/min，分散1h后取出浆料，静置1h后进行脱泡，制得导电浆料；
其中，所述导电剂为镍包碳纤维炭黑；液态高分子聚合物为环氧树脂与聚乙烯吡咯烷酮以重量比为1:2的混合；所述助剂为分散剂、润湿剂、增稠剂和消泡剂中；
所述导电浆料中，液态高分子聚合物固含量的质量分数占比为12%；分散剂固含量的质量分数占比为1%，润湿剂固含量的质量分数占比为0.8%，增稠剂固含量的质量分数占比为4%，消泡剂固含量的质量分数占比为2%；
S2. 制备导电EPP泡沫：准备EPP预发泡珠粒，所述EPP预发泡珠粒的发泡倍率为20倍，将步骤S1制备的导电浆料以高速混合方式均匀包覆在EPP预发泡珠粒表面，筛网过滤和超声过滤取出包覆有导电浆料的EPP泡沫粒珠，形成具有隔离结构导电EPP泡沫，如图1所示；
S3. 后处理：将具有隔离结构导电EPP泡沫在62℃的温度下烘10h，烘干后进行良品分选，将良品分选后的导电EPP泡沫导入载压罐，所述载压罐的级别为60kg，载压罐的蒸汽压力为0.4MPa，经过蒸汽熟化后，导电EPP泡沫导入蒸汽自动成型机成型，蒸汽自动成型机的温度范围为140℃，蒸汽压力为1.2MPa，将成型的样品在66℃的温度下烘10h，得具有隔离结构的导电EPP泡沫制品。
实施例4：一种具有隔离结构的导电EPP泡沫的制备方法，它包括以下步骤：
S1. 制备导电浆料：将导电剂、液态高分子聚合物和助剂加入高速分散机中进行分散，所述高速分散机的转速为550r/min，分散1h后取出浆料，静置1h后进行脱泡，制得导电浆料；
其中，所述导电剂为碳纤维、石墨烯、单层石墨烯和片状铁基合金粉末以任意比例的混合；液态高分子聚合物为苯丙乳液；所述助剂为消泡剂；
所述导电浆料中，液态高分子聚合物固含量的质量分数占比为25%；消泡剂固含量的质量分数占比为3%；
S2. 制备导电EPP泡沫：准备EPP预发泡珠粒，所述EPP预发泡珠粒的发泡倍率为38倍，将步骤S1制备的导电浆料以共混方式均匀包覆在EPP预发泡珠粒表面，所述共混方式为静置混合和超声混合，筛网过滤取出包覆有导电浆料的EPP泡沫粒珠，形成具有隔离结构导电EPP泡沫，如图1所示；
S3. 后处理：将具有隔离结构导电EPP泡沫在75℃的温度下烘11h，烘干后进行良品分选，将良品分选后的导电EPP泡沫导入载压罐，所述载压罐的级别为50kg，载压罐的蒸汽压力为0.6MPa，经过蒸汽熟化后，导电EPP泡沫导入蒸汽自动成型机成型，蒸汽自动成型机的温度范围为170℃，蒸汽压力为0.5MPa，将成型的样品在65℃的温度下烘11h，得具有隔离结构的导电EPP泡沫制品。
实验例1：
S1. 制备导电浆料：称取固含量为10%的EVA乳液100份、称取高导电炭黑粉末10份、称取分散剂10份、称取润湿剂5份、称取增稠剂5份、称取消泡剂5份，共同加入高速分散机中分散，分散1小时后取出静置，静置1小时后，放入真空脱泡机中脱泡，脱泡后制得浆料；
S2. 制备导电EPP泡沫：将EPP预发泡珠粒（发泡倍率20）和制得的浆料放入高速混合机内，调整搅拌速度300r/min，将上述导电浆料充分均匀包覆于包覆EPP预发泡珠粒，100目筛网过滤；
S3. 后处理：将具有隔离结构导电EPP泡沫进行烘干，烘箱温度80℃，上述获得导电EPP泡沫导电层厚度约为1mm；烘干后的导电EPP泡沫烘干进行良品振动筛网分选；将分选后的导电EPP泡沫导入载压罐，载压罐为80kg级，载压罐压力为0.8MPa。导电EPP泡沫经过蒸汽熟化后，导入蒸汽自动成型机，按照已设置好的全自动程序进行，蒸汽温度条件为180℃，蒸汽压力为0.8MPa，将成型后的导电EPP泡沫顶出，收集存放，进行恒温80℃干燥12h，制备出导电EPP泡沫成品。通过万能表测试导电EPP泡沫成品电阻约为700欧姆。
实验例2：
S1. 制备导电浆料：称取固含量为5%的EVA乳液100份、称取高导电炭黑粉末5份、称取分散剂5份、称取润湿剂2份、称取增稠剂2份、称取消泡剂2份，共同加入高速分散机中分散，分散1小时后取出静置。静置1小时后，放入真空脱泡机中脱泡，脱泡后制得浆料；
