CN105860229A - 一种芯层发泡复合管材及其制备工艺 - Google Patents
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Abstract
本发明公开了一种芯层发泡复合管材及其制备工艺,芯层发泡复合管材由内层材料、芯层发泡层、外层材料三层同轴依次组成;其中制备内层材料的原料包括:中密度聚乙烯,低密度聚乙烯,阻燃剂,碳酸钙,抗静电剂;制备芯层发泡层的原料包括:乙烯‑马来酸酐接枝共聚物,丁苯橡胶,发泡剂,稳定剂;制备外层材料的原料包括:聚氯乙烯,MBS树脂;制备工艺包括:内层管材挤出、芯层发泡层挤出、外层管材挤出,得到三层复合管材。本发明制备得到的芯层发泡复合管材充分地提高了发泡管材的综合性能。
Description
技术领域
本发明涉及塑料管材领域,具体涉及一种芯层发泡复合管材及其制备工艺。
背景技术
随着塑料管材应用范围和领域的不断扩大,对于塑料管材综合性能的提升和改善也越来越受到人们的重视。塑料管材的发展主要朝着高技术水平含量、高综合品质性能、高设计研发投入、低成本原料消耗等方向快速发展。在众多的新型塑料管材中,芯层发泡PVC塑料管是一种十分有前途的新型塑料管材。
芯层发泡PVC塑料管材不仅具有普通PVC塑料管材所具有的全部优点,而且还具有许多独特的优点。芯层发泡PVC材料在内外PVC表皮层中间填充了一层发泡材料,其突出的特点是材料质量轻,并且结构强度高,还很大程度上节约了原材料,降低了生产制造成本。
芯层发泡PVC材料是对传统PVC材料的结构优化和升级换代,具有非常广阔的应用环境。芯层发泡PVC材料使用寿命长、质轻强度高、耐弯折性强、抗老化性好、消音保温好,能够在建筑建材、水路管网、城市基础设施建设等领域推广使用。
中国专利CN201220416837.0公开了芯层发泡消音管,其包括:内实壁层和外实壁层,以及位于所述内外实壁层之间的低发泡芯层,所述内实壁层的内壁上设有多条螺旋凸起的导流线,所述导流线的螺旋角为75度。但是该专利仅对流通的流体而对管壁内层进行了结构优化,而未对芯层发泡消音管的综合性能进行充分提升。
中国专利CN201510796480.1公开了一种抗静电聚氯乙烯芯层发泡管,由以下重量份数组份组成:聚氯乙烯100份;发泡剂0.1~2份;泡孔改性剂2~5份;填充剂5~20份;硬脂酸添加剂0.1~1份;聚乙烯蜡0.1~1份;改性炭黑1~5份;其中,所述改性炭黑是在稀硝酸和盐酸的混合液中浸泡3min以上,并通过过滤、干燥和烘干而成。但是该专利中使用的炭黑材料在混酸中长时间浸泡,残留的混酸容易破坏芯层发泡管材的分子结构,导致其使用使用寿命明显降低。
因此需要发明一种新型芯层发泡复合管材,以充分提高发泡管材的综合性能。
发明内容
本发明针对上述问题,提供一种芯层发泡复合管材及其制备工艺。
本发明解决上述问题所采用的技术方案是:
一种芯层发泡复合管材,由内层材料、芯层发泡层、外层材料三层同轴依次组成;
其中制备内层材料的原料及其重量份包括:中密度聚乙烯50份~70份,低密度聚乙烯5份~15份,阻燃剂0.05份~0.15份,碳酸钙0.05份~0.15份,抗静电剂0.05份~0.15份;
制备芯层发泡层的原料及其重量份包括:乙烯-马来酸酐接枝共聚物60份~80份,丁苯橡胶3份~12份,发泡剂0.03份~0.09份,稳定剂0.01份~0.05份;
