WO2016197311A1 - 一种pvc发泡材料及其制备方法和pvc复合板材 - Google Patents

一种pvc发泡材料及其制备方法和pvc复合板材 Download PDF

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Publication number
WO2016197311A1
WO2016197311A1 PCT/CN2015/081030 CN2015081030W WO2016197311A1 WO 2016197311 A1 WO2016197311 A1 WO 2016197311A1 CN 2015081030 W CN2015081030 W CN 2015081030W WO 2016197311 A1 WO2016197311 A1 WO 2016197311A1
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WIPO (PCT)
Prior art keywords
pvc
parts
present
foaming
weight
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Application number
PCT/CN2015/081030
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English (en)
French (fr)
Inventor
鹂海星
Original Assignee
江苏肯帝亚木业有限公司
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Filing date
Publication date
Application filed by 江苏肯帝亚木业有限公司 filed Critical 江苏肯帝亚木业有限公司
Priority to PCT/CN2015/081030 priority Critical patent/WO2016197311A1/zh
Priority to EP15894581.6A priority patent/EP3309213A4/en
Publication of WO2016197311A1 publication Critical patent/WO2016197311A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • C08J9/10—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing nitrogen, the blowing agent being a compound containing a nitrogen-to-nitrogen bond
    • C08J9/102—Azo-compounds
    • C08J9/103—Azodicarbonamide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3442—Mixing, kneading or conveying the foamable material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0012—Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
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    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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    • C08J9/08—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing carbon dioxide
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2105/0094—Condition, form or state of moulded material or of the material to be shaped having particular viscosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
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    • B32B2266/0214—Materials belonging to B32B27/00
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • C—CHEMISTRY; METALLURGY
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    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/03—Extrusion of the foamable blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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    • C08J2203/02—CO2-releasing, e.g. NaHCO3 and citric acid
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/04—N2 releasing, ex azodicarbonamide or nitroso compound
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Definitions

  • the present application relates to the field of polyvinyl chloride, and in particular to a PVC foaming material, a preparation method thereof and a PVC composite board.
  • Sheet metal is a material widely used in the fields of construction, home decoration, transportation vehicles and the like.
  • wood panels were used extensively, such as solid wood panels, plywood, particleboard, and the like. Due to their light weight, easy processing and wide range of sources, they are still in large use until now.
  • PVC foaming material also known as Chevron board and Andy board
  • foaming agent such as PVC and filler. It is a typical plastic material.
  • PVC foaming material in China has made considerable progress, but its scale and product quality are difficult to meet the requirements of China's chemical building materials market.
  • the main problem is the poor shrinkage performance and residual sag of existing PVC foaming materials. Higher, resulting in its application in the field of chemical building materials has been restricted.
  • an object of the present invention is to provide a PVC foaming material, a preparation method thereof and a PVC composite board.
  • the PVC foaming material provided by the invention has good shrinkage performance and low residual dent.
  • the invention provides a PVC foaming material, which is prepared by melt plasticizing a material, and the material comprises:
  • the light calcium carbonate has a particle diameter of 1000 to 1500 mesh.
  • the AC foaming agent has a gas generating amount of 150 to 200 mL/g;
  • the decomposition temperature of the AC foaming agent is 170 to 180 °C.
  • the foaming regulators are of the type K-400P, K-385, K-418, PA-40, PA-60, LP-21, LP-23, LP-40, LP-90 and LP- One or more of 530.
  • the viscosity of the PVC is 73-106 mL/g.
  • the material further comprises one or more of a stabilizer, a lubricant, and an impact modifier.
  • the invention provides a preparation method of a PVC foaming material, comprising the following steps:
  • the material is melt-plasticized to obtain a PVC foamed material
  • the material comprises 600 to 900 parts by weight of PVC, 600 to 900 parts by weight of light calcium carbonate, 3 to 10 parts by weight of sodium hydrogencarbonate, 3 to 5 parts by weight of AC foaming agent, and 40 to 80 parts by weight.
  • Foaming regulator 600 to 900 parts by weight of PVC, 600 to 900 parts by weight of light calcium carbonate, 3 to 10 parts by weight of sodium hydrogencarbonate, 3 to 5 parts by weight of AC foaming agent, and 40 to 80 parts by weight.
  • the invention provides a PVC composite board comprising a substrate and a semi-rigid PVC layer disposed on the surface of the substrate;
  • the material of the substrate is the PVC foaming material according to any one of claims 1 to 7 or the PVC foaming material obtained by the method of claim 8;
  • the semi-rigid PVC layer comprises PVC, a filler and a plasticizer.
  • the mass ratio of the PVC, the filler and the plasticizer in the semi-rigid PVC layer is from 5 to 20:20 to 60:1 to 6.
