CN106977835A - 硬质聚氯乙烯复合材料及其加工方法 - Google Patents

硬质聚氯乙烯复合材料及其加工方法 Download PDF

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Publication number
CN106977835A
CN106977835A CN201710029136.9A CN201710029136A CN106977835A CN 106977835 A CN106977835 A CN 106977835A CN 201710029136 A CN201710029136 A CN 201710029136A CN 106977835 A CN106977835 A CN 106977835A
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China
Prior art keywords
parts
rpvc
base material
formula
layer
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CN201710029136.9A
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English (en)
Inventor
刘辉煌
黄荣泰
刘东岳
刘国俊
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SHANGHAI XIECHENGCHANG CHEMICAL CO Ltd
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SHANGHAI XIECHENGCHANG CHEMICAL CO Ltd
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Publication of CN106977835A publication Critical patent/CN106977835A/zh
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    • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
    • C09D175/04—Polyurethanes
    • C09D175/14—Polyurethanes having carbon-to-carbon unsaturated bonds
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Abstract

本发明公开了一种硬质聚氯乙烯复合材料，该硬质聚氯乙烯复合材料的配方，按重量计含有以下组分：聚氯乙烯75‑125份、氯化聚乙烯1‑5份、珍珠岩50‑80份、轻质碳酸钙160‑190份、稳定剂2‑6份、硬脂酸0.2‑1份和ACR改性剂0.5‑3.5份。本发明制得的基材硬度较强，具有良好的抗弯曲性能，极大的拓展了PVC基材的使用范围，且使用寿命延长；本发明制得的基材不含增塑剂，安全无害；本发明的配方中使用珍珠岩和轻质碳酸钙，在保持高性能的基础上，降低了产品的重量。

Description

硬质聚氯乙烯复合材料及其加工方法
技术领域
本发明涉及板材领域，尤其涉及一种不含增塑剂的硬质聚氯乙烯复合材料及其制得的板材及其加工方法。
背景技术
板材，例如地板、墙板、天花板等，被大量地使用在建筑装修中。随着人们生活水平、健康和环保意识的提高，人们既希望所用的板材具有优良的实用性能，又希望其健康无毒，长期使用过程中没有有害物质逸出。
实木板材，例如实木地板，由实木直接加工制成。虽然其具有美观的自然木纹、舒适的脚感和良好的隔热性，但是其成本高，容易伸缩变形甚至开裂，且耐磨耐热性能较差，也不利于森林资源的可持续发展。
为降低成本并提高板材性能，本领域技术人员采用PVC(聚氯乙烯)、LVT(石塑地板)等作为基材。作为层压板材的基材使用最多的当属PVC，因为PVC具有低廉的价格和优良的物理、化学性能。
