CN113910719B - 一种低回缩率pvc排水管及其制备方法 - Google Patents
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Abstract
本发明公开了一种低回缩率PVC排水管及其制备方法,由内层的玻纤增强层和外层的增韧层共挤出得到;其中:玻纤增强层按重量份计包括增强层基础颗粒80‑120份、玻纤增强母粒8‑25份;外层增韧层按重量份计包括PVC树脂粉80‑120份、钙锌稳定剂2‑5份、内滑0.4‑0.8份、外滑0.6‑1.1份、加工助剂0.5‑1.2份、增韧剂5‑10份、金红石钛白粉1‑3份、填料6‑10份;所述排水管可明显降低回缩率,避免由于温度变化在楼板和排水管结合处产生微小缝隙,消除渗漏的产生。
Description
技术领域
本发明属于PVC管材技术领域,具体涉及一种低回缩率PVC排水管及其制备方法。
背景技术
目前,PVC排水管在建筑行业中的用量处于垄断地位,在使用过程中,由于塑料制品都存在热胀冷缩的问题,长时间交替出现,就会在楼板和排水管结合处产生微小缝隙,一旦卫生间地板上洗澡等产生的污水流淌到此处,就会形成渗漏,对楼下住户造成不良影响。
有必要研究新型PVC排水管,降低PVC塑料排水管的回缩率,避免由于温度变化在楼板和排水管结合处产生微小缝隙,消除渗漏的产生。
发明内容
本发明目的在于提供一种低回缩率PVC排水管及其制备方法,以解决PVC塑料排水管的回缩率高、易生产缝隙,易发生渗漏的缺陷。
为实现上述目的,本发明的方案如下:
一种低回缩率PVC排水管,包括内层的玻纤增强层和外层的增韧层;其中:玻纤增强层按重量份计包括增强层基础颗粒80-120份、玻纤增强母粒8-25份;外层增韧层按重量份计包括PVC树脂粉80-120份、钙锌稳定剂2-5份、内滑0.4-0.8份、外滑0.6-1.1份、加工助剂0.5-1.2份、增韧剂5-10份、金红石钛白粉1-3份、填料6-10份。
进一步地,所述增强层基础颗粒料按重量份计包括PVC树脂粉100份、钙锌稳定剂3份、内滑0.4-0.8份、外滑0.6-1.1份、加工助剂0.5-1.2份、填料5-8份。
进一步地,所述玻纤增强层按重量份计包括增强层基础颗粒100份、玻纤增强母粒20份。
进一步地,所述外层增韧层按重量份计包括PVC树脂粉100份、钙锌稳定剂3份、内滑0.5份、外滑0.9份、加工助剂0.8份、增韧剂8份、金红石钛白粉2份、填料8份。
进一步地,所述玻纤增强母粒由PVC树脂作为包覆层与玻纤共混后挤出得到,所述玻纤增强母粒的长度为5-10mm,玻纤含量为70wt%。优选地,所述PVC树脂包覆层按重量份组成为:SG-8型PVC树脂粉100份、钙锌稳定剂3份、内滑0.5份、外滑0.8份、加工助剂0.6份、其它助剂2-5份。优选地,所述玻纤经0.1-0.2wt%的硅烷偶联剂浸渍后与包覆层共混挤出。
本发明还提供以上所述低回缩率PVC排水管的制备方法,包括如下步骤:分别按照重量份称取各组分并制备玻纤增强层母粒、增强层基础颗粒及外层增韧层颗粒;玻纤增强母粒和增强层基础颗粒料按重量份混合制备内层玻纤增强层颗粒料;将制备好的外层增韧层颗粒料和内层玻纤增强层颗粒料分别投入外层和内层单螺杆挤出机,塑化好的熔体经机头磨具和定型模具挤出得到低回缩率PVC排水管。
进一步地,所述玻纤增强母粒利用冷热混机混制出包覆用干混料,玻纤经液体硅烷偶联剂浸渍后进入直角机头,双螺杆挤出机使得包覆用干混料充分塑化,通过模具包覆在玻纤束外层,经冷却、牵引、切粒得到。
相比现有技术,本发明的有益效果为:采用本发明制备的低回缩率PVC排水管材,在150℃条件下使用时回缩率仅为0.2-0.4%,是普通PVC排水管材的十五分之一,能够达到和建筑紧密结合,不会由于热胀冷缩产生的回缩造成缝隙,避免了渗漏的产生;此外本发明所述PVC排水管在耐冲击性能、环刚度及阻燃性均有优异的性能。
