CN115397895A - 不含聚氯乙烯的均质片材 - Google Patents

不含聚氯乙烯的均质片材 Download PDF

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Publication number
CN115397895A
CN115397895A CN202180012907.8A CN202180012907A CN115397895A CN 115397895 A CN115397895 A CN 115397895A CN 202180012907 A CN202180012907 A CN 202180012907A CN 115397895 A CN115397895 A CN 115397895A
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China
Prior art keywords
sheet
film
synthetic rubber
chips
filler
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CN202180012907.8A
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English (en)
Inventor
张文军
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Zhejiang Gimig Technology Co ltd
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Zhejiang Gimig Technology Co ltd
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Publication of CN115397895A publication Critical patent/CN115397895A/zh
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Abstract

本发明包括一种均质片材，其不包括聚氯乙烯。该片材包括聚氨酯、合成橡胶混合物和填充剂。该合成橡胶混合物可包括合成橡胶和白油的预混合物。

Description

不含聚氯乙烯的均质片材
技术领域
本发明包括用于制备均质片材的组合物和方法。该片材适合用于地板或墙壁覆盖物并且是在未添加聚氯乙烯(PVC)的情况下制备得到。
背景技术
均质片材产品常基于聚氯乙烯(PVC)。由于PVC包含的增塑剂可能具有的不利效果，因而对PVC替代品的期望成为一种可能。授予Johansson等人(Johansson)的美国专利申请公开号2018/0291229A1披露了一种无卤素的均质表面覆盖物。组合物包含一种与热塑性聚氨酯组合的特定热塑性弹性体。
发明内容
一些实施例提供了组合物以及用于制备均质组合物的方法，这些组合物可形成膜或片材，克服了Johansson所披露覆盖物的缺陷。这通过提供适用于地板或墙壁覆盖物的片材或膜来实现，所述片材或膜具有尤其适用于地板的特性。所述均质组合物在未添加聚氯乙烯(PVC)的情况下制备。因此，由这些组合物制备的膜和片材不包括PVC。
一种制备均质片材的方法包括：提供包括热塑性聚氨酯、合成橡胶混合物和填充剂的片材组分；组合所述片材组分；通过模头或压延机将所述片材组分挤出成膜并冷却。取决于所期望的厚度，所述片材可以呈膜或片材的形式。所述膜或片材可以随后造粒并且与具有不同组成或不同添加剂的片材或薄膜组合以提供其他特性或外观。
另一种制备均质片材的方法包括：
(a)提供包括热塑性聚氨酯、合成橡胶混合物和填充剂的片材组分；
(b)组合所述片材组分；
(c)通过压延机将组分挤出成膜并冷却；
