CN108673987A - 一种仿釉面彩色塑胶琉璃瓦及其制备方法 - Google Patents

一种仿釉面彩色塑胶琉璃瓦及其制备方法 Download PDF

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CN108673987A
CN108673987A CN201810328311.9A CN201810328311A CN108673987A CN 108673987 A CN108673987 A CN 108673987A CN 201810328311 A CN201810328311 A CN 201810328311A CN 108673987 A CN108673987 A CN 108673987A
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glazed tiles
imitative glaze
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CN108673987B (zh
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陈旭
郑凌叶
邵世容
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Chengdu Fist New Material Co Ltd
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Abstract

本发明公开了一种仿釉面彩色塑胶琉璃瓦及其制备方法，属于塑料制品技术领域。所述琉璃瓦包括上层和下层，上层包括以下按质量百分比计的原料：AS树脂65～75％，AS树脂改性剂15～30％，着色颜料I 2.5～3.5％，助剂I0.5～5％；下层包括以下按质量百分比计的原料：PVC树脂50～60％，纳米活性CaCO3 30～40％，助剂II 3.5～5％，着色颜料II 0～3.5％；AS树脂改性剂为ASA树脂、丙烯酸酯中的至少一种；着色颜料I为透明颜料；纳米活性CaCO3的晶型为立方体晶型。本发明的琉璃瓦具有外观效果好，具有仿釉面的效果，且其耐候性、抗冲击性以及环境友好性均优于现有技术中的粘土琉璃瓦。

Description

一种仿釉面彩色塑胶琉璃瓦及其制备方法
技术领域
本发明涉及一种琉璃瓦，尤其涉及一种仿釉面彩色塑胶琉璃瓦及其制备方法，属于塑料制品技术领域。
背景技术
古建筑广泛分布于全国各地的城市建筑、宫殿、民居、寺庙、博物馆、公园，其楼、台、亭、阁、塔、牌坊、围墙都是中华传统文化的重要组成部分。琉璃瓦则是这些古建筑的“面子工程”，其金碧辉煌为中华古建筑增添了几千年的奇光异彩。然而，琉璃瓦由粘土上釉烧制而成，不耐冲击，年深日久，必然要翻新。随着人类文明的进步，保护耕地，保护环境，不用粘土制砖、烧瓦，保护环境保持可持续发展已是基本国策。节约能源，走可持续发展的道路，是当今各国必须坚持的经济发展之路，建筑节能和节能建筑，已在全世界蓬勃发展，使用耐候性好，经久耐用，隔热保温材料是节能建筑的首选。因此，人们必须寻找新的替代产品，以传承中华文化的辉煌。
发明内容
本发明旨在解决现有技术中的粘土制成的琉璃瓦存在的耐冲击性和耐候性不好，需要使用粘土，破坏耕地，影响生态环境的问题，提供一种仿釉面彩色塑胶琉璃瓦，通过采用树脂载体以及助剂实现良好的抗冲击性和耐候性，且颜色丰富，外观佳。
