CN108410078A - 一种环保木塑集成墙板及其制作方法 - Google Patents
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Abstract
本发明涉及环保高分子材料领域,公开一种环保木塑集成墙板及其制作方法,以聚氯乙烯树脂、聚氯已烯树脂为基材,以木粉、碳酸钙粉为填充剂,以聚乙烯蜡为润滑剂,以硬脂酸为稳定剂,以氯化聚乙烯135A为韧性和抗冲改性剂,以发泡AC‑02为发泡调节剂,以大孔型树脂、微米级碳球和沸石微粒复合形成吸附净化剂,在集成墙板内部形成有害气体吸附和解吸排出通道。本发明在集成墙板中加入沸石微粒、大孔型树脂和微米级碳球,复合形成吸附净化剂,在集成墙板内部形成吸附和解吸通道,使材料内部结构更加丰富,大孔、小孔、微孔的结合使吸附剂的孔隙率更大,增加了有害气体解吸排出集成墙板材料通道,有害气体吸附排出更加彻底,绿色环保。
Description
技术领域
本发明涉及环保高分子材料领域,具体涉及一种环保木塑集成墙板及其制作方法。
背景技术
木塑复合材料是用塑料、木纤维或稻壳、麦秸、玉米杆、花生壳等天然纤维加入化学添加剂和填料,经过专用配混设备加工制成的一种复合材料。木塑复合材料具有坚硬、强韧、持久、耐磨、尺寸稳定等优点。一般来说,木塑复合材料的硬度较未处理的木材高出2~8倍,耐磨性高出4~5倍,各种添加剂的应用还赋予其许多特殊的性能。它还是一种环保材料,可回收重复使用,且原料廉价丰富,在减少环境污染、保护森林资源、促进经济发展方面都有良好的效益,受到了众多研究者关注。此外,木塑复合材料还具有二次加工性,制作的各种产品外形美观。是木材理想的替代品之一。
由于其可以直接安装在毛坯墙上,节省时间和成本的同时,也具有个性化,时尚感十足,颠覆传统墙板。现在广泛应用于室内装潢,是一种新型建筑装饰材料。
家具制造中经常使用的普通人造板材主要包括刨花板、密度板、胶合板等人造板材,制造这种板材的过程是将木材处理成木屑,再加入粘合剂,通过高温挤压等方式,将木屑加工成板材。而甲醛存在于粘合剂中,绝大部分是由木材碎料经喷淋脲醛树脂胶粘剂后,经高温高压压制而成板。脲醛树脂是甲醛与尿素的直接化合物,每制造一张3平方米的人造板,要使用约4公斤的甲醛来合成脲醛树脂胶粘剂;脲醛树脂的缺点是化学性质极不稳定,在自然状态下都会持续分解还原为甲醛及尿素。长期接触甲醛可引起慢性呼吸道疾病、引起新生儿体质降低、染色体异常,甚至引起鼻咽癌,高浓度甲醛对神经系统、免疫系统、肝脏等都有较大毒害。
目前使用的木塑复合材料需要添加多种化学物质,使用的胶黏剂以及木粉中含有甲醛、苯、VOC等有害气体,累计含量超标,在装潢过程中以及装潢完成后持续释放甲醛、苯、VOC等有害气体,而且受到使用环境的影响,温度、湿度以及通风都会影响甲醛等有害气体的散发。此外,材料采购分散,价格昂贵,强度不够导致使用寿命短。
发明内容
为解决上述技术问题,本发明提供一种环保木塑集成墙板及其制作方法,在集成墙板中加入沸石微粒和大孔型树脂的同时,加入微米级碳球,复合形成吸附净化剂,在集成墙板内部形成吸附和解吸通道,使材料内部结构更加丰富,大孔、小孔、微孔的结合使吸附剂的孔隙率更大,增加了有害气体解吸排出集成墙板材料通道,有害气体吸附排出更加彻底,绿色环保。
具体技术方案如下:
一种环保木塑集成墙板,以聚氯乙烯树脂、聚氯已烯树脂为基材,以木粉、碳酸钙粉为填充剂,以聚乙烯蜡为润滑剂,以硬脂酸为稳定剂,以氯化聚乙烯135A为韧性和抗冲改性剂,以AC-02发泡剂为发泡调节剂,通过挤出机挤出成型,将大孔型树脂、微米级碳球和沸石微粒复合形成吸附净化剂,在集成墙板内部形成有害气体吸附和解吸排出通道。
