CN101688012B - 透光性泡沫聚合物片材及其制备方法 - Google Patents

透光性泡沫聚合物片材及其制备方法 Download PDF

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CN101688012B
CN101688012B CN200880021535XA CN200880021535A CN101688012B CN 101688012 B CN101688012 B CN 101688012B CN 200880021535X A CN200880021535X A CN 200880021535XA CN 200880021535 A CN200880021535 A CN 200880021535A CN 101688012 B CN101688012 B CN 101688012B
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乔纳斯·E·博格斯滕
勒内·德努伊杰
克里斯蒂安纳斯·J·J·马斯
伊尓科·范哈默斯维尔德
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SABIC Global Technologies BV
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Abstract

在一些实施方案中，泡沫聚合物片材包含：聚合物材料以及位于聚合物材料上的泡孔。泡孔的粒度分布D90大于或等于300μm且该片材的透光率大于或等于约5％。在另一实施方案中，沿着长轴测量的泡孔的平均直径为约1mm到约4mm，且片材的透光率大于或等于约5％。在另一个实施方案中，制备泡沫聚合物片材的方法包括：将发泡剂与聚合物材料结合形成混合物，在混合物中进行气泡成核，冷却混合物。混合物处于足够的温度下且泡孔具有足够的泡孔尺寸，使得该片材的透光率大于或等于10％。

Description

透光性泡沫聚合物片材及其制备方法
背景技术
本发明一般地涉及泡沫聚合物片材及其制备方法，特别地涉及透光性泡沫聚合物片材及其制备方法。
在必然的轻质结构(例如，温室、游泳池外壳、暖房、体育场、日光室，诸如此类)的建造中，玻璃被应用于许多场合作为透明的构造元件，诸如，窗、饰面以及屋顶。然而，由于数个显著的优点，聚合物片材在很多应用场合正在代替玻璃。
聚合物片材的一个优点是，相对于玻璃而言，其显示出优异的抗冲击性。这也就因此降低了在会遇到由毁坏、冰雹、收缩/膨胀等所引起的偶然破坏的应用中的维护成本。聚合物片材的另一个优点是其相对于玻璃而言重量明显减轻了。这使得聚合物片材相对于玻璃来说更容易安装，同时也降低了对安装结构部分的承重要求。
除了这些优点之外，聚合物片材的一个最重要的优势是其相对于玻璃而言提供了改进的绝缘性能。这一特性显著地影响了对聚合物片材的整体市场接受度，因为消费者希望具有改进的降低加热和/或冷却成本的作用的结构元件，并且倾向于降低重量。从而，人们希望使用泡沫聚合物片材。然而这种片材是不透明的，因此无法接受。
因此，本领域需要的是透光性泡沫聚合物片材。
发明概述
在此公开的是透光性泡沫聚合物片材及其制备方法。
在一些实施方案中，泡沫聚合物片材包含：聚合物材料和位于该聚合物材料上的泡孔。该泡孔的粒度分布D90大于或等于300μm，和该片材的透光率大于或等于约5％。
在另一实施方案中，泡沫聚合物片材包含：聚合物材料和位于该聚合物材料上的泡孔。该泡孔具有沿着长轴测量的约1mm到约4mm的平均直径，和该片材的透光率大于或等于约5％。
在一个实施方案中，制备泡沫聚合物片材的方法包括：熔融聚合物材料，将发泡剂与该聚合物材料在挤出机中结合形成混合物，在离开挤出机之前抑制发泡，在混合物中进行气泡成核(nucleating bubbles)，将该混合物成型为片材。该混合物在足够的温度下，从而使得能够产生具有沿长轴测量的大于或等于1mm的泡孔尺寸的泡孔，和该片材的透光率大于或等于5％。
