CN113337053A - 核壳结构的木塑材料及制备方法 - Google Patents

核壳结构的木塑材料及制备方法 Download PDF

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CN113337053A
CN113337053A CN202110667420.5A CN202110667420A CN113337053A CN 113337053 A CN113337053 A CN 113337053A CN 202110667420 A CN202110667420 A CN 202110667420A CN 113337053 A CN113337053 A CN 113337053A
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layer
core
wood
shell
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张小玲
肖志远
李彦辉
康敏
熊记
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Changzhou Bemate Home Technology Co Ltd
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Abstract

本发明公开了核壳结构的木塑材料及制备方法，涉及木塑材料技术领域。核壳结构的木塑材料，包括芯层和包覆于芯层上的壳层；以质量份数计，芯层的原料包括PVC树脂90‑110份、木粉100‑120份、粉煤灰10‑20份、物理发泡剂0.5‑1.5份、第一热稳定剂2‑6份和第一润滑剂0.5‑2份和第一增塑剂5‑15份；壳层的原料包括PVC树脂90‑110份、碳酸钙90‑110份、第二热稳定剂2‑6份、第二增塑剂3‑7份和第二润滑剂0.3‑1.0份。通过原料之间的科学配比，在显著降低密度的前提下还可以保证核壳材料的强度。

Description

核壳结构的木塑材料及制备方法
技术领域
本发明涉及木塑材料技术领域，具体而言，涉及核壳结构的木塑材料及制备方法。
背景技术
木塑即木塑复合材料，是蓬勃兴起的一类新型复合材料，指利用聚乙烯、聚丙烯和聚氯乙烯等，代替通常的树脂胶粘剂，与废植物纤维混合成新的木质材料，再经挤压、模压、注塑成型等塑料加工工艺，生产出的板材或型材。主要用于建材、家具、物流包装等行业。
木塑共挤发泡板材是一种性能优异的木塑复合材料，木塑共挤发泡板材具有隔声、吸声、隔热、保温等性能，还具有较高的硬度、弹性模量、握钉力及较小的应力，更适用于家具领域。
但是，现有的木塑共挤发泡板材存在着密度过小和强度不高的问题，这一定程度上制约了此类板材的推广应用。
鉴于此，特提出本发明。
发明内容
本发明的目的在于提供核壳结构的木塑材料及制备方法，旨在获得密度低且强度较高的材料。
本发明是这样实现的：
第一方面，本发明提供一种核壳结构的木塑材料，包括芯层和包覆于芯层上的壳层；
以质量份数计，芯层的原料包括PVC树脂90-110份、木粉100-120份、粉煤灰10-20份、物理发泡剂0.5-1.5份、第一热稳定剂2-6份和第一润滑剂0.5-2份和第一增塑剂5-15份；
以与芯层相同标准的质量份数计，壳层的原料包括PVC树脂90-110份、碳酸钙90-110份、第二热稳定剂2-6份、第二增塑剂3-7份和第二润滑剂0.3-1.0份。
第二方面，本发明提供一种核壳结构的木塑材料的制备方法，采用前述木塑材料中芯层和壳层的原料进行制备。
本发明具有以下有益效果：发明人通过改进芯层和壳层的配方，特别是在芯层中以PVC树脂粉、木粉为主要原料，配合碳酸钙、发泡剂、热稳定剂和润滑剂，通过原料之间的科学配比，在显著降低密度的前提下还可以保证核壳材料的强度。