S2. 制备导电EPP泡沫：将EPP预发泡珠粒（发泡倍率20）和制得的浆料放入高速混合机内，调整搅拌速度300r/min；将上述导电浆料充分均匀包覆于包覆EPP预发泡珠粒，100目筛网过滤；
S3. 后处理：将具有隔离结构导电EPP泡沫进行烘干，烘箱温度80℃,上述获得导电EPP泡沫导电层厚度约为0.5mm，烘干后的导电EPP泡沫烘干进行良品振动筛网分选，将分选后的导电EPP泡沫导入载压罐，载压罐为80kg级，载压罐压力为0.8MPa。导电EPP泡沫经过蒸汽熟化后，导入蒸汽自动成型机，按照已设置好的全自动程序进行，蒸汽温度条件为180℃，蒸汽压力为0.8MPa。将成型后的导电EPP泡沫顶出，收集存放，进行恒温80℃干燥12h，制备出导电EPP泡沫成品。通过万能表测试导电EPP泡沫成品电阻约为1000欧姆。
实验例3：
S1. 制备导电浆料：称取固含量为2%的EVA乳液100份、称取高导电炭黑粉末2份、称取分散剂2份、称取润湿剂1份、称取增稠剂1份、称取消泡剂1份，共同加入高速分散机中分散，分散1小时后取出静置，静置1小时后，放入真空脱泡机中脱泡，脱泡后制得浆料；
S2. 制备导电EPP泡沫：将EPP预发泡珠粒（发泡倍率20）和制得的浆料放入高速混合机内，调整搅拌速度300r/min。将上述导电浆料充分均匀包覆于包覆EPP预发泡珠粒，100目筛网过滤；
S3. 后处理：将具有隔离结构导电EPP泡沫进行烘干，烘箱温度80℃，上述获得导电EPP泡沫导电层厚度约为0.02mm。烘干后的导电EPP泡沫烘干进行良品振动筛网分选，将分选后的导电EPP泡沫导入载压罐，载压罐为80kg级，载压罐压力为0.8MPa。导电EPP泡沫经过蒸汽熟化后，导入蒸汽自动成型机，按照已设置好的全自动程序进行，蒸汽温度条件为180℃，蒸汽压力为0.8MPa。将成型后的导电EPP泡沫顶出，收集存放，进行恒温80℃干燥12h，制备出导电EPP泡沫成品。通过万能表测试导电EPP泡沫成品电阻约为2500欧姆。
实验例4：
S1. 制备导电浆料：称取固含量为10%的苯丙乳液100份、称取乙炔炭黑粉末10份、称取分散剂10份、称取润湿剂5份、称取增稠剂5份、称取消泡剂5份，共同加入高速分散机中分散，分散1小时后取出静置。静置1小时后，放入真空脱泡机中脱泡，脱泡后制得浆料；
S2. 制备导电EPP泡沫：将EPP预发泡珠粒（发泡倍率20）和制得的浆料放入高速混合机内，调整搅拌速度300r/min。将上述导电浆料充分均匀包覆于包覆EPP预发泡珠粒，100目筛网过滤；
S3. 后处理：将具有隔离结构导电EPP泡沫进行烘干，烘箱温度80℃。上述获得导电EPP泡沫导电层厚度约为0.8mm，烘干后的导电EPP泡沫烘干进行良品振动筛网分选，将分选后的导电EPP泡沫导入载压罐，载压罐为80 kg级，载压罐压力为0.8MPa。导电EPP泡沫经过蒸汽熟化后，导入蒸汽自动成型机，按照已设置好的全自动程序进行，蒸汽温度条件为180℃，蒸汽压力为0.8MPa。将成型后的导电EPP泡沫顶出，收集存放，进行恒温80℃干燥12h，制备出导电EPP泡沫成品。通过万能表测试导电EPP泡沫成品电阻约为400欧姆。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都涵盖在本发明的保护范围之内。
Claims (9)
1.一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，它包括以下步骤：
S1. 制备导电浆料：将导电剂、液态高分子聚合物和助剂加入高速分散机中进行分散，所述高速分散机的转速为400-600 r/min，分散1h后取出浆料，静置1h后进行脱泡，制得导电浆料；
