CN111171438A - 回收材料制成的复合材料、形成方法及其应用 - Google Patents
回收材料制成的复合材料、形成方法及其应用 Download PDFInfo
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- CN111171438A CN111171438A CN202010095273.4A CN202010095273A CN111171438A CN 111171438 A CN111171438 A CN 111171438A CN 202010095273 A CN202010095273 A CN 202010095273A CN 111171438 A CN111171438 A CN 111171438A
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Abstract
一种回收材料制成的复合材料、形成方法及其应用。复合材料由基体和功能性底膜组成,基体为多聚合物颗粒,由多种回收料颗粒及热塑性材料构成,功能性底膜赋予复合材料多种功能特性。复合材料由工业生产过程中产生的高分子材料的边角废料破碎后和热塑性材料制成多聚合物颗粒通过加温加压与功能性底膜制成。复合材料可直接作为铺地材料使用;或可用于复合地毯的背底、中间层;或可用于汽车用脚垫、轮罩、行李箱左右侧围板、备胎底板及盖板。本发明通过简单的形成方法,减小了生产过程中的污染,原材料来源广,可连续生产;所得的复合材料成型后的强度高且具有弹性,同时达到降低成本、实现废弃物再利用、减少环境污染的目的,能产生很高的经济效益。
Description
技术领域
本发明涉及工业生产过程中产生的边角废料回收利用,进一步制造可循环的复合材料、其形成方法以及包括有这样的复合材料的产品。具体地,涉及一种回收材料制成的复合材料、形成方法及其应用。
背景技术
工业生产过程中,特别是汽车内饰件制造产生的边角废料占总体成品的3-10%,按全国每年乘用车生产约2800万辆、平均每台车约产生4.2KG边角料,也就是每年会产生约12万吨边角废料,目前主机厂处理边角废料需向环保部门缴纳高额处理费,然后直接填埋或是焚烧。汽车内饰件使用的材料多数是高分子材料,自然降解需要几十年甚至百年的时间。焚烧涉及到焚烧工艺的问题,会有较大几率产生强有害气体,如二噁英是强致癌气体。且这两种处理方式都不是环境友好型的处理方式,即这两种选择对环境都会产生损害。
相比于填埋和焚烧,回收利用就能产生很高的经济效益。但是回收利用的成本过高,理念也就成为空谈。现有技术中,已有对汽车内饰件制造产生的边角废料进行回收利用的方案。
如中国专利(CN201710203308.X 一种新型汽车地毯回收材料应用方法)公开了以下技术方案:步骤一,材料分类,将不同汽车地毯回收材料按PET材质和BICO材质进行分类;步骤二,开毛斗投料,将PET材质和BICO材质的材料依次投入设备进料口;步骤三,粉碎开松,将大片的材料粉碎;步骤四,针刺复合,将PET颗粒和BICO颗粒通过针刺复合到一起。
再如中国专利(CN201410188993.X 废旧地毯回收方法)公开了如下技术方案:首先对废旧地毯进行除污清洗;然后根据废旧地毯的磨损程度进行分类,对第一类面层纤维磨损程度高和非丙烯聚合物的废旧地毯进行碾压处理,去除底部硬质胶层;对第二类面层纤维磨损程度低的丙烯聚合物废旧地毯进行碾压去除底部硬质胶层后,再完整剥离背衬布,分别收集面层纤维丝和背衬布。
汽车内饰件制造中大多都使用了PP、PA6、PA66或PET、PE、SBR、EPDM、PVC等材料,每种零件至少都会使用其中3种以上材料制成。现有的汽车内饰件边角料的利用思路是一致的,都是先对不同材料进行分类,然后分别利用或分别处理,制成地毯或是地毯的一部分,或是仅仅是分类回收。