附图说明
为了更清楚地说明本发明实施例的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，应当理解，以下附图仅示出了本发明的某些实施例，因此不应被看作是对范围的限定，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他相关的附图。
图1为本发明实施例得到壳核结构板材的结构示意图。
图标：10-耐磨层；20-彩膜层；30-SPC稳定层；40-木塑发泡层；50-SPC稳定层。
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，下面将对本发明实施例中的技术方案进行清楚、完整地描述。实施例中未注明具体条件者，按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
本发明实施例提供一种核壳结构的木塑材料，包括芯层和包覆于芯层上的壳层，以形成核壳结构的材料。
发明人对芯层和壳层的原料做了改进：以质量份数计，芯层的原料PVC树脂90-110份、木粉100-120份、粉煤灰10-20份、物理发泡剂0.5-1.5份、第一热稳定剂2-6份和第一润滑剂0.5-2份和第一增塑剂5-15份；以与芯层相同标准的质量份数计，壳层的原料包括PVC树脂90-110份、碳酸钙90-110份、第二热稳定剂2-6份、第二增塑剂3-7份和第二润滑剂0.3-1.0份。芯层和壳层的原料和配比控制在上述范围内为宜，在此范围内能够在显著降低核壳材料密度的前提下，还保证材料的强度较好。
具体地，PVC树脂是以PVC树脂粉的形式加入，碳酸钙也是以粉料的形式加入。
为进一步提高材料的综合性能，获得低密度高强度的材料，发明人对芯层和壳层的原料和配比做了进一步优化：以质量份数计，芯层的原料包括PVC树脂粉95-105份、木粉105-115份、粉煤灰13-17份、物理发泡剂0.8-1.2份、第一热稳定剂3-5份、第一润滑剂0.8-1.2份和第一增塑剂9-11份；以与芯层相同标准的质量份数计，壳层的原料包括PVC树脂粉95-105份、碳酸钙95-105份、第二热稳定剂3-5份、第二增塑剂4-6份和第二润滑剂0.3-0.8份。
需要说明的是，PVC树脂粉、木粉均为市购原料，木粉是指杨木、松木、杉木等速生材磨成的纤维粉末，纤维粉末的长度大致为0.5-1.5mm。碳酸钙的加入是增加材料的稳定性，有利于获得很优异的强度性能。
配方中的各添加剂有具体要求，具体如下：
在一些实施例中，物理发泡剂选自氮气和聚醚多元醇中的至少一种；均为市购原料。
在一些实施例中，第一增塑剂为邻苯二甲酸二异壬酯(DIHP)和邻苯二甲酸甲苯基丁酯(BBP)的混合物，第二增塑剂为对苯二甲酸二辛酯(DOTP)。
在一些实施例中，第一热稳定剂和第二热稳定剂均选自钙锌稳定剂和有机锡稳定剂中的至少一种；优选地，第一热稳定剂为钙锌稳定剂，第二稳定剂为有机锡稳定剂；
在一些实施例中，第一润滑剂和第二润滑剂均选自邻苯二甲酸二辛酯、PE蜡、氧化聚乙烯蜡中的至少一种；优选地，第一润滑剂为PE蜡和氧化聚乙烯蜡的混合物，第二润滑剂为邻苯二甲酸二辛酯(DOP)。
需要说明的是，通过对发泡剂、增塑剂、稳定剂和润滑剂做进一步优选，有利于提升材料的综合性能，获得低密度高强度的材料。
在一些实施例中，壳层还包括炭黑0.5-1.5份。通过加入适量的着色剂可以获得显色偏黑色的材料，适合于进一步加工为地板。
本发明实施例还提供一种核壳结构的木塑材料的制备方法，采用前述实施方式中任一项木塑材料中芯层和壳层的原料进行制备，发明人通过配料的改进配合常规的核壳结构材料的制备工艺即可以获得低密度高强度的复合材料。
S1、壳层母料制备