(d)将所述膜粒化以形成碎片；
(e)混合所述碎片并传送至载体；
(f)提供热量并且固结所述碎片以形成片材。所述片材可具有约0.3mm至约4mm的厚度。
还提供了一种基本上不含PVC的地板片材或地砖，其包含合成橡胶和白油的预混合物、热塑性聚氨酯、填充剂和至少一种功能添加剂。
附图说明
图1是用于由原材料制备某些实施例的片材的方法示意图。
图2是由图1所示工序得到颗粒制备片材的示意图。
具体实施方式
一个重要的方面是包括合成橡胶和白油的预混合物。这种预混合物允许将合成橡胶更好地包括在聚氨酯中，从而允许片材特性如硬度的更大改变。
一些实施方式的片材或膜也可以与装饰层组合。可选的装饰层可以是直接印刷、膜或饰面板。这些还可以与粘合剂组合。可替代地，通过组合来自两个或更多片材或膜的碎片，片材或膜本身可以是装饰性的。在需要多种颜色的情况下，具有第一颜料的第一片材可形成为碎片，其随后与来自具有不同颜料的第二片材的碎片组合。三种、四种或五种等颜色的组合可形成碎片并组合以为最终片材提供各种不同的视觉效果。
当需要膜时，厚度可以在任何合适范围内，诸如约0.1mm至约1.5mm。该膜可适合单独作为均质覆盖物，或可造粒并与其他具有相同或不同组成的造粒膜组合以形成另外的片材。如果膜将作为片材，如在直接挤出中的片材地板，厚度可以是任何合适厚度，如约0.3mm至约2.0mm。当将膜造粒成碎片并且可选地添加至其他造粒膜中并且固结以形成片材时，该片材可具有任何期望的厚度，如约1.0mm至约4.0mm。
聚氨酯是一类通常通过组合三类亚基前驱体而制备的材料：(1)一种或多种长链多元醇；(2)一种或多种聚异氰酸酯；和(3)一种或多种扩链剂，短链分子，其包含两个或更多能够与异氰酸酯基反应的含活性氢基团，如二元醇。长链多元醇(1)是衍生自聚酯、聚醚、聚碳酸酯或其混合物的多羟基化合物。合适的聚醚包括聚乙二醇、聚丙二醇、聚丁二醇或这些材料的共聚物。合适的聚酯可以由具有2至12个碳原子的二羧酸和含有2至10个碳(每分子包含两个或更多活性羟基)的多元醇来制备。该聚氨酯可以具有约20,000至约200,000或约20,000至约50,000的数均分子量。合适的流动点温度包括约120℃至约220℃、约155℃至约180℃、和约150℃至约200℃。具有约150℃至220℃的流动点温度的热塑性聚氨酯也是有用的。
聚异氰酸酯(2)可以是脂肪族的、脂环族的、或芳香族的，如己二异氰酸酯、异佛尔酮二异氰酸酯、环己烷二异氰酸酯、二苯甲烷二异氰酸酯、苯二异氰酸酯、萘二异氰酸酯、以及三或更高的异氰酸酯，每分子包含两个或更多反应性异氰酸酯基团。扩链剂(3)是含有能与异氰酸酯基反应的两种或更多种活性氢化合物的短链分子。扩链剂的实例包括但不限于甘油单烯丙基醚、三亚甲基二醇单烯丙基醚、甘油单油酸酯，以及类似化合物。各种亚基可以在本领域已知的工序中顺序或同时组合。
聚氨酯是本领域中常规的并且可以通过许多已知步骤合成，其中类型1、2和3的化合物在温度和混合的受控条件下组合。根据三种亚基类型的性质和相对比例，聚氨酯可以是基本上结晶的、半结晶的或基本上无固定形状的。
合成橡胶混合物是白油和合成橡胶的预混合物。这种预混合物可以通过任何适合的方法制备。一种方法包括在高速混合机中组合合成橡胶和白油并经合适时间混合以制备预混合物。预混合物可以以任何合适的比例存在，例如按片材组分重量的约0.01％至约20％存在。白油与合成橡胶的比率可以是任何合适的数量。合适数量的一个实例包括白油与合成橡胶的比率为约0.1％至约300％。
白油也称为液体石蜡，它是具有极纯、稳定、无色、无味、无毒和化学惰性特征的高度精制的矿物油。这些属性使得它们非常适合看重这些特性的任何应用，例如药物、化妆品和化学加工。
合成橡胶可以是本领域公知的任何一种。合成橡胶可以是衍生自包括苯乙烯单体的单体的嵌段共聚物或三元共聚物。非限制性实例包括SBS橡胶弹性体、合成橡胶、聚合弹性体SIBS、SEBS合成橡胶、聚合弹性体、聚合弹性体SEPS合成橡胶、天然橡胶、苯乙烯-丁二烯橡胶、丁基橡胶、丁二烯橡胶、氟橡胶、硅橡胶、以及它们的组合。