基于以上,地毯、汽车内饰件制造产生的边角废料,已给工厂带来处理压力、环境造成严重危害、迫切需要更多种新的处理方法,来解决现在的问题。
发明内容
为解决现有技术中存在的上述问题,本发明提供了一种回收材料制成的复合材料、形成方法及其应用。本发明通过简单的形成方法,减小了生产过程中的污染,原材料来源广,可连续生产;所得的复合材料成型后的强度高且具有弹性,同时达到降低成本、实现废弃物再利用、减少环境污染的目的,能产生很高的经济效益。
为实现上述目的,本发明提供了一种回收材料制成的复合材料,由基体和功能性底膜组成,所述基体为多聚合物颗粒,所述多聚合物颗粒由多种回收料颗粒及热塑性材料构成,所述功能性底膜赋予复合材料多种功能特性;
所述热塑性材料包括以下重量份的组分:
热塑性弹性体 25-35
胶印油墨树脂 40-45
塑化剂 1.5-2
固化剂 8-9
醋酮 22-25;
所述胶印油墨树脂包括以下重量份的组分:
松膏 110-120 2,2-双(4-羟环己基)丙烷 2-4
苯酚混合物 40-45 2,2-二甲基-1,3-丙烷二醇 3-4
甲醛溶液 10-15 顺丁烯二酸 10-12
混二甲酚 19-20 甲基乙二醇 7-8
纳米二氧化硅 5-8 纤维素甲醚 12-15
四羟甲基烷 12-15 氯化钙 3-4
硫酸溶液 0.2-0.4 金刚石颗粒 0.05-0.08;
所述热塑性材料包含TPE、TPR、TPV、PP、PE、EVA或EPDM中的一种或多种材料;
所述回收料颗粒来源于在民用地毯、车用地毯、工业毯或汽车内饰件制造中产生的边角废料。
优选的,所述回收料颗粒材质还包含PP、PA6、PET、PE、SBR、EVA、EPDM、PVC、ES、玻纤或麻纤维中的一种或多种材料;所述甲醛溶液的质量浓度为70-78%。
在上述任一方案中优选的是,所述胶印油墨树脂通过以下步骤制备:
(1)将上述重量份的混二甲酚、苯酚混合物和2,2-双(4-羟环己基)丙烷依次投入反应容器中,升温至75-80℃,搅拌15-20min,调节pH值至7.5-8.0,然后加入上述重量份的甲醛溶液,升温至95-98℃,保温反应120-150min,然后降温至75-80℃,调节pH至6.1-6.2,保持80-90min,停止加热,冷却至室温,调节pH值至7-7.2,得到缩合液;
(2)将上述重量份的松膏投入反应容器中,升温至185-190℃,待熔融完全,然后升温至230-240℃,依次加入上述重量份的顺丁烯二酸、甲基乙二醇、2,2-二甲基-1,3-丙烷二醇、四羟甲基烷、纤维素甲醚、氯化钙和硫酸溶液,保温反应220-260min,再升温至300-310℃,加入所述缩合液,保温反应220-240min,冷却至常温,得到胶印油墨树脂初体;
(3)室温下,向所述胶印油墨树脂初体中加入上述重量份的纳米二氧化硅和金刚石颗粒,机械搅拌25-28min,取出产品,真空干燥,即得最终的胶印油墨树脂。
在上述任一方案中优选的是,热塑性材料的融点范围在150℃-200℃;所述多聚合物颗粒的粒径范围为1-8mm;复合材料的厚度为1-15mm,面密度在1000-10000gsm;所述功能性底膜是由EVA、PE、PP、POE或TPU中的一种或几种复合而成,具有抗UV、耐摩擦、防滑、增加片材强度和美观功能,并可在背面加工花纹方式以增加防滑、疏水和装饰的功能性。
为实现上述目的,本发明还提供了一种回收材料制成的复合材料的形成方法,该方法为一种不用分选、一体回收利用的方法,包括以下步骤:
(1)将工业生产过程中产生的高分子材料的边角废料无需分选、破碎后加热至部分融化,形成塑性体,制成回收料颗粒;
(2)将回收料颗粒与热塑性材料混合搅拌均匀,经挤出制成多聚合物颗粒;