为实现上述发明目的，本发明的技术方案如下：
一种仿釉面彩色塑胶琉璃瓦，其特征在于：包括上层和下层，所述上层包括以下按质量百分比计的原料：AS树脂65～75％，AS树脂改性剂15～30％，着色颜料I 2.5～3.5％，助剂I0.5～5％；所述下层包括以下按质量百分比计的原料：PVC树脂50～60％，纳米活性CaCO330～40％，助剂II 3.5～5％，着色颜料II 0～3.5％；
所述AS树脂改性剂为ASA树脂、丙烯酸酯中的至少一种；
所述着色颜料I为透明颜料；
所述纳米活性CaCO3的晶型为立方体晶型，粒径为10～100nm，其中，粒径8～15nm的颗粒占总重量的50％以上。
对于纳米活性CaCO3的选择，首先对于晶型的选择，立方体晶型的产品流动性小，对塑料制品的表面光泽度影响小；选择粒径为10～100nm，其中，粒径8～15nm的颗粒占总重量的50％以上的材料，以保证在满足纳米碳酸钙具有的填充效果，即使制品表面光滑、光泽度好的同时，还具有良好的分散性，避免团聚，造成滤网堵塞以及表面起颗粒的问题。
为了更好地实现本发明，进一步地，所述着色颜料I为透明颜料。
进一步地，所述助剂I为分散剂、偶联剂、塑化剂中的至少一种。
进一步地，所述PVC树脂为五型粉状PVC树脂。
进一步地，所述助剂II为分散剂、偶联剂、塑化剂中的2～3种和稳定剂的混合物。
本发明的另一个目的是提供所述仿釉面彩色塑胶琉璃瓦的制备方法，其特征在于：包括以下步骤：
A.干燥、称量
对原料进行干燥，控制水份含量≤0.1％后，按配方称取各原料；
B.上层料混合
向混料机I投入AS树脂改性剂，再按重量从大到小的顺序加入着色颜料I和助剂I，混料3～5min后，再加入AS树脂，再混料3～5min，得到混合料I；
C.上层料挤出、造粒
将步骤B得到的混合料I于挤出机中挤出，并造粒，得到颗粒料I；
D.下层料混合
向混料机II投入纳米活性CaCO3，然后分散剂、偶联剂、塑化剂中的2～3种，混料8～12min，再投入PVC、稳定剂、着色颜料II，混料15～20min(混料时间过长，会使物料温度升高，造成PVC分解出HCl而变色)，得到混合料II；
E.共挤
将颗粒料I和混合料II于挤出机中共挤，得到上、下层瓦料，并在瓦楞辊设备上成型，分切、冷却得到所述塑胶琉璃瓦。
进一步地，步骤C中，挤出温度为180～230℃，模头压力为8.8～9.8Mpa。
进一步地，步骤E中，颗粒料I的挤出温度为180～200℃，混合料II的挤出温度为130～200℃。
进一步地，步骤E中，成型前先经过风冷，风冷后物料的进料温度为130～170℃，成型后物料出料温度为90～120℃；成型时，瓦楞辊的压力为2.5～3Mpa。
更进一步地，步骤E中，所述下层料挤出所使用的螺杆挤出机为单螺杆挤出机，所述单螺杆挤出机的螺纹块与螺筒之间的间歇为标准值的30～60％，且所述螺纹块为带分散盘的螺纹块，以提高挤出机的剪切力，进而提高纳米活性碳酸钙的分散效果。
本发明的有益效果：
(1)本发明与现有技术中的粘土琉璃瓦相比，具有抗冲击性和耐候性好的优点，且，采用树脂为主要材料，不影响生态环境。具体来说，本发明的琉璃瓦包括上层和下层，上层选用透明度好的AS树脂作为主体材料，以在加入透明颜料和助剂后，具有高的折射率，进而保证仿釉琉璃瓦金碧辉煌的视觉效果，用丙烯酸酯或ASA树脂对AS树脂改性、增强，改善AS树脂本身的抗冲击性、耐候性、抗静电性、耐酸碱性，使其更满足琉璃瓦的使用环境；下层采用PVC为主体材料，并通过纳米活性碳酸钙对PVC进行改性，以达到增韧、增强的效果，提高下层瓦的抗性强度和制品的弯曲弹性模量，并且纳米粒子可以更好填充体系的物理结构缺陷，降低制品的表面粗糙度，从而减少对光线的漫射作用，提高制品的光亮度；另外，下层材料还为琉璃瓦制品提供一定的保温、阻燃性能。
