CN110774707A - 一种防分层环保阻燃地板革 - Google Patents
一种防分层环保阻燃地板革 Download PDFInfo
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Abstract
本发明涉及地板革技术领域,具体涉及一种防分层环保阻燃地板革,包括以下步骤:1)基材层制备:取70~85份聚氯乙烯树脂、30~40份热塑性聚氨酯、25~30份增塑剂混合均匀后放入捏合机中,升温至120~130℃高温捏合1~3h,再向捏合机中加入8~10份卤系阻燃剂、2~3份阻燃助剂和3~5份稳定剂继续捏合0.5~1h,然后降温至110℃时,再加入10~14份改性膨胀石墨继续捏合0.5~1h后全部投入挤出机中,挤出成型得基材层;2)基材层表面处理;3)耐磨层制备和4)基材层、耐磨层辊压复合;本发明制备的地板革不仅阻燃性更佳,而且通过改性膨胀石墨有效吸附了燃烧时产生的有害气体,通过基材层的表面处理,使得得地板革之间层间结合力强,不易出现分层和翘边现象,提高了其使用寿命。
Description
技术领域
本发明涉及地板革技术领域,具体涉及一种防分层环保阻燃地板革。
背景技术
地板革,是一种由耐磨层、基材层和背毡层复合而成一种厚度不超过2mm的铺地材料,属于塑料制品,是现代居室装饰不可或缺的地面材料之一。随着人们对高分子材料的逐渐熟悉和接受,地板革的应用也越来越广泛,可以应用于车辆、室内及室外,越来越受到人们的欢迎。但是地板革存在一些致命的缺点,例如地板革因为其基材主要由聚氯乙烯制成,其阻燃性能差,遇明火易燃烧,此类缺点是由材料的自身性质决定,无法加以克服,只能对其进行改进。目前为了对地板革起到有效的阻燃效果,其主要手段是向基材层的原料中加入卤系阻燃剂或含磷阻燃剂以及阻燃助剂,但是在火灾过程中虽然阻燃剂能起到一定阻燃效果,但是其本身与地板革受热均会产生大量的氯化氢、氰化氢等有害气体,且经过统计火灾事故中的人员致死原因80 %以上与材料产生的浓烟和有毒气体有关,因此如何减少火灾阻燃时其有害气体的排放也是人们重点研究的方向。
另外,地板革使用过程中还会经常出现由于层间结合力不足,出现分层和翘边的现象,此类问题也严重影响了地板革的使用寿命。而在现有地板革生产加工的过程中,人们通过增加其压辊复合成型时的压辊压力来达到增加层间结合力的作用,但是其作用效果并不明显,其地板革仍会出现分层和翘边的现象。因此,针对上述现有地板革存在的不足,发明一种能解决以上技术问题的地板革是一项有待解决的技术问题。
发明内容
本发明所要解决的技术问题是设计了一种防分层环保阻燃地板革,以解决现有的地板革在阻燃时仍产生大量有害气体,以及由于层间结合力不足易出现分层的不足。
本发明是通过以下技术方案实现的:
一种防分层环保阻燃地板革,包括以下步骤:
1)基材层制备:取重量份数为70~85份聚氯乙烯树脂、30~40份热塑性聚氨酯、25~30份增塑剂混合均匀后放入捏合机中,升温至120~130℃高温捏合1~3h,再向捏合机中加入8~10份卤系阻燃剂、2~3份阻燃助剂和3~5份稳定剂继续捏合0.5~1h,然后降温至110℃时,再加入10~14份改性膨胀石墨继续捏合0.5~1h后全部投入挤出机中,挤出成型得基材层;
2)基材层表面处理:将步骤1)制备的基材层放在充满氮气的密封空间中,升温至45~50℃,然后使用60Co源产生的γ射线对其上下表面均辐射处理10~15min,其中辐射剂量为80~95Gy/min,然后取出基材层,对其上下表面进行电晕处理,备用;
3)耐磨层制备:取重量份数为50~60份聚氯乙烯树脂、40~50份环氧树脂、12~14份聚苯乙烯树脂放入捏合机中,升温至135~150℃高温捏合1~2h,然后加入20~26份无机耐磨填料、4~6份偶联剂和6~8份颜料继续捏合0.5~1h后,再以2~3℃/min的降温速度降至95℃保温处理10min后全部投入挤出机中,挤出成型得耐磨层;
