CN104309245A - 一种聚氯乙烯基包覆共挤木塑橱柜板及其制法 - Google Patents
一种聚氯乙烯基包覆共挤木塑橱柜板及其制法 Download PDFInfo
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Abstract
一种聚氯乙烯基包覆共挤木塑橱柜板,属于木塑复合材料技术领域,其特征是,它由包覆层和芯层组成,其中,所述芯层原料是:聚氯乙烯、生物质粉、无机阻燃剂、复合增塑剂、复合发泡剂、润滑型加工助剂、超高熔体强度型加工助剂、轻质碳酸钙、钙锌稳定剂、聚乙烯蜡、硬脂酸;所述包覆层的原料包括:ASA/PMMA共挤料,包覆层的厚度为0.3-0.5mm。本发明通过调整配方解决了木塑橱柜板的阻燃性、强度、芯层密度、表层色彩等问题,提高了木塑橱柜板的综合性能,拓宽了其室内外装饰装修的应用范围,使生物质粉得到更广泛的回收利用,变废为宝,保护环境。
Description
技术领域
本发明属于木塑复合材料技术领域,具体涉及一种聚氯乙烯基包覆共挤木塑橱柜板及其制法。
背景技术
目前生产橱柜的板材主要有实木板、石材板、人造板等。其中,实木板价格昂贵且消耗森林资源、石材板太重。现有技术最常用的是人造板,包括刨花板、密度板等,各种人造板基本上都是用胶黏剂制成,胶黏剂含有大量的甲醛,即使是绿色环保的胶黏剂,也有部分甲醛类有毒物质的残留,长期使用会伤害人体健康。
随着人们环保节能意识的不断提高,已经不能满足于现有的橱柜板,迫切需要一种环保节能、无毒无害的新型板材。木塑橱柜板就是符合这种需求的新型环保板材。木塑橱柜板是指以生物质粉(木粉、农业秸秆粉等)为填充材料,应用填充改性或高分子化学等手段,与热塑性塑料一起熔融、捏合、混炼,再经高温高压挤出,冷却而加工成型的一种可逆循坏利用的优质板材。该类材料具有抗酸碱,吸水率低,不易变形,机械性能好,可回收利用等优点。与现有的橱柜板材相比可一次成型,且零甲醛、防水、防潮、防霉、防蛀,具有良好的阻燃性能,其生产工艺简单、易于操作,稳定性好、易于加工,使用数年后,可100%回收再利用,是代替各种人造板的理想橱柜板。
鉴于木塑橱柜板的诸多优点,近年来木塑橱柜板市场份额增长很快,尤其表现在室内外装饰装修等。但另一方面,快速增长的市场需求同时对木塑橱柜板的性能提出了更高的要求,例如:橱柜板的阻燃性、强度、芯层密度、表层色彩等,为了提升木塑橱柜板的综合性能,拓宽其室内外装饰装修的应用范围,有必要对其配方和制备方法进行研究。
发明内容
为了解决木塑橱柜板的阻燃性、强度、芯层密度、表层色彩等问题,本发明提供了一种聚氯乙烯基包覆共挤木塑橱柜板。
本发明另一个目的是提供所述聚氯乙烯基包覆共挤木塑橱柜板的制法。
本发明采用的具体技术方案是:
一种聚氯乙烯基包覆共挤木塑橱柜板,其特征是,它由包覆层和芯层组成,其中,所述芯层由如下重量份的原料组成:
所述包覆层的原料包括:ASA/PMMA共挤料;
通过共挤工艺,包覆层包覆于芯层上,包覆层的厚度为0.3-0.5mm。
本发明中,包覆层原料与芯层的配比按照实际需要选择,包覆层的添加量只要满足其厚度为0.3-0.5mm即可。
进一步,所述包覆层中还可以包括有工艺量的着色剂,这样能获得彩色的木塑橱柜板,所述着色剂为适用的市售商品。
所述的聚氯乙烯为市售商品。
所述生物质粉颗粒为80-120目,含水率小于2%,例如:木粉、秸秆粉。