本发明的琉璃瓦的各项技术指标均符合国家标准：“WW/T 0073-2017清代宫式建筑修缮材料琉璃瓦”，能够完全替代现有技术中的粘土琉璃瓦，并在耐候性、抗冲击性以及环境保护方面优于粘土琉璃瓦。
(2)本发明中，着色颜料I为透明颜料，透明颜料与透明树脂共同为琉璃瓦的上层提供高光折射率，进一步提高视觉效果，实现仿釉面的目的。
(3)本发明的制备方法中，在混料前，先进行充分的干燥，尤其是AS、ASA、丙烯酸酯、纳米活性碳酸钙等易吸潮的原材料，以防止在生产过程中，产生气泡、流纹和接缝等质量问题。
(4)本发明的制备方法，步骤D中，通过采用助剂和纳米活性碳酸钙进行混合，实现对纳米碳酸钙再次进行表面处理，提高其使用性能。
具体实施方式
下面结合实施例对本发明作进一步地详细说明，但本发明的实施方式不限于此。
实施例1
一种仿釉面红色塑胶琉璃瓦，包括上层和下层，上层由以下按质量百分比的原料组成：AS2200 67％，ASA031H 30％，透明氧化铁红2.25％，酞青蓝0.0092％，桃红0.0048％，炭黑M430 0.2％，EBS 400A 0.49％，硅烷偶联剂7007 0.05％；所述下层包括以下按质量百分比计的原料：五型PVC 50％，纳米活性碳酸钙40％，氧化铁2.25％，酞青蓝0.0092％，桃红0.0048％，炭黑M430 0.2％，AV-A 1％，EBS 0.5％，硅烷偶联剂7007 1.2％，DOP 2.3％。
实施例2
一种仿釉面黄色塑胶琉璃瓦，包括上层和下层，上层由以下按质量百分比的原料组成：AS树脂2200 75％，丙烯酸酯18％，透明铁黄1.9％，钛白粉0.3％，桃红0.74％，EBS0.9％，DOP 3.15％，硅烷偶联剂7007 0.01％；所述下层包括以下按质量百分比计的原料：PVC五型60％，纳米活性碳酸钙30％，透明铁黄1.9％，钛白粉0.3％，AV-A 1.5％，EBS0.75％，DOP 2.9％，硅烷偶联剂7007 0.35％。
实施例3
一种仿釉面墨绿色塑胶琉璃瓦，包括上层和下层，上层包括以下按质量百分比的原料：AS树脂2200 65％，ASA031H 27％，酞青绿3.01％，炭黑0.01％，EBS 0.95％，DOP3.5％，硅烷偶联剂7007 0.45％；所述下层包括由以下按质量百分比计的原料组成：PVC五型56％，纳米活性碳酸钙35％，酞青绿2.9％，炭黑0.01％，EBS 1.2％，AV-A 1.7％，硅烷偶联剂7007 0.49％，DOP 2.7％。
实施例4
一种仿釉面灰色塑胶琉璃瓦，包括上层和下层，上层包括以下按质量百分比的原料：AS树脂72％，丙烯酸酯19.5％，硅烷偶联剂7007 0.2％，EBS 0.74％，DOP 4.3％，TIO23.1％，酞青蓝0.01％，炭黑0.015％；所述下层包括以下按质量百分比计的原料：PVC五型50％，纳米活性碳酸钙40％，TiO2 3.1％，炭黑0.016％，AV-A 1％，EBS 0.83％，硅烷偶联剂7007 0.5％，DOP 4.5％。
实施例5
