CN111791556A - 一种轻质石塑板及其制备方法 - Google Patents
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Abstract
本发明公开了一种轻质石塑板及其制备方法,轻质石塑板包括发泡层和密实层,所述的发泡层位于两层密实层之间,所述的密实层的厚度为0.5‑3mm,所述的发泡层的厚度为3‑20mm。本发明克服了现有技术的不足,通过发泡剂产生了一定量的气孔,降低了底材的密度,减轻了石塑板的重量,使石塑板的运输和安装变的更容易,而使用碳酸钙晶须替代部分的大理石石粉作为原料,使内部具有一定量气孔的石塑板的强度并未发生下降。
Description
技术领域
本发明属于石塑板技术领域,具体涉及一种轻质石塑板及其制备方法。
背景技术
石塑板又称之为石塑砖,正规的名称应该是“PVC片材板”,是一种高品质、高科技研究开发出来的新型装饰材料。常规SPC室内地板为保证尺寸稳定性,配方中添加有大量钙粉,密度达到1.9,导致产品质量过重,在生产、销售、安装过程中不易搬运,人工成本高,如何在产品强度和尺寸稳定性不变的情况下,降低产品密度,减轻产品重量,成为轻量化、高性能的室内地板,成为亟需解决的问题。
发明内容
本发明的目的在于提供一种轻质石塑板及其制备方法,以解决上述背景技术中提出的问题。
为实现上述目的,本发明提供如下技术方案:
一种轻质石塑板,包括发泡层和密实层,所述的发泡层位于两层密实层之间,所述的密实层的厚度为0.5-3mm,所述的发泡层的厚度为3-20mm。
其中,所述的发泡层按以下重量比的原料制成:PVC树脂粉80-95份,大理石石粉120-140份,碳酸钙晶须30-60份,发泡剂3-6份,钙锌复合稳定剂2-3份,ACR 3-5份,DOP 4-6份,色粉1-1.5份。
其中,所述的发泡剂的制备方法为将石蜡10-13份和司班-80 12-15份加热至40℃,搅拌混合均匀,然后,迅速加入过氧化二苯甲酰2-4份和偶氮二甲酰胺5-8份的混合物,同时停止加热,搅拌冷却至室温,得到发泡剂。
一种轻质石塑板的制备方法,包括如下步骤:
S1:将大理石石粉、碳酸钙晶须、ACR和DOP加入高速混合机中进行第一次混料;第一次混料完成后,再向高速混合机中加入PVC树脂粉和钙锌复合稳定剂,进行第二次混料;第二次混料完成后,再向高速混合机中依次加入发泡剂,进行第三次混料;第三次混料完成后,转入低速混合机中搅拌,得到混合料;
S2:将混合料直接在挤出机上105~115℃下挤出成型的发泡层,然后将密实层传输至发泡层的表面进行共挤,冷却后,经剪切机剪切得到石塑板。
其中,所述的高速搅拌机的搅拌速度为1500r/min。
其中,所述的第一次混料、第二次混料、第三次混料的温度相同,都为83℃。
其中,所述的第一次混料时间为5min,所述的第二次混料时间为20min,所述的第三次混料时间为5min,所述的低速混合机中搅拌时间为5min。
其中,所述的低速混合机的搅拌速度为600r/min,所述的低速混合机的搅拌温度为70℃。
其中,所述的密实层与发泡层经过热压辊组进行热压贴合,热压贴合温度为125℃,压力为9Mpa,时间为45min。
