CN112092464A - 一种具有高缓冲性能的epp护板及其制备方法 - Google Patents
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Abstract
本发明提供了一种具有高缓冲性能的EPP护板及其制备方法，EPP护板包括高密度骨架、低密度填充层、低密度缓冲板和高密度外板，高密度骨架包括高密度板材、设置在高密度板材上的多个缓冲槽和设置在缓冲槽内的高密度吸能条，相邻两个高密度吸能条之间间隔设有吸能槽，低密度填充层分别安装在高密度骨架的上下两侧面，低密度填充层包括低密度板材和与吸能槽对应的低密度吸能条，低密度缓冲板分别粘接安装在两个低密度填充层的外侧面，高密度外板共有两个，分别粘接安装在两个低密度缓冲板的外侧面。总之，本发明具有结构科学、制备方法简单、缓冲性能高等优点。
Description
技术领域
本发明属于材料制备技术领域，具体是涉及一种具有高缓冲性能的EPP护板及其制备方法
背景技术
EPP是发泡聚丙烯的缩写，是一种新型泡沫塑料的简称。EPP是聚丙烯塑料发泡材料，是一种性能卓越的高结晶型聚合物/气体复合材料，以其独特而优越的性能成为增长最快的环保新型抗压缓冲隔热材料。EPP还是一种环保材料，可回收再利用，可以自然降解，不会造成白色污染。
EPP比重轻、弹性好、抗震抗压、变形恢复率高、吸收性能好、耐油、耐酸、耐碱、耐各种化学溶剂、不吸水、绝缘、耐热(-40～130℃)，无毒无味，可100％循环使用且性能几乎毫不降低，是真正的环境友好型泡沫塑料。用EPP珠粒在成型机的模具中可模塑成各种不同形状的EPP制品。
EPP广泛应用在汽车上，如保险杠芯材、防撞块、顶棚等内衬件，车门填充、头枕、遮阳板等，可节省油耗又提高了乘客的安全系数。EPP在包装行业已广泛应用，如电子产品、医疗器械等，尤其在出口产品的包装上，应环保的要求已成为不可替代的包装物。由于其无毒又耐温性高，在食品包装和微波加热上也被广泛应用。
目前，EPP板材的利用方式是直接采用EPP材料一体成型得到EPP护板，这样得到的EPP护板缓冲性能有限，所以，本发明设计了一种具有高缓冲性能的EPP护板及其制备方法。
发明内容
针对上述存在的问题，本发明提供了一种具有高缓冲性能的EPP护板及其制备方法。
本发明的技术方案是：一种具有高缓冲性能的EPP护板，主要包括高密度骨架、低密度填充层、低密度缓冲板和高密度外板，
所述高密度骨架包括高密度板材、设置在所述高密度板材上下两侧面的多个缓冲槽和等距设置在所述缓冲槽内的高密度吸能条，相邻两个所述高密度吸能条之间间隔设有吸能槽，
所述低密度填充层共有两个，分别安装在所述高密度骨架的上下两侧面，低密度填充层包括低密度板材和分别安装在所述低密度板材上下两侧面且与所述吸能槽对应的低密度吸能条，
所述低密度缓冲板共有两个，分别粘接安装在所述两个低密度填充层的外侧面，两个低密度缓冲板的中间均为瓦楞结构，
所述高密度外板共有两个，分别粘接安装在所述两个低密度缓冲板的外侧面。
进一步地，所述高密度骨架的材料密度为33-35kg/m3，所述低密度填充层的密度为20-22kg/m3，所述低密度缓冲板的材料密度为23-25kg/m3，所述高密度外板的材料密度为30-32kg/m3，。高密度骨架作为EPP护板的核心板材，必须具备高密度的性质，而低密度填充层和低密度缓冲板的作用是吸能缓冲，所以密度较低，高密度外板需要承受外界的多种压力，所以密度较高。
进一步地，所述低密度填充层、低密度缓冲板和高密度外板之间采用QIS-3061发泡材料专用胶粘接，QIS-3061发泡材料专用胶粘接对于EPP板材之间的粘接效果很好，且性质稳定、耐候性好，不会对EPP板材产生腐蚀作用。
进一步地，所述低密度吸能条的体积略小于吸能槽的体积，用于在发生挤压时，吸能槽内留有用于低密度吸能条挤压移动的空间，在发生挤压碰撞时，吸能槽内预留的空间可以对低密度吸能条的位移变形产生缓冲。