中国专利CN103724863A公开了一种硬质PVC板，其中各组分的重量含量为：PVC100份、稳定剂8份、石英粉5份、竹纤维12份、玻纤维12份、纳米碳酸钙10份、轻质活性碳酸钙6份、氯化钙5份、钛白粉2份、糖蛋白2份、加工助剂2份。
中国专利CN103772852 A也公开了一种硬质PVC扣板，由下述重量份的原料组成的：PVC树脂80-90、环烷酸锌0.2-1、硼砂2-3、聚苯并咪唑纤维3-5、重质碳酸钙10-17、硅酸钠1-2、壳聚糖1-2、膨胀珍珠岩2-3、芬苯达唑0.2-0.5、辛基硫醇锡0TM-17N0.4-1、尾砂1-2、双十四碳醇酯2-4、醋酸丁酸纤维素1-2、改性助剂10-17。
现有技术中的PVC板材配方用到的利于硬度的原料含量较少，导致最终的产品硬度不够，不适合某些场合的装饰使用，例如：厨房等温度较高的地方。
为了增加PVC板材柔韧性并延长使用寿命，往往会使用增塑剂，例如对苯二甲酸二丁酯、邻苯二甲酸二辛酯等。地板的增塑剂含量虽不大，但随着长期使用，增塑剂往往会逐渐迁移至材料表面而逸出，对人们的健康造成一定的危害。
另外，目前市场上的PVC板材经常会出现“翘曲”现象(板材面积越大，此缺点越明显)，特别是多层板材，其通过粘结的方式结合，会导致稳定性不好，且通过粘结的方式会使用胶水，可能存在甲醛，不符合环保的要求，时间久了，胶水粘结处容易开裂。
鉴于以上情况，本领域技术人员致力于开发一种具有高性能，特别是具有理想硬度且不含增塑剂的PVC板材。另外，在保证板材具有理想硬度的前提下，同时要求板材尽可能轻质化。
发明内容
有鉴于现有技术的上述缺陷，本发明提供了一种硬度良好、不含增塑剂且轻质化的PVC基材，以及由其制得的具有功能层的板材。
本申请的发明人，在研究PVC复合材料的过程中，进行大量的实验，最终发现硬脂酸和ACR改性剂的共同使用能够替代现有配方中的增塑剂。硬脂酸的加入可以减少聚合物分子间的内聚力，降低其熔体粘度，从而削弱聚合物间的内摩擦；ACR为甲基丙烯酸甲酯、丙烯酸酯等单体的共聚物，它可使材料的抗冲击强度增大几十倍。
硬脂酸和ACR改性剂的共同使用不仅替代了现有的增塑剂，并且结合PVC复合材料中其他组分的使用，还大大改善了PVC复合材料的性能，特别是硬度。
另外，为了使板材轻质化，本申请的发明人使用了珍珠岩和轻质碳酸钙，替代了现有的重质碳酸钙。
具体而言，本发明提供了一种硬质聚氯乙烯复合材料，该硬质聚氯乙烯复合材料的配方，按重量计含有以下组分：聚氯乙烯75-125份、氯化聚乙烯1-5份、珍珠岩50-80份、轻质碳酸钙160-190份、稳定剂2-6份、硬脂酸0.2-1份和ACR改性剂0.5-3.5份。
优选的，聚氯乙烯为PVC-SG5型。
优选的，所述稳定剂为铅盐复合稳定剂、有机锡类稳定剂、钙锌复合稳定剂或钾锌复合稳定剂。
优选的，所述硬质聚氯乙烯复合材料的配方中，按重量计还含有：PE蜡0.2-1.1份。
优选的，所述硬质聚氯乙烯复合材料的配方中，按重量计还含有：钛白粉1-5份。
优选的，所述硬质聚氯乙烯复合材料的配方中，按重量计还含有：OB-1增白剂0.01-0.05份。
本发明还提供了一种聚氯乙烯基材，所述基材为单层基材，所述基材的的配方为前述硬质聚氯乙烯复合材料的配方。
本发明还提供了一种聚氯乙烯基材，所述基材为多层基材，所述多层基材中的一层或多层的配方为前述硬质聚氯乙烯复合材料的配方。
本发明还提供了一种前述单层聚氯乙烯基材的方法，包括以下步骤：
a.向搅拌机中加入权利要求7中所述配方的各个组分，热混到120-140℃，再冷混到30-50℃搅拌均匀；
b.搅拌完成后，物料转移至挤塑成型机中并加热至160-210℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小，将物料挤压成如权利要求7所述的聚氯乙烯基材。
本发明还提供了一种前述多层聚氯乙烯基材的方法，包括以下步骤：
a.分别将各层的配方中的物料热混到120-140℃，再冷混到30-50℃搅拌均匀；
b.搅拌完成后，将物料转移至挤塑成型机中，并加热至160-210℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小，将物料共挤出形成如权利要求8所述的聚氯乙烯基材。
