CN103739944A - 一种低气味玻纤增强聚丙烯复合材料及其制备方法 - Google Patents

一种低气味玻纤增强聚丙烯复合材料及其制备方法 Download PDF

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CN103739944A
CN103739944A CN201310660155.3A CN201310660155A CN103739944A CN 103739944 A CN103739944 A CN 103739944A CN 201310660155 A CN201310660155 A CN 201310660155A CN 103739944 A CN103739944 A CN 103739944A
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composite material
glass fiber
polypropylene composite
fiber reinforced
polypropylene
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CN103739944B (zh
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肖华明
刘乐文
陈国雄
宋晓东
李晟
张春怀
李欣
陶四平
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Kingfa Science and Technology Co Ltd
Tianjin Kingfa Advanced Materials Co Ltd
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Tianjin Kingfa Advanced Materials Co Ltd
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Abstract

本发明公开了一种低气味玻纤增强聚丙烯复合材料及其制备方法，包含组分：聚丙烯树37-83%；相容剂2-10%；玻璃纤维5-40%；矿物填料0-20%；水母粒0.5-5%；助剂0.1-3%；其制备方法是将聚丙烯树脂、相容剂、矿物填料和助剂在高混机里混合1-3min；混合均匀，置于双螺杆挤出机的主喂料口中，从侧喂料口加入水母粒，玻璃纤维也从挤出机的侧喂料口喂入，熔融挤出，造粒干燥，即得。本发明使用以高熔体发泡PP为载体的水母粒作为气提剂，可以有效去除加工过程中产生的各种挥发性小分子和有机化合物，所制备的玻纤增强聚丙烯复合材料具有低气味、机械强度高等特点。