与现有技术相比,本发明的有益效果是:本发明石塑板的发泡层内通过添加发泡剂,使发泡层内产生了大量的气孔,发泡剂中使用高温易分解的过氧化二苯甲酰和偶氮二甲酰胺,并以石蜡为基体,司班-80为辅助基体,避免过氧化二苯甲酰和偶氮二甲酰胺发泡过程中产生的气体发生逃逸,同时在该发泡剂加入到发泡层内时,石蜡可作为发泡层内PVC的润滑剂,该发泡剂具有润滑和发泡作用,同时降低了石塑板的密度,减轻了石塑板的重量;使石塑板的运输和安装变的更容易,而使用碳酸钙晶须替代部分的大理石石粉作为原料,碳酸钙晶须的交连作用,使内部具有一定量气孔的石塑板的强度并未发生下降;另外本发明采用三层共挤,将发泡层的两侧表面上复合密实层,使该石塑板的结构强度得到增强。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明中所有的原料中,抗冲改性剂(ACR)为山东瑞丰高分子材料股份有限公司产品;增塑剂(DOP)采用济南豪邦化工有限公司的产品;发泡剂为自制的发泡剂,发泡剂的制备方法为将石蜡13份和司班-80 10份加热至40℃,搅拌混合均匀,然后,迅速加入过氧化二苯甲酰4份和偶氮二甲酰胺6份的混合物,同时停止加热,搅拌冷却至室温,得到发泡剂;碳酸钙晶须的长径比在10以上,对其来源没有特别限定,在市场上购买的或按照本领域技术人员熟知的常规方法制备的即可。
本发明中所有的原料,对其纯度没有特别限定,本发明优选采用分析纯或复合材料领域使用的常规纯度。
实施例1
按重量比,将大理石石粉120份、碳酸钙晶须30份、ACR 3份和DOP 4份加入高速混合机中83℃进行第一次混料,搅拌速度为1500r/min,搅拌时间5min;第一次混料完成后,再向高速混合机中加入PVC树脂粉80份和钙锌复合稳定剂2份,进行第二次混料,搅拌速度为1500r/min,搅拌时间20min;第二次混料完成后,再向高速混合机中依次加入发泡剂3份,进行第三次混料,搅拌速度为1500r/min,搅拌时间5min,第一次混料、第二次混料、第三次混料的温度相同;第三次混料完成后,转入低速混合机中70℃进行搅拌,搅拌速度为600r/min,搅拌时间5min,得到混合料;将混合料直接在挤出机上105℃下挤出成型得发泡层,发泡层厚度为15mm,然后将密实层传输至发泡层两侧的表面经过热压辊组进行热压贴合,密实层为厚度为2.0mm的PVC膜,热压贴合温度为125℃,压力为9Mpa,时间为45min,冷却后,经剪切机剪切得到石塑板。
冷却后,石塑板收缩率为0.17%,按照本实施例方法生产的石塑板,制成5块304.8mm×304.8mm×5mm的板材,称重,计算得石塑板平均密度为1.6,采用抗压强度试验机测试石塑板的强度为192N;在市场上购买密实层和尺寸相同的石塑板5块,称重,计算得平均密度为1.8,采用抗压强度试验机测试石塑板的强度为187N,可见本实施例所制得石塑板较常规石塑板具有较低的密度和较高的强度。
实施例2
按重量比,将大理石石粉140份、碳酸钙晶须60份、ACR 5份和DOP 6份加入高速混合机中83℃进行第一次混料,搅拌速度为1500r/min,搅拌时间5min;第一次混料完成后,再向高速混合机中加入PVC树脂粉95份和钙锌复合稳定剂3份,进行第二次混料,搅拌速度为1500r/min,搅拌时间20min;第二次混料完成后,再向高速混合机中依次加入发泡剂6份,进行第三次混料,搅拌速度为1500r/min,搅拌时间5min,第一次混料、第二次混料、第三次混料的温度相同;第三次混料完成后,转入低速混合机中70℃进行搅拌,搅拌速度为600r/min,搅拌时间5min,得到混合料;将混合料直接在挤出机上115℃下挤出成型得发泡层,发泡层厚度为15mm,然后将密实层传输至发泡层两侧的表面经过热压辊组进行热压贴合,密实层为厚度为2.0mm的PVC膜,热压贴合温度为125℃,压力为9Mpa,时间为45min,冷却后,经剪切机剪切得到石塑板。
冷却后,石塑板收缩率为0.13%,按照本实施例方法生产的石塑板,制成5块304.8mm×304.8mm×5mm的板材,称重,计算得石塑板平均密度为1.5,采用抗压强度试验机测试石塑板的强度为196N;在市场上购买密实层和尺寸相同的石塑板5块,称重,计算得平均密度为1.8,采用抗压强度试验机测试石塑板的强度为187N,可见本实施例所制得石塑板较常规石塑板具有较低的密度和较高的强度。