(3)将多聚合物颗粒分撒到所述功能性底膜上,通过设备加热加压制成最终的复合材料;加热加压是通过对所述设备的轧辊进行加热后,使得撒有多聚合物颗粒的功能性底膜经过相贴设置的轧辊之间,依靠轧辊对功能性底膜加热、施压,通过高温热压的方式使得多聚合物颗粒和功能性底膜溶解固化并压为一体,完成熔接并得到性能稳定均匀的复合材料;所述设备采用轧辊热压装置实现,所述轧辊热压装置包括多个轧辊以及为轧辊加热的轧辊加热机构,所述多个轧辊分两排并列设置,轧辊两端设置在油缸的伸缩端上,油缸的固定端固定在机架上,油缸的伸缩方向正对轧辊方向设置;所述轧辊加热机构包括金属材质的轧辊内芯,还包括位于轧辊一侧外部的加热线圈,用于产生磁场并在轧辊旋转时使其内部的轧辊内芯中产生感应电流实现加热。
优选的,加热温度为150-220℃、加压强度为3-6MPa,加热加压时间为1-5min;所述多聚合物颗粒是由热塑性材料均匀包裹回收料颗粒制成。
在上述任一方案中优选的是,所述步骤(2)中是将热塑性材料及回收料颗粒中的较低融点材料,通过造粒机工作盘高速旋转摩擦使其熔融,均匀包裹回收料颗粒中较高融点材料。
在上述任一方案中优选的是,所述高分子材料的边角废料为较高融点材料时,可被较低融点的热塑性材料熔融包裹形成多聚合物颗粒;所述高分子材料的边角废料为较高融点材料和较低融点材料混合时,可被较低融点的热塑性材料熔融包裹形成多聚合物颗粒;所述高分子材料的边角废料为较低融点材料时,可与较低融点的热塑性材料熔融形成多聚合物颗粒。
为实现上述目的,本发明还提供了一种回收材料制成的复合材料的应用,复合材料为之前所述的复合材料,可直接作为铺地材料使用;或可用于复合地毯的背底、中间层;或可用于汽车用脚垫、轮罩、行李箱左右侧围板、备胎底板及盖板。
本发明的有益效果为:
1.本发明所用的边角料不做分类、分拣,工艺流程简洁,前期设备投入非常少,人力投入少,成本低,能够有效的产生经济效益;制备新产品的种类灵活,由于投入和运行成本不高,使用该工艺也能有效的提高经济效益,使其适用范围更广,更容易推广。
2.本发明通过简单的形成方法,减小了生产过程中的污染,原材料来源广,可连续生产;所得的复合材料成型后的强度高且具有弹性,同时达到降低成本、实现废弃物再利用、减少环境污染的目的,能产生很高的经济效益。
3.本发明的回收料颗粒有支撑作用、可作为骨架作用;热塑性材料的优点在于柔软性好、粘结度好,更好的包裹回收颗粒、具有较强的弹性;功能性底膜紧密的和多聚合物颗粒粘合,更有效的形成均匀、整齐的底面层,并具有抗UV、耐摩擦、防滑、增加片材强度、美观功能。
4.本发明在制备缩合液时促进了树脂的缩聚反应,减少反应时间,提高生产效率,能耗低;松膏参与改性过程中,分温度阶段反应,可使反应更加充分,提高树脂性能,有效提高树脂耐蚀性和耐热性。
5.本发明制备方法工艺简单,适合工业化大批量生产。
具体实施方式
下面将结合本申请的具体实施方式对本申请的技术方案进行详细的说明,但如下实施例仅是用以理解本发明,本申请中的实施例及实施例中的特征可以相互组合,本申请可以由权利要求限定和覆盖的多种不同方式实施。
实施例1
一种回收材料制成的复合材料,由基体和功能性底膜组成,所述基体为多聚合物颗粒,所述多聚合物颗粒由多种回收料颗粒及热塑性材料构成,所述功能性底膜赋予复合材料多种功能特性;
所述热塑性材料包括以下重量份的组分:
热塑性弹性体 25-35
胶印油墨树脂 40-45
塑化剂 1.5-2
固化剂 8-9
醋酮 22-25;
所述胶印油墨树脂包括以下重量份的组分:
松膏 110-120 2,2-双(4-羟环己基)丙烷 2-4
苯酚混合物 40-45 2,2-二甲基-1,3-丙烷二醇 3-4
甲醛溶液 10-15 顺丁烯二酸 10-12
混二甲酚 19-20 甲基乙二醇 7-8
纳米二氧化硅 5-8 纤维素甲醚 12-15
四羟甲基烷 12-15 氯化钙 3-4
硫酸溶液 0.2-0.4 金刚石颗粒 0.05-0.08;