在另一实施方案中，制备泡沫聚合物片材的方法包括：将发泡剂与聚合物材料结合形成混合物，在混合物中进行气泡成核形成泡孔，在校准板(calibration plates)之间冷却该混合物来制备泡沫聚合物片材。该混合物在足够的温度下，并且该泡孔具有足够的泡孔尺寸使得泡沫聚合物片材具有大于或等于10％的透光率。
下列图和详细说明例证了上述描述的及其它特性。
附图简述
现在参见作为实施方案示例的附图，其中相同的部件以相同的附图标记进行标记。
图1是制备透光性泡沫聚合物片材的连续工艺的示例性示意图。
图2是示例性多层片材的局部主视图。
图3是另一示例性多层片材的局部主视图。
详细说明
本申请公开的是透光性泡沫聚合物片材、透光性泡沫聚合物多层片材(multiwalled sheet)，及其制备方法。泡沫片材的透光率大于或等于1％，或特别地，大于或等于约5％，或更特别地，大于或等于约10％，或更特别地，大于或等于约20％，或还更特别地，约30％到约60％，或更特别地，约35％到约55％。除非在本申请中明确地指出例外，否则，透光率都是根据ASTM D-1003-00(方法B，分光光度计，使用光源C，扩散照明(diffuseillumination)和单向观察(unidirectional viewing))来测定的，其中透光率定义为： % T = ( I I O ) × 100 % - - - ( I ) 其中：I＝通过测试样品的光强度I0＝入射光的强度
在不受理论约束的情况下，人们已经发现在泡沫聚合物中影响透光率的一个因素是泡孔尺寸。有许多工艺产生小的泡孔尺寸(例如，小于或等于100微米(μm))。在这些泡孔尺寸下，泡沫聚合物是不透明的(0％透光率)，即使该聚合物在没有发泡时具有高的透光率(例如，大于80％)也是如此。因此，该泡沫聚合物具有足够的泡孔尺寸和/或孔径分布以达到所需要的透光率。本发明的泡沫聚合物具有密闭的泡孔，其孔径分布D90(即沿长轴测量的，大于或等于90％的泡孔的直径)大于或等于约300μm，或特别地，约300μm到约4mm，或更特别地，约500μm到约4mm，或还更特别地，约1mm到约3.5mm，或更特别地，约1.5mm到约3mm。平均泡孔尺寸(沿着长轴测量)大于或等于约1mm，或特别地，约1mm到约4mm，或更特别地，约1.5mm到约3.5mm，或更特别地，约1.5mm到约3mm，其中，标准偏差是2mm。
该泡沫聚合物在具有所需的透射率的同时，还可具有足够数量的泡孔以达到所需的性能。在一些实施方案中，泡孔的数目可小于或等于每立方厘米约500泡孔(例如，空隙)(c/cm3)，或特别地，约1c/cm3到约500c/cm3，或更特别地，约5c/cm3到约250c/cm3，且更特别地，约10c/cm3到约100c/cm3。
这些泡孔尺寸能够通过组合以下因素而获得：染色之前的压力、加工温度、发泡剂(类型和浓度)，和/或施加的发泡工艺。该泡沫聚合物可以以任何能够达到所需泡孔尺寸的工艺方法制备。例如，该泡沫聚合物可以通过挤压工艺制备。工艺方法中所用的温度应是足以达到所需泡孔尺寸的温度，例如，抑制泡孔的成核(例如，在发泡剂加入后抑制发泡)，并且同时保持所需粘度并使得在材料一旦离开挤出机后(例如，脱模后)就进行发泡。温度为可达到足以允许产生透光性泡沫聚合物片材(例如，其透光率大于或等于约5％)的泡孔尺寸的温度。对于聚碳酸酯，根据发泡剂的类型和用量，例如，温度可为约180℃到约260℃，或特别地，约200℃到约260℃，或更特别地，约220℃到约255℃，更特别地，约230℃到约250℃。
