CN101323176B - 塑木复合材料/硬泡沫复合轻质墙板的制备方法 - Google Patents

塑木复合材料/硬泡沫复合轻质墙板的制备方法 Download PDF

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CN101323176B
CN101323176B CN2007101109336A CN200710110933A CN101323176B CN 101323176 B CN101323176 B CN 101323176B CN 2007101109336 A CN2007101109336 A CN 2007101109336A CN 200710110933 A CN200710110933 A CN 200710110933A CN 101323176 B CN101323176 B CN 101323176B
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screw extruder
rigid foam
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wall
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梁光仁
薛平
陈亚伟
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JIANGSU SIFANG MACHINERY GROUP CO Ltd
Beijing University of Chemical Technology
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Beijing University of Chemical Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/918—Thermal treatment of the stream of extruded material, e.g. cooling characterized by differential heating or cooling
    • B29C48/9185—Thermal treatment of the stream of extruded material, e.g. cooling characterized by differential heating or cooling in the direction of the stream of the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/94—Lubricating
    • B29C48/95—Lubricating by adding lubricant to the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C2948/00—Indexing scheme relating to extrusion moulding
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    • B29C2948/92819—Location or phase of control
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92819—Location or phase of control
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    • B29C2948/92904—Die; Nozzle zone

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Abstract

本发明涉及一种塑木复合材料/硬泡沫复合轻质墙体构件制备方法，包括中空墙体构件外层的成型和现场芯层填充两步制造，将木质纤维材料、聚合物材料及各种助剂及添加剂通过混合塑炼，用螺杆挤出机制成塑木复合材料粒料；将粒料加入螺秆挤出机挤出成型墙体外层，经过机头、真空冷却定型、牵引、切割工序，制得中空墙体外层；用发泡灌注机将聚氨酯材料进行现场快速硬发泡填充到墙体外层中，制得塑木复合材料/硬泡沫复合轻质墙体板材。本发明避免了复合挤出时芯层与墙体外层的不同步问题，可以根据墙体的强度及现场要求罐装发泡不同密度的芯层，保证墙体的横向抗压强度，方便灵活，适宜范围广。