进一步地，高密度骨架、低密度填充层、低密度缓冲板和高密度外板均采用模具一体成型，使板材不易开裂。
一种具有高缓冲性能EPP护板的制备方法，主要包括以下步骤：
S1：制备板材
分别根据高密度骨架、低密度填充层、低密度缓冲板和高密度外板的体积和密度取不同规格的EPP珠粒备用，利用载压机向EPP珠粒内部冲入一定压力的气体，然后用喷注枪将载压EPP珠粒在压缩空气的带动下喷注至相应模具中，蒸汽加热模具使载压EPP珠粒内部气体受热膨胀，从而使EPP珠粒表面膨胀至互相熔接，冷却模具后即得到高密度骨架、低密度填充层、低密度缓冲板和高密度外板，
S2：组装粘接
先除去高密度骨架、低密度填充层、低密度缓冲板和高密度外板上的边角料，然后将两个低密度填充层分别对应安装在所述高密度骨架的上下两侧面，安装后将组装板材至于液压机下进行预压，使低密度填充层与高密度骨架紧密安装，预压后静置16-18h，使低密度填充层回弹，
等待低密度填充层回弹过程中，在两个低密度缓冲板的外侧面和高密度高外板的内侧面分别喷涂QIS-3061发泡材料专用胶，将两个高密度外板分别粘接在两个低密度缓冲板的外侧面，在通风阴凉处静置3-5h，使QIS-3061发泡材料专用胶干化，
向组装好的两个低密度填充层外侧面和低密度缓冲板的内侧面喷涂QIS-3061发泡材料专用胶，将粘接高密度外板后的两个低密度缓冲板分别粘接在两个低密度填充层的外侧面，在通风阴凉处静置3-5h，使QIS-3061发泡材料专用胶干化，得到EPP护板；
S3：剪切
按照工件形状对S2得到的EPP护板进行剪切，得到具有高缓冲性能的EPP护板。
优选地，S1中，冷却模具的方式为向模具吹拂4-8℃的低温气体，快速降温的同时不会影响EPP板材的性能。
进一步地，S2中，对于组装板材的预压压力为5-6KPa，既可以将低密度填充层紧密压接在高密度骨架上，又不会对低密度填充层和高密度骨架造成破坏。
本发明的有益效果是：本发明提供的一种具有高缓冲性能的EPP护板及其制备方法，通过将不同密度的EPP板材组合安装，得到具有高缓冲性能的EPP护板，通过设置高密度骨架作为EPP护板的核心板材，在高密度骨架上设置多个缓冲槽，缓冲槽内设置高密度缓冲条和吸能槽，并且在高密度骨架的上下两侧面安装低密度填充层，利用低密度填充层上的低密度吸能条将吸能槽填充，并且吸能槽内留有用于低密度吸能条挤压移动的空间，在发生挤压碰撞时，吸能槽内预留的空间可以对低密度吸能条的位移变形产生缓冲，在低密度填充层外侧粘接内部为瓦楞结构的低密度缓冲板，EPP护板外部收到的压力先经低密度缓冲板吸能，然后通过低密度填充层向高密度骨架的形变吸能，从而达到高缓冲性能。总之，本发明具有结构科学、制备方法简单、缓冲性能高等优点。
附图说明
图1是本发明EPP板材的爆炸结构示意图；
图2是本发明EPP板材的剖面结构示意图；
图3是本发明的高密度骨架结构示意图；
图4是本发明的低密度填充层结构示意图；
图5是本发明的低密度缓冲板结构示意图。
其中，1-高密度骨架、11-高密度板材、12-缓冲槽、13-高密度吸能条、14-吸能槽、2-低密度填充层、21-低密度板材、22-低密度吸能条、3-低密度缓冲板、4-高密度外板。
具体实施方式
为便于对本发明技术方案的理解，下面结合附图1-5和具体实施例对本发明做进一步的解释说明，实施例并不构成对发明保护范围的限定。
实施例1：如图1-2所示，一种具有高缓冲性能的EPP护板，主要包括高密度骨架1、低密度填充层2、低密度缓冲板3和高密度外板4，
如图3所示，高密度骨架1包括高密度板材11、设置在高密度板材11上下两侧面的多个缓冲槽12和等距设置在缓冲槽12内的高密度吸能条13，相邻两个高密度吸能条13之间间隔设有吸能槽14，