聚合物片材可由聚合物组合物形成，该聚合物组合物包括聚合物材料(诸如热塑性树脂(一种或多种)、热固性树脂(一种或多种)，以及包括上述至少一种的组合)，所述聚合物材料具有足够的初始透光率，使得一旦进行发泡，其就可具有所需的透光率。例如，聚合物材料的透光率可大于或等于约80％，或特别地，大于或等于约85％。除了透射率之外，要选择显示出具有足够抗冲击性的聚合物材料，这样片材就能够阻止由冲击(例如，冰雹、鸟、石头诸如此类)引起的破坏(例如，断裂、破裂，等等)。因此，根据ASTM D-256-93(伊佐德缺口冲击试验，Izod Notched Impact Test)测试方法，期望该聚合物显示的冲击强度大于或等于约7.5英尺-磅/平方英寸，ft-lb/in2(每平方厘米4.00焦耳，J/cm2)，或更特别地，大于约10.0ft-lb/in2(5.34J/cm2)或更特别地，大于或等于约12.5ft-lb/in2(6.67J/cm2)。此外理想的是，该聚合物材料具有足够的刚性以允许能够用于特殊应用场合的片材的制备，在这些应用场合中，片材通常是被支撑和/或被固定在该片材的两个或多个边上(例如，被固定在全部四个边上)，诸如在包括管式钢架结构的温室应用场合中。此处足够的刚性被定义为聚合物的杨氏模量(例如，弹性模量)大于或等于约200,000磅/平方英寸，psi(每平方厘米14,061千克(kg/cm2))，或更特别地，大于或等于约250,000psi(17,577kg/cm2)，或更特别地，大于或等于约300,000psi(21，092kg/cm2)。
热塑性树脂的例子包括，聚烯烃(例如，聚乙烯、聚丙烯、聚对苯二甲酸亚烷基二醇酯(诸如聚对苯二甲酸乙二醇酯(PET))、聚对苯二甲酸丁二醇酯、聚(对苯二甲酸乙二醇酯)二醇(PETG)))、聚碳酸酯、丙烯酸、聚缩醛类、苯乙烯(例如，抗冲击改性聚苯乙烯、丙烯腈-丁二烯-苯乙烯(ABS)、苯乙烯-丙烯腈)、聚(甲基)丙烯酸酯(例如，聚丙烯酸丁基酯、聚甲基丙烯酸甲酯)、聚醚酰亚胺、聚氨酯、聚苯硫醚、聚氯乙烯、聚砜、聚醚酮、聚醚醚酮、聚醚酮酮、诸如此类，以及包含上述至少一种的组合。热塑性树脂共混物的例子包括，丙烯腈-丁二烯-苯乙烯/尼龙、聚碳酸酯/丙烯腈-丁二烯-苯乙烯、丙烯腈-丁二烯-苯乙烯/聚氯乙烯、聚苯醚/聚苯乙烯、聚苯醚/尼龙、聚砜/丙烯腈-丁二烯-苯乙烯、聚碳酸酯/热塑性脲烷、聚碳酸酯/聚对苯二甲酸乙二醇酯、聚碳酸酯/聚对苯二甲酸丁二醇酯、热塑性弹性体合金、尼龙/弹性体、聚酯/弹性体、聚对苯二甲酸乙二醇酯/聚对苯二甲酸丁二醇酯、缩醛/弹性体、苯乙烯-马来酸酐/丙烯腈-丁二烯-苯乙烯、聚醚醚酮/聚醚砜、聚乙烯/尼龙、聚乙烯/聚缩醛类，等等。然而，在此说明的特定实施方案中，预期可使用聚碳酸酯材料，诸如以商品名
Figure G200880021535XD00051
的购自GeneralElectric Company，GE Plastics，Pittsfield，MA的那些。
可使用添加剂来改进聚合物材料的特性、性能，或加工。添加剂的例子包括，抗氧化剂，诸如，有机亚磷酸酯，例如，三(壬基-苯基)亚磷酸酯、三(2，4-二-叔丁基苯基)亚磷酸酯、双(2，4-二-叔丁基苯基)季戊四醇二亚磷酸酯或二硬脂基二亚磷酸季戊四醇酯、烷基化单酚、多酚和多酚与二烯的烷基化反应产物例如，四[亚甲基(3，5-二-叔丁基-4-羟基氢化肉桂酸酯)]甲烷、3，5-二-叔丁基-4-羟基氢化肉桂酸酯十八烷基、2，4-二-叔丁基苯基亚磷酸酯、对-甲酚和双环戊二烯的丁基化反应产物、烷基化对苯二酚、羟基化硫代二苯基醚、烷叉基-双酚、苄基化合物、β-(3，5-二-叔丁基-4-羟苯基)-丙酸与一元醇或多元醇的酯、β-(5-叔丁基-4-羟基-3-甲基苯基)-丙酸与一元醇或多元醇的酯；硫烷基或硫酰基化合物的酯，例如，二硬脂基硫代丙酸酯、二月桂基硫代丙酸酯、双十三烷基硫代二丙酸酯、β-(3，5-二-叔丁基-4-羟苯基)-丙酸的酰胺；填料和增强剂，例如，硅酸盐、纤维、玻璃纤维(包括连续和短切纤维)、云母及其他添加剂；例如，脱模剂、UV吸收剂、稳定剂诸如光稳定剂以及其它，润滑剂、增塑剂、颜料、染料、着色剂、防静电剂、阻燃剂、抗冲改性剂等。
