CN114126854A - 离散材料与塑料的多层复合板 - Google Patents

离散材料与塑料的多层复合板 Download PDF

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CN114126854A
CN114126854A CN202080040344.9A CN202080040344A CN114126854A CN 114126854 A CN114126854 A CN 114126854A CN 202080040344 A CN202080040344 A CN 202080040344A CN 114126854 A CN114126854 A CN 114126854A
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都明泰
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Abstract

本发明涉及一种离散材料与塑料的多层复合板。所述离散材料与塑料的多层复合板是通过提供独立分层的塑料层和离散材料层形成的，其中将熔融状态的交替塑料层和离散材料层进行压制并冷却。由于这种分层，集中式塑料层构成了高承载能力，压力低于正常挤出工艺压制的离散材料层构成了离散材料与塑料多层复合板的低密度。

Description

离散材料与塑料的多层复合板
技术领域
本发明涉及离散材料与塑料的多层复合板，例如木塑复合材料(WPC)。
背景技术
已知的WPC包括相容比例的木材和热塑性塑料(例如聚丙烯、聚乙烯或PVC等)。木材和塑料二者的成分都可以从回收资源中得到。WPC可以通过多种方式制造。目前，最常见的技术是挤出，其中将木材(磨成细粒)、热塑性塑料和添加剂共混成混合物，其可在高温高压下处于熔融状态并可在挤出模具中成型。WPC具有很好的防水性能且能避免翘曲或开裂……此外，由于它们对白蚁、木虫和其它自然因素具有免疫力，因此它们经久耐用。WPC最关键的缺点是承载能力低，因为它们在木材和塑料材料上均等分配。WPC的另一个缺点是密度高，因为在使用塑料(如聚丙烯或聚乙烯)的挤出过程中，木材在高温和高压下被压紧，因它们难以像PVC那样生成发泡体。
发明概述
本发明的目的是克服上述现有技术的缺点，更具体地说，是生产具有高负载能力和低密度、改进的离散材料与塑料之间融合性的离散材料与塑料的多层复合板。
为达到上述目的和其它目的，本发明提出了一种多层WPC板。与将木材(磨成细粒)、热塑性塑料和添加剂以熔融状态共混成混合物后在挤出模具中成型的普通WPC不同，离散材料与塑料的多层WPC板由独立分层的塑料层和离散材料层制成，塑料和离散材料的交替层在熔融状态下压制，并冷却。在压制过程中，离散材料层与来自相邻塑料层的熔融塑料共混，形成具有高比例离散材料的塑料-离散材料层。这些塑料-离散材料层与相邻塑料层结合成一体形成复合板。由于这种分层，集中式塑料层构成高承载能力，压力低于正常挤出工艺压制的离散材料层构成离散材料与塑料多层复合板的低密度。
附图简述
现在将基于附图说明本发明。为了说明本发明的目的，图示了目前优选的几种形式，但是应当理解，本发明不限于所示的精确布置和手段，其中：
图1A例示说明根据实施方案的离散材料与塑料的示例性多层复合板，其中该板包括两个塑料层和一个离散材料层；
图1B例示说明图1A上放大的区域A；
图2例示说明根据实施方案的离散材料与塑料的示例性多层复合板，其中该板包括三个塑料层和两个离散材料层；
图3例示说明根据实施方案的离散材料与塑料的多层复合板的生产方法；
图4例示说明离散材料与塑料的例示性多层复合板的另一种生产方法；
图5例示说明根据实施方案的离散材料与塑料的多层复合板的生产方法；
图6为离散材料与塑料的多层复合板的试生产方法。
实施方案的描述
现在将基于优选实施方案参考附图描述本发明。在附图中，相同的附图标记在不同的视图中通常表示相同的部分。
如图1A所示，根据本发明的离散材料与塑料的多层复合板1包括两个塑料层2和一个位于两个塑料层2中间的离散材料层3，其中，离散材料层包括与塑料32混合的离散材料31。
如图1B所示，由最初提供的两个塑料层得到的塑料32流入与离散材料结合成一体且根据一个实施方案可以彼此结合成一体。虽然塑料32是由两个塑料层2得到的，但中间层被称为塑料-离散材料层而不是离散材料层，以强调这一层包括与塑料层2混合并牢固结合成一体的离散材料31的事实，塑料层2因流入空隙而成为塑料-离散材料层3的一部分。
根据图2所示的另一个实施方案，离散材料与塑料的多层复合板1包括三个塑料层2和两个交替位于三个塑料层2之间的塑料-离散材料层3。这意味着本发明不限于图1A和图2所示的塑料层数，其中离散材料与塑料的多层复合板1包括至少两个塑料层2和至少一个塑料离散材料层3，其中每个塑料-离散材料层交替位于两个塑料层之间。
复合板1是通过提供独立分层的初始塑料层和离散材料层形成的，其中将所提供的熔融状态塑料层和沿塑料层表面交替放置的离散材料层进行压制并冷却。在此压制过程中，离散材料层与来自相邻塑料层的熔融塑料共混形成具有高比例离散材料的塑料-离散材料层。这些塑料-离散材料层与相邻的塑料层结合成一体形成复合板。由于分层，集中式塑料层构成了根据本发明的复合板的高承载能力，压力低于正常WPC挤出工艺压制的集中式离散材料层构成根据本发明的多层复合板的低密度。
本说明书中的术语“离散材料”是指板状或片状的材料，在铺层时会有空隙。根据本发明，用于形成足够大空隙使塑料流入的离散材料不是在表面上或更深处结合，而是作为形成层的一部分深度结合成一体，由此形成包括具有不太高密度的牢固结合层的复合材料板1。