  • the present invention provides a PVC foaming material, a preparation method thereof and a PVC composite sheet.
  • the PVC foaming material provided by the invention is prepared by melt plasticizing the material, and the material comprises: 600-900 parts of PVC; 600-900 parts of light calcium carbonate; 3-10 parts of sodium hydrogencarbonate; 3 to 5 parts of AC foaming agent; 40 to 80 parts of foaming regulator.
  • the invention uses sodium hydrogencarbonate and an AC foaming agent as a foaming agent, and at the same time, by adjusting the content of each component in the material, a PVC foaming material having good shrinkage performance and low residual dentity is prepared.
  • Experimental results show that the PVC provided by the present invention
  • the heat shrinkage rate (80 ° C, 6 h) of the foamed material is ⁇ 2%, and the residual dentity is ⁇ 3%.
  • the invention provides a PVC foaming material, which is prepared by melt plasticizing a material, and the material comprises:
  • the PVC foaming material provided by the present invention is made by melt plasticizing a material including PVC, light calcium carbonate, sodium hydrogencarbonate, an AC foaming agent and a foaming regulator.
  • the PVC is called polyvinyl chloride and is polymerized from vinyl chloride monomer.
  • the viscosity of the PVC is 73-106 mL/g; in another embodiment provided by the present invention, the viscosity of the PVC is 73-86 mL/g.
  • the PVC is of one or more of the types SG-6, SG-7 and SG-8.
  • the content of the PVC in the material is 600-900 parts by weight; in an embodiment provided by the present invention, the content of the PVC in the material is 700-800 parts by weight; In another embodiment provided by the present invention, the PVC is contained in the material in an amount of from 750 to 800 parts by weight.
  • the light calcium carbonate is also called precipitated calcium carbonate, and its sedimentation volume is 2.4 to 2.8 mL/g.
  • the action of the light carbonic acid serves to act as a filler and to improve shrinkage properties and residual dents of the PVC foamed material.
  • the light calcium carbonate has a particle diameter of 1000 to 1500 mesh; in another embodiment provided by the present invention, the light calcium carbonate has a particle diameter of 1200 to 1250 mesh.
  • the content of the light calcium carbonate in the material is 600 to 900 parts by weight; in an embodiment provided by the present invention, the content of the light calcium carbonate in the material is 700. ⁇ 800 parts by weight; in another embodiment provided by the present invention, the light carbonic acid The content of calcium in the material is 750 to 800 parts by weight.
  • the sodium hydrogencarbonate and the AC foaming agent function to foam the material during the melt plasticization process.
  • the AC foaming agent is also called azodicarbonamide foaming agent, and its main component is azodicarbonamide.
  • the AC foaming agent has a gas generating amount of 150 to 200 mL/g; in another embodiment provided by the present invention, the AC foaming agent has a gas generating amount of 170 to 200 mL. /g.
  • the AC blowing agent has a decomposition temperature of 170 to 180 °C. In one embodiment provided by the present invention, the AC blowing agent is of the type NH600.
  • the content of the sodium hydrogencarbonate in the material is 3 to 10 parts by weight; in an embodiment provided by the present invention, the content of the sodium hydrogencarbonate in the material is 5 to 10 In another embodiment provided by the present invention, the sodium hydrogencarbonate is present in the material in an amount of from 6 to 8 parts by weight.
  • the content of the AC foaming agent in the material is 3 to 5 parts by weight; in an embodiment provided by the present invention, the content of the AC foaming agent in the material is 4 ⁇ 5 parts by weight; in another embodiment provided by the present invention, the AC foaming agent is contained in the material in an amount of from 4 to 4.5 parts by weight.
  • the foaming regulator acts to adjust the degree of foaming of the foaming agent.
  • the foaming regulators are of the type K-400P, K-385, K-418, PA-40, PA-60, LP-21, LP-23, LP-40, One or more of LP-90 and LP-530.
  • the foaming regulators of the models K-400P, K-385 and K-418 are supplied by Rohm and Haas, USA, and the foaming regulators of the models PA-40 and PA-60 are provided.
  • the foaming regulators supplied by Japan Kanepo, models LP-21, LP-23, LP-40, LP-90 and LP-530 are supplied by Shandong Ruifeng.
  • the foaming regulator is contained in the material in an amount of 40 to 80 parts by weight; in an embodiment provided by the present invention, the foaming regulator is contained in the material in an amount of 50 ⁇ 70 parts by weight; in another embodiment provided by the present invention, the foaming regulator is contained in the material in an amount of from 60 to 70 parts by weight.
  • the material further includes one or more of a stabilizer, a lubricant, and an impact modifier.
  • the stabilizer is one or more of a calcium-zinc composite stabilizer, a lead salt composite stabilizer, an organotin stabilizer, a bismuth zinc composite stabilizer, and a potassium-zinc composite stabilizer.