4)基材层、耐磨层辊压复合:将步骤3)制备的耐磨层与经步骤2)表面处理的基材层粘合,通过加热辊压机导辊温度为85~90℃辊压成型,然后降温至60~65℃保温处理8~14h后,冷却至室温得地板革复合层;
其中,改性膨胀石墨的处理步骤为:向100份去离子水中加入12~14份聚乙烯醇搅拌溶解,再向去离子水中加入30~40份膨胀石墨后搅拌分散成浑浊液,然后旋转蒸发去除去离子水,将旋转蒸发后剩下的固体粉末放入球磨机中,再向球磨机中加入8~10份钛酸酯偶联剂,以800~1200r/min的转速研磨1~2h后即得。
优选地,所述步骤1)中的增塑剂为邻苯二甲酸二丁酯、邻苯二甲酸二辛酯、氯化石蜡或环氧大豆油其中的一种或多种。
优选地,所述步骤1)中的卤系阻燃剂为十溴二苯乙烷和十溴二苯醚其中的一种,所述阻燃助剂为三氧化二锑、三氧化二铁、氧化锌和硼酸锌其中的一种或多种。
优选地,所述步骤1)中所得的基材层厚度为1.4~1.6mm。
优选地,所述步骤2)中电晕处理的功率为15~20kv,处理时交流电压为3500~5000V/m。
优选地,所述步骤3)中的无机耐磨填料为滑石粉、碳酸钙、白炭黑、微硅粉和纳米氧化铝其中的一种或多种。
优选地,所述步骤4)所得的地板革复合层厚度为1.8~2.0mm。
有益效果:本发明与现有的地板革相比,将基材层的主要原料由聚氯乙烯改为按质量比为7:3左右的聚氯乙烯与热塑性聚氨酯混合料,两者混合协同作用不仅使得基材层的强韧性得到提升,而且还能减少地板革燃烧时有害气体的产生量;同时将本发明的膨胀石墨分散在聚乙烯醇溶液中,然后蒸发去除水后,使得膨胀石墨的总孔容积和比面积增大,而且还在膨胀石墨的表面和孔隙内部产生大量的含氧官能团,极大增加了其膨胀石墨的吸附性,再将其与钛酸酯偶联剂混合后机械球磨,使得膨胀石墨能均匀分散在基材层的混合树脂中,不会引起混合树脂的团聚和沉积,保证了基材层的力学性能,然后将改性后的膨胀石墨与卤系阻燃剂一起加入基材层,卤系阻燃剂在阻燃的过程产生的大量的有害气体能被受热膨胀后的石墨有效吸入其孔隙中,极大减少了有害气体的排放,保证了地板革的阻燃安全性,使得本地板革具有环保阻燃的优异效果。
另外,本发明还将基材层的表面先放在去氧的环境下γ射线辐射处理,使得聚氯乙烯表面大量的C-Cl和C-H键断裂形成活性基团,然后再将基材层电晕处理,使得表面的活性基团数量增多,且每个活性基团具有的能量更高,再将其与耐磨层在85~90℃温度下辊压复合成型后于60~65℃保温处理8~14h,使得耐磨层表面的聚合物与基材层表面的活性基团发生交联,形成大片的交联网络,极大增强了基材层与耐磨层之间的结合力,使得本发明制备的地板革不会因层间结合力不足而出现分层或翘边的现象,而且本发明耐磨层的混合树脂相容性较好,再向其中加入的大量的无机填料,不仅增加了其耐磨性,而且还一定程度上使得耐磨层的力学性能得到改进,从而延长了地板革的使用寿命。
具体实施方式
下面对本发明的具体实施方式作进一步说明。在此需要说明的是,对于这些实施方式的说明用于帮助理解本发明,但并不构成对本发明的限定。此外,下面所描述的本发明各个实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互组合。
实施例1:
一种防分层环保阻燃地板革,其具体步骤如下:
1)基材层制备:取80kg的聚氯乙烯树脂、35kg的热塑性聚氨酯、26kg的邻苯二甲酸二丁酯混合均匀后放入捏合机中,升温至128℃高温捏合2h,再向捏合机中加入10kg的十溴二苯乙烷、2kg的三氧化二锑和3kg的亚磷酸三苯酯继续捏合40min,然后降温至110℃时,再加入13kg的改性膨胀石墨继续捏合30min后全部投入挤出机中,挤出成型得厚度为1.5mm的基材层;
2)基材层表面处理:将步骤1)制备的基材层放在充满氮气的密封空间中,升温至45℃,然后使用60Co源产生的γ射线对其上下表面均辐射处理12min,其中辐射剂量为90Gy/min,然后取出基材层,对其上下表面进行电晕处理,其中电晕处理的功率为16kv,处理时交流电压为3650V/m,备用;
