CN107446154B - 一种高性能微发泡母粒及其制备方法和应用 - Google Patents

一种高性能微发泡母粒及其制备方法和应用 Download PDF

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CN107446154B
CN107446154B CN201710751682.3A CN201710751682A CN107446154B CN 107446154 B CN107446154 B CN 107446154B CN 201710751682 A CN201710751682 A CN 201710751682A CN 107446154 B CN107446154 B CN 107446154B
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沈剑
白二雷
霍耀楠
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Abstract

一种高性能微发泡母粒及其制备方法和应用。本发明涉及一种微发泡母粒，含有母粒和助剂，所述主剂与助剂的质量比为1:1；所述主剂包含如下重量份的组分：包覆树脂50‑60份，复合发泡剂15‑30份，交联剂5‑10份；所述助剂包含如下重量份的组分：包覆树脂80‑90份，活化剂2‑6份，成核剂4‑15份，调节剂2‑5份。添加这种微发泡母粒的发泡板材的发泡孔径分布在80～100μm，物理机械强度保持在95％以上，光泽度更好，同时显著降低内胆重量，提升冰箱保温效果。

Description

一种高性能微发泡母粒及其制备方法和应用
技术领域
本发明涉及一种高性能微发泡母粒及其制备方法和应用，属于冰箱内胆材料技术领域。
背景技术
发泡板材由于在轻量化、节能等方面有着明显优势，且兼具有隔音、隔热及绝缘等优良性质，适于应用在冰箱内胆上。但常规发泡板材的发泡孔径大、分布广、性能损失大，使得冰箱内胆吸塑后表面缺陷严重，出现冰箱内胆吸塑拉伸过程中产生断裂、表面有纹路、颜色不均匀等现象，限制了微发泡材料在冰箱行业的应用。
发明内容
针对上述技术问题，本发明开发一种高性能微发泡母粒，添加这种微发泡母粒的发泡板材的发泡孔径分布在80～100μm，物理机械强度保持在95％以上，在保持较好光泽度的同时显著降低内胆重量，提升冰箱保温效果。
本发明采用的技术方案如下。
一种微发泡母粒，含有主剂和助剂，所述主剂与助剂的质量比为1:1；所述主剂包含如下重量份的组分：包覆树脂50-60份，复合发泡剂15-30份，交联剂5-10份；所述助剂包含如下重量份的组分：包覆树脂80-90份，活化剂2-6份，成核剂4-15份，调节剂2-5份。
本发明通过选择合适的组分并以特定比例混合，得到高性能的微发泡母粒，将其制成的发泡板材用作冰箱内胆时，可显著提升冰箱保温效果，并减少冰箱内胆重量，从而降低冰箱成本。
下面对上述微发泡母粒中各组分做进一步说明。
在本发明所述主剂中，所述包覆树脂选择熔融指数10～20g/10min的低密度聚乙烯(LDPE)；主剂中各组分在聚合物熔融指数为2～3g/10min的LDPE中更易于溶解和扩散，气泡成核点多且发泡孔小而密。
为了使发泡孔径更小、分布更窄、机械性能损失更小，同时兼具更大的发泡孔隙率，本发明中所述复合发泡剂由有机发泡剂和无机发泡剂以质量比(15-30)：(10-25)组成；其中，所述无机发泡剂选自碳酸铵、亚硝酸盐或碳酸氢铵中的一种或多种，优选碳酸氢钠；所述有机发泡剂选自偶氮二甲酰胺(AC)、柠檬酸或OBSH中的一种或多种，优选AC。通过调整无机发泡剂和有机发泡剂比例使复合发泡剂为放热型发泡体系，从而更有利于提高发泡板材上下皮层的强度和表面性能。
所述交联剂选自过氧化二异丙苯(DCP)和/或过氧化苯甲酰(BPO)；交联剂的加入可显著提高熔体强度，提高闭孔的能力，防止气泡压力增大出现的串孔和破孔；同时提高了发泡板材中芯层的抗拉伸强度。
在所述助剂中，所述包覆树脂选自熔融指数2～3g/10min的抗冲击聚苯乙烯聚苯乙烯(PS)；优选HIPS。
所述活化剂选自纳米氧化锌、硼砂、硬脂酸或硬脂酸锌中的一种或多种；优选所述活化剂由纳米氧化锌和硬脂酸锌以质量比(1-3)：(1-3)组成。
所述成核剂选自滑石粉和/或碳酸钙，优选纳米级滑石粉。
所述调节剂选自硅氧烷和/或硬脂酸盐，优选硅氧烷可降低发泡孔的表面张力以使发泡孔更均匀。
作为本发明优选的实施方式，所述微发泡母粒由主剂和助剂按质量1:1组成；所述主剂由如下重量份的组分组成：LDPE 50％-60％，AC 15％-30％，碳酸氢钠10％-25％，DCP5％-10％；所述助剂由如下重量份的组分组成：HIPS 80％-90％，硬脂酸锌1％-3％，氧化锌1％-3％，滑石粉4％-15％，硅氧烷2％-5％。
本发明所述的微发泡母粒可采用本领域母粒常规熔融挤出制作方法制得。优选地，采用双螺杆挤出机和单螺杆挤出机复配的形式；同时为了获得更好的效果，可将主剂与助剂分别进行混合、挤出、切割和冷却的工序制作，再将两者混合造粒，从而保证各组成在基体中分散效果更好，提高发泡板材中芯层的抗拉伸强度。具体为：分别利用双螺杆挤出喂料，单螺杆挤出切粒，制备得到主剂和助剂；然后再将主剂：助剂按质量比1:1混合，熔融挤出造粒。
本发明所述的高性能微发泡母粒可用在以HIPS、ABS或PET为材质的制冷设备内胆中，特别适用于HIPS材质。添加本发明所述的微发泡母粒的HIPS材质经过挤出成型后，挤出板材具有坚韧发泡的芯层和光亮的上下皮层。
本发明还提供一种发泡板材，由上、下皮层和芯层组成；所述上、下皮层各占发泡板材总质量的5％，所述芯层占发泡板材总质量的90％；所述发泡板材以常规内胆材料为基材，并添加本发明所述的微发泡母粒。所述微发泡母粒的添加量为发泡板材总质量的1-5％；所述芯层中泡的孔径分布在80～120μm，优选80～100μm，占比在98％以上；所述芯层的密度为0.90～0.95g/cm3；所述上、下皮层的密度为1.06g/cm3左右。所述内胆材料选自HIPS、ABS或PET中的一种或多种。
本发明提供的发泡板材具有“坚韧发泡的芯层和光亮的上下皮层”，避免了现有发泡板在冰箱内胆吸塑拉伸成型中产生的断裂、表面有纹路和颜色不均匀等现象；同时由于添加了微发泡母粒，发泡板材相比现有发泡板可更显著降低内胆重量，并提升冰箱保温效果。
附图说明
图1为本发明所述发泡板材的结构示意图。
其中，上、下皮层温度低，芯层温度高，上下皮层泡核向高温熔体粘度小的芯层移动。
具体实施方式
以下实施例用于说明本发明，但不用来限制本发明的范围。
实施例1-3一种微发泡母粒
实施例1-3所述微发泡母粒的配方、对比例及添加1％高性能微发泡母粒的HIPS板材性能如表1。
表1
Figure BDA0001391288660000041
Figure BDA0001391288660000051
由上表可知，添加了1％高性能微发泡母粒的HIPS发泡板材中最佳的发泡孔径分布在80～120μm，优选在80～100μm之间，物理机械强度保持在95％以上。同时，添加1％发泡母粒的发泡板材HIPS作为冰箱内胆，使得内胆减重2％～13％，大大降低内胆重量。同时从上表数据可知，添加1％发泡母粒的发泡板材HIPS作为冰箱内胆也并不会降低现有冰箱内胆的其他相关性能。
虽然，上文中已经用一般性说明及具体实施方案对本发明作了详尽的描述，但在本发明基础上，可以对之作一些修改或改进，这对本领域技术人员而言是显而易见的。因此，在不偏离本发明精神的基础上所做的这些修改或改进，均属于本发明要求保护的范围。