具体实施方式
为了使本发明的目的、技术方案和有益技术效果更加清晰明白,以下结合具体实施方式,对本发明进行进一步详细说明。应当理解的是,本说明书中描述的具体实施方式仅仅是为了解释本发明,并不是为了限定本发明。
本发明提出一种低回缩率PVC排水管制备方法,步骤如下:
1、制备玻纤增强母粒。按照PVC包覆层配方称好料后,利用冷热混机,混制出包覆用干混料。盘卷的连续玻纤,经过添加表面活性剂的液体硅烷偶联剂槽,浸渍后进入直角机头,双螺杆挤出机使得包覆用干混料充分塑化,通过模具包覆在玻纤束外层,经冷却、牵引、切粒,形成玻纤增强母粒。
2、制备外层增韧层颗粒料。按配方称好料后,利用冷热混机,混制增韧层干混料,并投入造粒机造粒,制备出外层增韧层颗粒料。
3、制备内层玻纤增强层颗粒料。此颗粒料为增强层基础颗粒料和玻纤增强母粒按一定比例形成的混合料。先按配方称好料后,利用冷热混机,混制玻纤增强层基础颗粒料干混料,并投入造粒机造粒,制备出玻纤增强层基础颗粒料,然后将玻纤增强层基础颗粒料和玻纤增强母粒按照配方加入到立式颗粒料搅拌机混合均匀,制备出内层玻纤增强层颗粒料。
4、将制备好的外层增韧层颗粒料和内层玻纤增强层颗粒料分别投入外层和内层单螺杆挤出机,塑化好的熔体通过双层共挤机头模具、定型模具、牵引机、切割机、包装机、码垛机,经检验合格后,成为低回缩率PVC排水管材成品,产品符合GB/T5836.1-2018标准要求。
本发明中,所述玻纤增强母粒制备过程如下:盘卷的连续玻纤(直径13-14μm),添加0.1-0.2%液体硅烷偶联剂后进入直角机头,外部包覆一层PVC层,经冷却、牵引、切粒,形成玻纤增强母粒。PVC包覆层配方:SG-8型PVC树脂粉100份、钙锌稳定剂3份、内滑0.5份、外滑0.8份、加工助剂0.6份、其它助剂2-5份,其中玻纤含量为70wt%,同时保证了颗粒中玻纤长度就是母料颗粒长度,玻纤越长,越能发挥玻纤的性能。其它比如玻纤和PVC树脂、偶联剂等助剂经过高速混合后再造粒的方法,一般玻纤长度小于颗粒长度。但颗粒太长,不利于挤出机料斗的下料,优选颗粒长度为5-10mm。
本发明中,所述外层增韧层颗粒料配方:SG-5型PVC树脂粉80-120份、钙锌稳定剂2-5份、内滑0.4-0.8份、外滑0.6-1.1份、ACR401加工助剂0.5-1.2份、增韧剂CPE 5-10份、金红石钛白粉1-3份、填料6-10份。
本发明中,所述玻纤增强层配方为:增强层基础颗粒料80-120份、内层玻纤增强母粒8-25份。所述增强层基础颗粒配方:SG-5型PVC树脂粉100份、钙锌稳定剂3份、内滑0.4-0.8份、外滑0.6-1.1份、ACR401加工助剂0.5-1.2份、填料5-8份。在生产低回缩率PVC排水管材,要控制好玻纤增强母粒的份数和增强层基础颗粒的长度。
本发明所述内滑(内润滑剂)选自氧化聚乙烯蜡、硬脂酸、硬脂酸钙、单甘酯、乙撑双硬脂酸酰胺、硬脂酸季戊四醇三酯PETS-3、硬脂酸季戊四醇四酯PETS-4等市售产品中的一种或多种;外滑(外润滑剂)选自PE蜡、石蜡中的一种或多种。
本发明所述其它助剂为钛白粉、增白剂中的一种或多种。
本发明所述填充剂选自碳酸钙、滑石粉中的一种或多种。
本发明在制备低回缩率PVC排水管过程中使用到的设备及参数设定如下:
1)热混机型号1000/3000,热混放料温度为120℃,冷混放料温度为40℃。
2)制备玻纤增强母粒时,采用锥形双螺杆挤出机(65型)挤出,机筒1-4区温度分别为:180、185、170、160℃,机头温度:190℃。产量:180kg/h。
3)制备外层增韧层颗粒料时,采用锥形双螺杆挤出机(65型)挤出,机筒1-4区温度分别为:185、190、175、165℃,机头温度:190℃。产量:180kg/h。