实施例3
按重量比,将大理石石粉120份、碳酸钙晶须60份、ACR 3份和DOP 5份加入高速混合机中83℃进行第一次混料,搅拌速度为1500r/min,搅拌时间5min;第一次混料完成后,再向高速混合机中加入PVC树脂粉95份和钙锌复合稳定剂2份,进行第二次混料,搅拌速度为1500r/min,搅拌时间20min;第二次混料完成后,再向高速混合机中依次加入发泡剂5份,进行第三次混料,搅拌速度为1500r/min,搅拌时间5min,第一次混料、第二次混料、第三次混料的温度相同;第三次混料完成后,转入低速混合机中70℃进行搅拌,搅拌速度为600r/min,搅拌时间5min,得到混合料;将混合料直接在挤出机上113℃下挤出成型得发泡层,发泡层厚度为10mm,然后将密实层传输至发泡层两侧的表面经过热压辊组进行热压贴合,密实层为厚度为1.0mm的PVC膜,热压贴合温度为125℃,压力为9Mpa,时间为45min,冷却后,经剪切机剪切得到石塑板。
冷却后,石塑板收缩率为0.15%,按照本实施例方法生产的石塑板,制成5块304.8mm×304.8mm×5mm的板材,称重,计算得石塑板平均密度为1.3,采用抗压强度试验机测试石塑板的强度为189N;在市场上购买密实层和尺寸相同的石塑板5块,称重,计算得平均密度为1.8,采用抗压强度试验机测试石塑板的强度为187N,可见本实施例所制得石塑板较常规石塑板具有较低的密度和较高的强度。
实施例4
按重量比,将大理石石粉130份、碳酸钙晶须50份、ACR 4份和DOP 4份加入高速混合机中83℃进行第一次混料,搅拌速度为1500r/min,搅拌时间5min;第一次混料完成后,再向高速混合机中加入PVC树脂粉83份和钙锌复合稳定剂2.3份,进行第二次混料,搅拌速度为1500r/min,搅拌时间20min;第二次混料完成后,再向高速混合机中依次加入发泡剂6份,进行第三次混料,搅拌速度为1500r/min,搅拌时间5min,第一次混料、第二次混料、第三次混料的温度相同;第三次混料完成后,转入低速混合机中70℃进行搅拌,搅拌速度为600r/min,搅拌时间5min,得到混合料;将混合料直接在挤出机上115℃下挤出成型得发泡层,发泡层厚度为20mm,然后将密实层传输至发泡层两侧的表面经过热压辊组进行热压贴合,密实层为厚度为0.5mm的PVC膜,热压贴合温度为125℃,压力为9Mpa,时间为45min,冷却后,经剪切机剪切得到石塑板。
冷却后,石塑板收缩率为0.16%,按照本实施例方法生产的石塑板,制成5块304.8mm×304.8mm×5mm的板材,称重,计算得石塑板平均密度为1.4,采用抗压强度试验机测试石塑板的强度为193N;在市场上购买密实层和尺寸相同的石塑板5块,称重,计算得平均密度为1.8,采用抗压强度试验机测试石塑板的强度为187N,可见本实施例所制得石塑板较常规石塑板具有较低的密度和较高的强度。
本发明在石塑板生产原料中加入具有发泡功能的发泡剂,发泡剂中含有过氧化二苯甲酰和偶氮二甲酰胺,并以石蜡为基体,司班-80为辅助基体,避免过氧化二苯甲酰和偶氮二甲酰胺发泡过程中产生的气体发生逃逸,使石塑板原料在混合均匀后,立即进行挤出成型,在挤出成型的过程中,由于螺杆挤出机内的高温作用,发泡剂在挤出机内开始部分分解,产生气泡;碳酸钙晶须为白色篷松状固体,显微镜下为针状单晶体,摩擦系数高、耐磨性能稳定,碳酸钙晶须的长径比在10以上,将该碳酸钙晶须替代部分的大理石石粉作为原料,第一,碳酸钙晶须为篷松状固体,与大理石石粉混合,可以提高大理石石粉的蓬松度;第二,碳酸钙晶须的长径比在10以上,当与PVC树脂粉高温混合时,碳酸钙晶须会在PVC树脂基体内形成杂乱无章的交叉状态,使最终生产的石塑板内由于碳酸钙晶须的相互交叉起到了交连作用,提高了石塑板的结构强度;第三,石塑板原料在挤出的过程中,过氧化二苯甲酰和偶氮二甲酰胺在高温下发泡,产生的气泡加上交连的碳酸钙晶须的阻隔作用下,很难在挤出成型的过程中从材料中逃逸,使挤出的发泡层具有大量的气孔,因此,降低了生产出的石塑板的密度,减轻了石塑板的重量。