一种仿釉面紫色塑胶琉璃瓦，包括上层和下层，上层包括以下按质量百分比的原料：S树脂70％，ASA 15％，群青0.24％，透明氧化铁红3.25％，炭黑0.1％，硅烷偶联剂70070.35％，EBS 1.15％，DOP 3.5％；所述下层由以下按质量百分比计的原料组成：PVC五型50％，纳米活性碳酸钙38％，群青1.27％，透明氧化铁红2.23％，AV-A 1.1％，EBS 0.85％，硅烷偶联剂7007 2.28％，DOP 4.25％。
本实施例中的琉璃瓦制备方法如下：
A.称量、干燥
按配方称取各原料后，对原料进行干燥，控制水份含量≤0.1％；
B.上层料混合
向混料机I投入AS树脂改性剂ASA，再按重量从大到小的顺序加入透明氧化铁红、炭黑和硅烷偶联剂7007、EBS和DOP，混料3min后，再加入AS树脂，再混料3min，得到混合料I；
C.上层料挤出、造粒
将步骤B得到的混合料I于挤出机中挤出，并造粒，得到颗粒料I；
D.下层料混合
向混料机II投入纳米活性CaCO3，然后投入DOP和硅烷偶联剂7007，混料10min，再投入PVC、稳定剂AV-A、群青、透明氧化铁红后，混料15～20min，得到混合料II；
E.共挤
将颗粒料I和混合料II于挤出机中共挤，得到上、下层瓦料，并在瓦楞辊设备上成型，分切、冷却得到所述塑胶琉璃瓦。
琉璃瓦的脊瓦、檐瓦及建筑顶部装饰件直接采用混合料I注塑加工得到。
本实施例的步骤C中，挤出温度为180℃，模头压力为8.8Mpa。
本实施例的步骤E中，颗粒料I的挤出温度为180℃，混合料II的挤出温度为130℃。
本实施例的步骤E中，成型前先经过风冷，风冷后物料的进料温度为130℃，成型后物料出料温度为90℃；成型时，瓦楞辊的压力为2.5Mpa。
本实施例的步骤E中，所述下层料挤出所使用的螺杆挤出机为单螺杆挤出机，所述单螺杆挤出机的螺纹块与螺筒之间的间歇为标准值的60％，且所述螺纹块为带分散盘的螺纹块。
实施例6
一种仿釉面兰色塑胶琉璃瓦，包括上层和下层，上层包括以下按质量百分比的原料：AS树脂70.5％，丙烯酸酯15％，ASA 6.5％，分散剂EBS 0.65％，偶联剂硅烷7007 0.5％，塑化剂DOP 3.8％，酞青蓝2.8％，炭黑0.23％；所述下层由以下按质量百分比计的原料组成：PVC五型58％，纳米活性碳酸钙32％，酞青蓝2.7％，炭黑0.195％，AV-A 1.8％，EBS1.2％，硅烷偶联剂7007 0.86％，DOP 3.25％，上层和下层的厚度根据实际需要进行控制。
本实施例中的琉璃瓦制备方法如下：
A.称量、干燥
按配方称取各原料后，对原料进行干燥，控制水份含量≤0.1％；
B.上层料混合
向混料机I投入丙烯酸酯，再按重量从大到小的顺序加入酞青蓝、炭黑和塑化剂DOP、偶联剂硅烷7007、分散剂EBS，混料5min后，再加入AS树脂，再混料5min，得到混合料I；
C.上层料挤出、造粒
将步骤B得到的混合料I于挤出机中挤出，并造粒，得到颗粒料I；
D.下层料混合
向混料机II投入纳米活性CaCO3，然后投入DOP、硅烷偶联剂7007和EBS，混料12min，再投入PVC、稳定剂AV-A、群青、透明氧化铁红后，混料15～20min，得到混合料II；
E.共挤
将颗粒料I和混合料II于挤出机中共挤，得到上、下层瓦料，并在瓦楞辊设备上成型，分切、冷却得到所述塑胶琉璃瓦。
琉璃瓦的脊瓦、檐瓦及建筑顶部装饰件直接采用混合料I注塑加工得到。
本实施例的步骤C中，挤出温度为230℃，模头压力为9.8Mpa。
本实施例的步骤E中，颗粒料I的挤出温度为200℃，混合料II的挤出温度为200℃。