Description

塑木复合材料/硬泡沫复合轻质墙板的制备方法
技术领域
本发明涉及一种塑木复合材料/硬泡沫复合轻质墙板的制备方法，具体地说，是用塑木复合材料作墙板外层，聚氨酯硬发泡材料作芯层的轻质墙体构件，可用于做轻体建筑及隔断墙体。
背景技术
轻质墙板是我国墙体材料发展的主导产品，现有的轻钢结构厂房建筑，用作墙体和房顶的轻钢壁板是以薄铁皮和可发性聚苯乙烯板、铝箔、纸等材料复合，具有一定保温、隔音、抗震之功能，但较笨重，在稳固性、耐蚀性、装饰性上存在较大的缺陷，且安装性较差。近年来发展起来的塑木复合材料，由于其兼备塑料和木材的主要优点，因此可替代塑料和木材，产品可完全回收，是具有高附加值的新型绿色环保材料。已经广泛的应用于建筑、包装等许多领域。中国专利03279638.2公开了一种木塑/泡沫复合墙体型材的制造设备，用该设备制造墙体构件的方法是以双螺杆挤出机挤出墙板外层，单螺杆挤出机挤出芯层泡沫，直接复合成型制备出墙体构件，但在实际生产中这种复合成型很难做到外层与发泡芯层同步挤出，因此芯层只能采用高发泡，这样不仅芯层的发泡材料的强度很难得到保证，而且加工效率较低。
发明内容
本发明提供一种塑木复合材料/硬泡沫复合轻质墙板的制备方法，该方法可根据实际应用场合的需要配备不同密度的发泡芯层，适应性强，生产效率高。
本发明的生产方法包括中空墙体构件外层的成型和现场芯层填充两步制造，其中：
1、将木质纤维材料、聚合物材料及加工助剂和添加剂，通过混合塑炼，排除复合物中的水分与其他低分子挥发物，用螺杆挤出机制成塑木复合材料颗粒料；
2、采用螺杆挤出机挤出成型墙体外层，经过机头、真空冷却定型、牵引、切割工序，制得中空塑木复合墙体中空板材；
3、用发泡灌注机将聚氨酯材料进行现场快速硬发泡填充灌注，制得塑木复合材料/硬泡沫复合轻质墙体板材。
所述塑木复合材料中的聚合物材料通常可选用聚乙烯(PE)、聚丙烯(PP)、聚氯乙烯(PVC)和ABS材料，优选PVC材料，可以采用新料或再生材料。
所述的木质纤维材料为30-200目的木质粉如：锯木、刨花、稻壳、农作物秸杆、棉花杆、芦苇杆等。
所述的加工助剂为塑木复合材料加工用的助剂，包括：相容剂、润滑剂、分散剂、交联剂、抗氧剂等，优选常用的助剂是：聚烯烃接枝相容剂、聚乙烯蜡润滑剂、硬脂酸分散剂、DCP(过氧化二异丙苯)交联剂、PKB-215复合抗氧剂；
所述的添加剂是为改善材料的性能按需选择加入的公知的有机、无机填料或添加剂，如为改善材料力学性能添加的无机填料碳酸钙等；为增加材料的阻燃性加入的阻然剂微囊化红磷环保阻然剂等。添加剂的加入用公知的方法按需选择或调配。
在上述步骤1的塑木复合材料粒料制备中，各组分的加入量根据需要，可以按常规的方法在以下范围内调整，以质量百分比计：30-70％的木质纤维类材料、20-60％的聚合物材料、0.5-3.0％润滑剂、4.0-8.0％相容剂、0.1-0.5％交联剂、0.5-1.0％分散剂、0.1-0.5％抗氧剂及添加剂适量。
上述步骤1塑木复合材料粒料的挤出采用通常工艺，在100-150℃条件下高速混合塑炼20-50分钟，使用螺杆挤出机在130-200℃条件下制成颗粒材料。
上述步骤2的墙体外层挤出成型，与通常的成型方法一样，将粒料加入到挤出设备中进行成型，在温度130-200℃，熔体压力10-30MPa的条件下，冷却真空定型制得中空墙体板材。成型宽度可达600-1000mm，厚度可达80～150mm。
本发明优选的挤出成型设备采用锥形双螺杆挤出机，其优点是剪切速率小，物料不易分解，塑化混炼均匀，产量高，并且自洁性好。
上述步骤3所述的现场发泡灌注，采用灌注发泡机，根据密度要求进行定量灌注，灌注压力为3～4.5MPa，芯层聚氨酯发泡密度为30-40kg/m3，吸水厚度膨胀率≤1.0％。
本发明采用粒料、成型及现场灌注发泡分步制备塑木复合材料/硬泡沫复合轻质墙板，避免了复合挤出时芯层与墙体外层的不同步问题，可以根据墙体的强度及现场要求灌注发泡不同密度的芯层，保证墙板的强度，方便灵活，适宜范围广，产品静曲强度可达10-25Mpa，弯曲弹性模量1.0-3.0Gpa，1.0-1.5g/cm3，吸水厚度膨胀率≤1.0％。本发明制备的轻质墙板具有重量轻、阻燃、防水、防震、隔音、隔热、强度高、便于施工等优点。墙体板材“零甲醛”，不怕水浸泡、抗磨抗腐蚀，抗老化，质感更贴近天然材料。可以象木材一样进行锯、切、钻等加工，具有良好的机械性能，同时其表面还可以进行转印、油漆、印刷、贴面、耐磨等美观和功能性处理。
图1本发明轻质墙板截面示意图
具体实施方式：
以下结合实施例进一步阐述本发明，但不限于以下实施例。
实施例1：采用60目的杂木粉55wt％，高密度聚乙烯(HDPE)35wt％，聚烯烃接枝相容剂4.0wt％，润滑剂聚乙烯蜡1.0wt％，交联剂DCP(过氧化二异丙苯)0.3wt％，分散剂硬脂酸0.5wt％，PKB-215复合抗氧剂0.2wt％，无机填料碳酸钙5.0wt％，按以下步骤加工，
a.木粉加入高速混合机中，加热搅拌至110℃排除木粉中水分，同时加入分散剂及无机填料，制成干燥好的木粉原料；
b.在木粉原料中继续加入高密度聚乙烯、相容剂、润滑剂、交联剂、抗氧剂原料高速混合至120℃，对物料进行充分混合均匀，制成复合原料；
c.混合好的复合原料加入SJZ-80/156型锥型双螺杆挤出机中共混造粒，挤出机加料段、压缩段、排气段、均化段、合流区、造粒机头各段温度分别设定为：170℃、180℃、180℃、170℃、165℃、180℃。得到复合粒料。
d.将制得的粒料加入SJZ-92/188型锥型双螺杆挤出机中进行板材挤出，挤出机加料段、压缩段、排气段、均化段1、均化段2、合流区、机头各段温度分别设定为：130℃、150℃、160℃、165℃、170℃、170℃、170℃，经模具及冷却真空定型、牵引、切割等工序，制得塑木复合中空墙板，截面形状如图1所示。
e、中空部分使用聚氨酯现场发泡灌注机，以4.5MPa的灌注压力，进行泡沫快速充填，材料密度控制为40kg/m3。制备的塑木复合材料/硬泡沫复合轻质墙板制品长度为3000mm，宽度为600mm，厚度为120mm，产品冲击强度：≥10～12kJ/m3，拉伸强度：18～20MPa，静曲强度：25MPa，静曲弹性模量：≥2GPa。
实施例2：加工步骤同实施例1，粒料的配方中添加微囊化红磷阻燃剂，各组分配比为：采用60目的杂木粉55wt％，高密度聚乙烯(HDPE)30wt％，聚烯烃接枝相容剂4.0wt％，润滑剂聚乙烯蜡1.0wt％，交联剂DCP(过氧化二异丙苯)0.3wt％，分散剂硬脂酸0.5wt％，复合PKB-215抗氧剂0.2wt％，无机填料碳酸钙4.0wt％，微囊化红磷环保阻燃剂5.0wt％。利用本配方组分和实施例1的加工设备与工艺，制得阻燃复合轻质墙板。