Description

一种低气味玻纤增强聚丙烯复合材料及其制备方法
技术领域
本发明涉及一种玻纤增强聚丙烯复合材料，具体涉及一种低气味玻纤增强聚丙烯复合材料及其制备方法。
背景技术
玻纤增强聚丙烯具有机械强度高、耐热性好、耐化学腐蚀、尺寸稳定等优点，广泛应用于家用电器、汽车、机械等领域。玻纤增强聚丙烯的强度和模量能够媲美工程塑料，这进一步扩展了增强聚丙烯的应用前景。应用于汽车内饰件的玻璃纤维材料在应用过程中，除了要求具有良好的力学性能、加工性能、耐候性能外，还要有良好的低挥发性，其中气味要求是挥发性物质评价之一。
玻纤增强聚丙烯材料气味产生的原因是多方面的。首先，基体聚丙烯树脂在合成过程中使用的引发剂和催化剂体系本身含有刺激气味的化合物，而且，聚丙烯基体在进行改性的过程中，熔融状态的聚丙烯会发生自氧化降解，产生某些低分子化合物，这些物质包含在改性后的材料中，在成型制件及制件的使用过程中散发出来，产生更多的气味。其次，复合玻纤增强聚丙烯材料中的相溶剂组分一般使用一些酸酐类接枝物，其本身以及接枝过程中的小分子也具有刺激性气味。再者，玻纤增强聚丙烯材料中的无碱玻纤也会含有某些带有气味的杂质，同时为了满足各种要求，往往添加无机填料、弹性体、抗氧剂、耐划伤剂等物质。这些材料在加工过程中也会产生挥发性物质。如果气味大，将会严重污染车内空气，影响驾乘人员的身体健康。
减少气味可以采取下面几种措施：1、用低气味替代品来替代那些难闻的添加剂；2、采用更为纯净的树脂；3、加入吸附剂，包括化学反应及物理吸附方法。化学反应方法是指一些能与有气味小分子物质反应的添加剂，这些添加剂和小分子反应，产生分子链大、在一般环境中不能挥发出来的另一种化合物，从而消除气味，例如蓖麻油酸锌是通过螯合醛酮分子来降低气味的。而对于物理吸附来说，理论上讲，大量的空洞可以对任何产生气味或其他挥发份的小分子进行吸附，目前常用的物理吸附剂包括活性炭、硅胶、凹凸棒、粘土矿物体系、分子筛、沸石、硅灰石、膨润土等。
专利200510026760.0提到气味为树脂原材料、稳定剂、矿物填料以及加工裂解产生的，气味解决方法：纳米氧化锌和纳米二氧化钛。专利CN101817953B添加了气味吸附剂制备了一种低散发的改性聚丙烯复合材料，气味吸附剂包括：粘土，膨润土，多孔二氧化硅，活性氧化铝或分子筛。专利 CN102030945A添加了一种气味抑制剂来制备一种低气味的玻璃增强复合材料，其气味抑制剂为蓖麻油酸锌，金属氧化物及粘土矿物复配而成。
上述方法对聚丙烯材料的气味问题均由不同程度的解决，然而，上述方法仅仅是针对某一组份对气味的影响，从而添加吸附剂来降低气味，但实际上内饰件材料气味是多种组分气味相互作用的结果。因此，开发一种能够全面解决各种气味问题的聚丙烯复合材料显得尤为重要。
发明内容
为了克服上述现有技术的缺陷，本发明的首要目的在于提供一种低气味玻纤增强聚丙烯复合材料，该组合物通过添加水母粒，能有效去除加工过程中产生的各种挥发性小分子和有机化合物，同时不影响材料的机械性能。
本发明的另一目的在于提供一种上述低气味玻纤增强聚丙烯复合材料的制备方法。
本发明是通过以下技术方案实现：
一种低气味玻纤增强聚丙烯复合材料，按重量百分比计，包含以下组分： 
聚丙烯树脂                        37-83%；
相容剂                            2-10%；
玻璃纤维                          5-40%；
矿物填料                          0-20%
水母粒                            0.5-5%；
助剂                              0.1-3%；
  其中，所述水母粒按重量百分比计，包括以下组分：
聚丙烯                          1%-49%；
水                              50%-98%；
矿物填料                        0.1-5%；
本发明所述的水母粒，是由聚丙烯，矿物填料和水组成的复合物，该复合物含水量≥50%，优选60-90%。所述聚丙烯为高熔体强度聚丙烯，其熔体强度≥5cN。其中，熔体强度测试条件为：在190℃的实验温度下，使用长径比为10:1的毛细管口模，口模到滚轮的距离为24cm，柱塞下降速度为0.10mm/s，牵引滚轮的加速度为5mm/s2。
所述水母粒的制备方法，包括如下步骤：
（1）将聚丙烯与矿物填料按配比进行充分的混合，在挤出机中挤出条状聚丙烯，再将其切碎成聚丙烯预发泡颗粒；
（2）以水为发泡剂，将聚丙烯预发泡颗粒进行发泡，制备得到高熔体强度的发泡聚丙烯；
（3）将高熔体强度的发泡聚丙烯和水在高速混合器中混5-10min，制备得到水母粒，放出待用。 
本发明的水母粒加入量优选0.5-5%，加入过多的水母粒，水母粒会在螺杆中沸腾，从而不利于生产。
所述聚丙烯树脂为均聚PP和/或共聚PP的一种或几种，其熔体流动速率在230℃、2.16kg条件下为1-90g/10min。
所述相容剂为聚丙烯与不饱和酸或不饱和酸酐的接枝物，其接枝率为0.3-1.2%，熔融指数在190℃、2.16kg条件下为50-120g/10min。所述不饱和酸或不饱和酸酐为马来酸、丙烯酸、衣康酸、马来酸酐、丙烯酸缩水甘油脂中的一种或几种。
所述玻璃纤维为长玻璃纤维或短切玻璃纤维的一种或几种的混合。
优选的，所述长玻璃纤维为无碱玻璃纤维，直径为10-16μm；所述短切玻璃纤维的长度为0.2-10mm，直径为8-20μm。
所述矿物填料为滑石粉、碳酸钙、硫酸钡中的一种或一种以上的混合物。
本发明组合物还包括0.1-3%（重量百分比）的助剂，所述助剂为热稳定剂、光稳定剂、加工助剂、色粉或颜料中的一种或几种的混合。由于本发明为汽车内饰用聚丙烯组合物，可根据不同汽车内饰的结构、技术要求等对上述助剂进行单独使用，或者复合使用。热稳定剂可以提高材料在加工和使用过程中的耐热老化性能，通常可选自酚类、亚磷酸酯类、硫代酯类中的一种以上。光稳定剂可以提高材料在使用过程中的耐光老化性能，可为受阻胺类或紫外线吸收剂。加工助剂为低分子酯类硬脂酸、金属皂（Cast、Znst）、硬脂酸复合酯或酰胺类（芥酸酰胺）中的一种以上。