为了得到所需的发泡片材，该聚合物组合物还包括发泡剂(一种或多种)。发泡剂(一种或多种)可以是分解类型(化学分解时放出气体(例如，二氧化碳(CO2)、氮气(N2)、和/或氨气))，和/或蒸发类型(其在没有化学反应的情况下蒸发)。可能的发泡剂包括，碳酸氢钠、叠氮化合物、碳酸铵、亚硝酸铵、在与水的反应中放出氢气的轻金属、氯化烃类、氟氯化碳、偶氮二甲酰胺、N，N′-二亚硝基五亚甲基四胺、三氯氟代甲烷、三氯三氟代乙烷、二氯甲烷、有机羧酸类(诸如甲酸、乙酸、草酸、蓖麻醇酸、诸如此类)、戊烷、丁烷、乙醇、丙酮、CO2、N2、氨气、诸如此类，以及包含上述至少一种的组合。
发泡剂的用量取决于工艺方法、加工条件，以及特定的聚合物材料(一种或多种)。在一些实施方案中，发泡剂的用量为约0.5重量百分比(wt％)到约10wt％，或特别地，约0.5wt％到约5wt％，或更特别地，约1wt％到约4wt％，其中重量百分比是基于聚合物组合物(例如，聚合物材料(一种或多种)、添加剂(一种或多种)、发泡剂(一种或多种)、成核剂(一种或多种)，等等)的总重量。在一些实施方案中，发泡剂为约0.5wt％到约4wt％的CO2，或特别地，约1wt％到约3wt％的CO2，及约0.25wt％到约2wt％的其他发泡剂(一种或多种)(不同于CO2)，或特别地，约0.5wt％到约1.5wt％的其他发泡剂(一种或多种)。
添加剂或泡孔控制剂通过改变聚合物组合物的表面张力或通过作为泡孔生长的成核位点来影响泡孔的成核。可将成核剂(一种或多种)加入聚合物组合物中来促进在加工过程中气泡的形成。通过挑选成核剂来产生具有特定尺寸的泡孔。一些可能的成核剂包括滑石(硅酸镁)、玻璃-纤维、热解法二氧化硅、二氧化钛、柠檬酸和碳酸氢钠的混合物、氧化锌，等等，以及包含上述至少一种的组合。成核剂(一种或多种)的用量取决于工艺方法、加工条件、特定的聚合物材料(一种或多种)、发泡剂(一种或多种)，以及所需的泡孔尺寸。在一些实施方案中，成核剂(一种或多种)的用量可为小于或等于约7wt％，或特别地，约0.01wt％到约5wt％、或更特别地，约0.5wt％到约1wt％，其中重量百分比是基于聚合物组合物的总重量。
能够应用不同的技术形成透光性泡沫聚合物片材，包括连续法或分批法。分批法主要用于制备具有特定性能的泡沫材料或每批制备较小量。而连续法允许有助于规模化生产操作的高产出。在一个实施方案中，连续化工序使用了挤出机，例如，单螺杆-挤出机或串联装配。二种方法均可使用同向旋转双螺杆。该工艺方法包括：将聚合物材料和任意添加剂(一种或多种)加入到挤出机的进料口，将聚合物材料进行熔融，使发泡剂(一种或多种)溶解在熔融的聚合物材料中、将聚合物材料进行塑化、对气泡进行成核(例如，由于模头处的压降)、在模头之后后的气泡生成、泡孔结构稳定化(例如，在冷却和校准板步骤)。理想地，泡孔以限定的数目成核并且以相同的速度在所有方位生长以制备具有均一三维机械性能的透光性泡沫材料。
可将泡沫聚合物片材与其它层(一种或多种)进行共挤出。例如，该片材能够与相邻于发泡板材任意侧(例如，顶面、底面、和/或侧面(一种或多种))的覆盖层(cap-layer)进行共挤出。该覆盖层(其厚度小于或等于约200μm，或特别地，约20μm到约200μm，或更特别地，约30μm到约100μm)可含有一种不会将制品的透光率减少到所需水平以下的塑料。该非-泡沫塑料包括热塑性塑料(一种或多种)、热固性塑料(一种或多种)，以及含有上述至少一种的组合。一些塑料的例子包括以上确定为聚合物材料的那些材料。理想地，该塑料包含UV吸收剂(一种或多种)。