本发明还提供了一种板材，所述板材具有前述的基材。
优选的，所述板材具有覆盖于所述基材的上表面的上表面功能层。
优选的，所述上表面功能层为底层、木皮层、图案层、耐磨层、立体纹层、亮粉层、防滑层和面漆层中的一种或多种。
优选的，所述板材为以下多层板材中的一种：
a)依次包括所述基材及木皮层；
b)依次包括所述基材、木皮层及立体纹层；
c)依次包括所述基材、底层及立体纹层；
d)依次包括所述基材、底层、防滑层及亮粉层；
e)依次包括所述基材、底层、图案层及防滑层；
f)依次包括所述基材、底层、图案层、防滑层及亮粉层；
g)依次包括所述基材、底层、图案层、防滑层及立体纹层；
h)依次包括所述基材、底层、图案层、防滑层、立体纹层及亮粉层。
优选的，所述底层由UV固化涂料制得，所述UV固化涂料按重量计包括如下组分：UV树脂60-70份，助剂0.1-0.9份，稀释剂10-15份，填充物10-15份，光引发剂3-6份。进一步的，所述板材的制备方法还包括：滚涂所述UV固化涂料，并使用紫外照射固化干燥所述UV固化涂料。
优选的，所述图案层由UV固化涂料制得，所述UV固化涂料按重量计包括如下组分：UV树脂60-70份，助剂0.1-0.9份，稀释剂10-15份，色粉10-15份，光引发剂3-6份。进一步的，所述板材的制备方法还包括：滚涂所述UV固化涂料，并使用紫外照射固化干燥所述UV固化涂料。
优选的，所述耐磨层包括耐磨载粉层、耐磨粉和耐磨覆粉层。进一步的，所述耐磨载粉层和耐磨覆粉层由UV固化涂料制得，所述耐磨粉为选自金刚砂、玻璃珠、碳化硅、二氧化硅、氧化铝、氧化镁、钛白粉、塑胶粒中的一种或多种，所述板材的制备方法还包括：滚涂所述耐磨载粉层，在所述耐磨载粉层上撒所述耐磨粉，使用紫外照射部分固化所述耐磨载粉层，滚涂所述耐磨覆粉层，使用紫外照射固化干燥所述耐磨载粉层和耐磨覆粉层。进一步的，所述耐磨粉的平均粒径为75-500μm。
优选的，所述立体纹层由UV固化涂料制得，所述UV固化涂料按重量计包括如下组分：UV树脂70-85份，助剂0.1-0.9份，稀释剂5-10份，填充物10-15份，光引发剂3-6份。进一步的，所述板材的制备方法还包括：用滚涂设备滚涂所述UV固化涂料，并使用紫外照射固化干燥所述UV固化涂料，所述滚涂设备包括滚轮，所述滚轮的表面具有与所述立体纹层的纹路相匹配的蚀纹。
优选的，所述亮粉层包括亮粉载粉层、亮粉和亮粉覆粉层。进一步的，所述亮粉载粉层和亮粉覆粉层由UV固化涂料制得，所述板材的制备方法还包括：滚涂所述亮粉载粉层，在所述亮粉载粉层上撒所述亮粉，使用紫外照射部分固化所述亮粉载粉层，滚涂所述亮粉覆粉层，使用紫外照射固化干燥所述亮粉载粉层和亮粉覆粉层。
优选的，所述板材具有位于所述基材的下表面的垫层。
优选的，所述垫层选自PVC止滑膜、WPC、厚胶、软木垫、橡胶木、EVA和速生木中的一种或多种。
优选的，所述板材的下表面刷涂一层黏胶层，所述黏胶层按重量计包括如下组分：UV树脂70-85份，助剂0.1-0.9份，稀释剂5-10份，填充物10-15份，光引发剂3-6份。
本申请中涉及的PVC回收料是指生产PVC基材的边角料经过破碎、研磨得到的小粒径固体颗粒。
本发明相对于现有技术，取得了以下技术效果：
1、根据本申请的配方制得的基材硬度较强，具有良好的抗弯曲性能，极大的拓展了PVC基材的使用范围，且使用寿命延长。
2、本发明发现使用硬脂酸和ACR改性剂替代了现有技术中的增塑剂，避免了增塑剂的不利影响，安全无害。
3、本发明的配方中使用珍珠岩和轻质碳酸钙，在保持高性能的基础上，降低了产品的重量。
4、本发明制得的PVC基材，解决了现有板材的翘曲问题，提高了尺寸稳定性。
5、本发明使用共挤的工艺制得的双层或多层PVC基材，省时省力，工艺简单，还避免了胶水的使用，符合环保的要求。
6、本发明在制备双层或多层PVC基材时，其中的一层或多层可以采用PVC回收料，大大降低了生产成本。
具体实施方式
以下详细描述本发明。
下面结合实施例对本发明进行进一步描述。
