CN110733209A - 一种工程塑料与合金复合塑料模板及其制备方法 - Google Patents
一种工程塑料与合金复合塑料模板及其制备方法 Download PDFInfo
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- CN110733209A CN110733209A CN201910896908.8A CN201910896908A CN110733209A CN 110733209 A CN110733209 A CN 110733209A CN 201910896908 A CN201910896908 A CN 201910896908A CN 110733209 A CN110733209 A CN 110733209A
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- parts
- template
- pvc
- engineering plastic
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Landscapes
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- Medicinal Chemistry (AREA)
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- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- General Chemical & Material Sciences (AREA)
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- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
本发明提供了一种工程塑料合金复合塑料模板及其制备方法。所述工程塑料为丙烯腈/苯乙烯/丙烯酸酯接枝共聚工程塑料或者丙烯腈/苯乙烯/丙烯酸酯接枝共聚工程塑料合金材料作为本发明的表层材料;通过发泡技术将聚氯乙烯混合钙木粉等填充物,发泡挤出得到芯层材料;再将发泡芯材和表层工程塑料合金共挤成型,直接得到由两个表层是工程塑料。本发明通过以聚氯乙烯发泡层为基础,分别融合了聚氯乙烯和丙烯腈/苯乙烯/丙烯酸酯接枝共聚工程塑料相容性好,性能互补的特性,根据塑料建筑版的实际性能需求而设计,板材特别适合塑料建筑模板使用,且表层和芯层之间相容性好,没有污染环境的粘结剂,回收再利用过程中表层材料成为芯层材料的的改性剂。
Description
技术领域
本发明涉及一种工程塑料合金塑料模板及其制备方法。
背景技术
中国年基建规模为18万亿,其中模板约为5000亿,每年消耗160亿平方木质建筑模板,年砍伐2000万亩森林,然而这部分木材只经过4个月就变成建筑垃圾;建筑模板是建筑混凝土成型过程中的模具结构辅材,属于快速消耗品,中国每年不仅为了制造这巨量的木制建筑木板砍伐2000万亩森林,而且为了生产这些模板,年需要消耗油漆600万吨,含甲醛胶水500万吨,工地使用这些模板要消耗污染物脱模剂200万吨,年产生1.5亿吨垃圾,年中国巨大的环保压力下,我们投身新材料行业,使用可以循环回收的塑料做建筑模板,推广成功将减少森林砍伐和污染排放抑制垃圾的产生社会效益巨大。