3)耐磨层制备:取55kg的聚氯乙烯树脂、45kg的环氧树脂和12kg的聚苯乙烯树脂放入捏合机中,升温至145℃高温捏合1.5h,然后加入24kg的碳酸钙、5kg的硅烷偶联剂和6kg的颜料继续捏合50min后,再以3℃/min的降温速度降至95℃保温处理10min后全部投入挤出机中,挤出成型得耐磨层;
4)基材层、耐磨层辊压复合:将步骤3)制备的耐磨层与经步骤2)表面处理的基材层粘合,通过辊压机在90℃温度下辊压复合成型,然后降温至65℃保温处理10h后,冷却至室温得厚度为2.0mm的地板革复合层。
本实施例中改性膨胀石墨的处理步骤为:向100L的去离子水中加入12kg的聚乙烯醇搅拌溶解,再向去离子水中加入36kg的膨胀石墨后搅拌分散成浑浊液,然后旋转蒸发去除去离子水,将旋转蒸发后剩下的固体粉末放入球磨机中,再向球磨机中加入10kg的钛酸酯偶联剂,以1000r/min的转速研磨1.5h后即得。
实施例2:
一种防分层环保阻燃地板革,其具体步骤如下:
1)基材层制备:取70kg的聚氯乙烯树脂、30kg的热塑性聚氨酯、26kg的邻苯二甲酸二丁酯混合均匀后放入捏合机中,升温至125℃高温捏合1.5h,再向捏合机中加入10kg的十溴二苯乙烷、2kg的三氧化二锑和3kg的亚磷酸三苯酯继续捏合1h,然后降温至110℃时,再加入12kg的改性膨胀石墨继续捏合30min后全部投入挤出机中,挤出成型得厚度为1.5mm的基材层;
2)基材层表面处理:将步骤1)制备的基材层放在充满氮气的密封空间中,升温至50℃,然后使用60Co源产生的γ射线对其上下表面均辐射处理15min,其中辐射剂量为80Gy/min,然后取出基材层,对其上下表面进行电晕处理,其中电晕处理的功率为20kv,处理时交流电压为5000V/m,备用;
3)耐磨层制备:取50kg的聚氯乙烯树脂、50kg的环氧树脂和14kg的聚苯乙烯树脂放入捏合机中,升温至150℃高温捏合2h,然后加入20kg的白炭黑、4kg的硅烷偶联剂和6kg的颜料继续捏合50min后,再以3℃/min的降温速度降至95℃保温处理10min后全部投入挤出机中,挤出成型得耐磨层;
4)基材层、耐磨层辊压复合:将步骤3)制备的耐磨层与经步骤2)表面处理的基材层粘合,通过辊压机在85℃温度下辊压复合成型,然后降温至60℃保温处理14h后,冷却至室温得厚度为2.0mm的地板革复合层。
本实施例中改性膨胀石墨的处理步骤为:向100L的去离子水中加入12kg的聚乙烯醇搅拌溶解,再向去离子水中加入36kg的膨胀石墨后搅拌分散成浑浊液,然后旋转蒸发去除去离子水,将旋转蒸发后剩下的固体粉末放入球磨机中,再向球磨机中加入10kg的钛酸酯偶联剂,以1200r/min的转速研磨1h后即得。
实施例3:
一种防分层环保阻燃地板革,其具体步骤如下:
1)基材层制备:取85kg的聚氯乙烯树脂、30kg的热塑性聚氨酯、28kg的邻苯二甲酸二辛酯混合均匀后放入捏合机中,升温至130℃高温捏合2h,再向捏合机中加入8kg的十溴二苯乙烷、2kg的氧化锌和4kg的亚磷酸三苯酯继续捏合40min,然后降温至110℃时,再加入10kg的改性膨胀石墨继续捏合30min后全部投入挤出机中,挤出成型得厚度为1.6mm的基材层;
2)基材层表面处理:将步骤1)制备的基材层放在充满氮气的密封空间中,升温至45℃,然后使用60Co源产生的γ射线对其上下表面均辐射处理15min,其中辐射剂量为92Gy/min,然后取出基材层,对其上下表面进行电晕处理,其中电晕处理的功率为18kv,处理时交流电压为4200V/m,备用;
3)耐磨层制备:取60kg的聚氯乙烯树脂、40kg的环氧树脂和12kg的聚苯乙烯树脂放入捏合机中,升温至140℃高温捏合2h,然后加入24kg的纳米氧化铝、6kg的硅烷偶联剂和8kg的颜料继续捏合50min后,再以2℃/min的降温速度降至95℃保温处理10min后全部投入挤出机中,挤出成型得耐磨层;