低密度填充层2共有两个，分别安装在高密度骨架1的上下两侧面，如图4所示，低密度填充层2包括低密度板材21和分别安装在低密度板材21上下两侧面且与吸能槽14对应的低密度吸能条22，低密度吸能条22的体积略小于吸能槽14的体积，用于在发生挤压时，吸能槽14内留有用于低密度吸能条22挤压移动的空间，
低密度缓冲板3共有两个，分别粘接安装在两个低密度填充层2的外侧面，如图5所示，两个低密度缓冲板3的中间均为瓦楞结构，
高密度外板4共有两个，分别粘接安装在两个低密度缓冲板3的外侧面；
高密度骨架1、低密度填充层2、低密度缓冲板3和高密度外板4均采用模具一体成型，高密度骨架1的材料密度为33kg/m3，低密度填充层2的密度为20kg/m3，低密度缓冲板3的材料密度为23kg/m3，高密度外板4的材料密度为30kg/m3；
低密度填充层2、低密度缓冲板3和高密度外板4之间采用QIS-3061发泡材料专用胶粘接。
实施例2：与实施例1基本相同，不同之处在于：
高密度骨架1的材料密度为34kg/m3，低密度填充层2的密度为21kg/m3，低密度缓冲板3的材料密度为24kg/m3，高密度外板4的材料密度为31kg/m3。
实施例3：与实施例1基本相同，不同之处在于：
高密度骨架1的材料密度为35kg/m3，低密度填充层2的密度为22kg/m3，低密度缓冲板3的材料密度为25kg/m3，高密度外板4的材料密度为32kg/m3。
实施例4：一种具有高缓冲性能EPP护板的制备方法，主要包括以下步骤：
S1：制备板材
分别根据高密度骨架1、低密度填充层2、低密度缓冲板3和高密度外板4的体积和密度取不同规格的EPP珠粒备用，利用载压机向EPP珠粒内部冲入一定压力的气体，然后用喷注枪将载压EPP珠粒在压缩空气的带动下喷注至相应模具中，蒸汽加热模具使载压EPP珠粒内部气体受热膨胀，从而使EPP珠粒表面膨胀至互相熔接，冷却模具后即得到高密度骨架1、低密度填充层2、低密度缓冲板3和高密度外板4，冷却模具的方式为向模具吹拂4℃的低温气体，
S2：组装粘接
先除去高密度骨架1、低密度填充层2、低密度缓冲板3和高密度外板4上的边角料，然后将两个低密度填充层2分别对应安装在高密度骨架1的上下两侧面，安装后将组装板材至于液压机下进行预压，预压压力为5KPa，使低密度填充层2与高密度骨架紧密安装，预压后静置16h，使低密度填充层2回弹，
等待低密度填充层2回弹过程中，在两个低密度缓冲板3的外侧面和高密度高外板4的内侧面分别喷涂QIS-3061发泡材料专用胶，将两个高密度外板4分别粘接在两个低密度缓冲板3的外侧面，在通风阴凉处静置5h，使QIS-3061发泡材料专用胶干化，
向组装好的两个低密度填充层2外侧面和低密度缓冲板3的内侧面喷涂QIS-3061发泡材料专用胶，将粘接高密度外板4后的两个低密度缓冲板3分别粘接在两个低密度填充层2的外侧面，在通风阴凉处静置5h，使QIS-3061发泡材料专用胶干化，得到EPP护板；
S3：剪切
按照工件形状对S2得到的EPP护板进行剪切，得到具有高缓冲性能的EPP护板。
实验例：研究实施例1-3EPP护板的缓冲性能
实验对象：按照实施例4提供的制备方法分别制备实施例1-3的EPP护板各四块和市售的普通EPP护板四块，上述EPP护板面积相同。
实验条件：分别在实施例1-3得到的EPP护板和市售的EPP护板中心处高度50cm处垂直下落10kg重物，记录护板初始最大形变和5min回弹后形变，更换EPP护板后改变重物下落高度，重复记录。
实验结果：实验结果如表1-4所示：
表1 50cm处下落重物EPP护板形变结果对比表
表2 70cm处下落重物EPP护板形变结果对比表
表3 90cm处下落重物EPP护板形变结果对比表
表4 100cm处下落重物EPP护板形变结果对比表
实验结论：本发明提供的一种具有高缓冲性能的EPP护板及其制备方法，制备得到的EPP护板缓冲性能和回弹性能明显优于现有的EPP护板。