本实施例的步骤E中，成型前先经过风冷，风冷后物料的进料温度为170℃，成型后物料出料温度为120℃；成型时，瓦楞辊的压力为3Mpa。
本实施例的步骤E中，所述下层料挤出所使用的螺杆挤出机为单螺杆挤出机，所述单螺杆挤出机的螺纹块与螺筒之间的间歇为标准值的30％，且所述螺纹块为带分散盘的螺纹块。
实施例1～6制得的琉璃瓦的性能指标如下表1所示：
表1：
以上所述，仅是本发明的较佳实施例，并非对本发明做任何形式上的限制，凡是依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化，均落入本发明的保护范围之内。

Claims (9)

1.一种仿釉面彩色塑胶琉璃瓦，其特征在于：包括上层和下层，所述上层包括以下按质量百分比计的原料：AS树脂65～75％，AS树脂改性剂15～30％，着色颜料I 2.5～3.5％，助剂I0.5～5％；所述下层包括以下按质量百分比计的原料：PVC树脂50～60％，纳米活性CaCO330～40％，助剂II 3.5～5％，着色颜料II 0～3.5％；
所述AS树脂改性剂为ASA树脂、丙烯酸酯中的至少一种；
所述着色颜料I为透明颜料；
所述纳米活性CaCO3的晶型为立方体晶型，粒径为10～100nm，其中，粒径8～15nm的颗粒占总重量的50％以上。
2.如权利要求1所述的仿釉面彩色塑胶琉璃瓦，其特征在于：所述助剂I为分散剂、偶联剂、塑化剂中的至少一种。
3.如权利要求1所述的仿釉面彩色塑胶琉璃瓦，其特征在于：所述PVC树脂为五型粉状PVC树脂。
4.如权利要求1所述的仿釉面彩色塑胶琉璃瓦，其特征在于：所述助剂II为分散剂、偶联剂、塑化剂中的2～3种和稳定剂的混合物。
5.如权利要求4所述的仿釉面彩色塑胶琉璃瓦的制备方法，其特征在于：包括以下步骤：
A.干燥、称量
对原料进行干燥，控制水份含量≤0.1％后，按配方称取各原料；
B.上层料混合
向混料机I投入AS树脂改性剂，再按重量从大到小的顺序加入着色颜料I和助剂I，混料3～5min后，再加入AS树脂，再混料3～5min，得到混合料I；
C.上层料挤出、造粒
将步骤B得到的混合料I于挤出机中挤出，并造粒，得到颗粒料I；
D.下层料混合
向混料机II投入纳米CaCO3，然后投入分散剂、偶联剂、塑化剂中的2～3种，混料8～12min，再投入PVC、稳定剂、着色颜料II，混料15～20min，得到混合料II；
E.共挤
将颗粒料I和混合料II于挤出机中共挤，得到上、下层瓦料，并在瓦楞辊设备上成型，分切、冷却得到所述塑胶琉璃瓦。
6.如权利要求5所述的所述的仿釉面彩色塑胶琉璃瓦的制备方法，其特征在于：步骤C中，挤出温度为180～230℃，模头压力为8.8～9.8Mpa。
7.如权利要求6所述的所述的仿釉面彩色塑胶琉璃瓦的制备方法，其特征在于：步骤E中，颗粒料I的挤出温度为180～200℃，混合料II的挤出温度为130～200℃。
8.如权利要求7所述的所述的仿釉面彩色塑胶琉璃瓦的制备方法，其特征在于：步骤E中，成型前先经过风冷，风冷后物料的进料温度为130～170℃，成型后物料出料温度为90～120℃；成型时，瓦楞辊的压力为2.5～3Mpa。
9.如权利要求7所述的所述的仿釉面彩色塑胶琉璃瓦的制备方法，其特征在于：步骤E中，所述下层料挤出所使用的螺杆挤出机为单螺杆挤出机，所述单螺杆挤出机的螺纹块与螺筒之间的间歇为标准值的30～60％，且所述螺纹块为带分散盘的螺纹块。
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