环保木塑集成墙板的制作方法,具体步骤如下:
(1)配料
按照如下重量百分比称取各组分,混合均匀:
聚氯乙烯树脂:10~30%;
聚氯已烯树脂:12~20%;
木粉:2~4%;
碳酸钙粉:15~25%;
聚乙烯蜡:2~4%;
硬脂酸:2~4%;
氯化聚乙烯135A:2~4%;
色粉:4~8%;
AC-02发泡剂:3~5%;
(2)吸附净化剂的预处理
按照如下重量百分比称取吸附净化剂各组分:
沸石微粒:12~16%,筛分至80~200目以下;
大孔型树脂:8~15%,筛分至60~70目以下;
微米级碳球:4~6%,筛分至200~300目以下;
将吸附净化剂各组分混合均匀,先在吸附净化剂重量2~3倍的饱和食盐水中浸泡18~20h,然后排尽饱和食盐水,用无水乙醇漂洗净,再用2%~4%的氢氧化钠溶液中浸泡2~4h,排尽碱液后用无水乙醇冲洗直至排出水接近中性;
(3)混料
将经过预处理的吸附净化剂混入步骤(1)的混合组分中,搅拌均匀后待用;
(4)挤出定型:
将上述混合物上料,经由木塑板挤出机挤出成型,加料转速为7~8.5r/min,主机转速为7~8.8r/min,加料段温度140~160℃,机筒温度,130~150℃,模头温度160~180℃,当挤出稳定后,开通5~10℃冷却水,牵引切割后定型。
本方法的优点是:
(1)本发明在集成墙板中加入了适量大孔型树脂,利用大孔型树脂具有不连续的离散的孔眼的致孔特性,形成多孔海绵状构造的骨架,内部有大量永久性的微孔,孔径大小和数量都可以在制造时根据实际需求控制,应用更加灵活。大孔型树脂内部并存有微细孔和大网孔,增大孔道的表面积,这不仅为吸附提供了良好的接触条件,缩短了吸附扩散的路程,活性中心多,通过分子间的范德华引力产生分子吸附作用,能够吸附甲醛等多种非离子有害气体,且吸附扩散速度快。此外,大孔型树脂耐溶胀,不易碎裂,耐氧化,耐磨损,耐热及耐温度变化,较易吸附和交换,抗污染力强,适合用于建筑装饰材料中。
(2)本发明在集成墙板中加入适当比例的沸石微粒,沸石是孔状结构,沸石微粒配合大孔型树脂作用,其孔状结构作为大孔型树脂吸附有害气体后将有害气体解吸排出集成墙板材料的通道,此外,其本身具有较强的吸附性,可有效吸附覆膜过程中产生的甲醛等各种有害气体和异味,并分解产生负氧离子,净化空气。
(3)本发明在集成墙板中加入沸石微粒和大孔型树脂的同时,加入微米级碳球,复合形成吸附净化剂,在集成墙板内部形成吸附和解吸通道,使材料内部结构更加丰富,大孔、小孔、微孔的结合。一方面使吸附剂的孔隙率更大,微米级碳球的加入,增加了有害气体解吸排出集成墙板材料通道,减少了通道的阻隔,有效克服有害气体解吸排出集成墙板材料通道的死角,有害气体吸附排出更加彻底,绿色环保,环境友好。
(4)本发明使用聚乙烯蜡作为在挤出、压延加工中的润滑剂,可提高加工效率,防止和克服薄膜粘结,提高成品的平滑度和光泽度,显著改善成品外观。
(5)本发明以氯化聚乙烯135A为韧性和抗冲改性剂,其综合物理性能优良,低温韧性大,有较高的拉伸强度,与聚氯乙烯溶解参数相当接近,亲和性好,在产品内部形成网络结构,从而赋予产品优良的常、低温韧性和抗冲强度。
(6)本发明使用的基材易于取得,价格低廉,环境友好。
附图说明
图1为加入大孔型树脂的集成墙板内部有害气体排出示意图;
图2为加入大孔型树脂和沸石微粒的集成墙板内部有害气体排出示意图;
图3为加入大孔型树脂、沸石微粒和微米级碳球的集成墙板内部有害气体排出示意图。
具体实施方式
下面结合附图和实施例对本发明进行详细说明,但本发明的保护范围不受附图和实施例所限。