制备外层材料的原料及其重量份包括:聚氯乙烯80份~100份,MBS树脂0.5份~1.5份。
进一步地,阻燃剂为:二氧化硅。
更进一步地,二氧化硅的粒度为:过1500目~2000目筛。
进一步地,碳酸钙的粒度为:过2500目~3000目筛。
进一步地,抗静电剂为:聚氧化乙烯。
进一步地,发泡剂为:碳酸钙、碳酸镁、碳酸氢钠、炭黑中的任一种。
进一步地,稳定剂为:氧化钼、氧化钐、氧化铈中的任一种。
进一步地,内层材料、芯层发泡层、外层材料的厚度比为:1:3~5:1~1.5。
本发明的另一发明目的,在于提供一种上述芯层发泡复合管材的制备工艺,包括以下步骤:
步骤S1,内层管材挤出:将所述重量份的中密度聚乙烯、低密度聚乙烯、阻燃剂、碳酸钙、抗静电剂加入至料斗内,采用热熔挤出设备挤出定径做内层管材;
步骤S2,芯层发泡层挤出:将所述重量份的芯层发泡原料乙烯-马来酸酐接枝共聚物、丁苯橡胶、发泡剂、稳定剂热熔,沿内层管材外壁的轴向旋转前进,挤出成型,形成包覆内层管材的芯层发泡层;
步骤S3,外层管材挤出:将所述重量份的外层原料聚氯乙烯、MBS树脂热熔,在芯层发泡层外壁挤出成型,使其均匀裹覆在芯层发泡层外壁,得到三层复合管材。
进一步地,还包括在外层管材挤出之后将三层复合管材冷却、再次定径,得到芯层发泡复合管材的步骤。
本发明的优点是:
1.本发明制备的芯层发泡复合管材具有质轻强度高的特点,抗弯折性能好,抗冲击和拉伸性能优异,韧性大,结构坚固,并且耐温度冲击,使用寿命长;
2.本发明制备的芯层发泡复合管材输运能力强,流体流通快,能量耗散小,有利于输送各类能源资源,内层材料无毒、环保,且采用发泡层作为芯层材料,具有密度小、隔音效果好、保温效果好,成本低;
3.本发明采用的制备方法简便易操作,不需要更换新的设备,人工劳动强度低,中间环节少,有利于塑料管材的大规模批量生产。
具体实施方式
以下对本发明的实施例进行详细说明,但是本发明可以由权利要求限定和覆盖的多种不同方式实施。
实施例1
一种芯层发泡复合管材,由内层材料、芯层发泡层、外层材料三层同轴依次组成;
其中制备内层材料的原料及其重量份包括:中密度聚乙烯50份,低密度聚乙烯5份,过1500目筛的二氧化硅0.05份,过2500目筛的碳酸钙0.05份,聚氧化乙烯0.05份;
制备芯层发泡层的原料及其重量份包括:乙烯-马来酸酐接枝共聚物60份,丁苯橡胶3份,碳酸钙0.03份,氧化钼0.01份;
制备外层材料的原料及其重量份包括:聚氯乙烯80份,MBS树脂0.5份。
内层材料、芯层发泡层、外层材料的厚度比为:1:3:1。
实施例2
一种芯层发泡复合管材,由内层材料、芯层发泡层、外层材料三层同轴依次组成;
其中制备内层材料的原料及其重量份包括:中密度聚乙烯70份,低密度聚乙烯15份,过2000目筛的二氧化硅0.15份,过3000目筛的碳酸钙0.15份,聚氧化乙烯0.15份;
制备芯层发泡层的原料及其重量份包括:乙烯-马来酸酐接枝共聚物80份,丁苯橡胶12份,碳酸镁0.09份,氧化钐0.01份~0.05份;
制备外层材料的原料及其重量份包括:聚氯乙烯100份,MBS树脂1.5份。
内层材料、芯层发泡层、外层材料的厚度比为:1:5:1.5。
实施例3
一种芯层发泡复合管材,由内层材料、芯层发泡层、外层材料三层同轴依次组成;