  • the content of calcium stearate in the calcium-zinc composite stabilizer is 30-40% by weight, and the content of zinc stearate is 30-40% by weight; another embodiment provided by the present invention In the example, the content of calcium stearate in the calcium-zinc composite stabilizer is 35 to 38% by weight, and the content of zinc stearate is 30 to 32% by weight.
  • the stabilizer is contained in the material in an amount of 15 to 50 parts by weight; in another embodiment provided by the present invention, the stabilizer is contained in the material. It is 25 to 40 parts by weight; in other embodiments provided by the present invention, the stabilizer is contained in the material in an amount of 28 to 35 parts by weight.
  • the lubricant comprises an internal lubricant and/or an external lubricant.
  • the internal lubricant is of one or more of G-60, G-16, G-78, GH-4, N-16 and ZY-60.
  • the internal lubricants of the models G-60, G-16, G-78 and GH-4 are supplied by Corning, Germany, and the internal lubricants of the types N-16 and ZY-60.
  • the external lubricant is a polyethylene wax, also known as a PE wax.
  • the polyethylene wax is of the type H-108 and/or H-110.
  • polyethylene waxes of the types H-108 and H-110 are supplied by SQI Corporation of Thailand.
  • the lubricant comprises an inner lubricant and an outer lubricant, wherein the mass ratio of the inner lubricant to the outer lubricant is 5-10:1 to 5; in the present invention In another embodiment, the mass ratio of the inner lubricant to the outer lubricant in the lubricant is from 6 to 8:2 to 3; in other embodiments provided by the invention, the lubricant in the lubricant The mass ratio of the lubricant to the external lubricant is 7.5 to 8: 2.5 to 3.
  • the lubricant is contained in the material in an amount of 5 to 15 parts by weight; in another embodiment provided by the present invention, the lubricant is contained in the material. 8 to 11 parts by weight; in other embodiments provided by the present invention, the lubricant is contained in the material in an amount of 10 to 11 parts by weight; in other embodiments provided by the present invention, the lubricant is The content in the material is from 10 to 10.5 parts by weight.
  • the impact modifier is chlorinated polyethylene (CPE), acrylate copolymer (ACR), ethylene-vinyl acetate copolymer (EVA), methyl methacrylate- One or more of butadiene-styrene terpolymer graft copolymer (MBS) and acrylonitrile-butadiene-styrene copolymer (ABS).
  • the chlorinated polyethylene is of one or more of the types CPE-130A, CPE-135A, CPE-135B, CPE-135C, and CPE-140A.
  • chlorinated polyethylenes of the types CPE-130A, CPE-135A, CPE-135B, CPE-135C and CPE-140A are supplied by Shandong Ruifeng.
  • the acrylate copolymer is of one or more of the types LS-21, LS-22, LS-50, LS-51, LS-55, and LS-61.
  • the models are LS-21, LS-22, The acrylate copolymers of LS-50, LS-51, LS-55 and LS-61 were supplied by Shandong Ruifeng.
  • the impact modifier is contained in the material in an amount of 30 to 110 parts by weight; in another embodiment provided by the present invention, the impact modifier is The content of the material is 50 to 90 parts by weight; in other embodiments provided by the present invention, the impact modifier is contained in the material in an amount of 70 to 80 parts by weight; In an embodiment, the impact modifier is present in the material in an amount of from 70 to 75 parts by weight.
  • the impact modifier is a chlorinated polyethylene and an acrylate copolymer
  • the mass ratio of the chlorinated polyethylene and the acrylate copolymer in the impact modifier is 10 ⁇ 50:20 ⁇ 60; in another embodiment provided by the present invention, the mass ratio of the chlorinated polyethylene and the acrylate copolymer in the impact modifier is 20-40:30-50; In other embodiments provided, the mass ratio of chlorinated polyethylene to acrylate copolymer in the impact modifier is from 30 to 35:40 to 45.
  • the invention uses sodium hydrogencarbonate and an AC foaming agent as a foaming agent, and at the same time, by adjusting the content of each component in the material, a PVC foaming material having good shrinkage performance and low residual dentity is prepared.
  • the experimental results show that the PVC shrinkage material provided by the invention has a heat shrinkage rate (80 ° C, 6 h) ⁇ 2%, a residual sag degree ⁇ 3%, a heating warpage (80 ° C, 6 h) ⁇ 2 mm, and a water absorption rate ⁇ 1%.
  • the density is 0.8 ⁇ 0.1 g / cm 3 .
  • the invention provides a preparation method of a PVC foaming material, comprising the following steps:
  • the material is melt-plasticized to obtain a PVC foamed material
  • the material comprises 600 to 900 parts by weight of PVC, 600 to 900 parts by weight of light calcium carbonate, 3 to 10 parts by weight of sodium hydrogencarbonate, 3 to 5 parts by weight of AC foaming agent, and 40 to 80 parts by weight. Foaming tone.