本发明用大孔型树脂为沧州宝恩化工有限公司生产的D101型大孔型树脂,发泡调节剂为北京森昌泰和科技有限责任公司生产的AC-02发泡剂,韧性和抗冲改性剂为山东祥生塑胶有限公司生产的氯化聚乙烯135A,聚乙烯蜡为上海化熠化工助剂有限公司生产的CH-100型聚乙烯蜡。
图1为加入大孔型树脂的集成墙板内部有害气体排出示意图。如图所示,在集成墙板中加入了适量大孔型树脂,利用大孔型树脂具有不连续的离散的孔眼的致孔特性,形成多孔海绵状构造的骨架,内部有大量永久性的微孔,孔径大小和数量都可以在制造时根据实际需求控制,应用更加灵活。大孔型树脂内部并存有微细孔和大网孔,增大孔道的表面积,这不仅为吸附提供了良好的接触条件,缩短了吸附扩散的路程,活性中心多,通过分子间的范德华引力产生分子吸附作用,能够吸附甲醛等多种非离子有害气体,且吸附扩散速度快。此外,大孔型树脂耐溶胀,不易碎裂,耐氧化,耐磨损,耐热及耐温度变化,较易吸附和交换,抗污染力强,适合用于建筑装饰材料中
图2为加入大孔型树脂和沸石微粒的集成墙板内部有害气体排出示意图。如图所示,本发明在集成墙板中加入适当比例的沸石微粒,沸石是孔状结构,沸石微粒配合大孔型树脂作用,其孔状结构作为大孔型树脂吸附有害气体后将有害气体解吸排出集成墙板材料的通道,此外,其本身具有较强的吸附性,可有效吸附覆膜过程中产生的甲醛等各种有害气体和异味,并分解产生负氧离子,净化空气。
图3为加入大孔型树脂、沸石微粒和微米级碳球的集成墙板内部有害气体排出示意图。如图所示,本发明在集成墙板中加入沸石微粒和大孔型树脂的同时,加入微米级碳球,复合形成吸附净化剂,在集成墙板内部形成吸附和解吸通道,使材料内部结构更加丰富,大孔、小孔、微孔的结合。一方面使吸附剂的孔隙率更大,微米级碳球的加入,增加了有害气体解吸排出集成墙板材料通道,减少了通道的阻隔,有效克服有害气体解吸排出集成墙板材料通道的死角,使有害气体吸附排出更加彻底,使本发明制造出的集成墙板材料更加绿色环保,环境友好,有效降低对人体的伤害。
实施例1
(1)配料
按照如下重量百分比称取各组分,混合均匀:
聚氯乙烯树脂:10%;
聚氯已烯树脂:12%;
木粉:2%;
碳酸钙粉:15%;
聚乙烯蜡:2%;
硬脂酸:2%;
氯化聚乙烯135A:2%;
色粉:4%;
AC-02发泡剂:3%;
(2)吸附净化剂的预处理
按照如下重量百分比称取吸附净化剂各组分:
沸石微粒:12%,筛分至80目以下;
大孔型树脂:8%,筛分至60目以下;
微米级碳球:4%,筛分至200目以下;
将吸附净化剂各组分混合均匀,先在吸附净化剂重量2倍的饱和食盐水中浸泡18h,然后排尽饱和食盐水,用无水乙醇漂洗净,再用2%的氢氧化钠溶液中浸泡2h,排尽碱液后用无水乙醇冲洗直至排出水接近中性;
(3)混料
将经过预处理的吸附净化剂混入步骤(1)的混合组分中,搅拌均匀后待用;
(4)挤出定型:
将上述混合物上料,经由木塑板挤出机挤出成型,加料转速为7r/min,主机转速为7r/min,加料段温度140℃,机筒温度130℃,模头温度160℃,当挤出稳定后,开通5℃冷却水,牵引切割后定型。
实施例2
(1)配料
按照如下重量百分比称取各组分,混合均匀:
聚氯乙烯树脂:20%;
聚氯已烯树脂:16%;
木粉:3%;
碳酸钙粉:20%;
聚乙烯蜡:3%;
硬脂酸:3%;
氯化聚乙烯135A:3%;
色粉:6%;
AC-02发泡剂:4%;
(2)吸附净化剂的预处理
按照如下重量百分比称取吸附净化剂各组分:
沸石微粒:14%,筛分至100目以下;
大孔型树脂:10%,筛分至65目以下;