其中制备内层材料的原料及其重量份包括:中密度聚乙烯60份,低密度聚乙烯10份,过1800目筛的二氧化硅0.1份,过2700目筛的碳酸钙0.1份,聚氧化乙烯0.1份;
制备芯层发泡层的原料及其重量份包括:乙烯-马来酸酐接枝共聚物70份,丁苯橡胶8份,炭黑0.06份,氧化铈0.03份;
制备外层材料的原料及其重量份包括:聚氯乙烯90份,MBS树脂1.0份。
内层材料、芯层发泡层、外层材料的厚度比为:1:4:1.2。
实施例4
一种芯层发泡复合管材的制备工艺,包括以下步骤:
步骤S1,内层管材挤出:将所述重量份的中密度聚乙烯、低密度聚乙烯、阻燃剂、碳酸钙、抗静电剂加入至料斗内,采用热熔挤出设备挤出定径做内层管材;从料斗到口模的温度分别设定为:40℃,160℃,160℃,165℃,168℃,170℃,176℃,178℃,175℃;
步骤S2,芯层发泡层挤出:将所述重量份的芯层发泡原料乙烯-马来酸酐接枝共聚物、丁苯橡胶、发泡剂、稳定剂热熔,沿内层管材外壁的轴向旋转前进,挤出成型,形成包覆内层管材的芯层发泡层;从料斗到口模的温度分别设定为:40℃,155℃,155℃,160℃,163℃,168℃,170℃,173℃,170℃;
步骤S3,外层管材挤出:将所述重量份的外层原料聚氯乙烯、MBS树脂热熔,在芯层发泡层外壁挤出成型,使其均匀裹覆在芯层发泡层外壁,得到三层复合管材;从料斗到口模的温度分别设定为:40℃,160℃,160℃,165℃,168℃,170℃,176℃,178℃,175℃;然后将三层复合管材冷却、再次定径,得到芯层发泡复合管材的步骤。
实施例5
一种芯层发泡复合管材的制备工艺,包括以下步骤:
步骤S1,内层管材挤出:将所述重量份的中密度聚乙烯、低密度聚乙烯、阻燃剂、碳酸钙、抗静电剂加入至料斗内,采用热熔挤出设备挤出定径做内层管材;从料斗到口模的温度分别设定为:40℃,165℃,165℃,170℃,173℃,178℃,185℃,188℃,185℃;
步骤S2,芯层发泡层挤出:将所述重量份的芯层发泡原料乙烯-马来酸酐接枝共聚物、丁苯橡胶、发泡剂、稳定剂热熔,沿内层管材外壁的轴向旋转前进,挤出成型,形成包覆内层管材的芯层发泡层;从料斗到口模的温度分别设定为:40℃,160℃,160℃,165℃,168℃,173℃,180℃,183℃,180℃;
步骤S3,外层管材挤出:将所述重量份的外层原料聚氯乙烯、MBS树脂热熔,在芯层发泡层外壁挤出成型,使其均匀裹覆在芯层发泡层外壁,得到三层复合管材;从料斗到口模的温度分别设定为:40℃,165℃,165℃,170℃,173℃,178℃,185℃,188℃,185℃;然后将三层复合管材冷却、再次定径,得到芯层发泡复合管材的步骤。
实施例6
一种芯层发泡复合管材的制备工艺,包括以下步骤:
步骤S1,内层管材挤出:将所述重量份的中密度聚乙烯、低密度聚乙烯、阻燃剂、碳酸钙、抗静电剂加入至料斗内,采用热熔挤出设备挤出定径做内层管材;从料斗到口模的温度分别设定为:40℃,162℃,162℃,167℃,171℃,176℃,181℃,186℃,184℃;
步骤S2,芯层发泡层挤出:将所述重量份的芯层发泡原料乙烯-马来酸酐接枝共聚物、丁苯橡胶、发泡剂、稳定剂热熔,沿内层管材外壁的轴向旋转前进,挤出成型,形成包覆内层管材的芯层发泡层;从料斗到口模的温度分别设定为:40℃,157℃,157℃,162℃,165℃,170℃,175℃,180℃,177℃;