Claims (3)

1.一种塑木复合材料/硬泡沫复合轻质墙板的制备方法，其特征在于，包括中空墙体构件外层的成型和现场芯层填充两步制造，步骤是：
(1)将木质纤维材料、聚合物材料、加工助剂和添加剂，混合塑炼，用螺杆挤出机造粒制成塑木复合材料粒料；所述粒料各组分的配比以质量百分比计为：30-70％的木质纤维类材料、20-60％的聚合物材料、0.5-3.0％润滑剂、4.0-8.0％相容剂、0.1-0.5％交联剂、0.5-1.0％分散剂、0.1-0.5％抗氧剂及添加剂适量；所述的相容剂为聚烯烃接枝相容剂，交联剂为过氧化二异丙苯；
(2)将塑木复合材料粒料加入螺杆挤出机挤出成型墙体外层，经过机头、真空冷却定型、牵引、切割工序，制得中空墙体外层；所述螺杆挤出机挤出成型时，挤出机加料段、压缩段、排气段、均化段1、均化段2、合流区、机头各段温度分别为130℃、150℃、160℃、165℃、170℃、170℃、170℃；
(3)用发泡灌注机将聚氨酯材料现场硬发泡填充到墙体外层中，制得塑木复合材料/硬泡沫复合轻质墙体板材，所述发泡灌注机灌注压力为3～4.5MPa，聚氨酯发泡密度为30-40kg/m3。
2.根据权利要求1的制备方法，其特征在于，步骤(1)螺杆挤出机造粒，挤出机加料段、压缩段、排气段、均化段、合流区、造粒机头各段温度分别设定为：170℃、180℃、180℃、170℃、165℃、180℃。
3.根据权利要求1的制备方法，其特征在于，所述螺杆挤出机为锥形双螺杆挤出机。
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