所述无机阻燃剂为氢氧化镁,其是具有阻燃、抑烟、填充三重功能的优秀阻燃剂,具有无卤、低烟、无毒、阻滴、耐酸、无味、稳定性好、不挥发、分解温度高、不腐蚀设备等特点,是有机高分子聚合物实现无卤阻燃的首选材料。氢氧化镁阻燃剂通过受热分解时释放出结合水,吸收大量的潜热来降低它所填充的合成材料在火焰中的表面温度,具有抑制聚合物分解和对所产生的可燃气体进行冷却的作用。分解生成的氧化镁又是良好的耐火材料,也能帮助提高合成材料的抗火性能。同时它放出的水蒸气也可作为一种抑烟剂。
所述复合增塑剂是合成植物脂与邻苯二甲酸二辛酯(DOP)按照重量比1:1的混合物。所述合成植物脂为二甘醇二苯甲酸脂(DEDB)其分子式是C18H18O5结构式:-COOCH2-CH2-O-CH2-CH2OOC-。由天然油脂与醇酯化生成的一类具有较高分子量新型环保无毒增塑剂,其是淡黄色油状液体,色度(APHA)≤80;密度(20℃):1.09-1.13;闪点(开口)≥195℃;加热减量(125C±1C.3h)%≤0.4;沸点280℃;着火点340℃;折光率为1.4888(20℃);挥发速度0.13~0.3mmg/cm2h100℃;酯含量(%)≥99;冷凝点-18℃。经申请人验证,本发明的复合增塑剂,增塑效率高,毒性低于DOP,热稳定时间长,与聚合物相溶性好,挥发性低,能抑制渗出,增充剂容量大,制品光亮度高等优点。该复合增塑剂能大幅度的降低企业的生产成本,提高企业产品的市场竞争力。
所述复合发泡剂为市售商品,例如:选用美国KibbeChem公司的BLA-611复合发泡剂,粒状,橘黄色,密度为0.57gm/cc,气体发生为47cc/gm。
所述润滑型加工助剂为市售商品,其是一种丙烯酸酯类共聚物(ACR),将甲基丙烯酸甲酯(MMA)、丙烯酸丁酯(BA)、苯乙烯(ST)等进行配料,然后在聚合釜中进行乳液聚合所得到的无规共聚物。其为白色粉末,表观密度0.4-0.6g/cm3,挥发物≤1.3%,特性粘度1.8-2.2。选用山东日科化学股份有限公司的HL-175,它能明显改善聚氯乙烯的加工性能,促进混合料的塑化,同时具有优异的金属剥离性,能有效地防止熔体与金属表面的粘连,从而避免出现热金属粘附现象,并提高制品的表面光泽度。
所述超高熔体强度型加工助剂为市售商品,其是一种丙烯酸酯类聚合物,将丙烯酸丁酯或者甲基丙烯酸甲酯等单体在引发剂的作用下,自我聚合形成的丙烯酸酯类单体聚合而成具有超高分子量的产品。表观密度0.35-0.55g/cm3,挥发物≤1.5%,特性粘度11-12.5。选用山东日科化学股份有限公司的HL-100,其具有超高的熔体强度,优良的制品表面光泽度。
所述轻质碳酸钙为粒径1250目,白色粉末或无色结晶、无气味、密度2.711熔点1339℃。轻质碳酸钙是一种理想的化工生产填充剂,用轻质碳酸钙做填充剂制成的成品具有防水,绝缘、美观轻便、坚固耐用、光滑等独性能,并能够降低生产成本,提高质量,增加效益。
所述钙锌复合稳定剂为硬脂酸锌和硬脂酸钙的复合物,是白色粉末状,适用于无毒环保型制品中等。钙锌稳定剂具有无毒,价廉,良好润滑性等特点,是一种高效多功能稳定剂,热稳定性和透明性优良,用于制品时不会产生表面析出及迁移现象。
所述聚乙烯蜡为一种超低分子量聚合物,具有粘度低,软化点高,硬度好等性能,无毒,热稳定性好,高温挥发性低,既有极优的外部润滑作用,又有较强的内部润滑作用,可提供加工的生产效率,耐化学药品能力强,电性能优良,可提高成品的平滑度和光泽度,改善成品外观。