填充剂可以包括在这些片材组分之中。填充剂的形式可以是纤维、粉末、珠、以及它们的组合。合适填充剂的非限制性实例包括选自组：石灰石、滑石、云母、硅灰石、高岭石、云母、玻璃纤维、玻璃珠、以及它们的组合。通常，填充剂不会与组合物相互作用，或者以功能添加剂的方式提供功效。填充剂可以以按片材组分重量的约20％至约60％的量存在。填充剂尺寸可以是任何合适的尺寸，例如约30目至约8000目。其他合适的填充剂尺寸范围包括100目至约5000目。其他合适范围的填充剂尺寸也可包括在此。
功能添加剂将是为片材提供额外功效的或将与其他片材组分相互作用的添加剂。功能添加剂的非限制性实例可以选自阻燃剂、抗氧化剂、热稳定剂、光稳定剂、加工助剂、颜料、发光添加剂(在黑暗中可以“发光”的那些)、以及它们的组合。
所述阻燃剂可包括选自固体阻燃剂、液体阻燃剂、及其组合中的至少一种阻燃剂。阻燃剂的非限制性实例包括三水合氧化铝(ATH)、三聚氰胺、氰尿酸三聚氰胺、聚磷酸铵、三聚氰胺聚磷酸盐、次磷酸盐、苯氧基次磷酸盐、苯氧基环三磷腈；双酚A二磷酸酯(BDP)、四苯基间苯二酚双(磷酸二苯酯)(RDP)、氢氧化镁以及它们的组合。
在这些工序的不同方面中施加的热量可以是本领域已知的任何适合的方法。这些包括但不限于以下大致范围：
第一烘箱–140℃至240℃
第一压延辊–70℃至约100℃
第二烘箱140℃至240℃
第二压延机60℃至约100℃
实例
通过将60kg合成橡胶材料和40kg白油组合到高速混合机中来制备包含橡胶和白油的充油预混合物。将这些混合1至2分钟。
表1中的组分如下所述组合以制备均质片材或膜。在这个实例中，将该膜进一步加工成碎片并且与其他颜色的碎片固结以提供具有多于一种可识别颜色的视觉的片材。
Figure BDA0003782745590000051
将表1中的组分制成包括图1示意中所示方法的片材。量取热塑性聚氨酯、充油、滑石、氢氧化铝、三聚氰胺聚磷酸盐、抗氧化剂混合物、Tinuvin UV 770和硅油，并将其加入到高速混合机1中。将材料混合3-5分钟，然后排放到挤出机料斗10中，向其中添加按重量2％的蓝色颜料。材料在双螺杆挤出机2中在150-200℃下组合，然后通过平模12挤出，并在辊3上冷却。在冷却薄蓝色片材之后，将该片材造粒成小碎片。这些蓝色碎片指定为Al。
替换颜料并重复以上过程。颜料替换为1％的蓝色颜料。该膜也造粒成小碎片。这些浅蓝色碎片指定为A2。
替换颜料并第三次进行上述过程。颜料替换为2％的灰色颜料。该膜也造粒成小碎片。这些灰色碎片指定为Bl。
替换颜料并第四次进行上述过程。颜料替换为1％的黄色颜料。该膜也造粒成小碎片。这些黄色碎片指定为B2。
参考图2，碎片然后以下述比例A1：A2：B1：B2＝30：30：30：10固结。这些碎片在混合机中混合并转移到固结设备中。将碎片转移到固结线的料斗。碎片的均匀混合物在辊6处压制之前可选地通过烘箱(未示出)。然后组合物以10米/分钟的线速度通过温度为220-230℃的烘箱5，并最后在辊7处压制成厚度为2mm的均质片材。
根据US20180281229的披露制备对比例，包括热塑性弹性体20％、热塑性聚氨酯25％、增容剂5％、填充剂44％、硅酮3％、抗氧化剂0.3％、润滑剂1.6％、以及颜料1。这些材料在挤出机中在约170℃的温度下熔融混合，以股线形式递送单色化合物。表2提供了将本发明组合物与可商购的橡胶地板以及一种来自美国专利申请公开号2018/0291229(’299申请)的对比例进行特性比较。
Figure BDA0003782745590000061
与对比例相比，本发明组合物提供了更低的烟雾生成，这尤其对于商业用途是有利的。
尽管已经描述了目前认为是本发明的优选实施方式，但本领域技术人员将认识到，在不背离本发明的构思的情况下，可以对其进行改变和修改，并且旨在包括落在本发明的真实范围内的所有这样的改变和修改。