将壳层的原料混合挤出并破碎，以得到颗粒状母料。具体地，颗粒状母料的制备过程包括：将壳层的原料混合均匀之后挤出成型，并破碎为粒径为1-2mm的颗粒。将壳层的原料制成均匀的颗粒状材料，便于S3中形成均匀的壳层，此外，在造粒时可以经过滤网过滤掉一些杂质。
在一些实施例中，壳层的原料挤出成型过程中控制挤出机主机转速为8-12r/min(如8r/min、9r/min、10r/min、11r/min、12r/min等)，喂料转速为2-4r/min(如2r/min、3r/min、4r/min等)。
S2、芯层混合料制备
将芯层的原料混合后得到芯层混合料，用于后续S3中形成芯层。
在优选的实施例中，芯层混合料的制备过程包括：先在115-120℃(如115℃、116℃、117℃、118℃、119℃、120℃等)的条件下将原料混合均匀，再进行冷混以使原料温度降低至40-45℃(如40℃、41℃、42℃、43℃、44℃、45℃等)。通过冷混有利于芯层形成独立的层，而不会与壳层发生融合。
具体地，冷混是在冷辊机中混合8-10min，如8min、9min、10min等。
S3、核壳结构材料的制备
将颗粒状母料和芯层混合料分别挤出形成核壳结构的材料，采用现有挤出设备即可获得核壳结构的材料。
在实际操作过程中，将颗粒状母料置于单螺杆挤出机中，将芯层混合料置于双螺杆挤出机中，通过模具机头共挤复合，再进行冷却定型。具体地，单螺杆挤出机的转速为7-9r/min；双螺杆挤出机的主机转速为4-6r/min，喂料转速为1-3r/min。
在一些实施例中，冷却定型过程中是采用5-17℃的冷水进行定型，冷水的温度可以为5℃、8℃、10℃、12℃、15℃、17℃等，也可以为以上相邻温度值之间的任意值。
需要补充的是，本发明提供的核壳结构木塑材料的芯层采用发泡工艺降低密度，壳层材料在共挤出核-壳结构木塑复合材料中只占到了很少一部分，显然降低了生产过程中的成本，实现木塑制品的多样化，拓展木塑材料的应用领域。
S4、覆膜
在形成的核壳结构的材料上依次贴敷彩膜层和耐磨层，形成最终产品，如图1所示，自上而下依次为耐磨层10、彩膜层20、SPC稳定层30、木塑发泡层40和SPC稳定层50。其中，木塑发泡层40即为芯层，SPC稳定层50即为壳层。
具体地，耐磨层10、彩膜层20的原料为市购膜层，在此不做过多赘述。
以下结合实施例对本发明的特征和性能作进一步的详细描述。
实施例1
本实施例提供一种核壳结构的木塑材料的制备方法，包括如下步骤：
(1)木粉、碳酸钙和粉煤灰在混合前用鼓风干燥机干燥3小时，备用。
(2)壳层用料准备：将PVC树脂粉100份、碳酸钙粉100份、有机锡稳定剂4份、增塑剂DOTP 5份、润滑剂DOP 0.5份、炭黑1份置于高速混合机混合均匀，冷却至室温，放置24小时。将混好的原料置于异向双螺杆挤出机，挤出机主机转速为10r/min，喂料转速3r/min。将挤出物料置于爪刀静音破碎机破碎成颗粒状母料，完成表层备料。
(3)芯层用料准备：将PVC树脂粉100份、木粉110份、粉煤灰15份、氮气、聚醚多元醇2份、钙锌稳定剂4份、润滑剂(PE蜡0.5份、氧化聚乙烯蜡0.5份)、增塑剂(DIHP/BBP混合物，二者等量)10份，加入到高速混合机混合8min至各组分互相渗透，温度达到115℃后放置于冷辊机中冷混10min左右至温度达到45℃左右后，放入储料仓，备用。
(4)将步骤(2)中制备的表层母料置于单螺杆挤出机，单螺杆挤出机转速8r/min；将(3)中混好的芯层原料置于双螺杆挤出机，主机转速5r/min，喂料速度2r/min。通过模具机头共挤复合，然后在5℃左右的冷却水温下冷却定型，然后以0.95m/min的牵引速度牵引并切割制备出核壳结构的SPC共挤三层发泡板。
(5)通过覆膜辊在表层附上PVC耐磨层和彩膜层，表面纹路由压纹辊而定。
实施例2