图1显示了制备透光性泡沫聚合物片材的连续法的示例。如从图中可看到，聚合物材料(树脂)在混合挤出机的进料口引入。沿着挤出机前进方向，将发泡剂(一种或多种)加入到熔融树脂中。组合物从混合挤出机出来，进入冷却挤出机。从冷却挤出机出来，组合物被挤出通过模头(dye)(任选与其它层(一种或多种)共挤出)，此处压力变化诱导气泡发生成核作用。片材从模具出来通过校准板，在此处形成泡沫塑料板的最终物理形状，包括表面(例如，表层形成)。得到的泡沫聚合物片材的透光率可大于或等于约5％，厚度大于或等于约0.1mm(例如，约0.1mm到约40mm，或特别地，约4mm到约25mm)。片材的密度小于或等于约600千克每立方米(kg/m3)，或特别地，约60kg/m3到约600kg/m3，或更特别地，约70kg/m3到约400kg/m3，或更特别地，约80kg/m3到约200kg/m3，其是根据挤出机进行测定的(例如，由Berstorff，Hannover，Germany制造；DIN 53420/ISO845：1998)。U值大于或等于约0.5瓦特每平方米开尔文(W/m2K)。
具体地说，U值是在片材两侧温差为1°K的条件下，穿过1平方米片材2的热能的量。U值是根据EN 675和Deutches Institute fur Normung(“DIN”)European Norm“EN”)12667/12664测定的。U值是根据下列公式(II)计算得出： U = 1 1 / α i + 1 / χ + 1 / α a - - - ( II ) 其中：χ＝λ/sλ＝热传导率s＝片材厚度(1/αi)＝内部热转化阻力值(1/αa)＝外部热转化阻力值U值是通过利用Norm NEN 1068(2001年)中命名的热转化阻力系数(thermal transition resistance values)来计算的，其中(1/αi)是0.13平方米开氏温度每瓦特(m2K/W)，(1/αa)是0.04m2K/W。发泡片材的U值可小于或等于约5W/m2K，或特别地，小于或等于约3W/m2K，或更特别地，小于或等于约2W/m2K。
发泡片材可以是多层的片材。现在参见图2和3，多层片材的部分横剖面图的例子描述如下，其具有主层2，包括第一外层(例如，顶层)10和第二外层(例如，底层)12，二者是通过横断层(例如，肋材)4连接。顶层10和底层12，以及内层(一种或多种)14，通常彼此平行。横断层(一种或多种)4通常放置于顶层10和底层12之间，并且垂直于二者。
另外，片材具有足够数目的横断层4以达到所需的结构完整性。除了主层和横断层(肋材4)之外，也使用间隔层6，8。间隔层具有不同的几何形状诸如垂直(例如，交叉(例如，X)几何形状(例如，参见图2，交叉间隔层6)，正弦曲线的几何形状(例如，参见图3，正弦间隔层8)，以及任何其它几何形状以及包含至少一种这些几何形状的组合。
多层片材的层数取决于用户要求，诸如结构完整性、总厚度、透光性，以及绝缘性能。多层片材至少具有2层，或特别地，大于或等于3层(例如，主层)，或更特别地，约3层到约10层，以及更特别地，约4层到约8层。在一些实施方案中，每层的厚度可小于或等于约1毫米(mm)，或特别地，约0.2mm到约0.8mm，或更特别地，约0.3mm约0.6mm。尽管片材的总厚度(箭头16)可达到甚至超过约10厘米(cm)，通常，厚度小于或等于约32毫米(mm)，或特别地，小于或等于约16mm，或更特别地，小于或等于约12mm。通常，多层片材的总厚度是大于或等于约8mm。在一些实施方案中，每个横断层的厚度小于或等于约1mm，或更特别地，约0.2mm到约0.8mm，或更特别地，约0.25mm到约0.6mm。
每个泡孔18可具有约10mm的宽度，然而任何能够提供给预定用途(例如，作为屋顶或片材产品)足够的刚性的宽度都可使用。更特别地，当装配后，片材2能够暴露于由雪、雨、风，等等引起的多种作用力下。因此，如果片材是用作屋顶，人们希望其能够经受住这些作用力并且不发生损坏(例如，翘曲、开裂、凹陷，诸如此类)。可选择最终片材2的具体尺寸(例如，总宽、长度和厚度)，以及顶层4，底层6，以及肋材8的厚度以保证片材2能够经受住这些作用力。