  • the material is first melt-plasticized, and the material includes PVC, light calcium carbonate, sodium hydrogencarbonate, an AC foaming agent, and a foaming regulator.
  • the content of the PVC in the material is from 600 to 900 parts by weight, preferably from 700 to 800 parts by weight, more preferably from 750 to 800 parts by weight.
  • the content of the light calcium carbonate in the material is 600 to 900 parts by weight, preferably 700 to 800 parts by weight, more preferably 750 to 800 parts by weight.
  • the content of the sodium hydrogencarbonate in the material is from 3 to 10 parts by weight, preferably from 5 to 10 parts by weight, more preferably from 6 to 8 parts by weight.
  • the content of the AC foaming agent in the material is from 3 to 5 parts by weight, preferably from 4 to 5 parts by weight, more preferably from 4 to 4.5 parts by weight.
  • the content of the foaming regulator in the material is 40 to 80 parts by weight, preferably 50 to 70 parts by weight, more preferably 60 to 70 parts by weight.
  • the material further includes one or more of a stabilizer, a lubricant, and an impact modifier.
  • the content of the stabilizer in the material is preferably from 15 to 50 parts by weight, more preferably from 25 to 40 parts by weight, most preferably from 28 to 35 parts by weight.
  • the content of the lubricant in the material is preferably from 5 to 15 parts by weight, more preferably from 8 to 11 parts by weight, most preferably from 10 to 11 parts by weight.
  • the content of the impact modifier in the material is preferably from 30 to 110 parts by weight, more preferably from 50 to 90 parts by weight, most preferably from 70 to 80 parts by weight.
  • the temperature of the melt plasticization is preferably from 170 to 180 ° C; the time of the melt plasticization is preferably from 5 to 20 min, more preferably from 10 to 15 min.
  • the apparatus for the melt plasticization of the present invention is not particularly limited, and is preferably an extruder well known to those skilled in the art.
  • the above materials are uniformly mixed, and then the mixed mixture is subjected to melt plasticization.
  • the apparatus for mixing the materials of the present invention is not particularly limited, and is preferably a high-speed mixer well known to those skilled in the art.
  • the mixing time is preferably from 15 to 30 min.
  • the PVC foaming material provided by the present invention is obtained by setting.
  • the preparation method of the PVC foaming board provided by the invention uses sodium hydrogencarbonate and an AC foaming agent as a foaming agent, and at the same time, by adjusting the content of each component in the material, a good shrinkage property and a low residual dentity are prepared. PVC foam material.
  • the invention provides a PVC composite board comprising a substrate and a semi-rigid PVC layer disposed on the surface of the substrate;
  • the material of the substrate is the PVC foaming material described in the above technical solution or the PVC foaming material prepared by the method described in the above technical solution;
  • the semi-rigid PVC layer comprises PVC, a filler and a plasticizer.
  • the PVC composite sheet provided by the present invention comprises a substrate and a semi-rigid PVC layer.
  • the material of the substrate is the PVC foaming material or the PVC foaming material prepared by the method.
  • the substrate has a thickness of 3 to 5 mm.
  • the semi-rigid PVC layer is disposed on the surface of the substrate, and the semi-rigid PVC layer includes PVC, a filler, and a plasticizer.
  • the viscosity of the PVC is 73-106 mL/g; in another embodiment provided by the present invention, the viscosity of the PVC is 73-86 mL/g. In one embodiment provided by the present invention, the PVC is of one or more of the types SG-6, SG-7 and SG-8.
  • the filler is a stone powder.
  • the stone powder has a particle diameter of 100 to 200 mesh; in another embodiment provided by the present invention, The particle size of the stone powder is 150 to 200 mesh; in other embodiments provided by the present invention, the stone powder has a particle diameter of 160 to 180 mesh.
  • the plasticizer is dioctyl terephthalate (DOTP).
  • DBP dioctyl terephthalate
  • the mass ratio of PVC, filler and plasticizer in the semi-rigid PVC layer is from 5 to 20:20 to 60:1 to 6; another embodiment provided by the present invention
  • the mass ratio of the PVC, the filler and the plasticizer in the semi-rigid PVC layer is 10-20:40-60:2-6; in other embodiments provided by the present invention, the semi-rigid PVC layer
  • the mass ratio of PVC, filler and plasticizer is from 10 to 15:40 to 50:4 to 6.
  • the semi-rigid PVC layer further comprises a stabilizer.
  • the stabilizer is one or more of a calcium-zinc composite stabilizer, a lead salt composite stabilizer, an organotin stabilizer, a bismuth zinc composite stabilizer, and a potassium-zinc composite stabilizer.
