CN108676280A - 一种复合地板基材的发泡工艺 - Google Patents

一种复合地板基材的发泡工艺 Download PDF

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CN108676280A
CN108676280A CN201810431726.9A CN201810431726A CN108676280A CN 108676280 A CN108676280 A CN 108676280A CN 201810431726 A CN201810431726 A CN 201810431726A CN 108676280 A CN108676280 A CN 108676280A
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袁立新
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Abstract

本发明公开了一种可使复合地板更加环保、并可降低其树脂含量的复合地板基材的发泡工艺，包括：1)配料：按重量份计，用于生产复合地板基材的原料包括：90～110份PVC、90～100份重钙、7～9份发泡调节剂、4.4～4.8份钙锌稳定剂、0.2～0.4份黄发泡剂、0.7～0.9份白发泡剂、0.7～1.1份PE蜡、0.2～0.3份高温氧化聚乙烯蜡和0.6～0.8份内润滑剂；2)PVC低发泡原料混合：3)固体输送区塑化：4)融化区塑化：5)熔体输送区塑化；6)挤出定型冷却。本发明所述的复合地板基材发泡工艺尤其适用于PVC地板的生产中。

Description

一种复合地板基材的发泡工艺
技术领域
本发明涉及到一种PVC地板的发泡工艺，尤其涉及到一种复合地板基材的发泡工艺。
背景技术
随着我国经济的蓬勃发展，木材的需求量越来越大，然而，我国森林覆盖率本来较低，再加上近些年的滥砍滥伐，导致了木材供应量的逐年减少，随之而来的是木材的价格也逐年攀升。因此，我国早在上世纪80年代就提出了“以塑代木”的战略。
复合地板是目前市面上非常流行的一种地面装饰材料，是一种在欧美以及亚洲非常受欢迎的产品，风靡国内外。然而，传统的复合地板在单位体积内树脂的含量较高，制约了其成本下降的空间；而且，未发泡的复合地板对环境有一定污染，不利于再生利用。
发明内容
本发明所要解决的技术问题是：提供一种可使复合地板更加环保、并可降低其树脂含量的复合地板基材的发泡工艺。
为解决上述技术问题，本发明采用的技术方案为：一种复合地板基材的发泡工艺，包括以下步骤：
1)配料：按重量份计，用于生产复合地板基材的原料包括：90～110份PVC、 90～100份重钙、7～9份发泡调节剂、4.4～4.8份钙锌稳定剂、0.2～0.4份黄发泡剂、0.7～0.9份白发泡剂、0.7～1.1份PE蜡、0.2～0.3份高温氧化聚乙烯蜡和 0.6～0.8份内润滑剂；
2)混料：将步骤1)配制的原料放入桨叶搅拌装置中，边搅拌边加热，搅拌的速度控制在1500转/分钟以上，待温度上升至120～130℃之间时，保持这个温度继续搅拌5分钟以上，物料在桨叶的高速搅拌下形成漩涡状运动迅速混合均匀，此外，在物料间的摩擦热与容器外部加热源共同作用下，各种助剂迅速渗入PVC树脂，形成干混料，然后，通过容器内外套通入冷却水与桨叶的低速搅拌(搅拌的速度控制在500转/分钟以下)，将混合均匀的干混料边搅拌边冷却，使120～130℃左右的干混料在5分钟内迅速冷却到45℃以下；
3)固体输送区塑化：将经步骤2)混合均匀的干混料送入固体输送区，伴随螺杆转动，固体聚合物粒子向机头方向推进，PVC物料中的高分子、小分子等粒子逐渐被加热，使粒子在致密状态中充分接触、扩散、渗透；
4)融化区塑化：将经步骤3)得到的固体混合料送入融化区，通过螺杆的螺距、螺棱宽度变化，PVC颗粒间产生极大压力，将压实的颗粒变成密实的固体床，而固体床在移动时被逐渐破坏形成粘流态向前输送；
5)熔体输送区塑化；将经步骤4)得到的熔融状态的混合料送入熔体输送区，熔融大分子在剪切作用下与各种助剂进一步反应、一级粒子与少量初级粒子组成结晶体；
6)挤出定型冷却。
作为一种优选方案，在所述的一种复合地板基材发泡工艺中，步骤4)所述固体床是由一部分PVC高弹态与一部分PVC玻璃态、少量的PVC粘流态组成的混合状态，且固体床具有螺旋形螺槽的形状并能在螺槽内滑动。
本发明的有益效果是：本发明所述的复合地板基材发泡工艺有效地降低了地板单位体积内树脂的含有量，降低了地板的成本。此外，由于本发明所述的复合地板采用了基材发泡工艺，能在熔体输送区中得到可提高最终材料的强度与韧性的结晶体，又由于初级粒子表面积大，在受到冲击时可以吸收部分冲击能，提高韧性，所以，相比于普通的不发泡PVC地板，采用本发明所述的发泡工艺制得的地板具有更好的隔热性、声波阻尼性、高阻燃性和化学稳定性，并且，发泡后的复合地板对环境没有污染，可再生利用，符合绿色环保理念。当含有步骤5)所述结晶体材料被挤出、冷却后，在外力的作用下，初级粒子能够阻碍一级粒子的运动，从而进一步提高了材料的强度。
具体实施方式
下面结合具体的实施例，详细描述本发明所述的一种复合地板基材发泡工艺的具体实施方案。
本发明所述的一种复合地板基材的发泡工艺，包括以下步骤：
1)配料：按重量份计，按照90～110份、90～100份重钙、7～9份发泡调节剂、4.4～4.8份钙锌稳定剂、0.2～0.4份黄发泡剂、0.7～0.9份白发泡剂、0.7～ 1.1份PE蜡、0.2～0.3份高温氧化聚乙烯蜡、0.6～0.8份内润滑剂进行配料；
2)混料：将步骤1)配制的原料放入桨叶搅拌装置中，边搅拌边加热，搅拌的速度控制在1500转/分钟以上，待温度上升至120～130℃之间时，保持这个温度继续搅拌5分钟以上，物料在桨叶的高速搅拌下形成漩涡状运动迅速混合均匀，此外，在物料间的摩擦热与容器外部加热源共同作用下，各种助剂迅速渗入PVC树脂，形成干混料，然后，通过容器内外套通入冷却水与桨叶的低速搅拌(搅拌的速度控制在500转/分钟以下)，将混合均匀的干混料边搅拌边冷却，使120～130℃左右的干混料在5分钟内迅速冷却到45℃以下；
3)固体输送区塑化：将经步骤2)混合均匀的干混料送入固体输送区，伴随螺杆转动，固体聚合物粒子向机头方向推进，PVC物料中的高分子、小分子等粒子逐渐被加热，使粒子在致密状态中充分接触、扩散、渗透；
4)融化区塑化：将经步骤3)得到的固体混合料送入融化区，通过螺杆的螺距、螺棱宽度变化，PVC颗粒间产生极大压力，将压实的颗粒变成密实的固体床，而固体床在移动时被逐渐破坏形成粘流态向前输送；
5)熔体输送区塑化；将经步骤4)得到的熔融状态的混合料送入熔体输送区，熔融大分子在剪切作用下与各种助剂进一步反应、一级粒子与少量初级粒子组成结晶体；
6)挤出定型冷却；
在本实施例中，步骤4)所述固体床是由一部分PVC高弹态与一部分PVC 玻璃态、少量的PVC粘流态组成的混合状态，且固体床具有螺旋形螺槽的形状并能在螺槽内滑动。
综上所述，仅为本发明的较佳实施例而已，并非用来限定本发明实施的范围，凡依本发明权利要求范围所述的形状、构造、特征及精神所作的均等变化与修饰，均应包括在本发明的权利要求范围。