Claims (7)
1.一种具有高缓冲性能的EPP护板，其特征在于，主要包括高密度骨架(1)、低密度填充层(2)、低密度缓冲板(3)和高密度外板(4)，
所述高密度骨架(1)包括高密度板材(11)、设置在所述高密度板材(11)上下两侧面的多个缓冲槽(12)和等距设置在所述缓冲槽(12)内的高密度吸能条(13)，相邻两个所述高密度吸能条(13)之间间隔设有吸能槽(14)，
所述低密度填充层(2)共有两个，分别安装在所述高密度骨架(1)的上下两侧面，低密度填充层(2)包括低密度板材(21)和分别安装在所述低密度板材(21)上下两侧面且与所述吸能槽(14)对应的低密度吸能条(22)，
所述低密度缓冲板(3)共有两个，分别粘接安装在所述两个低密度填充层(2)的外侧面，两个低密度缓冲板(3)的中间均为瓦楞结构，
所述高密度外板(4)共有两个，分别粘接安装在所述两个低密度缓冲板(3)的外侧面。
2.根据权利要求1所述的一种具有高缓冲性能的EPP护板，其特征在于，所述高密度骨架(1)的材料密度为33-35kg/m3，所述低密度填充层(2)的密度为20-22kg/m3，所述低密度缓冲板(3)的材料密度为23-25kg/m3，所述高密度外板(4)的材料密度为30-32kg/m3。
3.根据权利要求1所述的一种具有高缓冲性能的EPP护板，其特征在于，所述低密度填充层(2)、低密度缓冲板(3)和高密度外板(4)之间采用QIS-3061发泡材料专用胶粘接。
4.根据权利要求1所述的一种具有高缓冲性能的EPP护板，其特征在于，高密度骨架(1)、低密度填充层(2)、低密度缓冲板(3)和高密度外板(4)均采用模具一体成型。
5.一种具有高缓冲性能EPP护板的制备方法，其特征在于，主要包括以下步骤：
S1：制备板材
分别根据高密度骨架(1)、低密度填充层(2)、低密度缓冲板(3)和高密度外板(4)的体积和密度取不同规格的EPP珠粒备用，利用载压机向EPP珠粒内部冲入一定压力的气体，然后用喷注枪将载压EPP珠粒在压缩空气的带动下喷注至相应模具中，蒸汽加热模具使载压EPP珠粒内部气体受热膨胀，从而使EPP珠粒表面膨胀至互相熔接，冷却模具后即得到高密度骨架(1)、低密度填充层(2)、低密度缓冲板(3)和高密度外板(4)，
S2：组装粘接
先除去高密度骨架(1)、低密度填充层(2)、低密度缓冲板(3)和高密度外板(4)上的边角料，然后将两个低密度填充层(2)分别对应安装在所述高密度骨架(1)的上下两侧面，安装后将组装板材至于液压机下进行预压，使低密度填充层(2)与高密度骨架紧密安装，预压后静置16-18h，使低密度填充层(2)回弹，
等待低密度填充层(2)回弹过程中，在两个低密度缓冲板(3)的外侧面和高密度高外板(4)的内侧面分别喷涂QIS-3061发泡材料专用胶，将两个高密度外板(4)分别粘接在两个低密度缓冲板(3)的外侧面，在通风阴凉处静置3-5h，使QIS-3061发泡材料专用胶干化，
向组装好的两个低密度填充层(2)外侧面和低密度缓冲板(3)的内侧面喷涂QIS-3061发泡材料专用胶，将粘接高密度外板(4)后的两个低密度缓冲板(3)分别粘接在两个低密度填充层(2)的外侧面，在通风阴凉处静置3-5h，使QIS-3061发泡材料专用胶干化，得到EPP护板；
S3：剪切
按照工件形状对S2得到的EPP护板进行剪切，得到具有高缓冲性能的EPP护板。
6.根据权利要求5所述的一种具有高缓冲性能EPP护板的制备方法，其特征在于，S1中，冷却模具的方式为向模具吹拂4-8℃的低温气体。
7.根据权利要求5所述的一种具有高缓冲性能EPP护板的制备方法，其特征在于，S2中，对于组装板材的预压压力为5-6KPa。
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