  • the content of calcium stearate in the calcium-zinc composite stabilizer is 30-40% by weight, and the content of zinc stearate is 30-40% by weight; in an embodiment provided by the present invention
  • the content of calcium stearate is 35 to 38% by weight, and the content of zinc stearate is 30 to 32% by weight.
  • the mass ratio of the PVC and the stabilizer in the semi-rigid PVC layer is 50 to 200:1 to 5; in another embodiment provided by the present invention, the semi-rigid The mass ratio of the PVC and the stabilizer in the PVC layer is from 100 to 200:2 to 5; in other embodiments provided by the present invention, the mass ratio of the PVC and the stabilizer in the semi-rigid PVC layer is from 100 to 150:2. ⁇ 3.
  • the semi-rigid PVC layer has a thickness of 0.5 to 3 mm; in another embodiment provided by the present invention, the semi-rigid PVC layer has a thickness of 1 to 2 mm; In other embodiments provided by the present invention, the semi-rigid PVC layer has a thickness of 1.5 to 1.65 mm.
  • the PVC composite sheet further includes a wear layer disposed on a surface of the semi-rigid PVC layer.
  • the abrasion resistance layer has a gloss of 5 to 30 Gs; in another embodiment provided by the present invention, the abrasion resistance layer has a gloss of 10 to 20 Gs; In other embodiments provided, the wear layer has a gloss of 15 ⁇ 5 Gs.
  • the light transmittance of the wear layer is 60 to 100%; in another embodiment provided by the present invention, the light transmittance of the wear layer is 80 ⁇ 20%. .
  • the wear layer has an elongation at break of ⁇ 30%; in another embodiment provided by the present invention, the wear layer has an elongation at break of ⁇ 50%.
  • the heat shrinkage rate of the wear layer (100 ° C, 30 min) ⁇ 5%; in another embodiment provided by the present invention, the heat shrinkage rate of the wear layer ( 100 ° C, 30 min) ⁇ 2%.
  • the wear layer has a thickness of 0.2 to 0.3 mm.
  • the PVC composite board further includes a color film layer disposed between the semi-rigid PVC layer and the wear layer for making the PVC composite board specific Pattern texture and color.
  • the PVC composite sheet further includes a coating layer disposed on a surface of the wear layer.
  • the coating layer is formed by curing a UV-curable coating.
  • the PVC composite sheet can be prepared as follows:
  • the above PVC foamed material is bonded to the above-mentioned semi-rigid PVC layer by glue, and then pressed to obtain a PVC composite sheet.
  • the PVC foamed material is first bonded to the semi-rigid PVC layer by glue.
  • the semi-rigid PVC layer may be a commercially available semi-rigid PVC sheet, or may be prepared as follows:
  • the raw material is sequentially melt-plasticized and shaped to obtain the semi-rigid PVC layer; the raw material includes PVC, a filler and a plasticizer.
  • the raw material is first melt-plasticized, and the raw material includes PVC, a filler, and a plasticizer.
  • the raw material preferably further includes a stabilizer.
  • the temperature of the melt plasticization is preferably from 180 to 190 °C.
  • the raw materials are preferably first mixed before being subjected to melt plasticization.
  • the mixing is preferably carried out in a high speed mixer.
  • the specific process of mixing the raw materials in a high-speed mixer is: first mixing PVC with a plasticizer, the PVC and a plasticizer.
  • the mixing temperature is preferably from 90 to 100 ° C, and the mixing time of the PVC and the plasticizer is preferably from 5 to 10 min; then the mixture obtained by mixing the PVC and the plasticizer is mixed with the filler, the mixture and
  • the temperature at which the filler is mixed is preferably normal temperature; the time during which the mixture is mixed with the filler is preferably 8 to 10 minutes.
  • a raw material comprising PVC, a filler, a plasticizer and a stabilizer
  • the specific process of mixing the raw materials in a high-speed mixer is: first mixing PVC, a plasticizer and a stabilizer,
  • the mixing temperature of the PVC, the plasticizer and the stabilizer is preferably from 90 to 100 ° C, and the mixing time of the PVC, the plasticizer and the stabilizer is preferably from 5 to 10 min; then the PVC, the plasticizer and the stabilizer are mixed.
  • the resulting mixture is mixed with the filler, and the temperature at which the mixture is mixed with the filler is preferably normal temperature; the mixing time of the mixture with the filler is preferably 8 to 10 minutes.
  • the plasticized raw material is shaped to obtain the semi-rigid PVC layer.
  • the specific process of melt plasticizing and shaping the raw material is:
  • the raw materials are firstly mixed and plasticized in an internal mixer, then opened and plasticized in an open mill, and finally plasticized in a calender and calendered to a design thickness, and then cooled and shaped.