目前市场上建筑模板的主流是木模板和胶合木质模板,使用的胶水是含甲醛的高污染物;木板周转次数少浪费资源,占据市场份额的90%。另外还有PVC结皮板脆性大,使用寿命低和pp中空塑料建筑模板成本高阻燃性差,收缩量大,模量偏低,因此推广困难。但是本发明的塑料模板是一种绿色环保节能型模板,不吸水,可以做到清水工程,使用塑料模板方便快捷、满足各种施工需要、能够实现“四节一环保”的文明施工要求,因此,复合塑料建筑模板具有广阔的应用前景。
市面上塑料模板存在以下问题:产品刚性强度低(弯曲弹性模量)、收缩性大、导致变形和漏浆、阻燃性差、火灾事故频发、产品耐候性差和对抗建筑工地复杂使用环境性能差,容易碎裂,材料耐温性差导致砼体出现波浪纹,最终导致市场推广受限。
现有技术中的存在的塑料建筑模板主要有以下几种;硬质PVC结皮发泡板,pp中空塑料建筑模板两大类其性能参数如下:
性能对比表
材料性能 | 弯曲弹性模量 | 阻燃 | 收缩㎜ | 耐温 | 冲击强度 |
PVC结皮 | 2100Map | V0 | 0.5 | 72℃ | 2-5Map |
Pp中空 | 1800Map | B2 | 3 | 82℃ | 6-8Map |
本发明材料 | 2400-3200Map | V0 | 0.6 | 80℃ | 8-30Map |
通过以上对比,本发明的工程塑料复合模板产品性能大幅度提升,特别是弯曲弹性模量和冲击强度大幅度提高,收缩性小,阻燃性好,耐温性提高后混凝土温度在固化过程中接近70度,合金工程塑料材料的耐温性比市面上的PVC结皮板材料提高10度左右,可以保持板材在混凝土放热情况下刚性强度变化远远小于传统模板。
发明内容
本发明提供了一种ASA工程塑料与PVC合金复合塑料模板及其制备方法。所述合金材料作为本发明的表层材料;通过发泡技术将硬质PVC混合碳酸钙木粉等填充物,添加稳定剂,抗氧剂加工助剂和发泡剂等材料挤出得到芯层材料;再将发泡芯材和表层工程塑料合金共挤成型,直接得到由两个表层是工程塑料,芯层是PVC发泡芯层的工程塑料合金复合塑料模板;所述工程塑料合金层和发泡芯层直接融合,两者接触界面形成粘结层无需粘结剂层,本发明的板材最终形成两个外表面是工程塑料合金层,表层内侧为紧贴表层的两个工程塑料粘结层;芯层为PVC发泡层的五层结构。本发明的工程塑料合包括芯层(1)、表层(2);粘结层(3),粘结层,是共挤过程自然形成的PVC合金层,具有较强的粘合力,保证表层和芯层的充分融合,提高产品的整体性。
本发明是专门为塑料建筑模板设计配方和结构,本发明充分的优化了最终产品的性能,本发明表层材料ASA可以很好地和PVC材料相容,进一步对提高材料的硬度,冲击强度弯曲强度拉伸强度有积极作用;合金添加EGDM材料进一步优化材料性能,提高其冲击强度,而确保其弯曲强度不下降;本发明优选云母粉5-12份,进一步提高材料的耐温性,进一步本发明充分考虑ASA和PVC材料的相容性最佳,ASA材料的耐候性20倍于PVC。
进一步的,表层材料可选择丙烯腈/苯乙烯/丙烯酸酯接枝共聚物(ASA),其是由以聚丙烯酸酯(PBA)橡胶相为核,苯乙烯-丙烯腈共聚物(SAN)为壳的核壳结构聚合物。具有良好的机械性能、耐腐蚀性、加工性、抗冲击性能和耐候性溶解度和PVC相近,因此两者之间可以复合共挤成型,达到两者之间的性能互补。
本发明通过以PVC发泡层为基础,分别融合ASA跟PVC相容性好,性能互补的特性,根据塑料建筑版的实际性能需求而设计,产品耐受环境能力强,老化周期长,冲击强度高,刚性强度高,不易碎裂,耐温性好的板材特别适合塑料建筑模板使用,且本发明工程塑料之间相容性好,没有污染环境的粘结剂,而且回收再利用过程中表层材料成为芯层材料的的增韧性能和耐候改性能。