所述硬脂酸的主要作用是软化增塑,作为外部润滑剂。
所述ASA共挤料是将ASA树脂、耐候着色剂、紫外吸收剂和抗氧剂等共混加工而成。其中ASA树脂是一种由丙烯腈、苯乙烯、丙烯酸酯组成的三元聚合物。所述PMMA共挤料是将PMMA树脂、增韧剂、耐候着色剂、紫外吸收剂和抗氧剂等共混加工而成。其中PMMA是由甲基丙烯酸甲酯单体聚合而成,即聚合丙烯酸甲酯。ASA/PMMA共挤料选用具有优良耐光性,耐候性,耐热性的颜料和原材料,生产出分散性,加工性能良好,耐候性强,高光泽,抗刮划的共挤料。此共挤料使用简单,只需将共挤粒料在共挤机上的单螺杆挤出机直接挤出,即可生产出耐候性强,高光亮度的共挤型材。例如可选用山东日科化学股份有限公司的ASA/PMMA共挤料。
上述聚氯乙烯基包覆共挤木塑橱柜板的制法,包括如下步骤:
1)芯层料的配制:按重量比例将生物质粉和无机阻燃剂加入高混机中混合,混合温度为105℃-110℃,混合时间为5-10分钟,然后将聚氯乙烯、轻质碳酸钙、复合增塑剂、钙锌稳定剂、聚乙烯蜡、硬脂酸、润滑型加工助剂、超高熔体强度型加工助剂、复合发泡剂等加入高混机混合,混合温度为105℃-110℃,混合时间为10-15分钟,待用。
2)将芯层料加入到锥形双螺杆主挤出机的料筒,将包覆层加入到单螺杆辅挤出机的料筒中,同时开机挤出成型,主挤出机温度在165℃-195℃之间,转速为40-50转/分钟,喂料机转速为4-5转/分钟,机头温度165℃,挤出速度600mm/min,辅挤出机温度在在175℃-215℃之间,转速为20-30转/分钟,喂料机转速为2-3转/分钟,机头温度115℃,挤出后定型冷却即可得到木塑橱柜板。
锥形双螺杆主挤出机上安装的模具不同,得到的材料厚度就不同,根据需要选择模具。包覆层的厚度根据使用要求和经济性来确定,一般不超过0.5mm。
本发明通过调整适当组分的配料,有效地解决了木塑橱柜板的阻燃性、强度、芯层密度、表层色彩等问题等问题,并得到了一种聚氯乙烯基包覆共挤木塑橱柜板,提高了木塑橱柜板的综合性能,拓宽了其室内外装饰装修的应用范围,使生物质粉得到更广泛的回收利用,变废为宝,保护环境。
本发明所使用的无机阻燃剂为氢氧化镁,其通过受热分解时释放出结合水,吸收大量的潜热来降低它所填充的合成材料在火焰中的表面温度,具有抑制聚合物分解和对所产生的可燃气体进行冷却的作用。分解生成的氧化镁又是良好的耐火材料,也能帮助提高合成材料的抗火性能。同时它放出的水蒸气也可作为一种抑烟剂。
具体实施方式
1、配方
序号 | 各组分名称 | 实施例1 | 实施例2 | 实施例3 |
1 | 聚氯乙烯 | 100 | 100 | 100 |
2 | 生物质粉 | 50 | 50 | 50 |
3 | 无机阻燃剂 | 4 | 3 | 5 |
4 | 轻质碳酸钙 | 30 | 30 | 30 |
5 | 复合发泡剂 | 2 | 1 | 3 |
6 | 复合增塑剂 | 15 | 15 | 15 |
7 | 钙锌稳定剂 | 5 | 5 | 5 |
8 | 聚乙烯蜡 | 1 | 1 | 1 |
9 | 硬脂酸 | 0.8 | 0.8 | 0.8 |
10 | 润滑型加工助剂 | 1.2 | 1.2 | 1.2 |
11 | 超高熔体强度型加工助剂 | 0.5 | 1.0 | 1.5 |
12 | 双色共挤料 | 100 | 100 | 100 |
2、制备方法
选择实施例1-3中任一项的原料配比,按照如下步骤制备:
1)芯层料的配制:按重量比例将生物质粉和无机阻燃剂加入高混机中混合,混合温度为105℃-110℃,混合时间为5-10分钟,然后将聚氯乙烯、轻质碳酸钙、复合增塑剂、钙锌稳定剂、聚乙烯蜡、硬脂酸、润滑型加工助剂、超高熔体强度型加工助剂、复合发泡剂等加入高混机混合,混合温度为105℃-110℃,混合时间为10-15分钟,待用。
2)将芯层料加入到锥形双螺杆主挤出机的料筒,将包覆层加入到单螺杆辅挤出机的料筒中,同时开机挤出成型,主挤出机温度在165℃-195℃之间,转速为40-50转/分钟,喂料机转速为4-5转/分钟,机头温度165℃,挤出速度600mm/min,辅挤出机温度在在175℃-215℃之间,转速为20-30转/分钟,喂料机转速为2-3转/分钟,机头温度115℃,挤出后定型冷却即可得到木塑橱柜板。
按照标准对复合材料测试,实施例1-3的测试结果如下:
Claims (5)
1.一种聚氯乙烯基包覆共挤木塑橱柜板,其特征是,它由包覆层和芯层组成,其中,所述芯层由如下重量份的原料组成:
所述包覆层的原料包括:ASA/PMMA共挤料;
通过共挤工艺,包覆层包覆于芯层上,包覆层的厚度为0.3-0.5mm。
2.根据权利要求1所述的聚氯乙烯基包覆共挤木塑橱柜板,其特征是,所述包覆层中还可以包括有工艺量的着色剂。
3.根据权利要求1或2所述的聚氯乙烯基包覆共挤木塑橱柜板,其特征是,所述生物质粉颗粒为80-120目,含水率小于2%;所述无机阻燃剂为氢氧化镁;所述复合增塑剂是二甘醇二苯甲酸脂与邻苯二甲酸二辛酯(DOP)按照重量比1:1的混合物;所述润滑型加工助剂为丙烯酸酯类共聚物,其为白色粉末,表观密度0.4-0.6g/cm3,挥发物≤1.3%,特性粘度1.8-2.2;所述轻质碳酸钙为粒径1250目,白色粉末或无色结晶、无气味、密度2.711熔点1339℃。
4.根据权利要求3所述的聚氯乙烯基包覆共挤木塑橱柜板,其特征是,所述二甘醇二苯甲酸脂,其分子式是C18H18O5结构式:-COOCH2-CH2-O-CH2-CH2OOC-,色度(APHA)≤80;密度(20℃):1.09-1.13;闪点(开口)≥195℃;加热减量(125C±1C.3h)%≤0.4;沸点280℃;着火点340℃;折光率为1.4888(20℃);挥发速度0.13~0.3mmg/cm2h100℃;酯含量(%)≥99;冷凝点-18℃。
5.权利要求1的聚氯乙烯基包覆共挤木塑橱柜板的制法,其特征是,包括如下步骤:
1)芯层料的配制:按权利要求1的重量比例将生物质粉和无机阻燃剂加入高混机中混合,混合温度为105℃-110℃,混合时间为5-10分钟,然后将聚氯乙烯、轻质碳酸钙、复合增塑剂、钙锌稳定剂、聚乙烯蜡、硬脂酸、润滑型加工助剂、超高熔体强度型加工助剂、复合发泡剂等加入高混机混合,混合温度为105℃-110℃,混合时间为10-15分钟,待用。
2)将芯层料加入到锥形双螺杆主挤出机的料筒,将包覆层加入到单螺杆辅挤出机的料筒中,同时开机挤出成型,主挤出机温度在165℃-195℃之间,转速为40-50转/分钟,喂料机转速为4-5转/分钟,机头温度165℃,挤出速度600mm/min,辅挤出机温度在在175℃-215℃之间,转速为20-30转/分钟,喂料机转速为2-3转/分钟,机头温度115℃,挤出后定型冷却即可得到木塑橱柜板。
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