CN110272592A - 一种高抗冲、轻质聚丙烯复合件及成型工艺 - Google Patents

一种高抗冲、轻质聚丙烯复合件及成型工艺 Download PDF

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CN110272592A
CN110272592A CN201810249579.3A CN201810249579A CN110272592A CN 110272592 A CN110272592 A CN 110272592A CN 201810249579 A CN201810249579 A CN 201810249579A CN 110272592 A CN110272592 A CN 110272592A
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composite materials
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李熹平
叶鑫
曾水萍
王博文
王耀辉
侯蒨
杨文杰
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Zhejiang Normal University CJNU
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Abstract

本发明涉及一种高抗冲、轻质聚丙烯复合件及成型工艺。其特征在于，复合件由共聚聚丙烯52‑81份、滑石粉10‑25份、热塑性弹性体5‑25份、发泡剂0.2‑0.5份、热稳定剂1‑2份、光稳定剂1‑2份组成。本发明通过控制无规共聚聚丙烯材料的配方、原料挤出和注塑发泡等关键参数，不仅可使加工成型的PP塑料制品的重量降低20％‑30％，达到轻量化、节约生产成本的效果，而且微孔发泡PP的孔径均匀，加工成型的PP塑料制品具有冲击强度高(≥360J/m)，且表面光滑等良好的物理性能。本发明工艺参数易于控制，生产成本低廉，易于推广。