本实施例提供一种核壳结构的木塑材料的制备方法，包括如下步骤：
(1)木粉、碳酸钙和粉煤灰在混合前用鼓风干燥机干燥3小时，备用。
(2)壳层用料准备：将PVC树脂粉100份、碳酸钙粉100份、有机锡稳定剂4份、增塑剂DOTP 5份、润滑剂DOP 0.5份、炭黑1份置于高速混合机混合均匀，冷却至室温，放置24小时。将混好的原料置于异向双螺杆挤出机，挤出机主机转速为10r/min，喂料转速3r/min。将挤出物料置于爪刀静音破碎机破碎成颗粒状母料，完成表层备料。
(3)芯层用料准备：将PVC树脂粉100份、木粉80份、碳酸钙粉5份、粉煤灰15份、氮气、聚醚多元醇1.8份、钙锌稳定剂4份、润滑剂(PE蜡0.5份、氧化聚乙烯蜡0.5份)、增塑剂(DIHP/BBP混合物，二者等量)10份，加入到高速混合机混合10min至各组分互相渗透，温度达到120℃后放置于冷辊机中冷混10min至温度达到40℃后，放入储料仓，备用。
(4)将步骤(2)中制备的表层母料置于单螺杆挤出机，单螺杆挤出机转速8r/min；将(3)中混好的芯层原料置于双螺杆挤出机，主机转速5r/min，喂料速度2r/min。通过模具机头共挤复合，然后在17℃左右的冷却水温下冷却定型，然后以0.95m/min的牵引速度牵引并切割制备出核壳结构的SPC共挤三层发泡板。
(5)通过覆膜辊在表层附上PVC耐磨层和彩膜层，表面纹路由压纹辊而定。
实施例3
本实施例提供一种核壳结构的木塑材料的制备方法，包括如下步骤：
(1)木粉、碳酸钙和粉煤灰在混合前用鼓风干燥机干燥3小时，备用。
(2)壳层用料准备：将PVC树脂粉100份、碳酸钙粉100份、有机锡稳定剂4份、增塑剂DOTP 5份、润滑剂DOP 0.5份、炭黑1份置于高速混合机混合均匀，冷却至室温，放置24小时。将混好的原料置于异向双螺杆挤出机，挤出机主机转速为10r/min，喂料转速3r/min。将挤出物料置于爪刀静音破碎机破碎成颗粒状母料，完成表层备料。
(3)芯层用料准备：将PVC树脂粉100份、70份木粉、碳酸钙粉10份、粉煤灰15份、氮气、聚醚多元醇1.7份、钙锌稳定剂4份、润滑剂(PE蜡0.5份、氧化聚乙烯蜡0.5份)、增塑剂(DIHP/BBP混合物，二者等量)10份，加入到高速混合机混合10min至各组分互相渗透，温度达到115-120°后放置于冷辊机中冷混9min至温度达到40℃后，放入储料仓，备用。
(4)将步骤(2)中制备的表层母料置于单螺杆挤出机，单螺杆挤出机转速8r/min；将(3)中混好的芯层原料置于双螺杆挤出机，主机转速5r/min，喂料速度2r/min。通过模具机头共挤复合，然后在10℃左右的冷却水温下冷却定型，然后以0.95m/min的牵引速度牵引并切割制备出核壳结构的SPC共挤三层发泡板。
(5)通过覆膜辊在表层附上PVC耐磨层和彩膜层，表面纹路由压纹辊而定。
对比例1
本对比例提供一种核壳结构的木塑材料的制备方法，与实施例1不同之处仅在于：将芯层的木粉替换为碳酸钙粉。
对比例2
本对比例提供一种核壳结构的木塑材料的制备方法，与实施例1不同之处仅在于：使用偶氮类化学发泡剂发泡。
对比例3
市购共挤发泡板材，主要成分为PVC、碳酸钙粉、木塑粉、DOTP塑化剂、AC发泡剂(偶氮二甲酰胺)、钙锌稳定剂、固体石蜡等。
试验例1
测试实施例和对比例中得到板材的密度、静曲强度、热稳定性，结果见表1，静曲强度测试方法参照GB17657 4.7静曲强度和弹性模量测试(三点弯曲)，热稳定性测试方法参照EN434弹性地板覆盖物尺寸稳定性和受热卷曲的测定。
表1板材性能测试结果
组别 密度/g/cm3 静曲强度/MPa 80℃/6h翘曲度/mm
实施例1 1.25 28 0.65
实施例2 1.19 25 0.72
实施例3 1.10 23 0.83
对比例1 1.35 12.8 1.31