步骤S3,外层管材挤出:将所述重量份的外层原料聚氯乙烯、MBS树脂热熔,在芯层发泡层外壁挤出成型,使其均匀裹覆在芯层发泡层外壁,得到三层复合管材;从料斗到口模的温度分别设定为:40℃,163℃,163℃,166℃,168℃,173℃,178℃,183℃,180℃;然后将三层复合管材冷却、再次定径,得到芯层发泡复合管材的步骤。
实验例1
对实施例1~6所制的芯层发泡复合管材的性能进行测试,测试结果如表1所示。
其中环刚度和环柔度根据GB/T9647-2003测试。抗冲击强度根据GB/T15142-2001测试。拉伸弹性模量根据ISO527-2测试。耐低温性能根据GB5470-2008测试塑料管材的脆化温度。落锤冲击试验根据GB/T14152,测试温度为0℃。
表1芯层发泡复合管材的性能测试结果
以上仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种芯层发泡复合管材,其特征在于,由内层材料、芯层发泡层、外层材料三层同轴依次组成;
其中制备所述内层材料的原料及其重量份包括:中密度聚乙烯50份~70份,低密度聚乙烯5份~15份,阻燃剂0.05份~0.15份,碳酸钙0.05份~0.15份,抗静电剂0.05份~0.15份;
制备所述芯层发泡层的原料及其重量份包括:乙烯-马来酸酐接枝共聚物60份~80份,丁苯橡胶3份~12份,发泡剂0.03份~0.09份,稳定剂0.01份~0.05份;
制备所述外层材料的原料及其重量份包括:聚氯乙烯80份~100份,MBS树脂0.5份~1.5份。
2.根据权利要求1所述的芯层发泡复合管材,其特征在于,所述阻燃剂为:二氧化硅。
3.根据权利要求2所述的芯层发泡复合管材,其特征在于,所述二氧化硅的粒度为:过1500目~2000目筛。
4.根据权利要求1所述的芯层发泡复合管材,其特征在于,所述碳酸钙的粒度为:过2500目~3000目筛。
5.根据权利要求1所述的芯层发泡复合管材,其特征在于,所述抗静电剂为:
聚氧化乙烯。
6.根据权利要求1所述的芯层发泡复合管材,其特征在于,所述发泡剂为:碳酸钙、碳酸镁、碳酸氢钠、炭黑中的任一种。
7.根据权利要求1所述的芯层发泡复合管材,其特征在于,所述稳定剂为:氧化钼、氧化钐、氧化铈中的任一种。
8.根据权利要求1所述的芯层发泡复合管材,其特征在于,所述内层材料、芯层发泡层、外层材料的厚度比为:1:3~5:1~1.5。
9.一种如权利要求1~8中任一项所述的芯层发泡复合管材的制备工艺,其特征在于,包括以下步骤:
步骤S1,内层管材挤出:将所述重量份的中密度聚乙烯、低密度聚乙烯、阻燃剂、碳酸钙、抗静电剂加入至料斗内,采用热熔挤出设备挤出定径做内层管材;
步骤S2,芯层发泡层挤出:将所述重量份的芯层发泡原料乙烯-马来酸酐接枝共聚物、丁苯橡胶、发泡剂、稳定剂热熔,沿内层管材外壁的轴向旋转前进,挤出成型,形成包覆内层管材的芯层发泡层;
步骤S3,外层管材挤出:将所述重量份的外层原料聚氯乙烯、MBS树脂热熔,在芯层发泡层外壁挤出成型,使其均匀裹覆在芯层发泡层外壁,得到三层复合管材。
10.根据权利要求9所述的制备工艺,其特征在于,还包括在外层管材挤出之后将三层复合管材冷却、再次定径,得到芯层发泡复合管材的步骤。
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