本发明中的UV固化涂料含有至少一种可辐射固化树脂，例如UV树脂，选自不饱和聚酯树脂、环氧丙烯酸树脂、聚氨酯丙烯酸树脂，聚醚丙烯酸树脂，聚酯丙烯酸树脂、氨基丙烯酸树脂、硅改性丙烯酸酯、氟改性丙烯酸酯及其改质物或其衍生物中的一种或多种。可辐射固化树脂在紫外光、电子束等能源的辐射下，能够迅速固化成型。使用紫外光固化时，通常需要加入光引发剂，其可以是二苯酮或取代二苯酮，例如α-羟基酮，包括：2-羟基-2-甲基-1-苯基-丙-1-酮；2-羟基-1-[4-(2-羟乙氧基)苯基]-2-甲基-1-丙酮。其他合适的紫外光引发剂包括：苯乙酮和取代苯乙酮；安息香和它的烷基酯；氧杂蒽酮和取代的氧杂蒽酮；二乙氧基苯乙酮；安息香甲醚；安息香乙醚；安息香异丙醚；二乙氧基氧杂蒽酮；氯噻吨酮；N-甲基二乙醇胺二苯酮；1-苯甲酰环己醇；2-苄基-2-(二甲基氨基)-1-[4-(4-吗啉基)苯基]-1-丁酮；氨基酮；苯偶酰二甲基酮缩醇；2，4，6三甲基苯甲酰基二氧化膦，含有或不含有1-羟基-环己基苯基酮；茂金属；二苯酮，和它们的混合物。
本发明中所述的“预处理”是指：将基材表面进行清洁、表面调整等处理，增强涂料在原始板材表面的附着力。
本申请所述的配比，如无特别指出，均按重量计。
一)PVC基材的制备和性能测试
实施例1
按重量计将聚氯乙烯75份、氯化聚乙烯1份、珍珠岩50份、轻质碳酸钙160份、铅盐复合稳定剂2、硬脂酸0.2和ACR改性剂0.5份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
实施例2
按重量计将聚氯乙烯125份、氯化聚乙烯5份、珍珠岩80份、轻质碳酸钙190份、铅盐复合稳定剂6份、硬脂酸1份和ACR改性剂3.5份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
实施例3
按重量计将聚氯乙烯100份、氯化聚乙烯3份、珍珠岩60份、轻质碳酸钙170份、有机锡类稳定剂3份、硬脂酸0.5份和ACR改性剂2份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
实施例4
按重量计将聚氯乙烯110份、氯化聚乙烯3份、珍珠岩80份、轻质碳酸钙180份、钙锌复合稳定剂6份、硬脂酸0.2份、ACR改性剂3.5份和PE蜡0.2份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
实施例5
按重量计将聚氯乙烯120份、氯化聚乙烯1份、珍珠岩70份、轻质碳酸钙170份、钾锌复合稳定剂2份、硬脂酸0.5份、ACR改性剂2份、PE蜡1.1份和钛白粉1份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
实施例6
按重量计将聚氯乙烯125份、氯化聚乙烯5份、珍珠岩80份、轻质碳酸钙190份、钾锌复合稳定剂6份、硬脂酸1份、ACR改性剂3份、PE蜡1份、钛白粉5份和OB-1增白剂0.05份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
实施例7
按重量计将聚氯乙烯75份、氯化聚乙烯1份、珍珠岩50份、轻质碳酸钙160份、有机锡类稳定剂2份、硬脂酸0.2份、ACR改性剂0.5份、PE蜡0.2份、钛白粉1份和OB-1增白剂0.01份加入到搅拌机中，加热至40℃并搅拌均匀。
搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
以上实施例得到的是单层PVC基材。
实施例8
本实施例制备双层基材
第一层的配方为实施例1中的配方。
第二层的配方为：按重量计PVC回收料75份、珍珠岩10份、轻质碳酸钙70份、有机锡类稳定剂2份、PE蜡0.2份、硬脂酸0.3份、黄发泡剂0.05份、白发泡剂0.6份和氯化聚乙烯2份。
分别加热第一层的配方和第二层的配方至150℃，并搅拌均匀。
搅拌完成后，将第一层的物料和第二层的物料转移至挤塑成型机中，并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头共挤成双层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
本实施例中的第一层的配方也可以是实施例2-7中的配方，第二层的配方可以是实施例1-7的配方，也可以是任一已知的可以用来共挤的基材配方。
实施例9
本实施例制备三层基材
第一层的配方为实施例1中的配方。