所述热塑性材料包含TPE、TPR、TPV、PP、PE、EVA或EPDM中的一种或多种材料;
所述回收料颗粒来源于在民用地毯、车用地毯、工业毯或汽车内饰件制造中产生的边角废料。
所述回收料颗粒材质还包含PP、PA6、PET、PE、SBR、EVA、EPDM、PVC、ES、玻纤或麻纤维中的一种或多种材料;所述甲醛溶液的质量浓度为70-78%。
所述胶印油墨树脂通过以下步骤制备:
(1)将上述重量份的混二甲酚、苯酚混合物和2,2-双(4-羟环己基)丙烷依次投入反应容器中,升温至75-80℃,搅拌15-20min,调节pH值至7.5-8.0,然后加入上述重量份的甲醛溶液,升温至95-98℃,保温反应120-150min,然后降温至75-80℃,调节pH至6.1-6.2,保持80-90min,停止加热,冷却至室温,调节pH值至7-7.2,得到缩合液;
(2)将上述重量份的松膏投入反应容器中,升温至185-190℃,待熔融完全,然后升温至230-240℃,依次加入上述重量份的顺丁烯二酸、甲基乙二醇、2,2-二甲基-1,3-丙烷二醇、四羟甲基烷、纤维素甲醚、氯化钙和硫酸溶液,保温反应220-260min,再升温至300-310℃,加入所述缩合液,保温反应220-240min,冷却至常温,得到胶印油墨树脂初体;
(3)室温下,向所述胶印油墨树脂初体中加入上述重量份的纳米二氧化硅和金刚石颗粒,机械搅拌25-28min,取出产品,真空干燥,即得最终的胶印油墨树脂。
热塑性材料的融点范围在150℃-200℃;所述多聚合物颗粒的粒径范围为1-8mm;复合材料的厚度为1-15mm,面密度在1000-10000gsm;所述功能性底膜是由EVA、PE、PP、POE或TPU中的一种或几种复合而成,具有抗UV、耐摩擦、防滑、增加片材强度和美观功能,并可在背面加工花纹方式以增加防滑、疏水和装饰的功能性。
实施例2
一种回收材料制成的复合材料,由基体和功能性底膜组成,所述基体为多聚合物颗粒,所述多聚合物颗粒由多种回收料颗粒及热塑性材料构成,所述功能性底膜赋予复合材料多种功能特性;
所述热塑性材料包括以下重量份的组分:
热塑性弹性体 25-35
胶印油墨树脂 40-45
塑化剂 1.5-2
固化剂 8-9
醋酮 22-25;
所述胶印油墨树脂包括以下重量份的组分:
松膏 110-120 2,2-双(4-羟环己基)丙烷 2-4
苯酚混合物 40-45 2,2-二甲基-1,3-丙烷二醇 3-4
甲醛溶液 10-15 顺丁烯二酸 10-12
混二甲酚 19-20 甲基乙二醇 7-8
纳米二氧化硅 5-8 纤维素甲醚 12-15
四羟甲基烷 12-15 氯化钙 3-4
硫酸溶液 0.2-0.4 金刚石颗粒 0.05-0.08;
所述热塑性材料包含TPE、TPR、TPV、PP、PE、EVA或EPDM中的一种或多种材料;
所述回收料颗粒来源于在民用地毯、车用地毯、工业毯或汽车内饰件制造中产生的边角废料。
所述回收料颗粒材质还包含PP、PA6、PET、PE、SBR、EVA、EPDM、PVC、ES、玻纤或麻纤维中的一种或多种材料;所述甲醛溶液的质量浓度为70-78%。
所述胶印油墨树脂通过以下步骤制备:
(1)将上述重量份的混二甲酚、苯酚混合物和2,2-双(4-羟环己基)丙烷依次投入反应容器中,升温至75-80℃,搅拌15-20min,调节pH值至7.5-8.0,然后加入上述重量份的甲醛溶液,升温至95-98℃,保温反应120-150min,然后降温至75-80℃,调节pH至6.1-6.2,保持80-90min,停止加热,冷却至室温,调节pH值至7-7.2,得到缩合液;
(2)将上述重量份的松膏投入反应容器中,升温至185-190℃,待熔融完全,然后升温至230-240℃,依次加入上述重量份的顺丁烯二酸、甲基乙二醇、2,2-二甲基-1,3-丙烷二醇、四羟甲基烷、纤维素甲醚、氯化钙和硫酸溶液,保温反应220-260min,再升温至300-310℃,加入所述缩合液,保温反应220-240min,冷却至常温,得到胶印油墨树脂初体;