对比例2 1.23 11.6 1.52
对比例3 1.21 14.9 1.67
从表1可以看出，本发明实施例制备得到的壳核材料具有很低的密度，且具有较高的强度。
以上仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

1.一种核壳结构的木塑材料，其特征在于，包括芯层和包覆于所述芯层上的壳层；
以质量份数计，所述芯层的原料包括PVC树脂90-110份、木粉100-120份、粉煤灰10-20份、物理发泡剂0.5-1.5份、第一热稳定剂2-6份和第一润滑剂0.5-2份和第一增塑剂5-15份；
以与所述芯层相同标准的质量份数计，所述壳层的原料包括PVC树脂90-110份、碳酸钙90-110份、第二热稳定剂2-6份、第二增塑剂3-7份和第二润滑剂0.3-1.0份。
2.根据权利要求1所述的木塑材料，其特征在于，以质量份数计，所述芯层的原料包括PVC树脂粉95-105份、木粉105-115份、粉煤灰13-17份、物理发泡剂0.8-1.2份、第一热稳定剂3-5份、第一润滑剂0.8-1.2份和第一增塑剂9-11份；
以与所述芯层相同标准的质量份数计，所述壳层的原料包括PVC树脂粉95-105份、碳酸钙95-105份、第二热稳定剂3-5份、第二增塑剂4-6份和第二润滑剂0.3-0.8份。
3.根据权利要求1或2所述的木塑材料，其特征在于，所述壳层还包括炭黑0.5-1.5份。
4.根据权利要求1或2所述的木塑材料，其特征在于，所述物理发泡剂选自氮气和聚醚多元醇中的至少一种；
优选地，所述第一增塑剂为邻苯二甲酸二异壬酯和邻苯二甲酸甲苯基丁酯的混合物，所述第二增塑剂为对苯二甲酸二辛酯。
5.根据权利要求1或2所述的木塑材料，其特征在于，所述第一热稳定剂和所述第二热稳定剂均选自钙锌稳定剂和有机锡稳定剂中的至少一种；
优选地，所述第一热稳定剂为钙锌稳定剂，所述第二热稳定剂为有机锡稳定剂；
优选地，所述第一润滑剂和所述第二润滑剂均选自邻苯二甲酸二辛酯、PE蜡、氧化聚乙烯蜡中的至少一种；优选地，所述第一润滑剂为PE蜡和氧化聚乙烯蜡的混合物，所述第二润滑剂为邻苯二甲酸二辛酯。
6.根据权利要求1所述的木塑材料，其特征在于，在所述壳层上还贴敷有耐磨层和彩膜层，所述彩膜层位于所述壳层和所述耐磨层之间。
7.一种核壳结构的木塑材料的制备方法，其特征在于，采用权利要求1-6中任一项所述木塑材料中所述芯层和所述壳层的原料进行制备。
8.根据权利要求7所述的制备方法，其特征在于，包括：
将所述壳层的原料混合挤出并破碎，以得到颗粒状母料；
将所述芯层的原料混合后得到芯层混合料，将颗粒状母料和所述芯层混合料分别挤出形成核壳结构的材料；
优选地，所述颗粒状母料的制备过程包括：将所述壳层的原料混合均匀之后挤出成型，并破碎为粒径为1-3mm的颗粒；
更优选地，所述壳层的原料挤出成型过程中控制挤出机主机转速为8-12r/min，喂料转速为2-4r/min；
优选地，还包括在形成的核壳结构的材料上依次贴敷彩膜层和耐磨层。
9.根据权利要求8所述的制备方法，其特征在于，包括：所述芯层混合料的制备过程包括：先在115-120℃的条件下将原料混合均匀，再进行冷混以使原料温度降低至40-45℃；
优选地，所述冷混是在冷辊机中混合8-10min。
10.根据权利要求9所述的制备方法，其特征在于，将所述颗粒状母料置于单螺杆挤出机中，将所述芯层混合料置于双螺杆挤出机中，通过模具机头共挤复合，再进行冷却定型；
优选地，所述单螺杆挤出机的转速为7-9r/min；
优选地，所述双螺杆挤出机的主机转速为4-6r/min，喂料转速为1-3r/min；
优选地，所述冷却定型过程中是采用5-17℃的冷水进行定型。
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