CN105860318A - 共挤双发泡高分子复合材料地板及其加工方法 - Google Patents

共挤双发泡高分子复合材料地板及其加工方法 Download PDF

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CN105860318A
CN105860318A CN201610195722.6A CN201610195722A CN105860318A CN 105860318 A CN105860318 A CN 105860318A CN 201610195722 A CN201610195722 A CN 201610195722A CN 105860318 A CN105860318 A CN 105860318A
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薛平
高小磊
贾明印
丁筠
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Beijing University of Chemical Technology
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Abstract

本发明提供共挤双发泡高分子复合材料地板及其加工方法，所述地板包括表层和芯层，表层位于芯层的上表面和两侧的上半部分，所述表层为发泡表层，其包括如下重量百分比的材料：聚氯乙烯粉料60％，木粉30％，发泡助剂0.4‑0.7％，发泡成核剂4‑7％，色母粒3％；所述芯层为发泡芯层，其包括如下重量百分比的材料：聚氯乙烯40‑45％、钙粉10％、粉煤灰30‑35％、木粉5‑10％、发泡成核剂3‑6％、发泡剂0.4‑0.7％、交联剂0.2‑0.5％、助发泡剂1‑2％、聚乙烯蜡1‑2％。本发明具有耐磨性和抗老化性好、颜色多样和不易翘曲的优点。