Claims (2)

1.一种复合地板基材的发泡工艺，包括以下步骤：
1)配料：按重量份计，用于生产复合地板基材的原料包括：90～110份PVC、90～100份重钙、7～9份发泡调节剂、4.4～4.8份钙锌稳定剂、0.2～0.4份黄发泡剂、0.7～0.9份白发泡剂、0.7～1.1份PE蜡、0.2～0.3份高温氧化聚乙烯蜡和0.6～0.8份内润滑剂；
2)混料：将步骤1)配制的原料放入桨叶搅拌装置中，边搅拌边加热，搅拌的速度控制在1500转/分钟以上，待温度上升至120～130℃之间时，保持这个温度继续搅拌5分钟以上，然后，将混合均匀的干混料边搅拌边冷却，搅拌的速度控制在500转/分钟以下，使得干混料在5分钟内迅速冷却至45℃以下；
3)输送区塑化：将经过步骤2)得到的干混料送入螺杆挤出机中，在螺杆挤出机的固体输送区，通过螺杆的转动，使得干混料中的固体聚合物粒子在向前移动过程中在致密状态下充分接触、扩散和渗透，形成固体混合料；
4)融化区塑化：将经过步骤3)得到的固体混合料送入螺杆挤出机中，在进入融化区时，由于螺杆在融化区内的螺距和螺棱逐渐变小，使得固体混合料中的PVC颗粒间产生极大的压力，将压实的颗粒变成密实的固体床，固体床在移动过程中被逐渐破坏、形成粘流态向前输送；
5)熔体区塑化；将经过步骤4)得到的熔融状态的混合料送入至螺杆挤出机的熔体区，熔融状态的大分子在剪切作用下与各种助剂进一步反应，使得一级粒子与少量初级粒子组成结晶体；
6)挤出定型冷却。
2.根据权利要求1所述的复合地板基材的发泡工艺，其特征在于：步骤4)所述的固体床为包含PVC高弹态、PVC玻璃态和PVC粘流态的混合状态。
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