其中，所述导电剂为石墨、鳞状石墨、炭黑、高导电炭黑、乙炔炭黑、纳米炭黑颗粒、碳纳米管、多壁碳纳米管、碳纤维、碳纳米纤维、石墨纳米片、石墨烯、单层石墨烯、少层石墨烯、多层石墨烯、镍包石墨粉、镍包碳纤维炭黑、金属粉、液态金属、片状铁基金属粉末、片状铁基合金粉末、片状铁硅铝合金粉末、片状铁硅合金粉末、片状铁硅铬合金粉末、片状钴基合金粉末、片状铁镍合金粉末中的一种或多种组成；
液态高分子聚合物为聚氨酯树脂、硅树脂、丙烯酸树脂、环氧树脂、聚酰亚胺、乙烯-醋酸乙烯共聚物、聚乙烯醇、聚乙烯吡咯烷酮、苯丙乳液、水溶性改性聚丙烯中的一种或多种组成；
所述助剂为分散剂、润湿剂、增稠剂、消泡剂中的一种或多种组成；
S2. 制备导电EPP泡沫：准备EPP预发泡珠粒，所述EPP预发泡珠粒的发泡倍率为10-45倍，将步骤S1制备的导电浆料以共混方式均匀包覆在EPP预发泡珠粒表面，过滤取出包覆有导电浆料的EPP泡沫粒珠，形成具有隔离结构导电EPP泡沫。
2.根据权利要求1所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，步骤S1中所述导电浆料中，液态高分子聚合物固含量的质量分数占比为0.1-30%。
3.根据权利要求1所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，步骤S1中所述导电浆料中，分散剂固含量的质量分数占比为0.01-10%，润湿剂固含量的质量分数占比为0.01-5%，增稠剂固含量的质量分数占比为0.01-5%，消泡剂固含量的质量分数占比为0.01-5%。
4.根据权利要求1所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，步骤S2中所述共混方式为普通搅拌、高速混合、静置混合、超声混合方式中的一种或多种组合。
5.根据权利要求1所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，步骤S2中所述过滤的方式为直接漏取、筛网过滤、超声过滤等方式中的一种或多种组合。
6.根据权利要求1所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，步骤S2中所述具有隔离结构导电EPP泡沫的导电层厚度通过控制浆料的浓度、用量及共混方式进行控制，所述导电层厚度为0.01-1mm。
7.根据权利要求1所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，它还包括后处理步骤，具体为：将具有隔离结构导电EPP泡沫在50-80℃的温度下烘8-12h，烘干后进行良品分选，将良品分选后的导电EPP泡沫导入载压罐，经过蒸汽熟化后，导电EPP泡沫导入蒸汽自动成型机成型，将成型的样品在50-80℃的温度下烘8-12h，得具有隔离结构的导电EPP泡沫制品。
8.根据权利要求7所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，所述载压罐的级别有50kg、60kg、70kg或80kg级，载压罐的蒸汽压力为0.2-0.8MPa。
9.根据权利要求7所述的一种具有隔离结构的导电EPP泡沫的制备方法，其特征在于，所述蒸汽自动成型机的温度范围为120-180℃，蒸汽压力为0.5-1.2MPa。
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| US4496627A (en) * | 1981-11-25 | 1985-01-29 | Fujimori Kogyo Co., Ltd. | Electrical conductive foam beads and molded electrical conductive foamed articles obtained therefrom |
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