根据各种实施方案，离散材料可以不同。离散材料31可以是木材、碎片、植物纤维、玻璃纤维、织物纤维、壳、碎布等的颗粒或板条。此外，塑料-离散材料层可以包括两种或更多种类型的离散材料。对于包括多个塑料-离散材料层如图2所示的两个塑料-离散材料层的复合板1，每层甚至可以包括各种不同离散材料。
离散材料可根据材料来源具有各种尺寸。根据本发明的优选实施方案，离散材料31是尺寸为0.5-15mm的木材颗粒。
根据另一优选实施方案，离散材料31是通过造粒挤出技术预制的颗粒，其中离散材料例如木材的颗粒或板条、碎片、植物纤维、玻璃纤维、织物纤维、壳、碎布等被研磨成0.5-5mm的颗粒，将热塑性塑料和添加剂在熔融状态共混，然后在挤出模具中形成1-5mm的线状，冷却后切成1-15mm的颗粒。
塑料层的组成是多种多样的，可以是PP、PE、PS、ABS、PA、PET、PVC等塑料类型中的任意一种。
根据另一方面，本发明提出了离散材料与塑料的多层复合板的生产方法。离散材料与塑料的多层复合板的生产方法如下：
步骤1:提供至少两个塑料层；
步骤2:交替地并沿塑料层表面撒布至少一层离散材料；
步骤3：将熔融状态的塑料层与离散材料压制并冷却下来，使与离散材料层相邻的两个塑料层与离散材料结合成一体。
塑料层在离散材料层撒布之前可能已经处于熔融状态，或者在离散材料层撒布时塑料层可以处于冷却状态。
参见图3，塑料层直接以熔融状态从挤出机通过挤出模具4挤出，离散材料通过撒布器5撒布。每个撒布器5交替放置在挤出模具4之间以在塑料层间交替撒布离散材料层。
参照图4，塑料层由可用的塑料片6提供并由加热器7加热，离散材料通过撒布器5撒布。每个撒布器5交替放置在塑料膜之中，以在塑料层间交替撒布离散材料层。
参见图3和图4，这些交替的离散材料层和熔融的塑料层被辊压机9压制和冷却以形成复合板。
根据另一个如图5所示的优选实施方案，塑料层处于冷却状态时撒布离散材料层。然后通过夹具8间接熔融塑料层。塑料层交替布置在离散材料层之间，然后在加热板之间压制并冷却以形成WPC板。塑料层也可以通过红外线、高频感应加热、高压蒸汽……等热源直接熔融。
复合板生产过程中用于压制和冷却的辊压机可以替换为等效结构。
实施例
参见图6，复合板的试生产采用双螺杆挤出机，直径65mm，长度3000mm，产能300kg/h。塑料材质为PE。离散材料是将研磨成3-5mm大小的木颗粒。PE在挤出机10的机筒中熔融至170℃，从三个模具4挤出，形成三层宽1200mm厚2mm的熔融态塑料层。这三个熔融的塑料层流经三个挤出通道11到成型辊压机9。三个挤出通道被加热到160℃以保持塑料层的熔融状态。两层木颗粒在成型辊压机9前，由撒布机5交替铺在熔融状态的三个塑料层之间，形成宽1200mm、厚15mm的复合板。将该复合板移动至光滑结构，其中复合板的外表面在170℃的温度下通过加热板12塑化，然后通过冷却板13冷却和光滑。尺寸切割后，试生产的产品为尺寸为2440mm x 1220mm x 15mm的WPC板，符合标准，将用作建筑模板。
虽然已就优选实施方案示出和描述了本发明，但是本领域技术人员将理解，在不脱离以下权利要求所定义的本发明精神和范围的情况下，可以做出各种改变和修改。
附图标记列表
1 复合板
2 塑料层
3 离散材料层
31 离散材料
32 塑料
4 挤出模具
5 撒布机
6 塑料片
7 加热器
8 夹具
9 辊压机
A 放大区域
10 挤出机
11 挤出通道
12 加热板
13 冷却板
权利要求书(按照条约第19条的修改)
1.一种离散材料与塑料的多层复合板，包含至少两个塑料层和至少一个塑料-离散材料层，其中：
每个塑料-离散材料层交替地放置在两个塑料层的之间；
所述塑料-离散材料层包括与两个相邻塑料层的塑料混合的离散材料，它是通过将熔融状态的所述两个相邻塑料层和沿所述两个相邻塑料层表面撒布的离散材料进行压制并冷却所生成的，从而使相邻所述塑料-离散材料层的两个塑料层与离散材料结合成一体。
2.根据权利要求1的复合板，其中所述离散材料包含至少一种选自木材颗粒或木屑、碎片、植物纤维、玻璃纤维、织物纤维、壳、碎布等的材料。
3.根据权利要求2的复合板，其中所述离散材料为木屑。
4.根据权利要求1的复合板，其中所述离散材料是通过挤出造粒技术预制的颗粒，其中离散材料，例如木材颗粒或木屑、碎片、植物纤维、玻璃纤维、织物纤维、壳、碎布等，被研磨成0.5-5mm大小的颗粒，热塑性塑料和添加剂在熔融状态下共混，然后在挤出模具中形成尺寸为1-5mm的线状，然后冷却并切割成尺寸为1-15mm的颗粒。
5.一种离散材料与塑料的多层复合板的生产方法，包括：
步骤1:提供至少两个塑料层；
步骤2:交替地并沿所述塑料层表面撒布至少一层离散材料；
步骤3：将熔融状态的塑料层与离散材料压制并冷却下来，使与所述离散材料层相邻的两个塑料层与所述离散材料结合成一体。
6.根据权利要求5的生产方法，其中在撒布所述离散材料层之前，塑料层处于熔融状态。
7.根据权利要求6的生产方法，其中塑料层直接从挤出机挤出，并通过辊压机或等效夹具进行压制。
8.根据权利要求6的生产方法，其中塑料层由可用塑料片提供，并由加热器加热，然后由辊压机或等效夹具压制。
9.根据权利要求5的生产方法，其中当撒布离散材料层时，塑料层处于冷却状态。
10.根据权利要求9的生产方法，其中塑料层通过夹具间接熔化并通过夹具压制。
11.根据权利要求9的生产方法，其中塑料层通过红外、高频感应加热、高压蒸汽等热源直接熔融。