本发明所述的低气味玻纤增强聚丙烯复合材料的制备方法，包括以下步骤：
（1）按重量百分比称取聚丙烯树脂、相容剂、矿物填料和助剂在高混机里混合1-3min；混合均匀，得到预混料；
（2）将预混料置于双螺杆挤出机的主喂料口中，从侧喂料口加入水母粒，玻璃纤维也从挤出机的侧喂料口喂入，熔融挤出，造粒干燥，即得。
本发明与现有技术相比，具有如下有益效果：
1)本发明使用以高熔体发泡PP为载体的水母粒作为气提剂，可以有效去除加工过程中产生的各种挥发性小分子和有机化合物，所制备的玻纤增强聚丙烯复合材料具有低气味、机械强度高的特性；
2) 本发明使用的水母粒简单易得，制备工艺简单，成本低，能有效去除气味的同时，而又
不影响组合物的机械性能；
3）本发明提出的低气味玻纤增强聚丙烯复合材料的制备方法简单易行，采取侧喂料加料的
方式加入水母粒，避免了从主喂料加入时而导致水母粒中的水分过早挥发的问题，能更加有效的去除气味。 
具体实施方式
下面通过具体实施方式来进一步说明本发明，以下实施例为本发明较佳的实施方式，但本发明的实施方式并不受下述实施例的限制。 
以下实施例和对比例中，挤出机熔融挤出的加工条件如下：一区温度210-230℃，二区温度220-240℃，三区温度220-240℃，四区温度220-240℃，五区温度230-250℃，六区温度240-260℃，七区温度230-250℃，八区温度220-240℃，九区温度200-220℃，主机转速250-600转/分钟。
长玻璃纤维：选自巨石集团的通用长玻纤，纤维直径为13μm ，线密度为2000tex，型号为ER13-2000-988A；
短切玻璃纤维：选自美国OCV公司生产的玻纤147A系列，其玻璃纤维的长度为4mm，直径为14μm。
水母粒的制备：
将不同熔体强度的高熔体强度聚丙烯与矿物填料（滑石粉、碳酸钙或硫酸钡）按表1所示配比进行充分的混合，在挤出机中挤出条状聚丙烯，再将其切碎成聚丙烯预发泡颗粒；以水为发泡剂，将聚丙烯预发泡颗粒进行发泡，制备得到高熔体强度的发泡聚丙烯；将高熔体强度的发泡聚丙烯和水在高速混合器中混5-10min，通过控制混合时间，制备得到如表1所示含水量的水母粒，放出待用。
表1 水母粒的各组分含量（重量百分比）
Figure 2013106601553100002DEST_PATH_IMAGE001
实施例1-5
一种低气味玻纤增强聚丙烯复合材料，其原料配方如表3所示，其制备方法包括以下步骤：
（1）按重量百分比称取好聚丙烯、相容剂、矿物填料和助剂，在高混机里混合1-3min；混合均匀，得到预混料；
（2）将预混料置于双螺杆挤出机的主喂料口中，从侧喂料口加入水母粒，玻璃纤维也从挤出机的侧喂料口喂入，熔融挤出，造粒干燥。其性能测试如表4所示。
其中，实施例1中共聚聚丙烯：选自新加坡聚烯烃公司的AS164(熔体流动速率（230℃/2.16kg）为1.5g/10min)；均聚聚丙烯选自Moplen的EP540V(熔体流动速率（230℃/2.16kg）为87g/10min)。
实施例2中均聚聚丙烯：选自中石化茂名的HC9012-M(熔体流动速率（230℃/2.16kg）为10g/10min)。
实施例3中共聚聚丙烯选自中海壳牌的EP300M (熔体流动速率（230℃/2.16kg）为10g/10min)。
实施例4中共聚聚丙烯选自韩国油化的HJ4045(熔体流动速率（230℃/2.16kg）为45g/10min)。
实施例5中共聚聚丙烯选自中海壳牌的EP300M (熔体流动速率（230℃/2.16kg）为10g/10min)；均聚聚丙烯选自中海壳牌的HP550J(熔体流动速率（230℃/2.16kg）为3g/10min)。
对比例1
一种玻纤增强聚丙烯复合材料，其原料配方如表3所示，其制备方法包括以下步骤：
（1）按重量百分比称取好聚丙烯、相容剂、矿物填料，水母粒和助剂，在高混机里混合1-3min；混合均匀，得到预混料；
（2）将预混料置于双螺杆挤出机的主喂料口中，玻璃纤维从挤出机的侧喂料口喂入，熔融挤出，造粒干燥。
对比例2
一种玻纤增强聚丙烯复合材料，其原料配方如表3所示，其制备方法包括以下步骤：
（1）按重量百分比称取好聚丙烯、相容剂、矿物填料和助剂，在高混机里混合1-3min；混合均匀，得到预混料；
（2）将预混料置于双螺杆挤出机的主喂料口中，玻璃纤维从挤出机的侧喂料口喂入，熔融挤出，造粒干燥。
对比例3
一种玻纤增强聚丙烯复合材料，其原料配方如表3所示，其制备方法同对比例2。
对比例4
一种玻纤增强聚丙烯复合材料，其原料配方如表3所示，其制备方法同实施例1。
实施例和对比例得到的聚丙烯复合材料采用以下方法测试其相关性能：
（1）气味测定标准：按德国大众汽车公司VW′s PV3900E标准，采用1~6级评价，级别越高，气味越大。具体规定如表2
表2 大众汽车公司VW′s PV3900E标准
Figure 327709DEST_PATH_IMAGE002
（2）力学性能：分别按如下标准进行测试
a拉伸强度：按ISO527测试；速度为50mm/min；
b悬臂梁缺口冲击强度：按ISO180测试；
c弯曲强度，弯曲模量：按ISO178测试，速度为2mm/min；
d断裂伸长率：按ISO527测试。
表3  实施例和对比例的聚丙烯复合材料的原料配方（按重量百分比）
Figure 979271DEST_PATH_IMAGE003
表4  实施例和对比例的聚丙烯复合材料的性能数据
Figure 2013106601553100002DEST_PATH_IMAGE004
由实施例2与对比例2,实施例3与对比例3对比可以看出，以高熔体发泡PP为载体的水母粒的加入，确实可以有效去除聚丙烯复合材料中的各种挥发性小分子和有机化合物。本发明制备的的玻纤增强聚丙烯复合材料，具有低气味、机械强度高的特点。
另外，由实施例1和对比例1对比可以看出，对比例1采取主喂料加料方式加入水母粒，实施例1采取侧喂料加料的方式，其效果更佳优异；这是因为从主喂料加入会导致水母粒中的水分会过早挥发掉，影响其效果。
实施例4与对比例4比较，对比例4水母粒的含水量较低，制备的玻纤增强聚丙烯复合材料气味较差。