Description

共挤双发泡高分子复合材料地板及其加工方法
技术领域
本发明涉及装修材料技术领域，具体涉及共挤双发泡高分子复合材料地板及其加工方法。
背景技术
现有技术中，多采用防腐木材、实木地板或木塑复合地板作为室内地板。防腐木、实木地板需要消耗大量的木材，铺设使用后耐水性差，防腐性差，且易开裂、翘曲。普通的木塑复合地板采用木屑、废旧塑料经混合挤压而成，虽具有防腐、防水等优点，但抗老化性差，面层颜色较少，易褪色，使用寿命短。
相关技术中，为解决上述问题，发明了一种成本较低的粉煤灰复合材料板材，但这种板材若不做表层处理，其颜色比较单一并且抗老化性及机械性能得不到改善，并且通常包覆层硬度及表面亮度较差，容易产生划痕，单层包覆时若表层不发泡会与发泡的芯层产生不同收缩率，从而产生板材的翘曲。
发明内容
针对上述问题，本发明提供了一种共挤双发泡高分子复合材料地板及其加工方法，解决上述地板耐磨性和抗老化性差、颜色单一和易翘曲的问题。
本发明的目的采用以下技术方案来实现：
提供了共挤双发泡高分子复合材料地板，包括表层和芯层，表层位于芯层的上表面和两侧的上半部分，所述表层为发泡表层，其包括如下重量百分比的材料：聚氯乙烯粉料60％，木粉30％，发泡助剂0.4-0.7％，发泡成核剂4-7％，色母粒3％；所述芯层为发泡芯层，其包括如下重量百分比的材料：聚氯乙烯40-45％、钙粉10％、粉煤灰30-35％、木粉5-10％、发泡成核剂3-6％、发泡剂0.4-0.7％、交联剂0.2-0.5％、助发泡剂1-2％、聚乙烯蜡1-2％。
其中，所述表层和芯层通过共挤复合一次性连续成型。
其中，所述表层的厚度范围为1.5-2.0mm。
优选地，所述发泡成核剂为超细活性碳酸钙，发泡剂为偶氮二甲酰胺，助发泡剂为ZnO。
本发明还提供了上述任一项所述的共挤双发泡高分子复合材料地板的加工方法，所述方法包括以下步骤：
(1)将表层材料按比例称取后加入到高速混合机，高速混合7-10min后，经过锥形双螺杆挤出机造粒，然后排放到表层贮料仓；
(2)将芯层材料按比例称取后加入到高速混合机中高速混合10-15min，控制混合温度不超过110℃，然后排放到冷却混合机中进行冷却混合至40℃以下，最后排放到芯层贮料仓；
(3)添加不同颜色的色母粒至表层贮料仓的表层材料中；
(4)将表层贮料仓的表层材料通过第一挤出机进行熔融塑化，将芯层贮料仓的芯层材料通过第二挤出机进行熔融塑化，塑化后的表层材料和芯层材料由模具分配器分配后通过共挤板材模具进行复合，所述芯层材料及表层均离模后同时发泡膨胀；
(5)将复合后的表层材料和芯层材料通过定型台冷却定型后通过表面压花机和牵引机，再通过自动定长切割装置进行定长切割，得到共挤双发泡高分子复合材料地板。
其中，所述芯层和表层的厚度通过所述共挤板材模具的模唇间隙进行调整。
优选地，所述第一挤出机为Φ45型单螺杆挤出机，所述第二挤出机为SJSZ65/132型锥形双螺杆挤出机。
其中，所述Φ45型单螺杆共挤机的温度设定为：固体输送段160℃、压缩段170℃、熔融段200℃、计量段190℃；所述SJSZ65/132型锥形双螺杆挤出机的温度设定为：固体输送段185℃、压缩段180℃、排气段175℃、计量段175℃、合流芯170℃；所述共挤板材模具的温度设定为：180℃。
本发明的有益效果为：
1、采用共挤复合工艺，芯层表层双发泡，表层发泡结皮，可以提高表面强度，硬度高，不易产生划痕，提高耐磨性和抗老化性；
2、表层材料中采用了聚氯乙烯粉料与木粉，可以使表层发泡结皮，提高亮度，且表面可以产生木纹效果；
3、可通过共挤板材模具的模唇间隙进行芯层和表层的厚度调整，从而避免板材产生翘曲；
4、采用聚氯乙烯、粉煤灰和木粉作为芯层材料的主要材料，尤其是工业废弃物粉煤灰的添加量可达到45％，能有效降低产品成本，并且变废为宝，实现资源的循环利用。
附图说明
利用附图对本发明作进一步说明，但附图中的实施例不构成对本发明的任何限制，对于本领域的普通技术人员，在不付出创造性劳动的前提下，还可以根据以下附图获得其它的附图。
图1本发明共挤双发泡高分子复合材料地板的结构示意图；
图2是本发明的制备工艺流程图。
附图标记：
1-表层；2-芯层。
具体实施方式
结合以下实施例对本发明作进一步描述。
实施例1：
参见图1，双发泡共挤高分子复合材料地板包括一体成型的表层1和芯层2，所述表层1包括如下重量百分比的材料：聚氯乙烯粉料60％、聚乙烯蜡1％、无机着色剂4％，、泡剂成核剂3％、发泡剂0.5％、交联剂0.5％、助发泡剂1％、木粉30％；所述芯层2包括如下重量百分比的材料：聚氯乙烯40％、木粉6％、粉煤灰45％、超细活性碳酸钙6％、偶氮二甲酰胺0.7％、DCP0.3％、ZnO1％、聚乙烯蜡1％。
参见图2，所述双发泡共挤高分子复合材料地板的加工方法如下：
(1)将表层材料按比例称取后加入到高速混合机，高速混合7-10min后，经锥形双螺杆挤出机造粒，之后排放到表层贮料仓，经弹簧上料器自动上料至表层加工用的Φ45型单螺杆挤出机的加料斗中；
(2)将芯层材料按比例称取后加入到高速混合机中高速混合15min，控制混合温度为110℃，然后排放到冷却混合机中进行冷却混合至40℃以下，最后排放到芯层贮料仓；
(3)将混合好的表层材料和芯层材料分别通过Φ45型单螺杆挤出机和SJSZ65/132型锥形双螺杆挤出机熔融塑化，塑化后的表层材料和芯层材料由模具分配器分配后通过共挤板材模具进行复合，芯层材料及表层材料均离模后同时发泡膨胀，芯层和表层厚度可以通过共挤板材模具的模唇间隙进行调整；所述Φ45型单螺杆挤出机的温度设定为：固体输送段160℃、压缩段170℃、熔融段200℃、计量段190℃，所述SJSZ65/132型锥形双螺杆挤出机的温度设定为：固体输送段185℃、压缩段180℃、排气段175℃、计量段175℃、合流芯170℃；所述共挤板材模具的温度设定为：180℃。
(4)表层材料和芯层材料通过共挤板材模具复合后，通过定型台冷却定型，之后通过表面压花机和牵引机，最后通过自动定长切割装置定长切割，得到双发泡共挤高分子复合材料地板。
本实例制备出的共挤复合材料地板，表层厚度为1.5mm，密度为0.9g/cm3，弯曲破坏载荷为2800N，吸水率为0.5％，低温落锤冲击为-10℃无裂纹，表面耐磨达0.05(g/100r)。
实施例2：
双发泡共挤高分子复合材料地板包括表层1和芯层2，所述表层1包括如下重量百分比的材料：经过改性后聚氯乙烯粉料70％、聚乙烯蜡2％、无机着色剂3％，、泡剂成核剂5％、发泡剂0.7％、交联剂0.5％、助发泡剂2％、木粉20％：芯层材料配比：聚氯乙烯40％、木粉10％、粉煤灰40％、超细活性碳酸钙5％、偶氮二甲酰胺0.6％、DCP0.4％、ZnO2％、聚乙烯蜡2％。
双发泡共挤高分子复合材料地板加工方法如下：
(1)将表层材料按比例称取后加入到高速混合机，高速混合7-10min后，经锥形双螺杆挤出机造粒，之后排放到表层贮料仓，经弹簧上料器自动上料至表层加工用Φ45型单螺杆挤出机的加料斗中；
(2)将芯层材料按比例称取后加入到高速混合机中高速混合15min，控制混合温度为110℃，然后排放到冷却混合机中进行冷却混合至40℃以下，最后排放到芯层贮料仓；
(3)将混合好的表层材料和芯层材料分别通过Φ45型单螺杆挤出机和SJSZ65/132型锥形双螺杆挤出机熔融塑化，塑化后的表层材料和芯层材料由模具分配器分配后通过共挤板材模具进行复合，芯层物料及表层材料均离模后同时发泡膨胀，芯层和表层厚度可以通过共挤板材模具的模唇间隙进行调整；表层材料加工用Φ45型单螺杆挤出机的温度设定为：固体输送段160℃、压缩段170℃、熔融段200℃、计量段190℃，芯层材料加工用SJSZ65/132型锥形双螺杆挤出机的温度设定为：固体输送段185℃、压缩段180℃、排气段175℃、计量段175℃、合流芯170℃；所述共挤板材模具的温度设定为：180℃。
(4)表层材料和芯层材料通过共挤板材模具复合后，通过定型台冷却定型，之后通过表面压花机和牵引机，最后通过自动定长切割装置定长切割，得到双发泡共挤高分子复合材料地板。
本实例制备出的共挤复合材料地板，表层厚度为2mm，密度为0.8g/cm3，弯曲破坏载荷为2600N，吸水率为0.7％，低温落锤冲击为-10℃无裂纹，表面耐磨达0.05(g/100r)。
最后应当说明的是，以上实施例仅用以说明本发明的技术方案，而非对本发明保护范围的限制，尽管参照较佳实施例对本发明作了详细地说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的实质和范围。