进一步发明人还发现,通过特定配比的两种助剂分别加入PVC芯层和表层材料中,提高两种材料的复合强度,提高粘结强度,并且使内芯材料和表面材料满足模板不同性能的需求。进一步的,芯层加入特定组分的第一助剂调节芯层的价格性能和发泡倍率,是芯层能够很好地控制板材的堆积密度控制在0.4-0.66之间进行微调;纤维可以增加弹性模量降低成本;第二助剂中加入提高表层的相容性和耐候性和材料之间的协同效应,进一步改善表层材料韧性差,耐温低的缺陷,使塑料模板的品质均一。
鉴于以上发现,发明人提供以下方案:
一种丙烯腈/苯乙烯/丙烯酸酯接枝共聚物(ASA)工程塑料与聚氯乙烯(PVC)合金复合塑料模板,所述工程塑料合金复合模板包括两层工程塑料板层为表层(2),聚氯乙烯发泡层为芯层(1),所述表层丙烯腈/苯乙烯/丙烯酸酯接枝共聚物(ASA)工程塑料板层夹持所氯乙烯发泡芯层,其特征在于:所述工程塑料合金复合塑料模板,通过将芯层和所述工程塑料合金双机共挤模内复合,直接得到由两层工程塑料合金板层夹持芯层的复合结构,通过冷却定型,即为所述工程塑料合金复合建筑模板,所述表层和芯层之间存在接触界面,其接触界面为组分不特定的工程塑料合金层,且所述接触界面不含有粘结剂。
进一步的,所述表层为ASA材料。
进一步的,所述工程塑料合金复合模板的表层为ASA/PVC共混合金材料,ASA\PVC共混合金材料包括组成:6-40份的ASA高胶粉、100份的PVC、2-6份的热稳定剂、1.5-2.5份的润滑剂、3-8份的增韧剂、0.3-1.2份的加工助剂和3-12份的刚性粒子。
进一步的,所述热稳定剂为:钙锌复合热稳定剂、有机锡热稳定剂、稀土铅盐复合热稳定剂中的一种或两种以上任意比例的混合物;所述的润滑剂为PE蜡;所述增韧剂为CPE或ACR中的一种或者两种的混合物;加工助剂为硬脂酸锌或硬脂酸钙,刚性粒子为纳米碳酸钙或者云母粉。进一步的,刚性粒子优选白云母粉5-12份。
进一步的,所述工程塑料合金复合模板的聚氯乙烯发泡芯层材料包括硬质PVC以及助剂,其中助剂包括稳定剂,加工助剂、抗氧剂、发泡剂、增韧剂和填充物,填充物选自碳酸钙粉,或者碳酸钙粉、木粉和玻纤粉的混合物;稳定剂选自铅盐复合稳定剂,钙锌稳定剂,有机锡热稳定剂、稀土热稳定剂中的一种或两种以上任意比例的混合物;加工助剂选自CPE、DOP,PE蜡;增韧剂选自CPE,ACR一种或者几种的混合组分。
进一步的,所述聚氯乙烯硬质PVC发泡芯层包括质量组分含量计:
PVC 100份,
填充物 15-50份
稳定剂 三盐基硫酸铅、二盐基亚磷酸铅、钙锌热稳定剂混合组分2-5份
抗氧剂;双酚A 0.5-1份、环氧大豆油0.5-2份,
润滑剂PE蜡1-2份,
加工助剂 CPE 2-8份
增韧剂ACR 1-6份
发泡剂AC,0.4-0.6.份
进一步的,所述聚氯乙烯硬质PVC发泡芯层第一助剂,按PVC 100份为基准计算,所述第一助剂的质量组成为:
引发剂 偶氮二异丁晴0.1-0.5份和过硫酸铵0.1-0.5份
发泡调节剂 甲基丙烯酸酯2-6份。
硬脂酸钙 0.6-3份。
进一步的,所述ASA中还包括第二助剂,按ASA 100份为基准计算,第二助剂组分的质量组成为;
EGDM铰链剂 0.7-1.5份
环氧大豆油 1-5份
超细云母粉 5-12份。
进一步的,所述PVC\ASA合金还包括第二助剂,按PVC 100份为基准计算,第二助剂组分的质量组成为;
EGDM铰链剂 0.7-1.5份
环氧大豆油 1-5份
超细云母粉 5-12份。