4)制备玻纤增强层基础颗粒料时,采用锥形双螺杆挤出机(65型)挤出,机筒1-4区温度分别为:185、195、180、165℃,机头温度:190℃。产量:180kg/h。
5)制备内层玻纤增强层颗粒料时,采用HB1000型立式颗粒料搅拌机,搅拌5分钟出料。
6)制备低回缩率PVC排水管材时,采用60单螺杆挤出外层增韧层,机筒1-5区温度分别为:160、165、180、180、185℃;采用80单螺杆挤出内层增强层,机筒1-6区温度分别为:165、170、180、185、185℃;合流芯温度:170℃;模具温度:170、180、185、185、190℃。根据实际情况调整两台挤出机的喂料、转速以及电流,牵引机速度与之匹配。产量:350kg/h。
上述配方及方法生产DN110管材(厚度3.2-3.8mm)时,正常生产可控制到3.22-3.35mm之间。其中,外层增韧层壁厚与内层增强层壁厚之比为1:2,可以实现回缩率降低为0.2-0.4%。
以下是本发明提供的具体配方,以及制备所得产品的性能,用于验证本发明的原理及技术效果。
实施例
1.PVC包覆层配方:SG-8型PVC树脂粉100kg、钙锌稳定剂3kg、内滑0.5kg、外滑0.8kg、加工助剂ACR 0.6kg、其它助剂3kg;
2.增强层基础颗粒料配方:SG-5型PVC树脂粉100kg、钙锌稳定剂3kg、内滑0.5kg、外滑0.8kg、ACR401加工助剂1kg、填料6kg。
3.玻纤增强层配方:按照上述配方的PVC包覆层与增强层基础颗粒料,并按照如下配方进行制备:
配方1:增强层基础颗粒料80kg、内层玻纤增强母粒10kg(玻纤长度5mm);
配方2:增强层基础颗粒料120kg、内层玻纤增强母粒25kg(玻纤长度8mm);
配方3:增强层基础颗粒料120kg、内层玻纤增强母粒20kg(玻纤长度10mm)。
4.外层增韧层颗粒料配方
配方1:SG-5型PVC树脂粉80kg、钙锌稳定剂2kg、内滑0.4kg、外滑0.6kg、ACR401加工助剂0.5kg、增韧剂CPE 5kg、金红石钛白粉1kg、填料6kg。
配方2:SG-5型PVC树脂粉100kg、钙锌稳定剂3kg、内滑0.5kg、外滑1kg、ACR401加工助剂1kg、增韧剂CPE 10kg、金红石钛白粉2kg、填料8kg。
配方3:SG-5型PVC树脂粉120kg、钙锌稳定剂5kg、内滑0.8kg、外滑1.1kg、ACR401加工助剂1.2kg、增韧剂CPE 9kg、金红石钛白粉3kg、填料10kg。
对比例
1.按照实施例PVC包覆层和增强层基础颗粒料,制备得到如下玻纤增强层配方:
配方1:增强层基础颗粒料80kg、内层玻纤增强母粒5kg(玻纤长度5mm);
配方2:增强层基础颗粒料100kg、内层玻纤增强母粒30kg(玻纤长度8mm);
配方3:增强层基础颗粒料80kg、内层玻纤增强母粒10kg(玻纤长度3mm)。
2.外层增韧层颗粒料配方
配方1:SG-5型PVC树脂粉70kg、钙锌稳定剂2kg、内滑0.4kg、外滑0.6kg、ACR401加工助剂0.5kg、增韧剂CPE 8kg、金红石钛白粉1kg、填料6kg。
配方2:SG-5型PVC树脂粉150kg、钙锌稳定剂5kg、内滑0.8kg、外滑1.1kg、ACR401加工助剂1.2kg、增韧剂CPE 5kg、金红石钛白粉3kg、填料10kg。
实验例
上述实施例及对比例中的内层玻纤增强层和外层增韧层按照前述制备方法制得低回缩率PVC排水管,以DN110管材(厚度在3.2-3.8mm)为例,正常生产可控制到3.22-3.35之间。其中,外层增韧层壁厚与内层增强层壁厚之比为1:2。
1)按照GB/T5836.1-2018标准的要求,分别检测排水管的回缩率(%)和耐外冲击性能(0℃,D90落锤在2m高度冲击下能承受的极限重量,kg),结果分别如表1和表2所示。