第二层的配方为：按重量计PVC回收料75份、重质碳酸钙80份、铅盐复合稳定剂2份、PE蜡0.2份、硬脂酸0.3份、黄发泡剂0.05份、白发泡剂0.3份和氯化聚乙烯2份。
第三层的配方为：按重量计PVC回收料75份、重质碳酸钙80份、铅盐复合稳定剂2份、PE蜡0.2份、硬脂酸0.3份、黄发泡剂0.05份、白发泡剂0.3份和氯化聚乙烯2份。
分别加热第一层的物料、第二层的物料和第三层的物料至40℃，并搅拌均匀。
搅拌完成后，将第一层的物料、第二层的物料和第三层的物料转移至挤塑成型机中，并加热至150-160℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小。经过螺杆的充分塑化后通过窄逢机头共挤成三层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
此处挤塑成型机没有特别限制，传统挤塑成型机均可使用。
本实施例制得的基材的厚度可根据实际需求调整，一般作为地板的基材可以调整厚度为0.2-30mm，更常用的厚度为1-20mm。
本实施例中的第一层的配方也可以是实施例2-7中的配方；第二层的配方可以是实施例1-7的配方，也可以是任一已知的可以用来共挤的基材配方；第三层的配方可以是实施例1-7的配方，也可以是任一已知的可以用来共挤的基材配方。
性能测试
接着，测试上述实施例1-9所制得聚氯乙烯基材的性能参数。
实施例1-9的性能测试结果示于表1。
表1
二)具有上表面功能层的板材
实施例10具有木皮层的板材的制备
木皮层选用实木木皮，木皮层厚度为0.1-2.0mm皆可，更常用的是0.5-5mm。黏胶剂选用常规聚氨酯热熔胶。具体制作方法包括以下步骤：
a)对实施例1-9制得的基材的上表面进行清理，对木皮层的下表面进行清理；
b)在步骤a中清理完成的基材的上表面均匀涂覆聚氨酯热熔胶；
c)将木皮功能层的下表面和基材的上表面贴合在一起；
d)将上述贴合在一起的基材和木皮层置于冷压机上冷压40-60分钟得到基材上贴木皮层的板材。
该实施例所制备的板材采用基材贴木皮层的方式，既节省了木材，又可以实现与实木地板同等的效果。
作为该实施例的变形，木皮层也可以采用竹木层。木皮层也可以被替换成金属板或泡沫板。
实施例11具有耐磨层的板材的制备
依配方11中的物料配比，按照这样的步骤制备耐磨载粉层涂料：将聚氨酯丙烯酸树脂加热至液态，倒入分散釜中，在搅拌下加入光引发剂、稀释剂丙烯酸酯、填充剂和助剂等，继续搅拌至均匀即制得耐磨载粉层涂料。
配方11
将实施例1-9中制得的基材或实施例10和12-16制得的板材置于传输速度为5m/min的传送带上，首先预处理基材或板材；然后依次进行下述步骤：
步骤1、基材或板材经过滚涂机，将制得的耐磨载粉层涂料涂装于基材或板材表面，再经过紫外固化装置，从而形成固化程度为70％的耐磨载粉层。
步骤2、经步骤1处理过的基材或板材经过喷粉机，使得15g平均粒径为75μm的氧化铝均匀分布在步骤1中得到的耐磨载粉层上；然后将基材或板材传送至温度为70℃的装置，使得氧化铝颗粒在软化后的耐磨载粉层中沉降附着。
步骤3、经过步骤2处理后，基材或板材被传送至紫外固化装置2，进行固化干燥，由此得到涂装有耐磨层的板材。
本实施例中，UV树脂除了使用聚氨酯丙烯酸树脂外，还可以是氨基丙烯酸酯树脂、环氧丙烯酸酯树脂、聚氨酯丙烯酸酯树脂，聚醚丙烯酸酯树脂，聚酯丙烯酸酯树脂、硅改性丙烯酸酯树脂、氟改性丙烯酸酯树脂、光固化聚丁二烯低聚物树脂及其其衍生物中的一种或多种。
本实施例中的防滑粉除了使用氧化铝外，还可以是金刚砂、玻璃珠、碳化硅、二氧化硅、氧化铝、氧化镁、钛白粉、塑胶粒中的一种或多种。
按照ASTM D 4060以及DN13329标准对本实施例中的耐磨层进行测试，使用泰伯尔(TABLE)磨耗仪测试，测试结果为：
原装TABER S-33测试砂纸条，磨损指数：标准≤0.08g/100r；耐磨层磨穿时的转数为4000。
实施例12具有防滑层的板材的制备
依配方12中的物料配比，按照这样的步骤制备UV固化涂料：将聚氨酯丙烯酸树脂加热至液态，倒入分散釜中，在搅拌下加入光引发剂、稀释剂丙烯酸酯、填充剂和助剂等，继续搅拌至均匀即制得UV固化涂料。
配方12
将实施例1-9中制得的基材或实施例10-11和13-16制得的板材置于传输速度为5m/min的传送带上，首先预处理基材或板材，然后依次进行下述步骤：