Description

一种高抗冲、轻质聚丙烯复合件及成型工艺
技术领域
本发明涉及高分子复合材料技术领域，尤其涉及一种高抗冲、轻质聚丙烯复合件及其成型工艺。
背景技术
聚丙烯(PP)因其优良的综合力学性能、化学稳定性和耐热性、较好的成型加工性能和相对低廉的价格而在工业领域中扮演越来越重要的角色。但由于PP在使用过程中存在如下缺点，如冲击韧性低、低温易脆裂、耐候性差、强度/模量/硬度低、成型收缩大、尺寸稳定性差、制件易变形等，使其在工程领域的应用受到限制。因此，研究开发良好的PP基复合材料，并在保证使用要求的前提下，进一步降低PP零部件的成本和重量，对促进该类材料在汽车领域的应用意义重大。
注塑发泡技术是指采用注塑的方式在料筒内形成气相和熔融聚合物的单相溶液，再由快速的压力降和温度变化引起熔体的热力学不稳定性，从而在所生产的制件中形成大量的泡孔结构。与传统的注塑工艺相比，该技术具有优异的尺寸精度、较短的成型周期，较小的制品翘曲和残余应力，并可显著降低材料的用量，在工程上的应用日益得到重视。PP微发泡材料具有密度低、吸收冲击功强、隔音隔热等特点，具有广阔的应用前景。
然而，PP的熔体强度较低，使得其可发泡性较差，发泡过程中易出现泡孔破裂、并泡等现象，同时，注塑发泡工艺复杂，成型过程中注射速率、射胶量、熔体温度等参数对产品的泡孔结构和性能也会产生重要影响，因此开发可获得优良泡孔结构的发泡材料，并优化其成型工艺，是工程领域应用中需要迫切解决的问题。
发明内容
本发明的目的是提供一种高抗冲、轻质聚丙烯复合件及其成型工艺，得到的成型件具有较高的冲击强度，较小的质量，且成型方法简单，满足工业应用的成本和性能需求。
为达到上述目的，本发明通过以下技术方案来实现：
(1)一种高抗冲、轻质聚丙烯复合件，其特征在于，复合件由共聚聚丙烯52-81份、滑石粉10-25份、热塑性弹性体5-25份、发泡剂0.2-0.5份、热稳定剂1-2份、光稳定剂1-2份组成。
其中，所述的共聚聚丙烯为无规共聚聚丙烯，熔融指数15-70g/10min，230℃，拉伸强度330kg/cm2，热变形温度为77℃；所述熔融指数的测量是根据ASTM D-1238，条件为230℃/2.16kg重量进行的。
所述的滑石粉粒径为1-10um，长径比2-12，其表面经活性化处理；
所述的热塑性弹性体为乙烯和辛烯共聚高聚物，熔融指数1-7g/10min，190℃，门尼粘度5-30MU(121℃)，拉伸伸长率为700-1200％，所述熔融指数的测量是根据ASTM D-1238，条件为190℃/2.16kg重量进行的；
所述的发泡剂为以聚烯烃弹性体为基体的偶氮二甲酰胺发泡母粒；
所述的热稳定剂为酚类和磷类稳定剂，其作用是抑制加工过程中产生的降解和氧化；
所述的光稳定剂为邻羟基二苯甲酮类、苯并三唑类、水杨酸酯类、三嗪类、取代丙烯腈类等任意一种或两种以上的混合物，其作用是注塑发泡件使用过程中遮蔽或反射紫外线，使光不能透入塑料内部，从而起到保护塑料、抑制降解、延长使用寿命的作用；
(2)本发明还提供了一种高抗冲、轻质聚丙烯复合件的成型工艺，包括以下步骤：
所述的一种高抗冲、轻质聚丙烯复合件的前期原料制备过程，其特征是：将共聚聚丙烯、滑石粉、热塑性弹性体、热稳定剂和光稳定剂经高混机混合均匀后，加入到同向双螺杆挤出机中熔融分散，然后挤出、切粒，得到强化的共聚聚丙烯复合颗粒材料。为保证造粒与产品质量，提高混合材料的分布均匀性，所述的双螺杆直径要求D＝20-30mm；长径比要求为L/D＝25-45；
所述的一种高抗冲、轻质聚丙烯复合件的后期成型工艺，其特征是：将按照上述制备过程得到的强化的共聚聚丙烯母粒干燥后，与发泡剂母粒0.2-0.5份充分混合均匀，然后在注塑机中按设定的注塑工艺进行发泡成型。其中，复合材料干燥温度为85-95摄氏度，干燥时间为2小时。注塑工艺要求的注射熔体温度190-230℃，模具温度60-90℃；保压压力和保压时间均为0；塑化背压0.2-0.3MPa；注射压力90-150Mpa，注射速度95-115cm3/s。
与现有技术相比，本发明具有以下有益效果：
本发明通过控制无规共聚聚丙烯材料的配方、原料挤出和注塑发泡等关键参数，不仅可使加工成型的PP塑料制品的重量降低20％-29％，达到轻量化、节约生产成本的效果，而且微孔发泡PP的孔径均匀，加工成型的PP塑料制品具有冲击强度高(≥360J/m)，且表面光滑等良好的物理性能。本发明中的热稳定剂的作用是抑制加工过程中产生的降解和氧化，光稳定剂的作用是注塑发泡件使用过程中遮蔽或反射紫外线，使光不能透入塑料内部，从而起到保护塑料、抑制降解、延长使用寿命的作用。本发明工艺参数易于控制，生产成本低廉，易于推广。
具体实施方式
为使本发明更明显易懂，以下采用实施例具体说明本发明的一种高抗冲、轻质聚丙烯复合件及成型工艺。
对比例一
将87份共聚聚丙烯，5份粒径为6.3um，长径比为2.0的活性化处理的滑石粉，5份弹性体，1份热稳定剂，2份光稳定剂，放入高混机中，充分混合均匀。然后利用同向双螺杆挤出机挤出造粒，其中螺杆直径为30mm，螺杆长径比为36，挤出机料筒各段温度为190-230℃。
将造好的塑料颗粒干燥后，添加发泡剂0.2份，放入注塑机中注射成型标准试样。其中熔体温度设置为200℃，注射速度为60cm3/s，注射压力40MPa，塑化背压为为0，模具温度为40℃。
将成型后的试样按相应的测试标准进行性能测试，得到如下结果。
性能指标 单位 测试标准 测试结果
缺口冲击强度 J/m ASTM D 256 260.2
拉伸强度 MPa ASTM D 638 18.8
弯曲模量 MPa ASTM D 638 1120
减重比例 ％ 按样品密度测量 0
实施实例1
将81份共聚聚丙烯，10份粒径为6.3um、长径比为2.0的活性化处理的滑石粉，7份弹性体，1份热稳定剂，1份光稳定剂，放入高混机中，充分混合均匀。然后利用同向双螺杆挤出机挤出造粒，其中螺杆直径为30mm，螺杆长径比为36，挤出机料筒各段温度为190-230℃。
将造好的塑料颗粒干燥后，添加发泡剂0.2份，放入注塑机中注射成型标准试样。其中熔体温度设置为200℃，注射速度为95cm3/s，注射压力100MPa，塑化背压为0.1MPa，模具温度为60℃。
将成型后的试样按相应的测试标准进行性能测试，得到如下结果。
性能指标 单位 测试标准 测试结果
缺口冲击强度 J/m ASTM D 256 360.2
拉伸强度 MPa ASTM D 638 16.8
弯曲模量 MPa ASTM D 638 831.2
减重比例 ％ 按样品密度测量 20
实施实例2
将63份共聚聚丙烯，15份粒径为1.1um，长径比为2.0的活性化处理的滑石粉，18份弹性体，1.5份热稳定剂，2.5份光稳定剂，放入高混机中，充分混合均匀。然后利用同向双螺杆挤出机挤出造粒，其中螺杆直径为30mm，螺杆长径比为36，挤出机料筒各段温度为190-230℃。
将造好的塑料颗粒干燥后，添加发泡剂0.3份，放入注塑机中注射成型标准试样。其中熔体温度设置为210℃，注射速度为100cm3/s，注射压力105MPa，塑化背压为0.2MPa，模具温度为70℃。
将成型后的试样按相应的测试标准进行性能测试，得到如下结果。
实施实例3
将52份共聚聚丙烯，20份粒径为2.0um，长径比为5的活性化处理的滑石粉，24份弹性体，2份热稳定剂，2份光稳定剂，放入高混机中，充分混合均匀。然后利用同向双螺杆挤出机挤出造粒，其中螺杆直径为25mm，螺杆长径比为36，挤出机料筒各段温度为190-230℃。
将造好的塑料颗粒干燥后，添加发泡剂0.4份，放入注塑机中注射成型标准试样。其中熔体温度设置为210℃，注射速度为110cm3/s，注射压力110MPa，塑化背压为0.3MPa，模具温度为90℃。
测试结果
性能指标 单位 测试标准 测试结果
缺口冲击强度 J/m ASTM D 256 575.6
拉伸强度 MPa ASTM D 638 11.4
弯曲模量 MPa ASTM D 638 465.1
减重比例 ％ 按样品密度测量 29