进一步的,一种制备所述模板的方法,将聚氯乙烯硬质PVC发泡芯层的各原料加入高混机搅拌10-20分钟,然后投放到双螺杆挤出机中挤出(下称主机),所述双螺杆挤出机的螺杆将熔体推进到所述主机的流道,进入分配器再进入模具;将把皮层的各种原料一起投入高混机混合20分钟,然后进入双螺杆挤出机的造粒将造好的颗粒投入挤出机(下称辅机)辅机挤出,然后通过所述副辅机螺杆将熔体推进到分配器,然后通过所述分配器进入模具型腔,在所述模具型腔中,表层工程塑料合金材料均匀的分布到发泡材料表面,经所述分配器处理后的材料进入模具口发泡,进入定型版,定型、冷却和切割,通过牵引机完成所述模板的连续成型。
进一步的,所述主机在所述进料口和所述挤出机的机头出口之间分为五段,其中所述温度的分布为:第一加热段180℃;第二加热段170℃;第三加热段165℃;第四加热段160℃;第五加热段145℃;所述副机在所述进料口和所述挤出机的机头出口之间分为五段,其中所述温度的分布为:第一加热段190℃;第二加热段185℃;第三加热段180℃;第四加热段170℃;第五加热段165℃;所述主机和辅机的工艺温度可以根据材料和实际需求进行微调。
进一步的,所述工程塑料合金复合模板的表层厚度通过调整辅机和主机的转速比值进行调整,所述表层厚度为0.2-1.5毫米。
进一步的,所述工程塑料合金复合模板的整体厚度为12-55毫米,优选为15-16毫米或18毫米。
本发明具有如下有益效果:
1、通过双机共挤将工程塑料合金和发泡PVC复合,简化了生产工艺,降低了生产成本;
2、第一助剂中增加内芯的加工性能,进一步提芯层的均匀度。
3、第二助剂提高表层的强度和耐候性;在提高材料韧性的基础上,确保材料的拉伸性能和弯曲模量以及耐温性提高,铰链剂和偶联剂的加入进一步提供了材料界面的结合性,进而提高材料性能。
4、内芯中的填充物,尤其是玻璃纤维或者木粉能够在界面作为连接桥梁,提高芯层的抗弯强度;
本发明制备得到复合塑料建筑模板,具有良好的机械性能,满足建筑材料的要求,并且工艺简单,成本低廉,易于大规模生产。
具体实施方式
本发明下面将通过具体的实施例进行更详细的描述,但本发明的保护范围并不受限于这些实施例。
本发明的模板通过以下方法制备,将聚氯乙烯硬质PVC发泡芯层的各原料加入高混机搅拌20分钟,然后投放到双螺杆挤出机中挤出(下称主机),所述双螺杆挤出机的螺杆将熔体推进到所述主机的流道,进入分配器再进入模具;将把皮层的各种原料一起投入高混机混合20分钟,然后进入双螺杆挤出机的造粒将造好的颗粒投入挤出机(下称辅机)辅机挤出,然后通过所述副辅机螺杆将熔体推进到分配器,然后通过所述分配器进入模具型腔,在所述模具型腔中,表层工程塑料合金材料均匀的分布到发泡材料表面,经所述分配器处理后的材料进入模具口发泡,进入定型版,定型、冷却和切割,通过牵引机完成所述模板的连续成型。所述主机在所述进料口和所述挤出机的机头出口之间分为五段,其中所述温度的分布为:第一加热段180℃;第二加热段170℃;第三加热段165℃;第四加热段160℃;第五加热段145℃;所述副机在所述进料口和所述挤出机的机头出口之间分为五段,其中所述温度的分布为:第一加热段190℃;第二加热段185℃;第三加热段180℃;第四加热段170℃;第五加热段165℃;所述工程塑料合金复合模板的表层厚度为0.5毫米,所述工程塑料合金复合模板的整体厚度为15毫米。
其中所述主机和辅机的工艺温度可以根据材料和实际需求进行微调,所述工程塑料合金复合模板的表层厚度通过调整辅机和主机的转速比值进行调整,所述工程塑料合金复合模板的整体厚度也可根据出口的尺寸调整,并不限于上述参数范围。
实施例1
表层材料:ASA
芯层材料:
PVC 100份,
填充物30份,填充物为碳酸钙粉、玻纤粉10份的混合物
稳定剂 钙锌复合热稳定剂2.8份
抗氧剂;双酚A 0.3份、环氧大豆油2份,
润滑剂PE蜡1份,
加工助剂CPE 2份
增韧剂ACR 1份