(3)室温下,向所述胶印油墨树脂初体中加入上述重量份的纳米二氧化硅和金刚石颗粒,机械搅拌25-28min,取出产品,真空干燥,即得最终的胶印油墨树脂。
热塑性材料的融点范围在150℃-200℃;所述多聚合物颗粒的粒径范围为1-8mm;复合材料的厚度为1-15mm,面密度在1000-10000gsm;所述功能性底膜是由EVA、PE、PP、POE或TPU中的一种或几种复合而成,具有抗UV、耐摩擦、防滑、增加片材强度和美观功能,并可在背面加工花纹方式以增加防滑、疏水和装饰的功能性。
此外,为进一步保证效果,所述EPDM由以下重量份的组分制成:EPDM本体115-120、十八酸钠10-12份、乙烯基甲酸3-4、交联剂DCP0.5-0.8。
该EPDM通过以下方法制备:将EPDM、乙烯基甲酸、交联剂DCP、十八酸钠加入双螺杆挤出机中挤出造粒,挤出造粒时采用的螺杆转速是40-50r/min;双螺杆挤出机温度设置如下:一区为115-120℃,二区为130-135℃,三区为140-145℃,四区为150-155℃,机头温度为150℃。
该实施例中的EPDM形成物理交联成为离聚体,提高了强度。并保证得到的材料其他综合性能均稳定,以满足市场多样化的需求。
实施例3
除了具有实施例1和2的内容之外,所述SBR由以下重量份的组分制成:SBR本体110-115、阁土粉50-60,煤焦油树脂20-25、锌白粉10-15、十八烷酸5-8、抗氧剂2-3、促进剂5-8.
该SBR通过以下方法制备:将上述重量份的组分混炼,得到复合材料;将混炼的复合材料,在温度152-155℃、时间10-15min、压力10-12MPa下进行硫化,得到最终的SBR。
本实施例工艺简单,制备出的复合材料成本低廉,其性能达到国标要求, 可以运用到普通的工业化规模生产中。
实施例4
一种回收材料制成的复合材料的形成方法,该方法为一种不用分选、一体回收利用的方法,包括以下步骤:
(1)将工业生产过程中产生的高分子材料的边角废料无需分选、破碎后加热至部分融化,形成塑性体,制成回收料颗粒;
(2)将回收料颗粒与热塑性材料混合搅拌均匀,经挤出制成多聚合物颗粒;
(3)将多聚合物颗粒分撒到所述功能性底膜上,通过设备加热加压制成最终的复合材料;加热加压是通过对所述设备的轧辊进行加热后,使得撒有多聚合物颗粒的功能性底膜经过相贴设置的轧辊之间,依靠轧辊对功能性底膜加热、施压,通过高温热压的方式使得多聚合物颗粒和功能性底膜溶解固化并压为一体,完成熔接并得到性能稳定均匀的复合材料;所述设备采用轧辊热压装置实现,所述轧辊热压装置包括多个轧辊以及为轧辊加热的轧辊加热机构,所述多个轧辊分两排并列设置,轧辊两端设置在油缸的伸缩端上,油缸的固定端固定在机架上,油缸的伸缩方向正对轧辊方向设置;所述轧辊加热机构包括金属材质的轧辊内芯,还包括位于轧辊一侧外部的加热线圈,用于产生磁场并在轧辊旋转时使其内部的轧辊内芯中产生感应电流实现加热。
加热温度为150-220℃、加压强度为3-6MPa,加热加压时间为1-5min;所述多聚合物颗粒是由热塑性材料均匀包裹回收料颗粒制成。
所述步骤(2)中是将热塑性材料及回收料颗粒中的较低融点材料,通过造粒机工作盘高速旋转摩擦使其熔融,均匀包裹回收料颗粒中较高融点材料。
所述高分子材料的边角废料为较高融点材料时,可被较低融点的热塑性材料熔融包裹形成多聚合物颗粒;所述高分子材料的边角废料为较高融点材料和较低融点材料混合时,可被较低融点的热塑性材料熔融包裹形成多聚合物颗粒;所述高分子材料的边角废料为较低融点材料时,可与较低融点的热塑性材料熔融形成多聚合物颗粒。
实施例5