在片材2的生产中，还可以使用共挤出方法和/或涂层法来为片材几何形状的任何表面部分提供不同聚合物，以改进和/或改变片材的特性，和/或降低原材料成本。在一实施方案中，使用共挤出工艺方法能够给顶层10加入美观的着色剂。可将涂层(一种或多种)置于任何片材表面来改进片材性能和/或特性。涂层或共挤层的例子包括，抗真菌涂层、疏水性涂层、亲水性涂层、光分散涂层、抗缩合涂层、耐刮擦涂层、紫外线吸收涂层、光稳定涂层，等等。对共挤出技术领域的技术人员而言显而易见的是能够利用共挤出工艺生产大量的实施方案。
实施例
对聚合物材料的发泡的评估是对线性聚碳酸酯(即
Figure G200880021535XD00091
(102X)，购自GE Plastics，Pittsfield，MA)，和支化聚碳酸酯(即
Figure G200880021535XD00092
(ML3324)，同样购自GE Plastics)而进行的。样品1包含102X/ML3324，而其它样品包含ML3324。
所使用的不同的发泡剂(此处也称起泡剂)显示在表1中。在一些情况下，除了另一发泡剂外还用到了二氧化碳CO2。与戊烷、丁烷、和/或IPA混合的CO2可以得到优选的泡沫结构，特别是当挤出机不是在最大扭矩下运行时可以得到优选的泡沫结构。表1和2中提供了温度分布线，其中“Tz”是温度区间，“T”是温度，“P”是压力。单位如下：l/min是升每分钟；kW是千瓦；amp是安培；Kg/h是千克每小时；g/s是克每秒；％是百分数；V是伏特。
Figure G200880021535XD00093
Figure G200880021535XD00101
Figure G200880021535XD00102
Figure G200880021535XD00111
对于测试样品，测定了平均密度(根据DIN 53420/ISO 845：1998)、U值(DIN EN 12664/12667)、透光率，以及泡孔尺寸，并显示在表3中。参数相互之间有关系，但干扰该分析的一个参数是表层几何形状，对于透光率值特别是这样。当在样品厚度之间密度没有大变化时，可以看到U值随着样品厚度降低。由于泡孔尺寸11mm样品和23mm样品在主要方面没有不同，可预期U值与样品厚度之间是线性关系。但是透光率对泡孔尺寸的变化更敏感。因此6mm样品比11mm样品在透光率和样品厚度之间具有更有利的关系。在23mm样品的情况下，这会成比例地比11mm样品差，主要是由于形成不均匀的表层导致的。
Figure G200880021535XD00112
本发明的泡沫聚合物片材可用于任何需要聚合物片材的应用场合。应用的例子包括轻质结构(例如，温室、日光房、游泳池外壳、浴室外壳)、遮阳篷、座舱盖、护罩、窗、照明设施、日光浴床(sun-tanning beds)、露天运动场屋顶，诸如此类。
此处公开的范围是包含端点的并可结合(例如，“多至约25wt％，或更特别地，约5wt％到约20wt％”的范围，是包含“约5wt％到约25wt％”范围的端点和所有范围内的值)。“结合”是共混物、混合物、衍生物、合金、反应产物，诸如此类的总称。此外，术语“第一”，“第二”诸如此类，在此处没有限定其任何顺序、数量，或重要性，而是用来区别一个部件和另一个部件，且术语“a”和“an”此处没有表示量的限制，而是表示存在至少一个参考项目。与数量联用的修改词“约”是记载值(state value)的总称且具有范围规定的意义，(例如，包括与特定数量的测量值有关联的误差度)。这里用到的尾标“(一种或多种)”意思是包括其修饰的术语的单数和复数，因此包括一个或多个术语(例如，着色剂(一种或多种)包括一种或多种着色剂)。贯穿全部说明书“一个实施方案”，“另一个实施方案”，“实施方案”，诸如此类，意思指与实施方案关联描述的一个特定的要素(例如，特性、结构、和/或特性)被归入此处描述的至少一种实施方案，且能或不能存在于其它实施方案中。另外，可以理解的是描述的要素可以以任何合适的方式在各种实施方案中结合。