4)基材层、耐磨层辊压复合:将步骤3)制备的耐磨层与经步骤2)表面处理的基材层粘合,通过辊压机在90℃温度下辊压复合成型,然后降温至65℃保温处理14h后,冷却至室温得厚度为2.0mm的地板革复合层。
本实施例中改性膨胀石墨的处理步骤为:向100L的去离子水中加入14kg的聚乙烯醇搅拌溶解,再向去离子水中加入30kg的膨胀石墨后搅拌分散成浑浊液,然后旋转蒸发去除去离子水,将旋转蒸发后剩下的固体粉末放入球磨机中,再向球磨机中加入10kg的钛酸酯偶联剂,以1000r/min的转速研磨1.5h后即得。
实施例4:
一种防分层环保阻燃地板革,其具体步骤如下:
1)基材层制备:取77kg的聚氯乙烯树脂、33kg的热塑性聚氨酯、28kg的邻苯二甲酸二丁酯混合均匀后放入捏合机中,升温至122℃高温捏合3h,再向捏合机中加入10kg的十溴二苯醚、2kg的三氧化二锑和4kg的亚磷酸三苯酯继续捏合40min,然后降温至110℃时,再加入10kg的改性膨胀石墨继续捏合30min后全部投入挤出机中,挤出成型得厚度为1.4mm的基材层;
2)基材层表面处理:将步骤1)制备的基材层放在充满氮气的密封空间中,升温至45℃,然后使用60Co源产生的γ射线对其上下表面均辐射处理10min,其中辐射剂量为80Gy/min,然后取出基材层,对其上下表面进行电晕处理,其中电晕处理的功率为15kv,处理时交流电压为3500V/m,备用;
3)耐磨层制备:取55kg的聚氯乙烯树脂、45kg的环氧树脂和12kg的聚苯乙烯树脂放入捏合机中,升温至145℃高温捏合1.5h,然后加入24kg的碳酸钙、5kg的硅烷偶联剂和6kg的颜料继续捏合50min后,再以3℃/min的降温速度降至95℃保温处理10min后全部投入挤出机中,挤出成型得耐磨层;
4)基材层、耐磨层辊压复合:将步骤3)制备的耐磨层与经步骤2)表面处理的基材层粘合,通过辊压机在90℃温度下辊压复合成型,然后降温至65℃保温处理10h后,冷却至室温得厚度为1.8mm的地板革复合层。
本实施例中改性膨胀石墨的处理步骤为:向100L的去离子水中加入12kg的聚乙烯醇搅拌溶解,再向去离子水中加入40kg的膨胀石墨后搅拌分散成浑浊液,然后旋转蒸发去除去离子水,将旋转蒸发后剩下的固体粉末放入球磨机中,再向球磨机中加入8kg的钛酸酯偶联剂,以800r/min的转速研磨2h后即得。
对比组1:
对比组1与实施例1相比,将步骤1)中80kg的聚氯乙烯树脂和35kg的热塑性聚氨酯改成115kg的聚氯乙烯树脂,除此之外的方法步骤均相同。
对比组2:
对比组2与实施例1相比,将步骤1)中的改性膨胀石墨改成普通膨胀石墨,除此之外的方法步骤均相同。
对比组3:
对比组3与实施例1相比,省略步骤2),除此之外的方法步骤均相同。
对比组4:
对比组4与实施例1相比,省略步骤4)中降温至65℃保温处理10h,除此之外的方法步骤均相同。
常规对照组:
网上购得的莱诺地板官方旗舰店出售的2.0mm厚的两层地板革。
为对比本发明制备的地板革在阻燃性有益效果,现按GB8410-2006和GB/T8627-2007对实施例、对比组以及常规对照组的地板革进行燃烧速度和烟密度等级SDR进行测定,并记录数据如下表1:
表1:
由上述表1中的数据可以看出,本发明制备的地板革,其阻燃性好,且阻燃过程中产生的有害气体浓度减少,使得其阻燃效果更佳。
为对比本发明制备的地板革的有益效果,现按GB-T5210-1985《涂层附着力的测定法拉开法》对地板革的上层与下层之间进行结合力试验测定,其中将实施例、对比组和常规对照组裁剪成面积相同的条状,然后测定其上下出现分层时施加的负荷力,重复性试验进行3次,并记录数据如下表2:
表2:
由上述表2中的数据可以看出,本发明的地板革其层间结合力高,能够有效解决现有地板革易出现分层或者翘边的现象。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (7)