Claims (11)

1.一种离散材料与塑料的多层复合板，包含至少两个塑料层和至少一个塑料-离散材料层，其中：
每个塑料-离散材料层交替地放置在两个塑料层的中间；
所述塑料-离散材料层包括混有塑料的离散材料，它是通过将熔融状态塑料层和沿塑料层表面撒布的离散材料进行压制并冷却所生成的，从而使相邻所述塑料-离散材料层的两个塑料层与离散材料结合成一体。
2.根据权利要求1的复合板，其中所述离散材料包含至少一种选自木材颗粒或木板、碎片、植物纤维、玻璃纤维、织物纤维、壳、碎布等的材料。
3.根据权利要求2的复合板，其中所述松散材料为木板。
4.根据权利要求1的复合板，其中所述离散材料是通过挤出造粒技术预制的颗粒，其中离散材料，例如木材颗粒或木板、碎片、植物纤维、玻璃纤维、织物纤维、壳、碎布等，被研磨成0.5-5mm大小的颗粒，热塑性塑料和添加剂在熔融状态下共混，然后在挤出模具中形成尺寸为1-5mm的线状，然后冷却并切割成尺寸为1-15mm的颗粒。
5.一种离散材料与塑料的多层复合板的生产方法，包括：
步骤1:提供至少两个塑料层；
步骤2:交替地并沿所述塑料层表面撒布至少一层离散材料；
步骤3：将熔融状态的塑料层与离散材料压制并冷却下来，使与所述离散材料层相邻的两个塑料层与所述离散材料结合成一体。
6.根据权利要求5的生产方法，其中在撒布所述离散材料层之前，塑料层处于熔融状态。
7.根据权利要求6的生产方法，其中塑料层直接从挤出机挤出，并通过辊压机或等效夹具进行压制。
8.根据权利要求6的生产方法，其中塑料层由可用塑料片提供，并由加热器加热，然后由辊压机或等效夹具压制。
9.根据权利要求5的生产方法，其中当撒布松散材料层时，塑料层处于冷却状态。
10.根据权利要求9的生产方法，其中塑料层通过夹具间接熔化并通过夹具压制。
11.根据权利要求9的生产方法，其中塑料层通过红外、高频感应加热、高压蒸汽等热源直接熔融。
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