步骤1、基材或板材经过滚涂机，将制得的UV固化涂料涂装于基材或板材表面，再经过紫外固化装置，从而形成固化程度为70％的防滑载粉层。
步骤2、将步骤1处理过的基材或板材经过喷粉机，使得45g平均粒径为80μm的氧化铝均匀分布在步骤1中得到的防滑载粉层上；然后将基材或板材传送至温度为70℃的装置，使得氧化铝颗粒在软化后的防滑载粉层中沉降附着。
步骤3、经过步骤2处理的基材或板材传送至紫外固化装置，进行固化干燥，由此得到涂装有防滑层的板材。
本实施例中，UV树脂除了使用聚氨酯丙烯酸树脂外，还可以是氨基丙烯酸酯树脂、环氧丙烯酸酯树脂、聚氨酯丙烯酸酯树脂，聚醚丙烯酸酯树脂，聚酯丙烯酸酯树脂、硅改性丙烯酸酯树脂、氟改性丙烯酸酯树脂、光固化聚丁二烯低聚物树脂及其其衍生物中的一种或多种。
本实施例中的防滑粉除了使用氧化铝外，还可以是金刚砂、玻璃珠、碳化硅、二氧化硅、氧化铝、氧化镁、钛白粉、塑胶粒中的一种或多种。
使用斜坡法(油湿状态)，按照DIN51130、AS/NZS4586:2013附录D以及GB/T26542标准对本实施例中的防滑层进行测试，测试结果为：
防滑等级及对应的临界角度为：R10 10°≤X<19°。
实施例13具有立体纹层的板材的制备
(1)制备立体纹层涂料
该具体实施例中的立体纹层涂料为UV固化涂料，该UV固化涂料按重量计包括如下组分：UV树脂70份，助剂0.9份，稀释剂10份，填充物15份，光引发剂6份，其中UV树脂为氨基丙烯酸酯树脂，助剂包括流平剂、填料、消泡剂、密着剂、湿润剂和抑制剂，稀释剂为丙烯酸酯稀释剂，填充物为碳酸钙，光引发剂为α-羟基酮。以上原料皆为工业常规原料。
制备立体纹层涂料的工艺为：将UV树脂在60-120℃加热至流动性好的液态；然后向液态的UV树脂中，按上述比例加入助剂、稀释剂、填充物、光引发剂等材料，搅拌至均匀，备用。
(2)增加基材或板材表面的密着性
选择实施例1-9中制备的基材或者实施例10-12和14-16制得的板材，使用第一滚涂机将乙醇涂装至基材或板材的上表面，滚涂过程中，传送带的速度设置为5-20m/min。
(3)滚涂立体纹层
使用滚涂机将步骤(1)制备的立体纹层涂料滚涂于基材或板材的上表面，该滚涂机的滚轮的表面具有与所需要的立体纹层的纹路相匹配的蚀纹。滚涂过程中，传送带的速度设置为15-30m/min；调整滚轮与基材板表面的距离至0.01-0.5mm；重复滚涂2-5次，直至立体纹层涂料在基材或板材的上表面形成所期望的厚度。
(4)光固化
使用紫外灯对步骤(3)中得到的涂层进行固化干燥，固化干燥的参数设置为：紫外灯的功率为100w-25kw；传送带的速度为5-20m/min；紫外灯距离传送带的高度为10-35cm。
该具体实施例直接利用滚涂的方式将UV固化涂料涂覆于基材或板材上，形成的立体纹理清晰美观，手触有纹路感。由于UV固化涂料本身的优良特性，形成的立体纹不易存在黄变、剥离等状况。而且，材料环保；流水线生产，操作简便，减少人员操作的失误率，降低人工成本；产线控制，能有效降低产品的次品率。
作为该具体实施例的变形，UV树脂也可以采用环氧丙烯酸酯树脂、聚氨酯丙烯酸酯树脂、聚醚丙烯酸酯树脂、聚酯丙烯酸酯树脂、硅改性丙烯酸酯树脂、氟改性丙烯酸酯树脂、光固化聚丁二烯低聚物树脂及它们的衍生物。稀释剂也可以采用其它的丙烯酸酯类单体或溶剂。光引发剂也可以采用其它的自由基聚合引发剂或活性胺。填充物也可以采用陶土、滑石粉、硫酸钡等。
实施例14具有亮粉层的板材的制备
(1)制备亮粉载粉层涂料和亮粉覆粉层涂料
该具体实施例中的亮粉载粉层涂料按重量计包括如下组分：UV树脂73份，助剂0.7份，稀释剂6份，填充物14份，光引发剂6份。亮粉覆粉层涂料按重量计包括如下组分：UV树脂67份，助剂0.5份，稀释剂13份，填充物14份，光引发剂5份。其中UV树脂为氨基丙烯酸酯树脂，助剂包括流平剂、填料、消泡剂、密着剂、湿润剂和抑制剂，稀释剂为丙烯酸酯稀释剂，填充物为碳酸钙，光引发剂为α-羟基酮。以上原料皆为工业常规原料。
制备亮粉载粉层涂料和亮粉覆粉层的工艺为：将UV树脂在60-120℃加热至流动性好的液态；然后向液态的UV树脂中，按上述比例加入助剂、稀释剂、填充物、光引发剂等材料，搅拌至均匀，备用。
(2)滚涂亮粉层