Claims (8)

1.一种高抗冲、轻质聚丙烯复合件，其特征在于，复合件由共聚聚丙烯52-81份、滑石粉10-25份、热塑性弹性体5-25份、发泡剂0.2-0.5份、热稳定剂1-2份、光稳定剂1-2份组成。
2.如权利要求1所述的高抗冲、轻质聚丙烯复合件，所述的共聚聚丙烯为无规共聚聚丙烯，熔融指数在230℃、2.16kg压力下的熔融指数为15-70g/10min，热变形温度为77℃。
3.如权利要求1所述的高抗冲、轻质聚丙烯复合件，所述的滑石粉粒径为1-10um，长径比2-12。
4.如权利要求1所述的高抗冲、轻质聚丙烯复合件，所述的热塑性弹性体为乙烯和辛烯共聚高聚物，熔融指数1-7g/10min，190℃，门尼粘度5-30MU(121℃)，拉伸伸长率为700-1200％，所述熔融指数的测量是根据ASTM D-1238，条件为190℃/2.16kg重量进行的。
5.如权利要求1所述的高抗冲、轻质聚丙烯复合件，所述的发泡剂为以聚烯烃弹性体为基体的偶氮二甲酰胺发泡母粒。
6.如权利要求1所述的高抗冲、轻质聚丙烯复合件，所述的热稳定剂为酚类和磷类稳定剂任意一种或两种以上的混合物。
7.如权利要求1所述的高抗冲、轻质聚丙烯复合件，所述的光稳定剂为邻羟基二苯甲酮类、苯并三唑类、水杨酸酯类、三嗪类、取代丙烯腈类等任意一种或两种以上的混合物。
8.本发明还提供了一种高抗冲、轻质聚丙烯复合件的成型工艺，包括以下步骤：
所述的一种高抗冲、轻质聚丙烯复合件的前期原料制备过程，其特征是：将共聚聚丙烯、滑石粉、热塑性弹性体、热稳定剂和光稳定剂经高混机混合均匀后，加入到同向双螺杆挤出机中熔融分散，然后挤出、切粒，得到强化的共聚聚丙烯复合颗粒材料。为保证造粒与产品质量，提高混合材料的分布均匀性，所述的双螺杆直径要求D＝20-30mm；长径比要求为L/D＝25-45；
所述的一种高抗冲、轻质聚丙烯复合件的后期成型工艺，其特征是：将按照上述制备过程得到的强化的共聚聚丙烯母粒干燥后，与发泡剂母粒0.2-0.5份充分混合均匀，然后在注塑机中按设定的注塑工艺进行发泡成型。其中，复合材料干燥温度为85-95摄氏度，干燥时间为2小时。注塑工艺要求的注射熔体温度190-230℃，模具温度60-90℃；保压压力和保压时间均为0；塑化背压0.2-0.3MPa；注射压力90-150Mpa，注射速度95-115cm3/s。
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