Claims (8)

1.共挤双发泡高分子复合材料地板，包括表层和芯层，表层位于芯层的上表面和两侧的上半部分，其特征在于，所述表层为发泡表层，其包括如下重量百分比的材料：聚氯乙烯粉料60％，木粉30％，发泡助剂0.4-0.7％，发泡成核剂4-7％，色母粒3％；所述芯层为发泡芯层，其包括如下重量百分比的材料：聚氯乙烯40-45％、钙粉10％、粉煤灰30-35％、木粉5-10％、发泡成核剂3-6％、发泡剂0.4-0.7％、交联剂0.2-0.5％、助发泡剂1-2％、聚乙烯蜡1-2％。
2.根据权利要求1所述的共挤双发泡高分子复合材料地板，其特征在于，所述表层和芯层通过共挤复合一次性连续成型。
3.根据权利要求1所述的共挤双发泡高分子复合材料地板，其特征在于，所述表层的厚度范围为1.5-2.0mm。
4.根据权利要求1所述的共挤双发泡高分子复合材料地板，其特征在于，所述发泡成核剂为超细活性碳酸钙，发泡剂为偶氮二甲酰胺，助发泡剂为ZnO。
5.根据权利要求1-4任一项所述的共挤双发泡高分子复合材料地板的加工方法，其特征在于，包括以下步骤：
(1)将表层材料按比例称取后加入到高速混合机，高速混合7-10min后，经过锥形双螺杆挤出机造粒，然后排放到表层贮料仓；
(2)将芯层材料按比例称取后加入到高速混合机中高速混合10-15min，控制混合温度不超过110℃，然后排放到冷却混合机中进行冷却混合至40℃以下，最后排放到芯层贮料仓；
(3)添加不同颜色的色母粒至表层贮料仓的表层材料中；
(4)将表层贮料仓的表层材料通过第一挤出机进行熔融塑化，将芯层贮料仓的芯层材料通过第二挤出机进行熔融塑化，塑化后的表层材料和芯层材料由模具分配器分配后通过共挤板材模具进行复合；
(5)将复合后的表层材料和芯层材料通过定型台冷却定型后通过表面压花机和牵引机，再通过自动定长切割装置进行定长切割，得到共挤双发泡高分子复合材料地板。
6.根据权利要求5所述的共挤双发泡高分子复合材料地板的加工方法，其特征在于，所述芯层和表层的厚度通过所述共挤板材模具的模唇间隙进行调整。
7.根据权利要求5所述的共挤双发泡高分子复合材料地板的加工方法，其特征在于，所述第一挤出机为Φ45型单螺杆挤出机，所述第二挤出机为SJSZ65/132型锥形双螺杆挤出机。
8.根据权利要求7所述的共挤双发泡高分子复合材料地板的加工方法，其特征在于，所述Φ45型单螺杆共挤机的温度设定为：固体输送段160℃、压缩段170℃、熔融段200℃、计量段190℃；所述SJSZ65/132型锥形双螺杆挤出机的温度设定为：固体输送段185℃、压缩段180℃、排气段175℃、计量段175℃、合流芯170℃；所述共挤板材模具的温度设定为：180℃。
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