一种回收材料制成的复合材料的应用,复合材料为之前所述的复合材料,可直接作为铺地材料使用;或可用于复合地毯的背底、中间层;或可用于汽车用脚垫、轮罩、行李箱左右侧围板、备胎底板及盖板。
检测
本发明的回收材料制成的复合材料的主要性能测试
对上述实施例制备的复合材料依照GBT 528-2009进行力学性能测试,如下表所示:
表1 主要性能参数
项目 | 指标 | 结果 |
冲击吸收 | 35-50 | 48-49 |
拉伸强度 | ≥0.5 MPa | 1.2-1.5MPa |
拉断伸长率 | ≥40 | 150-180% |
压缩复原率 | ≥90% | 95%-98% |
另外,可以直观的感受到,本发明制得的产品不刺鼻,基本无味,由此可知,本发明具有更低的VOC排放,显示出了更优的环保性能。
由上述实施例可知,本发明所用的边角料不做分类、分拣,工艺流程简洁,前期设备投入非常少,人力投入少,成本低,能够有效的产生经济效益;制备新产品的种类灵活,由于投入和运行成本不高,使用该工艺也能有效的提高经济效益,使其适用范围更广,更容易推广。
本发明通过简单的形成方法,减小了生产过程中的污染,原材料来源广,可连续生产;所得的复合材料成型后的强度高且具有弹性,同时达到降低成本、实现废弃物再利用、减少环境污染的目的,能产生很高的经济效益。
本发明的回收料颗粒有支撑作用、可作为骨架作用;热塑性材料的优点在于柔软性好、粘结度好,更好的包裹回收颗粒、具有较强的弹性;功能性底膜紧密的和多聚合物颗粒粘合,更有效的形成均匀、整齐的底面层,并具有抗UV、耐摩擦、防滑、增加片材强度、美观功能。
本发明在制备缩合液时促进了树脂的缩聚反应,减少反应时间,提高生产效率,能耗低;松膏参与改性过程中,分温度阶段反应,可使反应更加充分,提高树脂性能,有效提高树脂耐蚀性和耐热性。
本发明制备方法工艺简单,适合工业化大批量生产。
以上所述,仅是本发明的较佳实施例而已,并非是对本发明作其它形式的限制,任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容,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、等同变化与改型,仍属于本发明技术方案的保护范围。
Claims (9)
1.一种回收材料制成的复合材料,其特征在于,由基体和功能性底膜组成,所述基体为多聚合物颗粒,所述多聚合物颗粒由多种回收料颗粒及热塑性材料构成,所述功能性底膜赋予复合材料多种功能特性;
所述热塑性材料包括以下重量份的组分:
热塑性弹性体 25-35
胶印油墨树脂 40-45
塑化剂 1.5-2
固化剂 8-9
醋酮 22-25;
所述胶印油墨树脂包括以下重量份的组分:
松膏 110-120 2,2-双(4-羟环己基)丙烷 2-4
苯酚混合物 40-45 2,2-二甲基-1,3-丙烷二醇 3-4
甲醛溶液 10-15 顺丁烯二酸 10-12
混二甲酚 19-20 甲基乙二醇 7-8
纳米二氧化硅 5-8 纤维素甲醚 12-15
四羟甲基烷 12-15 氯化钙 3-4
硫酸溶液 0.2-0.4 金刚石颗粒 0.05-0.08;
所述热塑性材料包含TPE、TPR、TPV、PP、PE、EVA或EPDM中的一种或多种材料;
所述回收料颗粒来源于在民用地毯、车用地毯、工业毯或汽车内饰件制造中产生的边角废料。
2.根据权利要求1所述的一种回收材料制成的复合材料,其特征在于,所述回收料颗粒材质还包含PP、PA6、PET、PE、SBR、EVA、EPDM、PVC、ES、玻纤或麻纤维中的一种或多种材料;所述甲醛溶液的质量浓度为70-78%。
3.根据权利要求1-2所述的一种回收材料制成的复合材料,其特征在于,所述胶印油墨树脂通过以下步骤制备:
(1)将上述重量份的混二甲酚、苯酚混合物和2,2-双(4-羟环己基)丙烷依次投入反应容器中,升温至75-80℃,搅拌15-20min,调节pH值至7.5-8.0,然后加入上述重量份的甲醛溶液,升温至95-98℃,保温反应120-150min,然后降温至75-80℃,调节pH至6.1-6.2,保持80-90min,停止加热,冷却至室温,调节pH值至7-7.2,得到缩合液;
(2)将上述重量份的松膏投入反应容器中,升温至185-190℃,待熔融完全,然后升温至230-240℃,依次加入上述重量份的顺丁烯二酸、甲基乙二醇、2,2-二甲基-1,3-丙烷二醇、四羟甲基烷、纤维素甲醚、氯化钙和硫酸溶液,保温反应220-260min,再升温至300-310℃,加入所述缩合液,保温反应220-240min,冷却至常温,得到胶印油墨树脂初体;
(3)室温下,向所述胶印油墨树脂初体中加入上述重量份的纳米二氧化硅和金刚石颗粒,机械搅拌25-28min,取出产品,真空干燥,即得最终的胶印油墨树脂。
4.根据权利要求1-3所述的一种回收材料制成的复合材料,其特征在于,热塑性材料的融点范围在150℃-200℃;所述多聚合物颗粒的粒径范围为1-8mm;复合材料的厚度为1-15mm,面密度在1000-10000gsm;所述功能性底膜是由EVA、PE、PP、POE或TPU中的一种或几种复合而成,具有抗UV、耐摩擦、防滑、增加片材强度和美观功能,并可在背面加工花纹方式以增加防滑、疏水和装饰的功能性。
5.一种根据权利要求1-4所述的回收材料制成的复合材料的形成方法,其特征在于,该方法为一种不用分选、一体回收利用的方法,包括以下步骤:
(1)将工业生产过程中产生的高分子材料的边角废料无需分选、破碎后加热至部分融化,形成塑性体,制成回收料颗粒;
(2)将回收料颗粒与热塑性材料混合搅拌均匀,经挤出制成多聚合物颗粒;
(3)将多聚合物颗粒分撒到所述功能性底膜上,通过设备加热加压制成最终的复合材料;加热加压是通过对所述设备的轧辊进行加热后,使得撒有多聚合物颗粒的功能性底膜经过相贴设置的轧辊之间,依靠轧辊对功能性底膜加热、施压,通过高温热压的方式使得多聚合物颗粒和功能性底膜溶解固化并压为一体,完成熔接并得到性能稳定均匀的复合材料;所述设备采用轧辊热压装置实现,所述轧辊热压装置包括多个轧辊以及为轧辊加热的轧辊加热机构,所述多个轧辊分两排并列设置,轧辊两端设置在油缸的伸缩端上,油缸的固定端固定在机架上,油缸的伸缩方向正对轧辊方向设置;所述轧辊加热机构包括金属材质的轧辊内芯,还包括位于轧辊一侧外部的加热线圈,用于产生磁场并在轧辊旋转时使其内部的轧辊内芯中产生感应电流实现加热。
6.根据权利要求5所述的复合材料的形成方法,其特征在于,加热温度为150-220℃、加压强度为3-6MPa,加热加压时间为1-5min;所述多聚合物颗粒是由热塑性材料均匀包裹回收料颗粒制成。
7.根据权利要求5-6所述的复合材料的形成方法,其特征在于,所述步骤(2)中是将热塑性材料及回收料颗粒中的较低融点材料,通过造粒机工作盘高速旋转摩擦使其熔融,均匀包裹回收料颗粒中较高融点材料。
8.根据权利要求7所述的复合材料的形成方法,其特征在于,所述高分子材料的边角废料为较高融点材料时,可被较低融点的热塑性材料熔融包裹形成多聚合物颗粒;所述高分子材料的边角废料为较高融点材料和较低融点材料混合时,可被较低融点的热塑性材料熔融包裹形成多聚合物颗粒;所述高分子材料的边角废料为较低融点材料时,可与较低融点的热塑性材料熔融形成多聚合物颗粒。
9.一种回收材料制成的复合材料的应用,其特征在于,复合材料为根据权利要求1-4所述的回收材料制成的复合材料,可直接作为铺地材料使用;或可用于复合地毯的背底、中间层;或可用于汽车用脚垫、轮罩、行李箱左右侧围板、备胎底板及盖板。
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