1.一种防分层环保阻燃地板革,其特征在于,包括以下步骤:
1)基材层制备:取重量份数为70~85份聚氯乙烯树脂、30~40份热塑性聚氨酯、25~30份增塑剂混合均匀后放入捏合机中,升温至120~130℃高温捏合1~3h,再向捏合机中加入8~10份卤系阻燃剂、2~3份阻燃助剂和3~5份稳定剂继续捏合0.5~1h,然后降温至110℃时,再加入10~14份改性膨胀石墨继续捏合0.5~1h后全部投入挤出机中,挤出成型得基材层;
2)基材层表面处理:将步骤1)制备的基材层放在充满氮气的密封空间中,升温至45~50℃,然后使用60Co源产生的γ射线对其上下表面均辐射处理10~15min,其中辐射剂量为80~95Gy/min,然后取出基材层,对其上下表面进行电晕处理,备用;
3)耐磨层制备:取重量份数为50~60份聚氯乙烯树脂、40~50份环氧树脂、12~14份聚苯乙烯树脂放入捏合机中,升温至135~150℃高温捏合1~2h,然后加入20~26份无机耐磨填料、4~6份偶联剂和6~8份颜料继续捏合0.5~1h后,再以2~3℃/min的降温速度降至95℃保温处理10min后全部投入挤出机中,挤出成型得耐磨层;
4)基材层、耐磨层辊压复合:将步骤3)制备的耐磨层与经步骤2)表面处理的基材层粘合,通过加热辊压机导辊温度为85~90℃辊压成型,然后降温至60~65℃保温处理8~14h后,冷却至室温得地板革复合层;
其中,改性膨胀石墨的处理步骤为:向100份去离子水中加入12~14份聚乙烯醇搅拌溶解,再向去离子水中加入30~40份膨胀石墨后搅拌分散成浑浊液,然后旋转蒸发去除去离子水,将旋转蒸发后剩下的固体粉末放入球磨机中,再向球磨机中加入8~10份钛酸酯偶联剂,以800~1200r/min的转速研磨1~2h后即得。
2.根据权利要求1所述的一种防分层环保阻燃地板革,其特征在于:所述步骤1)中的增塑剂为邻苯二甲酸二丁酯、邻苯二甲酸二辛酯、氯化石蜡或环氧大豆油其中的一种或多种。
3.根据权利要求1所述的一种防分层环保阻燃地板革,其特征在于:所述步骤1)中的卤系阻燃剂为十溴二苯乙烷和十溴二苯醚其中的一种,所述阻燃助剂为三氧化二锑、三氧化二铁、氧化锌和硼酸锌其中的一种或多种。
4.根据权利要求1所述的一种防分层环保阻燃地板革,其特征在于:所述步骤1)中所得的基材层厚度为1.4~1.6mm。
5.根据权利要求1所述的一种防分层环保阻燃地板革,其特征在于:所述步骤2)中电晕处理的功率为15~20kv,处理时交流电压为3500~5000V/m。
6.根据权利要求1所述的一种防分层环保阻燃地板革,其特征在于:所述步骤3)中的无机耐磨填料为滑石粉、碳酸钙、白炭黑、微硅粉和纳米氧化铝其中的一种或多种。
7.根据权利要求1所述的一种防分层环保阻燃地板革,其特征在于:所述步骤4)所得的地板革复合层厚度为1.8~2.0mm。
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CN111976255A (zh) * | 2020-08-20 | 2020-11-24 | 苏州伍得人造板设备有限公司 | 一种三聚氰胺饰面板中基材板的处理工艺 |
CN112625378A (zh) * | 2020-12-19 | 2021-04-09 | 界首市鑫豪塑胶有限公司 | 采用微发泡技术制备的轻质地板革基材 |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN111976255A (zh) * | 2020-08-20 | 2020-11-24 | 苏州伍得人造板设备有限公司 | 一种三聚氰胺饰面板中基材板的处理工艺 |
CN112625378A (zh) * | 2020-12-19 | 2021-04-09 | 界首市鑫豪塑胶有限公司 | 采用微发泡技术制备的轻质地板革基材 |
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