CN107299717A - 一种绿色防水无胶型卫浴墙体板材及其制作方法 - Google Patents
一种绿色防水无胶型卫浴墙体板材及其制作方法 Download PDFInfo
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Abstract
本发明公开了一种绿色防水无胶型卫浴墙体板材及其制作方法,从外表面至背面依次为面层、基层、加固层,加固层中包裹设有结构体。本发明采用多层复合层,其中PVC石塑板在高温挤塑再与PVC膜一体化热熔热敷结合到一起,两者之间不用胶水,粘结力强不脱层且环保;纤维增强塑料涂刷在成型后的PVC石塑板上,固化后两层之间会形成极强的粘附力,也不再需要其他粘结剂;原材料环保安全,生产过程中无毒副作用;通过调整基层中成分的相对比例来调整PVC石塑层材质的柔韧度和硬度,通过合适比例的不饱和聚脂树脂和增强纤维形成的加固层来改善整体的强度、刚度和耐冲击性等力学性能,其自身能够与基层产生极强的粘附力;独特的网格状龙骨提高了整板的结构承载力。
Description
技术领域
本发明涉及一种绿色防水无胶型卫浴墙体板材及其制作方法,属于卫浴设备。
背景技术
当前预制式卫浴间使用的墙体板材主要以SMC复合材料为主,SMC复合材料是玻璃钢的一种,具有一定的电绝缘性能、热稳定性和耐化学防腐性,但是当作为卫浴板材应用于淋浴房中时,其自身不耐污、不耐磨、不防火的弊端更加突出,且其色彩单一、质感较差,因此在制造整体卫浴间的过程中需要增加一些辅助材料同时配合多种工艺来改变这些缺陷,但是对于产品的整体质量改观很有限,板材形成的墙体无质感、档次低,难以在市面上被广泛推广应用。且现有的复合板材基本都需要化学粘合剂将各层结合起来,而化学粘合剂一方面对人体有很大的危害,另一方面时间久了粘合剂会老化,粘结效果大大降低、导致各层分离强度下降,直接降低了板材的使用寿命。
发明内容
针对上述现有技术存在的问题,本发明的目的是提供一种易清洁、耐磨、保温隔热且表面质感好、能够满足不同需求的绿色防水无胶型卫浴墙体板材;本发明的另一目的在于提供提供一种制备过程简单易操作,不需要使用粘合剂、粘结效果好,且对人体无害的绿色防水无胶型卫浴墙体板材的制备方法。
为实现上述目的,本发明采用的技术方案是:一种绿色防水无胶型卫浴墙体板材,从外表面至背面依次为面层、基层、加固层,
所述面层为纯PVC膜或由UV光油经紫外线照射光固化形成的耐磨高光层和PVC膜叠加组成,面层厚度0.1-0.2mm;
所述基层为聚氯乙烯树脂、碳酸钙粉复合而成的PVC石塑板,厚度为2.5-5mm;所述聚氯乙烯树脂与碳酸钙粉的质量比为1:1~3;
加固层包括两层不饱和聚脂树脂和增强纤维复合成的纤维增强塑料,所述两层纤维增强塑料中包裹设有结构体,所述结构体为由金属杆件或管件组成的网格状龙骨。
优选的,所述UV光油由丙烯酸树脂、单体、光引发剂、助剂、溶剂组成。
基层的主要作用是为PVC覆膜提供一个平整的表面,在生产中厚度对整个工艺影响最大,太薄成品率低,且容易损坏;太厚浪费材料,成品重,且挤出后冷却阶段内外温差导致平整度不易控制。经过多次设计和试验后,发现在厚度在2.5-3.5mm效果最佳。
增强纤维可以选择芳纶纤维、碳纤维等材料,添加时以不饱和聚脂树脂将增强纤维完全浸润为标准,增强纤维占纤维增强塑料整体的质量分数在5-15wt%之间。优选的,每层纤维增强塑料的厚度为1-5mm,所用的不饱和聚脂树脂为牌号为191的临苯型不饱和聚酯树脂,增强纤维为玻璃纤维。牌号为191的临苯型不饱和聚酯树脂价格合理,与玻璃纤维复合后具有足够的刚度和耐冲击性,且临苯型不饱和聚酯树脂会对PVC石塑板的材料表面形成微腐蚀,相互贴合渗透,从而产生超强的粘结性。
优选的,所述网格状龙骨为截面宽、高为20mm,厚1.2mm的镀锌方钢管焊接而成的网格,镀锌方钢管之间的间距不大于300mm。采用这样的网格状龙骨强度高、稳定性好,结构承载力高且不易变形。
本发明还提供了一种绿色防水无胶型卫浴墙体板材的制备方法,包括如下步骤:
A.用板材挤塑设备将聚氯乙烯树脂和碳酸钙粉在180-220℃的温度下挤塑成PVC石塑板基层,在挤出完成后冷却至80-150℃,并与PVC膜进行一体化热熔热敷,将PVC膜热覆到基层上;