  • the temperature of the refining plasticization is preferably 180 to 190 ° C; and the time of the refining plasticization is preferably 8 to 10 min.
  • the temperature of the opening and plasticizing is preferably from 180 to 190 °C.
  • the time for the plasticization and plasticization of the invention is not particularly limited, and the raw material can be processed into a subsequent process after being smelted and plasticized to no obvious powder.
  • the calender roll pitch is preferably 2 to 3 mm; the calender roll speed is preferably 10 to 20 m/min; and the calender roll temperature of the calender is preferably 180 to 190 °C.
  • a wear layer is preferably provided on the surface of the semi-rigid PVC layer.
  • the wear resistant layer material was coated on the surface of the semi-rigid PVC layer obtained above, and then pressed to obtain a semi-rigid PVC layer provided with a wear resistant layer.
  • the gloss of the wear layer material is preferably 5 to 30 Gs, more preferably 10 to 20 Gs, and most preferably 15 ⁇ 5 Gs; and the light transmittance of the wear layer material is preferably 60 to 100%, more preferably 80 ⁇ 20%; the elongation at break of the wear layer material is preferably ⁇ 30%, more preferably ⁇ 50%; the heat shrinkage rate of the wear layer material is preferably (100° C., 30 min) ⁇ 5%, more preferably ⁇ 2%.
  • the pressing is performed by hot pressing first and then cold pressing.
  • the hot pressing temperature is preferably 120 to 140 ° C;
  • the hot pressing time is preferably 20 to 30 min; and the hot pressing pressure is preferably 5 to 10 mPa.
  • the cold pressing pressure is preferably 15 to 20 mPa; and the cold pressing time is preferably 20 to 25 min.
  • a color film layer between the semi-rigid PVC layer and the wear resistant layer by first covering the color film layer on the surface of the semi-rigid PVC layer obtained above, and then applying the wear resistant layer. The material covers the surface of the color film layer and is then pressed.
  • a coating layer on the surface of the wear layer after the wear layer is disposed on the surface of the semi-rigid PVC layer, the process is: applying a UV-curable coating on the surface of the wear layer, and curing the coating Thereafter, the coating forms a coating layer on the surface of the wear layer.
  • the pressing pressure is preferably 5 to 10 mPa; and the pressing time is preferably 12 to 24 hours. After the pressing is completed, the PVC composite sheet provided by the present invention is obtained.
  • the PVC composite sheet provided by the invention adopts a PVC foaming material with good shrinkage performance and low residual depression as a substrate, and the surface layer is made of semi-rigid PVC material. Compared with a single semi-rigid PVC sheet, the composite sheet provided by the invention has high strength and small density and good application prospect.
  • 100kg PVC SG-8, 40kg DOTP and 2kg calcium-zinc composite stabilizer (38wt% calcium stearate, 32wt% zinc stearate and the balance of calcium zinc composite stabilizer conventional additives) are mixed in a high-speed mixer. Mix for 5 min at 90-100 °C. The mixed mixture and 400 kg of stone powder (160 mesh, whiteness 80) were mixed in a cold mixer for 8 to 10 minutes to obtain a mixture.
  • the above mixture is added to an internal mixer, and after being plasticized for 8 to 10 minutes, the mixed material is fed to an open mill to continue plasticizing, and the temperature of the opening is controlled at 180 to 190 °C.
  • the material to be wrapped on the mill is plasticized evenly, and after no obvious powder, it is sent to the calender.
  • the calender roll distance was adjusted to 2 mm, the roll speed was 20 m/min, and the calender roll temperature was controlled at 180 to 190 °C.
  • the material was further plasticized in a calender and calendered to a thickness of 1.65 mm. After the calendered material was cooled and characterized, it was cut to obtain a negative film of 1280 mm ⁇ 990 mm ⁇ 1.65 mm.
  • the backsheet prepared above, a color film having a thickness of 0.05 mm, and a wear layer having a thickness of 0.3 mm are stacked, and the gloss of the wear layer is 15 ⁇ 5 Gs, the light transmittance is 80 ⁇ 20%, and the elongation is ⁇ 50%, heat shrinkage rate (100 ° C, 30 Min) ⁇ 2.0%.
  • hot pressing is performed, and the hot pressing temperature is 120 to 140 ° C, the time is 20 min, and the pressure is 5 mPa.
  • cold pressing is performed, the cold pressing pressure is 15 mPa, and the cold pressing time is 20-25 min.
  • the cold-pressed sheet was coated with UV-curable coating (Hunan Hengxing, HX5A01), and the coating was cured to obtain a semi-rigid PVC board.
  • UV-curable coating Haunan Hengxing, HX5A01
  • the semi-rigid PVC board obtained in this example has a size of 1228 ⁇ 950 ⁇ 2 mm and a density of 1.7 g / cm 3 .