发泡剂AC 0.4份
以及第一助剂:
引发剂 偶氮二异丁晴0.5份和过硫酸铵0.2份
发泡调节剂 甲基丙烯酸酯6份。
硬脂酸钙 0.6份。
实施例2
表层材料:
ASA高胶粉40份
PVC 100份
热稳定剂4份,所述热稳定剂为:钙锌复合热稳定剂
润滑剂1.5份,所述的润滑剂为PE蜡
增韧剂8份,所述增韧剂为CPE
加工助剂1.2份,加工助剂为硬脂酸钙
刚性粒子12份,刚性粒子为云母粉
芯层材料:
PVC 100份,
填充物50份,填充物为碳酸钙粉、木粉的混合物
稳定剂复合铅盐稳定剂5份
抗氧剂;双酚A1份、环氧大豆油2份,
润滑剂PE蜡2份,
加工助剂CPE 4份
增韧剂ACR 4份
发泡剂AC 0.6.份
实施例3
表层材料:
ASA高胶粉10份
PVC100份
热稳定剂4份,所述热稳定剂为:稀土铅盐复合热稳定剂
润滑剂2份,所述的润滑剂为PE蜡
增韧剂5份,所述增韧剂为CPE
加工助剂0.8份,加工助剂为硬脂酸锌
刚性粒子7份,刚性粒子为云母粉
芯层材料:
PVC 100份,
填充物30份,填充物为碳酸钙粉、木粉和玻纤粉的混合物
稳定剂三盐基硫酸铅、二盐基亚磷酸铅、钙锌热稳定剂混合组分3份
抗氧剂;双酚A 0.5份、环氧大豆油1份,
润滑剂PE蜡1.5份,
加工助剂CPE 5份
增韧剂ACR 3份
发泡剂AC 0.5份
实施例4
表层材料:
ASA高胶粉
芯层材料:
PVC 100份,
填充物30份,填充物为碳酸钙粉、木粉和玻纤粉的混合物
稳定剂三盐基硫酸铅、二盐基亚磷酸铅、钙锌热稳定剂混合组分3份
抗氧剂双酚A 0.5份、环氧大豆油1份,
润滑剂PE蜡1份,
加工助剂CPE 5份
增韧剂ACR 3份
发泡剂AC 0.6份
实施例5
表层添加第二助剂,其他成分与实施例1相同
第二助剂:按ASA100份计算
EGDM铰链剂 1份
环氧大豆油 2份
超细云母粉 7份。
实施例6
芯层和表层分别添加第一助剂和第二助剂,其他成分与实施例2相同
第一助剂:
引发剂 偶氮二异丁晴0.5份和过硫酸铵0.5份
发泡调节剂 甲基丙烯酸酯6份。
硬脂酸钙 3份。
第二助剂:
EGDM铰链剂 1.5份
环氧大豆油 5份
超细云母粉 12份。
实施例7
芯层和表层分别添加第一助剂和第二助剂,其他成分与实施例3相同
第一助剂:
引发剂 偶氮二异丁晴0.6份和过硫酸铵0.3份
发泡调节剂 甲基丙烯酸酯4份。
硬脂酸钙 2份。
第二助剂:
EGDM铰链剂 0.7份
环氧大豆油 1份
超细云母粉 5份。
实施例8
芯层和表层分别添加第一助剂和第二助剂,其他成分与实施例4相同
第一助剂:
引发剂 偶氮二异丁晴0.4份和过硫酸铵0.2份
发泡调节剂 甲基丙烯酸酯3份。
硬脂酸钙 2份。
第二助剂:
EGDM铰链剂 1份
环氧大豆油 2份
超细云母粉 7份。
实验与数据
本发明依据表层厚度0.5毫米,板材整体厚度15毫米进行统一测试。
具体数据如下;
性能对比表
通过以上具体实例可以说明在表层材料厚度相同的情况下,ASA共挤芯层发泡的PVC性能优越,从模量,收缩,阻燃和耐冲击性能更加优化,满足工地需求,本发明的第一助剂和第二助剂对产品成型有利,提高了材料性能。特别是第一实例,第五第六第七第八实例更说明本发明的配方有利。
尽管本发明的内容已经通过上述优选实施例作了详细介绍,但是应当认识到上述的描述不应被认为是对本发明的限制。
Claims (10)