所有列举的专利、专利申请，以及其它参考文献在此处被全文引入。但是，如果本申请中的术语与引入的参考文献中的术语有冲突或不一致，本申请的术语优先于引入的参考文献的冲突术语。
在为了说明的目的提出典型的实施方案的同时，上述描述不应该被认为是对本发明范围的限制。因此，在不违背本发明本质和范围的情况下，本领域技术人员可以作出不同的改进、调整以及替换。

Claims (19)

1.一种泡沫聚合物片材，其包含：
聚碳酸酯材料片材；和
位于该聚碳酸酯材料片材中的泡孔，其中该泡孔的粒度分布D90为300μm至1.5mm；
相邻于该聚碳酸酯材料片材任意侧的一个或多个覆盖层，所述聚碳酸酯材料片材与所述覆盖层共挤出；
其中所述覆盖层包括包含UV吸收剂的塑料，其中所述塑料不会将制品的透光率减少到所需水平以下；且
其中该片材的透光率大于或等于5％。
2.一种泡沫聚合物片材，其包含：
聚碳酸酯材料片材；和
位于该聚碳酸酯材料片材中的泡孔，其中该泡孔沿着长轴测量的平均直径为1mm到1.5mm；
相邻于该聚碳酸酯材料片材任意侧的一个或多个覆盖层，所述聚碳酸酯材料片材与所述覆盖层共挤出；
其中所述覆盖层包括包含UV吸收剂的塑料，其中所述塑料不会将制品的透光率减少到所需水平以下；且
其中该片材的透光率大于或等于5％。
3.根据权利要求1或2的片材，其中透光率大于或等于10％。
4.权利要求3的片材，其中透光率大于或等于20％。
5.权利要求4的片材，其中透光率为30％到60％。
6.权利要求1或2的片材，其中所述一个或多个覆盖层的厚度小于或等于200μm。
7.权利要求1或2的片材，其中所述泡孔包括封闭的泡孔。
8.制备泡沫聚合物片材的方法，其包括：
熔融聚合物材料；
将发泡剂与该聚合物材料在挤出机中结合形成混合物；
在离开挤出机之前抑制发泡；
在混合物中进行气泡成核，其中该混合物处于足以使得能够产生粒度分布D90为300μm至1.5mm的泡孔的温度；和
将该混合物成型为片材；
其中，该片材的透光率大于或等于5％。
9.权利要求8的方法，其中所述透光率大于或等于10％。
10.制备泡沫聚合物片材的方法，其包括：
将发泡剂与聚合物材料结合形成混合物；
在该混合物中进行气泡成核形成泡孔；和
在校准板之间冷却该混合物来制备泡沫聚合物片材；
其中混合物处于的温度并且该泡孔具有的泡孔尺寸足以使得泡沫聚合物片材具有大于或等于10％的透光率。
11.权利要求8-10中任一项的方法，其中所述片材的密度小于或等于600kg/m3。
12.权利要求8-10中任一项的方法，其中所述挤出机的冷却部分的足够的温度为180℃到260℃。
13.权利要求8-10中任一项的要求，其中与所述聚合物材料结合的发泡剂的量为0.5wt％到10wt％，基于混合物的总重量。
14.权利要求13的方法，其中发泡剂的用量为0.5wt％到5wt％。
15.权利要求8-10中任一项的方法，其中与所述聚合物材料结合的发泡剂的量为0.5wt％到4wt％的CO2，和0.25wt％到2wt％的其他发泡剂，其中重量百分比是基于混合物的总重量。
16.权利要求8或10的方法，进一步地包括将成核剂与聚合物材料结合，其中成核剂选自由如下物质组成的组：滑石、玻璃纤维、热解法二氧化硅、二氧化钛、柠檬酸和碳酸氢钠混合物、氧化锌，以及包含至少一种上述物质的组合。
17.权利要求16的方法，其中成核剂包括滑石。
18.权利要求8-10中任一项的方法，其中发泡剂是选自由如下物质组成的组：戊烷、丁烷、乙醇、异丙醇、丙酮、CO2、N2、氨气，以及包含至少一种上述物质的组合。
19.权利要求8-10中任一项的方法，其中将该混合物成型为片材包括将混合物形成为多层片材。
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US7887909B2 (en) 2011-02-15

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