B.在热敷PVC膜的那一面涂覆UV光油,加热至50-60℃并保持3-5min流平,用2KW的UV固化机照射表面10s,进行快速紫外线光固化;
C.在PVC石塑板未热敷PVC膜的那一面喷涂不饱和聚脂树脂和玻璃纤维组成的混合料,形成纤维增强塑料;
D.上述纤维增强塑料固化前,在纤维增强塑料表面铺设网格状龙骨;
E.在网格状龙骨铺设完成后继续喷涂不饱和聚脂树脂和玻璃纤维组成的混合料,将龙骨包裹在里面,整体在20-25℃的温度下固化1-2小时。
相对于现有技术,本发明具有如下优势:
(1)本发明通过调整基层中聚氯乙烯树脂和碳酸钙粉的相对比例来调整PVC石塑层材质的柔韧度和硬度;通过特定比例的不饱和聚脂树脂和增强纤维形成的纤维增强塑料来改善整体的强度、刚度和耐冲击性等力学性能,且其自身能够与本发明的基层产生极强的粘附力,不需要额外的粘结剂;独特的网格状龙骨提高了整板的结构承载力。
(2)本发明采用多层复合层,其中PVC石塑板在高温挤塑再与PVC膜一体化热熔热敷结合到一起,两者之间不用胶水,粘结力强不脱层且环保;纤维增强塑料涂刷在成型后的PVC石塑板上,固化后在石塑板表面形成微腐蚀,从而两层之间会形成极强的粘附力,也不再需要其他粘结剂;所用的原材料PVC石塑板、不饱和聚脂树脂、纤维增强材料等均环保安全,生产过程中也无毒副作用,不会对人体和环境造成伤害;
(3)本发明的材料采用不同层次的材质进行有机结合,结构稳定、整体强度高、轻便易安装;并且使用的材质皆耐火,能够满足卫浴间要求的保温隔热等性能;一体化热熔热敷的PVC膜防水、防腐蚀,最外层光固化形成的耐磨高光层具有耐划、抗菌洁净、易清洁的特点,且面层表面质感好、PVC膜外观花色多样,可以根据客户需求制作出仿大理石、石材、木材等多种材质,得到了消费者的广泛认可,从根本上改变了当前日式整体卫浴间因SMC墙板无质感、色彩单一等缺点在我国一直无法大面积推广使用的现状。
附图说明
图1为本发明的结构示意图;
图2为本发明的制造工艺图;
图中,1.面层,2.基层,3.纤维增强塑料,4.结构体。
具体实施方式
下面结合附图对本发明作进一步详细说明。
实施例1
将聚氯乙烯树脂和碳酸钙粉以1:1的质量比置于挤塑设备中,在180℃的温度下挤塑成5mm厚的PVC石塑板基层2,在挤出完成后冷却至80℃,在表层与PVC膜进行一体化热熔热敷,形成厚度0.1mm的面层1;在PVC石塑板未热敷PVC膜的另一面喷涂2mm厚的191临苯型不饱和聚酯树脂与芳纶纤维的混合物(混合物中芳纶纤维含量为5wt%,191临苯型不饱和聚酯树脂将芳纶纤维完全浸润),固化前铺设网格状龙骨作为结构体4,网格状龙骨由宽高20mm、厚1.5mm,间距250mm网格状镀锌方管组成,再喷1.5mm厚的191临苯型不饱和聚酯树脂与芳纶纤维的混合物将网格状龙骨全部包裹,25摄氏度下固化1小时使混合物皆固化为纤维增强塑料3,正面覆成品保护膜,得到成品板材。
实施例2
将聚氯乙烯树脂和碳酸钙粉以1:1的质量比置于挤塑设备中,在220℃的温度下挤出3.5mm厚PVC石塑板基层2,在挤出完成后冷却至150℃,基层正面真空热覆一层PVC膜,并涂覆UV光油、加热至50℃并保持3min流平,用2KW的UV固化机照射表面10s,进行快速紫外线光固化处理得到耐磨高光层,PVC膜和耐磨高光层共同形成面层1;在PVC石塑板背面喷涂1mm厚的2608二甲苯型不饱和聚酯树脂与碳纤维的混合物(混合物中碳纤维含量为10wt%,2608二甲苯型不饱和聚酯树脂将碳纤维完全浸润),固化后铺设网格状龙骨作为结构体4,网格状龙骨由宽高20mm、厚2mm,间距280mm网格状镀锌方管焊接而成,再喷5mm厚的2608阻燃型二甲苯型不饱和聚酯树脂与碳纤维的混合物将结构体4全部包裹,20摄氏度下固化2小时使混合物固化为纤维增强塑料3,正面覆成品保护膜,得到成品板材。
实施例3