使用滚涂机将步骤(1)制备的亮粉载粉层涂料滚涂于实施例1-9中制备的基材或者实施例10-13和15-16制得的板材上表面，以形成亮粉载粉层。滚涂过程中，传送带的速度设置为5-20m/min；调整滚轮与基材或板材表面的距离，使得亮粉载粉层涂料在基材或板材的上表面形成所期望的厚度，通常，亮粉载粉层厚度为1μm-100μm。
使用撒粉机将亮粉均匀撒至滚涂的亮粉载粉层之上，并进一步加热，以使亮粉部分地陷于亮粉载粉层。
使用紫外灯对涂层进行部分固化，固化的参数设置为：紫外灯的功率为100w-25kw；传送带的速度为5-20m/min；紫外灯距离传送带的高度为10-35cm。
使用滚涂机将步骤(1)制备的亮粉覆粉层涂料滚涂于撒有亮粉的亮粉载粉层的表面，以形成亮粉覆粉层。
(3)光固化
使用紫外灯对步骤(2)中得到的涂层进行固化干燥，固化干燥的参数设置为：紫外灯的功率为100w-25kw；传送带的速度为5-20m/min；紫外灯距离传送带的高度为10-35cm。
作为该具体实施例的变形，UV树脂也可以采用环氧丙烯酸酯树脂、聚氨酯丙烯酸酯树脂、聚醚丙烯酸酯树脂、聚酯丙烯酸酯树脂、硅改性丙烯酸酯树脂、氟改性丙烯酸酯树脂、光固化聚丁二烯低聚物树脂及它们的衍生物。稀释剂也可以采用其它的丙烯酸酯类单体或溶剂。光引发剂也可以采用其它的自由基聚合引发剂或活性胺。填充物也可以采用陶土、滑石粉、硫酸钡等。
实施例15具图案层的板材的制备
(1)制备图案层涂料
该具体实施例中的图案层涂料按重量计包括如下组分：UV树脂60份，助剂0.9份，稀释剂15份，色粉15份，光引发剂6份。其中UV树脂为氨基丙烯酸酯树脂，助剂包括流平剂、填充物、消泡剂、密着剂、湿润剂和抑制剂，稀释剂为丙烯酸酯稀释剂，填充物为碳酸钙，光引发剂为α-羟基酮。以上原料皆为工业常规原料。
制备图案层涂料的工艺为：将UV树脂在60-120℃加热至流动性好的液态；然后向液态的UV树脂中，按上述比例加入助剂、稀释剂、填充物、光引发剂等材料，搅拌至均匀。制备好不同颜色的涂料备用。
(2)滚涂图案层
使用滚涂机以四色转印方法将图案层涂料涂于实施例1-9中制备的基材或者实施例10-14和16制得的板材的上表面，以形成图案层。滚涂过程中，传送带的速度设置为5-20m/min；调整滚轮与基材板表面的距离，使得图案层涂料在基材或板材的上表面形成所期望的厚度，通常，图案层厚度为1μm-100μm。
(3)光固化
使用紫外灯对步骤(2)中得到的涂层进行固化干燥，固化干燥的参数设置为：紫外灯的功率为100w-25kw；传送带的速度为5-20m/min；紫外灯距离传送带的高度为10-35cm。
作为该具体实施例的变形，UV树脂也可以采用环氧丙烯酸酯树脂、聚氨酯丙烯酸酯树脂、聚醚丙烯酸酯树脂、聚酯丙烯酸酯树脂、硅改性丙烯酸酯树脂、氟改性丙烯酸酯树脂、光固化聚丁二烯低聚物树脂及它们的衍生物。稀释剂也可以采用其它的丙烯酸酯类单体或溶剂。光引发剂也可以采用其它的自由基聚合引发剂或活性胺。填充物也可以采用陶土、滑石粉、硫酸钡等。
实施例16具有胶黏层的板材的制备
(1)制备胶黏剂
本实施例中的胶黏剂采用UV胶黏剂，按重量计包括如下组分：UV树脂70份，助剂0.1份，稀释剂5份，填充物10份，光引发剂3份。其中UV树脂为氨基丙烯酸酯树脂，助剂包括流平剂、消泡剂、密着剂、湿润剂和抑制剂，稀释剂为丙烯酸酯稀释剂，填充物为碳酸钙，光引发剂为α-羟基酮。以上原料皆为工业常规原料。
将UV树脂在60-120℃加热至流动性好的液态；然后向液态的UV树脂中，按上述比例加入助剂、稀释剂、填充物、光引发剂等材料，搅拌至均匀，备用。
(2)板材预处理
选取实施例10-15制得的板材，对需要贴合的下表面进行清灰处理。
(3)刷涂胶黏层
通过滚涂机将步骤(1)制备的胶黏剂滚涂在板材的下表面上，形成胶黏层。滚涂过程中，传送带的速度设置为5-20m/min；调整滚轮与板材的下表面的距离，使得胶黏剂在板材的下表面形成所期望的厚度。
(4)封装
在步骤(3)制备的胶黏层表面及板材的四周覆盖一层离型纸，防止胶黏剂暴露在光线下，避免固化。
作为该具体实施例的变形，UV树脂也可以采用环氧丙烯酸酯树脂、聚氨酯丙烯酸酯树脂、聚醚丙烯酸酯树脂、聚酯丙烯酸酯树脂、硅改性丙烯酸酯树脂、氟改性丙烯酸酯树脂、光固化聚丁二烯低聚物树脂及它们的衍生物。稀释剂也可以采用其它的丙烯酸酯类单体或溶剂。光引发剂也可以采用其它的自由基聚合引发剂或活性胺。