Claims (13)

1. 一种低气味玻纤增强聚丙烯复合材料，其特征在于：按重量百分比计，包含以下组分： 
聚丙烯树脂                        37-83%；
相容剂                            2-10%；
玻璃纤维                          5-40%；
矿物填料                          0-20%
水母粒                            0.5-5%；
助剂                              0.1-3%；
  其中，所述水母粒按重量百分比计，包括以下组分：
聚丙烯                          1%-49%；
水                              50%-98%；
矿物填料                        0.1-5%；
所述聚丙烯为高熔体强度聚丙烯,其熔体强度≥5cN。
2.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述聚丙烯树脂为均聚PP和/或共聚PP的一种或几种，其熔体流动速率在230℃、2.16kg条件下为1-90g/10min。
3.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述相容剂为聚丙烯与不饱和酸或不饱和酸酐的接枝物，其接枝率为0.3-1.2%，熔融指数在190℃、2.16kg条件下为50-120g/10min。
4.根据权利要求3所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述不饱和酸或不饱和酸酐为马来酸、丙烯酸、衣康酸、马来酸酐、丙烯酸缩水甘油脂中的一种或几种。
5.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述玻璃纤维为长玻璃纤维或短切玻璃纤维的一种或几种的混合。
6.根据权利要求5所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述长玻璃纤维为无碱玻璃纤维，直径为10-16μm；所述短切玻璃纤维的长度为0.2-10mm，直径为8-20μm。
7.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述矿物填料为滑石粉、碳酸钙、硫酸钡中的一种或一种以上的混合物。
8.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述助剂为热稳定剂、光稳定剂、加工助剂、色粉或颜料中的一种或几种的混合。
9.根据权利要求8所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述热稳定剂为酚类、亚磷酸酯类、硫代酯类中的一种以上；所述光稳定剂为受阻胺类或紫外线吸收剂中的一种或几种的混合；所述加工助剂为低分子酯类硬脂酸、金属皂、硬脂酸复合酯或酰胺类中的一种以上。
10.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述水母粒中含水量为60-90%。
11.根据权利要求1所述的低气味玻纤增强聚丙烯复合材料，其特征在于：所述水母粒的制备方法，包括如下步骤：
（1）将聚丙烯与矿物填料按配比进行充分的混合，在挤出机中挤出条状聚丙烯，再将其切碎成聚丙烯预发泡颗粒；
（2）以水为发泡剂，将聚丙烯预发泡颗粒进行发泡，制备得到高熔体强度的发泡聚丙烯；
（3）将高熔体强度的发泡聚丙烯和水在高速混合器中混5-10min，制备得到不同含水量的水母粒，放出待用。 
12.权利要求1~11任一项所述的低气味玻纤增强聚丙烯复合材料的制备方法，其特征在于：包括以下步骤：
（1）按重量百分比称取聚丙烯树脂、相容剂、矿物填料和助剂在高混机里混合1-3min；混合均匀，得到预混料；
（2）将预混料置于双螺杆挤出机的主喂料口中，从侧喂料口加入水母粒，玻璃纤维也从挤出机的侧喂料口喂入，熔融挤出，造粒干燥，即得。
13.根据权利要求12所述的低气味玻纤增强聚丙烯复合材料的制备方法，其特征在于：所述熔融挤出的加工条件为：一区温度210-230℃，二区温度220-240℃，三区温度220-240℃，四区温度220-240℃，五区温度230-250℃，六区温度240-260℃，七区温度230-250℃，八区温度220-240℃，九区温度200-220℃，主机转速250-600转/分钟。
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