总的来说,通过4个实施例与现有市场上的石塑板密度与强度的对比可知,碳酸钙晶须的交连作用不仅保证了石塑板的结构强度没有得到降低,而且交连的碳酸钙晶须和石蜡与司班-80对发泡剂产生的气泡的阻隔作用,使石塑板内形成了气孔,石塑板的密度得到了降低。
在本说明书的描述中,参考术语“一个实施例”、“一些实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中,对上述术语的示意性表述不必须针对的是相同的实施例或示例。而且,描述的具体特征、结构、材料或者特点可以在任一个或多个实施例或示例中以合适的方式结合。此外,在不相互矛盾的情况下,本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。
以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (9)
1.一种轻质石塑板,包括发泡层和密实层,其特征在于,所述的发泡层位于两层密实层之间,所述的密实层的厚度为0.5-3mm,所述的发泡层的厚度为3-20mm。
2.根据权利要求1所述的一种轻质石塑板,其特征在于:所述的发泡层按以下重量比的原料制成:PVC树脂粉80-95份,大理石石粉120-140份,碳酸钙晶须30-60份,发泡剂3-6份,钙锌复合稳定剂2-3份,ACR 3-5份,DOP 4-6份,色粉1-1.5份。
3.根据权利要求2所述一种轻质石塑板,其特征在于:所述的发泡剂的制备方法为将石蜡10-13份和司班-80 12-15份加热至40℃,搅拌混合均匀,然后,迅速加入过氧化二苯甲酰2-4份和偶氮二甲酰胺5-8份的混合物,同时停止加热,搅拌冷却至室温,得到发泡剂。
4.权利要求1-3任意一项所述的一种轻质石塑板的制备方法,其特征在于,包括如下步骤:
S1:将大理石石粉、碳酸钙晶须、ACR和DOP加入高速混合机中进行第一次混料;第一次混料完成后,再向高速混合机中加入PVC树脂粉和钙锌复合稳定剂,进行第二次混料;第二次混料完成后,再向高速混合机中依次加入发泡剂和色粉,进行第三次混料;第三次混料完成后,转入低速混合机中搅拌,得到混合料;
S2:将混合料直接在挤出机上105~115℃下挤出成型的发泡层,然后将密实层传输至发泡层表面进行共挤,冷却后,经剪切机剪切得到石塑板。
5.根据权利要求4所述的一种轻质石塑板的制备方法,其特征在于:所述的高速搅拌机的搅拌速度为1500r/min。
6.根据权利要求4所述的一种轻质石塑板的制备方法,其特征在于:所述的第一次混料、第二次混料、第三次混料的温度相同,都为83℃。
7.根据权利要求4所述的一种轻质石塑板的制备方法,其特征在于:所述的第一次混料时间为5min,所述的第二次混料时间为20min,所述的第三次混料时间为5min,所述的低速混合机中搅拌时间为5min。
8.根据权利要求4所述的一种轻质石塑板的制备方法,其特征在于:所述的低速混合机的搅拌速度为600r/min,所述的低速混合机的搅拌温度为70℃。
9.根据权利要求4所述的一种轻质石塑板的制备方法,其特征在于:所述的覆膜与发泡层经过热压辊组进行热压贴合,热压贴合温度为125℃,压力为9Mpa,时间为45min。
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