1.一种丙烯腈/苯乙烯/丙烯酸酯接枝共聚物(ASA)工程塑料与聚氯乙烯(PVC)合金复合塑料模板,所述工程塑料合金复合模板包括两层工程塑料板层为表层(2),聚氯乙烯发泡层为芯层(1),所述表层丙烯腈/苯乙烯/丙烯酸酯接枝共聚物(ASA)工程塑料板层夹持所氯乙烯发泡芯层,其特征在于:所述工程塑料合金复合塑料模板,通过将芯层和所述工程塑料合金双机共挤模内复合,直接得到由两层工程塑料合金板层夹持芯层的复合结构,通过冷却定型,即为所述工程塑料合金复合建筑模板,所述表层和芯层之间存在接触界面,其接触界面为组分不特定的工程塑料合金层,且所述接触界面不含有粘结剂。
2.如权利要求1所述的模板,所述工程塑料合金复合模板的表层为ASA材料。
3.如权利要求1所述的模板,所述工程塑料合金复合模板的表层为ASA/PVC共混合金材料,ASA\PVC共混合金材料包括组成:6-40份的ASA高胶粉、100份的PVC、2-6份的热稳定剂、1.5-2.5份的润滑剂、3-8份的增韧剂、0.3-1.2份的加工助剂,和3-12份的刚性粒子。
4.如权利要求3所述的模板,所述热稳定剂为:钙锌复合热稳定剂、有机锡热稳定剂、稀土铅盐复合热稳定剂中的一种或两种以上任意比例的混合物;所述的润滑剂为PE蜡;所述增韧剂为CPE或ACR中的一种或者两种的混合物;加工助剂为硬脂酸锌或硬脂酸钙,刚性粒子为纳米碳酸钙或者云母粉,优选白云母粉5-12份。
5.如权利要求1所述的模板,所述工程塑料合金复合模板的聚氯乙烯发泡芯层材料包括硬质PVC以及助剂,其中助剂包括稳定剂,加工助剂、抗氧剂、发泡剂、增韧剂和填充物,填充物选自碳酸钙粉,或者碳酸钙粉、木粉和玻纤粉的混合物;稳定剂选自铅盐复合稳定剂,钙锌稳定剂,有机锡热稳定剂、稀土热稳定剂中的一种或两种以上任意比例的混合物;加工助剂选自CPE、DOP,PE蜡;增韧剂选自CPE,ACR一种或者几种的混合组分。
6.如权利要求5所述的模板,所述聚氯乙烯硬质PVC发泡芯层包括质量组分含量计:
PVC 100份,
填充物 15-50份
稳定剂三盐基硫酸铅、二盐基亚磷酸铅、钙锌热稳定剂混合组分2-5份
抗氧剂;双酚A 0.5-1份、环氧大豆油0.5-5份,
润滑剂PE蜡1-2份,
加工助剂CPE 2-8份
增韧剂ACR 1-6份
发泡剂AC,0.4-0.6.份。
7.如权利要求5所述的模板,所述聚氯乙烯硬质PVC发泡芯层第一助剂,按PVC 100份为基准计算,所述第一助剂的质量组成为:
引发剂 偶氮二异丁晴0.1-0.5份和过硫酸铵0.1-0.5份发泡调节剂 甲基丙烯酸酯2-6份。
硬脂酸钙 0.6-3份。
8.如权利要求2所述的模板,所述ASA中还包括第二助剂,按ASA 100份为基准计算,第二助剂组分的质量组成为;
EGDM铰链剂 0.7-1.2份
环氧大豆油 1-4份
超细云母粉 5-10份。
9.如权利要求3或4所述的模板,所述PVC\ASA合金还包括第二助剂,按PVC 100份为基准计算,第二助剂组分的质量组成为;
EGDM铰链剂 0.7-1.5份
环氧大豆油 1-5份
超细云母粉 5-12份。
10.一种制备权利要求1-9任一项所述模板的方法,其特征在于:
将聚氯乙烯硬质PVC发泡芯层的各原料加入高混机搅拌10-20分钟,然后投放到双螺杆挤出机中挤出(下称主机),所述双螺杆挤出机的螺杆将熔体推进到所述主机的流道,进入分配器再进入模具;将把皮层的各种原料一起投入高混机混合20分钟,然后进入双螺杆挤出机的造粒将造好的颗粒投入挤出机(下称辅机)辅机挤出,然后通过所述副辅机螺杆将熔体推进到分配器,然后通过所述分配器进入模具型腔,在所述模具型腔中,表层工程塑料合金材料均匀的分布到发泡材料表面,经所述分配器处理后的材料进入模具口发泡,进入定型版,定型、冷却和切割,通过牵引机完成所述模板的连续成型。
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