将聚氯乙烯树脂和碳酸钙粉以1:2的质量比置于挤塑设备中,在180℃的温度下挤出3.5mm厚PVC石塑板基层2,在挤出完成后冷却至150℃,基层正面真空热覆一层PVC膜,并涂覆UV光油、加热至50℃并保持3min流平,用2KW的UV固化机照射表面10s,进行快速紫外线光固化处理得到耐磨高光层,PVC膜和耐磨高光层共同形成面层1;在PVC石塑板未热敷PVC膜的一面喷涂2mm厚的191临苯型不饱和聚酯树脂与玻璃纤维混合物(混合物中玻璃纤维含量为15wt%),固化后铺设网格状龙骨作为结构体4,龙骨由宽高20mm、厚1.2mm,间距250mm的网格状镀锌方管组成,再喷1.5mm厚的196阻燃型临苯型不饱和聚酯树脂与玻璃纤维混合物(混合物中玻璃纤维含量为15wt%)将龙骨全部包裹,20摄氏度下固化2小时,使不饱和聚酯树脂与玻璃纤维的混合物皆固化为纤维增强塑料3,正面覆成品保护膜,得到成品板材。
采用本实施例制备得到的基层厚度3.5mm,不仅为整体板材提供了足够的强度,且厚度合适、成品质量轻,基层冷却阶段内外温差不大、平整度高;各层相互间粘结强度高,没有出现松脱的现象。
实施例4
将聚氯乙烯树脂和碳酸钙粉以1:3的质量比置于挤塑设备中,在200℃的温度下挤出2.5mm厚PVC石塑板基层2,在挤出完成后冷却至100℃,基层正面真空热覆一层PVC膜,并涂覆UV光油、加热至60℃并保持5min流平,用2KW的UV固化机照射表面10s,进行快速紫外线光固化处理得到耐磨高光层,PVC膜和耐磨高光层共同形成面层1;在PVC石塑板未热敷PVC膜的一面喷涂2mm厚的191临苯型不饱和聚酯树脂与玻璃纤维混合物(混合物中玻璃纤维含量为5wt%),固化后铺设网格状龙骨作为结构体4,龙骨由宽高20mm、厚1.2mm,间距250mm的网格状镀锌方管组成,再喷1.5mm厚的196阻燃型临苯型不饱和聚酯树脂与玻璃纤维混合物(混合物中玻璃纤维含量为5wt%)将龙骨全部包裹,25摄氏度下固化1小时,使不饱和聚酯树脂与玻璃纤维的混合物皆固化为纤维增强塑料3,正面覆成品保护膜,得到成品板材。
采用本实施例制备得到的基层厚度2.5mm,从挤塑设备挤出后冷却速度更快,更容易控制平整度,用料少、成本低,使整体重量更轻,且强度也能够满足预制式卫浴间的使用条件,非常适合简易型拼装式卫浴间使用。
Claims (6)
1.一种绿色防水无胶型卫浴墙体板材,其特征在于,从外表面至背面依次为面层、基层、加固层,
所述面层为纯PVC膜或由UV光油经紫外线照射光固化形成的耐磨高光层和PVC膜叠加组成,面层厚度0.1-0.2mm;
所述基层为聚氯乙烯树脂、碳酸钙粉复合而成的PVC石塑板,厚度为2.5-5mm;所述聚氯乙烯树脂与碳酸钙粉的质量比为1:1~3;
加固层包括两层不饱和聚脂树脂和增强纤维复合成的纤维增强塑料,所述两层纤维增强塑料中包裹设有结构体,所述结构体为由金属杆件或管件组成的网格状龙骨。
2.根据权利要求1所述的绿色防水无胶型卫浴墙体板材,其特征在于,所述UV光油由丙烯酸树脂、单体、光引发剂、助剂、溶剂组成。
3.根据权利要求1所述的绿色防水无胶型卫浴墙体板材,其特征在于,所述基层厚度为2.5-3.5mm。
4.根据权利要求1所述的绿色防水无胶型卫浴墙体板材,其特征在于,所述每层纤维增强塑料的厚度为1-5mm,所用的不饱和聚脂树脂为牌号为191的临苯型不饱和聚酯树脂,增强纤维为玻璃纤维。
5.根据权利要求1所述的绿色防水无胶型卫浴墙体板材,其特征在于,所述网格状龙骨为截面宽、高为20mm,厚1.2mm的镀锌方钢管焊接而成的网格,镀锌方钢管之间的间距不大于300mm。
6.一种绿色防水无胶型卫浴墙体板材的制备方法,其特征在于,包括如下步骤:
A.用板材挤塑设备将聚氯乙烯树脂和碳酸钙粉在180-220℃的温度下挤塑成PVC石塑板基层,在挤出完成后冷却至80-150℃,并与PVC膜进行一体化热熔热敷,将PVC膜热覆到基层上;
B.在热敷PVC膜的那一面涂覆UV光油,加热至50-60℃并保持3-5min流平,用2KW的UV固化机照射表面10s,进行快速紫外线光固化;
C.在PVC石塑板未热敷PVC膜的那一面喷涂不饱和聚脂树脂和玻璃纤维组成的混合料,形成纤维增强塑料;
D.上述纤维增强塑料固化前,在纤维增强塑料表面铺设网格状龙骨;
E.在网格状龙骨铺设完成后继续喷涂一层不饱和聚脂树脂和玻璃纤维组成的混合料,将龙骨包裹在里面,整体在20-25℃的温度下固化1-2小时成型。
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