本实施例直接利用刷涂的方式在板材的底面涂覆一层胶黏层，使得板材在铺装时节省了刷涂胶水的施工工序，提高了板材的铺装效率；同时采用的胶黏剂材料环保，不含甲醛等有害物质。离型纸能有效防止胶黏层在储存和运输过程中与其他物体接触或暴露在光线下产生固化。
以上详细描述了本发明的较佳具体实施例。应当理解，本领域的普通技术人员无需创造性劳动就可以根据本发明的构思作出诸多修改和变化。因此，凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的实验可以得到的技术方案，皆应在由权利要求书所确定的保护范围内。

Claims (10)

1.一种硬质聚氯乙烯复合材料，其特征在于，所述硬质聚氯乙烯复合材料的配方，按重量计含有以下组分：聚氯乙烯75-125份、氯化聚乙烯1-5份、珍珠岩50-80份、轻质碳酸钙160-190份、稳定剂2-6份、硬脂酸0.2-1份和ACR改性剂0.5-3.5份。
2.根据权利要求1所述的硬质聚氯乙烯复合材料，其特征在于，所述聚氯乙烯为PVC-SG5型。
3.根据权利要求1所述的硬质聚氯乙烯复合材料，其特征在于，所述稳定剂为铅盐复合稳定剂、有机锡类稳定剂、钙锌复合稳定剂或钾锌复合稳定剂。
4.根据权利要求1所述的硬质聚氯乙烯复合材料，其特征在于，所述硬质聚氯乙烯复合材料的配方中，按重量计还含有：PE蜡0.2-1.1份。
5.根据权利要求4所述的硬质聚氯乙烯复合材料，其特征在于，所述硬质聚氯乙烯复合材料的配方中，按重量计还含有：钛白粉1-5份。
6.根据权利要求5所述的硬质聚氯乙烯复合材料，其特征在于，所述硬质聚氯乙烯复合材料的配方中，按重量计还含有：OB-1增白剂0.01-0.05份。
7.一种聚氯乙烯基材，其特征在于，所述基材为单层基材，所述基材的的配方为根据权利要求1-6中任一项所述的硬质聚氯乙烯复合材料的配方。
8.一种聚氯乙烯基材，其特征在于，所述基材为多层基材，所述多层基材中的一层或多层的配方为根据权利要求1-6中任一项所述的硬质聚氯乙烯复合材料的配方。
9.一种制备如权利要求7所述的聚氯乙烯基材的方法，其特征在于，包括以下步骤：
a.向搅拌机中加入权利要求7中所述配方的各个组分，热混到120-140℃，再冷混到30-50℃搅拌均匀；
b.搅拌完成后，物料转移至挤塑成型机中并加热至160-210℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小，将物料挤压成如权利要求7所述的聚氯乙烯基材。
10.一种制备如权利要求8所述的聚氯乙烯基材的方法，其特征在于，包括以下步骤：
a.分别将各层的配方中的物料热混到120-140℃，再冷混到30-50℃搅拌均匀；
b.搅拌完成后，将物料转移至挤塑成型机中，并加热至160-210℃，依据加工要求的厚度调整模具模唇的厚度及定厚辊隙的大小，将物料共挤出形成如权利要求8所述的聚氯乙烯基材。
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CN107650353A (zh) * 2017-08-31 2018-02-02 四川塑塑料制品有限公司 一种型材的加工工艺
CN109135116A (zh) * 2018-08-15 2019-01-04 马鞍山卓凡新材料科技有限公司 一种具有降噪特性的pvc-u排水管
CN109824996A (zh) * 2018-12-29 2019-05-31 广东技塑新材料股份有限公司 抗滑耐冲击pvc塑胶跑道用预制型面层材料及其制备方法
CN109836734A (zh) * 2019-03-15 2019-06-04 郭艳 一种抗紫外pvc复合材料的改性方法
CN109836734B (zh) * 2019-03-15 2021-04-09 浙江新洁新材料科技有限公司 一种抗紫外pvc复合材料的改性方法
CN110698972A (zh) * 2019-09-21 2020-01-17 漳州市和兴涂料有限公司 耐黄变亮光uv漆及生产工艺

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