微米级碳球:5%,筛分至250目以下;
将吸附净化剂各组分混合均匀,先在吸附净化剂重量2.5倍的饱和食盐水中浸泡19h,然后排尽饱和食盐水,用无水乙醇漂洗净,再用3%的氢氧化钠溶液中浸泡3h,排尽碱液后用无水乙醇冲洗直至排出水接近中性;
(3)混料
将经过预处理的吸附净化剂混入步骤(1)的混合组分中,搅拌均匀后待用;
(4)挤出定型:
将上述混合物上料,经由木塑板挤出机挤出成型,加料转速为7.5r/min,主机转速为8.5r/min,加料段温度150℃,机筒温度140℃,模头温度170℃,当挤出稳定后,开通8℃冷却水,牵引切割后定型。
实施例3
(1)配料
按照如下重量百分比称取各组分,混合均匀:
聚氯乙烯树脂:30%;
聚氯已烯树脂:20%;
木粉:4%;
碳酸钙粉:25%;
聚乙烯蜡:4%;
硬脂酸:4%;
氯化聚乙烯135A:4%;
色粉:8%;
AC-02发泡剂:5%;
(2)吸附净化剂的预处理
按照如下重量百分比称取吸附净化剂各组分:
沸石微粒:16%,筛分至200目以下;
大孔型树脂:15%,筛分至70目以下;
微米级碳球:6%,筛分至300目以下;
将吸附净化剂各组分混合均匀,先在吸附净化剂重量3倍的饱和食盐水中浸泡20h,然后排尽饱和食盐水,用无水乙醇漂洗净,再用4%的氢氧化钠溶液中浸泡4h,排尽碱液后用无水乙醇冲洗直至排出水接近中性;
(3)混料
将经过预处理的吸附净化剂混入步骤(1)的混合组分中,搅拌均匀后待用;
(4)挤出定型:
将上述混合物上料,经由木塑板挤出机挤出成型,加料转速为8.5r/min,主机转速为8.8r/min,加料段温度160℃,机筒温度150℃,模头温度180℃,当挤出稳定后,开通10℃冷却水,牵引切割后定型。
Claims (2)
1.一种环保木塑集成墙板,以聚氯乙烯树脂、聚氯已烯树脂为基材,以木粉、碳酸钙粉为填充剂,以聚乙烯蜡为润滑剂,以硬脂酸为稳定剂,以氯化聚乙烯135A为韧性和抗冲改性剂,以AC-02发泡剂为发泡调节剂,通过挤出机挤出成型,其特征在于:将大孔型树脂、微米级碳球和沸石微粒复合形成吸附净化剂,在集成墙板内部形成有害气体吸附和解吸排出通道。
2.根据权利要求1所述的环保木塑集成墙板的制作方法,具体步骤如下:
(1)配料
按照如下重量百分比称取各组分,混合均匀:
聚氯乙烯树脂:10~30%;
聚氯已烯树脂:12~20%;
木粉:2~4%;
碳酸钙粉:15~25%;
聚乙烯蜡:2~4%;
硬脂酸:2~4%;
氯化聚乙烯135A:2~4%;
色粉:4~8%;
AC-02发泡剂:3~5%;
(2)吸附净化剂的预处理
按照如下重量百分比称取吸附净化剂各组分:
沸石微粒:12~16%,筛分至80~200目以下;
大孔型树脂:8~15%,筛分至60~70目以下;
微米级碳球:4~6%,筛分至200~300目以下;
将吸附净化剂各组分混合均匀,先在吸附净化剂重量2~3倍的饱和食盐水中浸泡18~20h,然后排尽饱和食盐水,用无水乙醇漂洗净,再用2%~4%的氢氧化钠溶液中浸泡2~4h,排尽碱液后用无水乙醇冲洗直至排出水接近中性;
(3)混料
将经过预处理的吸附净化剂混入步骤(1)的混合组分中,搅拌均匀后待用;
(4)挤出定型:
将上述混合物上料,经由木塑板挤出机挤出成型,加料转速为7~8.5r/min,主机转速为7~8.8r/min,加料段温度140~160℃,机筒温度130~150℃,模头温度160~180℃,当挤出稳定后,开通5~10℃冷却水,牵引切割后定型。
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