Claims (20)

1.一种制备均质片材或膜的方法，包括：
(a)提供包括热塑性聚氨酯、合成橡胶混合物和填充剂的片材组分；
(b)组合所述片材组分；
(c)通过模头或压延机将所述片材组分挤出成膜并冷却。
2.根据权利要求1所述的方法，其中，所述膜是具有厚度约0.1mm至约4.0mm的片材地板。
3.根据权利要求1所述的方法，其中，所述膜是具有厚度约0.1mm至约2.0mm的片材地板。
4.根据权利要求1所述的方法，其中，所述膜与装饰层组合。
5.根据权利要求1所述的方法，还包括：
(d)将所述膜粒化以形成碎片；
(e)在载体上组合所述碎片；
(f)提供热量并且固结所述碎片以形成片材。
6.根据权利要求5所述的方法，其中，在挤出之前将第一颜料添加到所述片材组分中；制备包括第二颜料的第二膜；并且在提供热量和压制所述碎片以形成片材之前，将来自所述膜和所述第二膜的碎片组合。
7.根据权利要求5所述的方法，其中，所述压制是通过固结辊，随后退火和冷却。
8.根据权利要求7所述的方法，其中，在固结之后并且在退火之前添加涂层。
9.根据权利要求1所述的方法，其中，所述热塑性聚氨酯衍生自选自聚酯、聚醚、以及它们的组合的聚合物。
10.根据权利要求9所述的方法，其中，所述热塑性聚氨酯以按所述片材组分重量的约20％至约60％的量存在。
11.根据权利要求1所述的方法，其中，所述合成橡胶混合物包含衍生自包括苯乙烯单体的单体的嵌段共聚物或三元共聚物。
12.根据权利要求11所述的方法，其中，所述合成橡胶混合物是由合成橡胶和白油制备的预混合物。
13.根据权利要求1所述的方法，其中，所述填充剂选自由石灰石、滑石、云母、硅灰石、高岭石、云母、玻璃纤维、玻璃珠、以及它们的组合组成的组。
14.根据权利要求13所述的方法，其中，所述填充剂以按所述片材组分重量的约20％至约60％的量存在。
15.根据权利要求1所述的方法，其中，所述组分还包含选自由以下组成的组中的至少一种功能添加剂：阻燃剂、抗氧化剂、热稳定剂、光稳定剂、荧光或磷光添加剂、发光添加剂、加工助剂、颜料以及它们的组合。
16.根据权利要求15所述的方法，其中，所述阻燃剂包括选自由以下组成的组中的至少一种阻燃剂：固体阻燃剂、液体阻燃剂、以及它们的组合。
17.一种制备均质片材的方法，包括：
(a)提供包括热塑性聚氨酯、合成橡胶混合物和填充剂的片材组分；
(b)组合所述片材组分；
(c)通过压延机将所述组分挤出成膜并冷却；
(d)将所述膜粒化以形成碎片；
(e)混合所述碎片并传送至载体；
(f)提供热量并且固结所述碎片以形成片材。
18.根据权利要求17所述的方法，其中，所述膜是具有厚度约0.3mm至约4.0mm的片材地板。
19.一种基本上不含PVC的地板片材或地砖，包括合成橡胶和白油的预混合物、热塑性聚氨酯、填充剂和至少一种功能添加剂。
20.根据权利要求19所述的片材或地砖，其中，所述功能添加剂选自由阻燃剂、抗氧化剂、光稳定剂、加工助剂、颜料以及它们的组合组成的组。
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