  • the semi-rigid PVC board was tested for performance, and its performance met the requirements of the standard GB/T4085-2005 semi-rigid polyvinyl chloride block floor.
  • the above mixture was melt-plasticized in an extruder at 170 ° C for 10 min and extruded through a die to the true In the airtight device.
  • the extrudate is cut after being shaped in a vacuum setting device to obtain a low-foamed PVC board.
  • the size of the low-foamed PVC board obtained in this embodiment is 1230 mm ⁇ 50 mm ⁇ 3 mm.
  • the PVC foaming material is tested for heat shrinkage performance, residual sag, water absorption and density, wherein the heating yield refers to GB/T 4085-2005, the heating warpage refers to GB/T 4085-2005, and the residual sag refers to GB.
  • the test results are: heating shrinkage rate (80 ° C, 6h) ⁇ 1.5%, heating warping (80 ° C, 6h) ⁇ 2mm, residual sag ⁇ 2%, water absorption ⁇ 1%, density 0.8 ⁇ 0.1 g / cm 3 . It can be seen from the above test data that the PVC foamed material obtained in the present embodiment has a low heat shrinkage rate and heat warpage, indicating that the PVC foamed material has good shrinkage properties; meanwhile, the PVC foamed material is obtained in this embodiment. The residual sag is ⁇ 2% and the residual sag is low.
  • the PVC foamed sheet produced in this example was tested for cold and heat resistance:
  • Air convection drying oven constant temperature sensitivity ⁇ 1 ° C, temperature range 40 ° C -200 ° C;
  • l 1 The dimensions of the test piece before the test, in millimeters (mm).
  • the average value that is, the dimensional change rate of the low-foaming PVC sheet provided in the present embodiment, is accurate to 0.02 mm.
  • the above mixture was melt-plasticized in an extruder at 170 ° C for 10 min and extruded through a die into a vacuum setting device.
  • the extrudate is cut after being shaped in a vacuum setting device to obtain a low-foamed PVC board.
  • the size of the low-foamed PVC sheet obtained in this example was 1230 mm ⁇ 50 mm ⁇ 3 mm.
  • the PVC foaming material is tested for heat shrinkage performance, residual sag, water absorption and density, wherein the heating yield refers to GB/T 4085-2005, the heating warpage refers to GB/T 4085-2005, and the residual sag refers to GB.
  • test results are: heating shrinkage (80 ° C, 6h) ⁇ 1.8%, heating warp (80 ° C, 6h) ⁇ 2mm, residual sag ⁇ 2.5 %, water absorption rate ⁇ 1%, density is 0.8 ⁇ 0.1 g / cm 3 .
  • the PVC foamed material obtained in the present embodiment has a low heat shrinkage rate and heat warpage, indicating that the PVC foamed material has good shrinkage properties; meanwhile, the PVC foamed material is obtained in this embodiment.
  • the residual sag is ⁇ 2.5%, and the residual sag is low.
  • the cold and hot resistance test of the PVC foamed sheet obtained in the present example was carried out according to the method of Example 2. test. The test results are shown in Table 2:
  • the above mixture was melt-plasticized in an extruder at 170 ° C for 10 min and extruded through a die into a vacuum setting device.
  • the extrudate is cut after being shaped in a vacuum setting device to obtain a low-foamed PVC board.
  • the size of the low-foamed PVC sheet obtained in this example was 1230 mm ⁇ 50 mm ⁇ 3 mm.
  • the PVC foaming material is tested for heat shrinkage performance, residual sag, water absorption and density, wherein the heating yield refers to GB/T 4085-2005, the heating warpage refers to GB/T 4085-2005, and the residual sag refers to GB.
  • test results are: heating shrinkage (80 ° C, 6h) ⁇ 1.7%, heating warp (80 ° C, 6h) ⁇ 2mm, residual sag ⁇ 2.8 %, water absorption rate ⁇ 1%, density 0.8 ⁇ 0.1 g / cm 3 .
  • the PVC foamed material obtained in the present embodiment has a low heat shrinkage rate and heat warpage, indicating that the PVC foamed material has good shrinkage properties; meanwhile, the PVC foamed material is obtained in this embodiment.
  • the residual sag is ⁇ 2.8%, and the residual sag is low.
  • the PVC foamed sheet obtained in the present example was tested for cold and heat resistance according to the method of Example 2.
  • the test results are shown in Table 3:
  • the semi-rigid PVC board prepared in Example 1 was pressed together with the low-foamed PVC material coated with glue to obtain a semi-rigid PVC/low-foamed PVC board.
  • the laminated semi-rigid PVC/low foamed PVC board was cold pressed at a pressure of 5.0 mPa for 12 hours. After the cold pressing is finished, the sheet is punched and grooved to obtain a PVC composite sheet.