Claims (7)

1.一种微发泡母粒，其特征在于，含有主剂和助剂，所述主剂与助剂的质量比为1:1；
所述主剂由如下重量份的组分组成：熔融指数10～20g/10min的LDPE 50％-60％，AC15％-30％，碳酸氢钠10％-25％，DCP 5％-10％；
所述助剂由如下重量份的组分组成：熔融指数为2～3g/10min HIPS 80％-90％，硬脂酸锌1％-3％，氧化锌1％-3％，滑石粉4％-15％，硅氧烷2％-5％。
2.权利要求1所述微发泡母粒的制备方法，其特征在于，分别利用双螺杆挤出喂料、单螺杆挤出切粒制备得到主剂和助剂；然后再将主剂：助剂按质量比1:1混合、熔融挤出造粒。
3.权利要求1所述微发泡母粒在以HIPS、ABS或PET为材质的制冷设备内胆中的应用。
4.根据权利要求3所述的应用，其特征在于，所述制冷设备内胆的材质为HIPS。
5.一种发泡板材，其特征在于，在基材中添加1-5％的权利要求1所述的微发泡母粒。
6.根据权利要求5所述的发泡板材，其特征在于，由上、下皮层和芯层组成；所述上、下皮层各占发泡板材总质量的5％，所述芯层占发泡板材总质量的90％；
所述芯层中的泡孔径分布在80～120μm；占比在98％以上；
所述芯层的密度为0.90～0.95g/cm3；
所述上、下皮层的密度为1.06g/cm3。
7.根据权利要求6所述的发泡板材，其特征在于，所述芯层中的泡孔径分布在80～100μm。
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