表1:回缩率测试结果
表2:耐外冲击性能检测结果
由表1和表2的结果不难看出,随着玻纤增强层配方中玻纤增强母粒含量的上升,回缩率逐渐减小,但随着添加量的增大回缩率性能开始下降,内层玻纤增强母粒最佳用量为25份。此时,回缩率为0.2%,且耐外冲击性能符合要求(小于2mm);此外内层玻纤增强层中玻纤的长度在5-10mm时回缩率符合要求,低于5mm时,回缩率增大,此外根据前文的描述在高于10mm时,影响到下料,因此结合上述配方优选的玻纤的长度在5-10mm。
另外,外层增韧层的配方也会影响到回缩率和耐外冲击性能,随着增韧成分用量的增大,耐冲击性能增强,但回缩率到达一定程度后不再继续降低,本发明外层增韧层配方在内层玻纤增强母粒用量为8-25份时可以表现出优良的综合性能。
按照本发明生产的低回缩率PVC排水管材经系统适用性实验和长期客户走访,未出现因回缩率大产生缝隙导致渗漏的情况。
2)分别按照GB/T 9647-2015《热塑性塑料管材环刚度的测定》的方法及标准评价上述实施例管材的环刚度,检测结果如表3所示;以及按照GB8624-2012《建筑材料及制品燃烧性能分级》的方法及标准评价材料的燃烧性能,评价结果如表4所示。
表3:环刚度测试结果
表4:燃烧性能测试结果
上述参照具体实施方式对本发明技术方案进行了详细的描述,但实施实例的描述是说明性而并非限定性的,可按照所限定范围列举出若干个实施例,因此在不脱离本发明技术的实质和范围下的变化和优化,应属本发明的保护范围之内。
Claims (5)
1.一种低回缩率PVC排水管,其特征在于,包括内层的玻纤增强层和外层的增韧层;其中:玻纤增强层按重量份计包括增强层基础颗粒80-120份、玻纤增强母粒8-25份;外层增韧层按重量份计包括PVC树脂粉80-120份、钙锌稳定剂2-5份、内滑0.4-0.8份、外滑0.6-1.1份、加工助剂0.5-1.2份、增韧剂5-10份、金红石钛白粉1-3份、填料6-10份;
所述玻纤增强母粒的长度为5-10mm,玻纤含量为70wt%;
所述增强层基础颗粒按重量份计包括PVC树脂粉100份、钙锌稳定剂3份、内滑0.4-0.8份、外滑0.6-1.1份、加工助剂0.5-1.2份、填料5-8份;
所述玻纤增强母粒由PVC树脂作为包覆层与玻纤共混后挤出得到,所述包覆层按重量份组成为:SG-8型PVC树脂粉100份、钙锌稳定剂3份、内滑0.5份、外滑0.8份、加工助剂0.6份、其它助剂2-5份;
所述玻纤增强母粒利用冷热混机混制出包覆用干混料,玻纤经液体硅烷偶联剂浸渍后进入直角机头,双螺杆挤出机使得包覆用干混料充分塑化,通过模具包覆在玻纤束外层,经冷却、牵引、切粒得到。
2.根据权利要求1所述的低回缩率PVC排水管,其特征在于,所述玻纤增强层按重量份计包括增强层基础颗粒100份、玻纤增强母粒20份。
3.根据权利要求1所述的低回缩率PVC排水管,其特征在于,所述外层增韧层按重量份计包括PVC树脂粉100份、钙锌稳定剂3份、内滑0.5份、外滑0.9份、加工助剂0.8份、增韧剂8份、金红石钛白粉2份、填料8份。
4.根据权利要求1所述的低回缩率PVC排水管,其特征在于,所述玻纤经0.1-0.2wt%的硅烷偶联剂浸渍后与包覆层共混挤出。
5.权利要求1所述低回缩率PVC排水管的制备方法,其特征在于,包括如下步骤:分别按照重量份称取各组分并制备玻纤增强层母粒、增强层基础颗粒及外层增韧层颗粒;玻纤增强母粒和增强层基础颗粒料按重量份混合制备内层玻纤增强层颗粒料;将制备好的外层增韧层颗粒料和内层玻纤增强层颗粒料分别投入外层和内层单螺杆挤出机,塑化好的熔体经机头模具和定型模具挤出得到低回缩率PVC排水管。
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