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Abstract

本申请涉及聚氯乙烯领域，尤其涉及一种PVC发泡材料及其制备方法和PVC复合板材。本申请提供的PVC发泡材料由物料熔融塑化制成，以重量份数计，所述物料包括：PVC 600～900份；轻质碳酸钙600～900份；碳酸氢钠3～10份；AC发泡剂3～5份；发泡调节剂40～80份。本申请以碳酸氢钠和AC发泡剂作为发泡剂，同时通过调节各组分在物料中的含量，制备得到了具有良好收缩性能和较低残余凹陷度的PVC发泡材料。实验结果表明，本申请提供的PVC发泡材料的加热收缩率(80℃、6h)≤2％、残余凹陷度≤3％。

Description

一种PVC发泡材料及其制备方法和PVC复合板材 技术领域
本申请涉及聚氯乙烯领域，尤其涉及一种PVC发泡材料及其制备方法和PVC复合板材。
背景技术
板材是建筑、家居装饰、交通车辆等领域中大量使用的一种材料。过去大量使用的是木质板材，例如：实木板、胶合板、刨花板等。由于它们质轻、易加工、来源广泛，直到现在仍在大量的使用。
随着国家经济的发展，木材供应已经越来越紧张，其主要原因是我国森林覆盖率本来就低，经过几十年来的滥砍滥伐，大片林海变成秃山，因此许多省事地区的政府部门已经开始命令禁伐，从而导致木材供应量的大大减少，价格也不断攀升。而在国际上，随着参林资源的减少和环境保护意识的增强，各国也都制定了限采伐、限出口的相关政策，造成木质板材的来源越来越少，价格越来越昂贵。此外，木质板材在建筑和家居的装修中易产生甲醛污染，危害人的身体健康。因此，我国政府部门早在八十年代末就提出了“以塑代木”的要求。
PVC发泡材料又称为雪弗板和安迪板，由PVC和填料等原材料在发泡剂存在下发泡制得，是典型的塑料材料。近年来，我国PVC发泡材料的生产颇有进展，但其规模和产品质量方面均难以满足我国化工建材市场的要求，其主要问题是现有PVC发泡材料的收缩性能较差、残余凹陷度较高，导致其在化工建材领域中的应用受到了制约。
发明内容
为了解决以上技术问题，本发明的目的在于提供一种PVC发泡材料及其制备方法和PVC复合板材，本发明提供的PVC发泡材料具有良好的收缩性能和较低残余凹陷度。
本发明提供了一种PVC发泡材料，由物料熔融塑化制成，以重量份数计，所述物料包括：
Figure PCTCN2015081030-appb-000001
优选的，所述轻质碳酸钙的粒径为1000～1500目。
优选的，所述AC发泡剂的发气量为150～200mL/g；
优选的，所述AC发泡剂的分解温度为170～180℃。
优选的，所述发泡调节剂的型号为K-400P、K-385、K-418、PA-40、PA-60、LP-21、LP-23、LP-40、LP-90和LP-530中的一种或多种。
优选的，所述PVC的黏数为73～106mL/g。
优选的，所述物料还包括稳定剂、润滑剂和抗冲改性剂中的一种或多种。
本发明提供了一种PVC发泡材料的制备方法，包括以下步骤：
物料熔融塑化，得到PVC发泡材料；
所述物料包括600～900重量份的PVC、600～900重量份的轻质碳酸钙、3～10重量份的碳酸氢钠、3～5重量份的AC发泡剂和40～80重量份的发泡调节剂。
本发明提供了一种PVC复合板材，包括基底和设置在基底表面的半硬质PVC层；
所述基底的材料为权利要求1～7任一项所述的PVC发泡材料或权利要求8所述方法制得的PVC发泡材料；
所述半硬质PVC层包括PVC、填料和增塑剂。
优选的，所述半硬质PVC层中PVC、填料和增塑剂的质量比为5～20：20～60：1～6。
与现有技术相比，本发明提供了一种PVC发泡材料及其制备方法和PVC复合板材。本发明提供的PVC发泡材料由物料熔融塑化制成，以重量份数计，所述物料包括：PVC 600～900份；轻质碳酸钙600～900份；碳酸氢钠3～10份；AC发泡剂3～5份；发泡调节剂40～80份。本发明以碳酸氢钠和AC发泡剂作为发泡剂，同时通过调节各组分在物料中的含量，制备得到了具有良好收缩性能和较低残余凹陷度的PVC发泡材料。实验结果表明，本发明提供的PVC 发泡材料的加热收缩率(80℃、6h)≤2％、残余凹陷度≤3％。
具体实施方式
为了进一步理解本发明，下面结合实施例对本发明优选实施方案进行描述，但是应当理解，这些描述只是为进一步说明本发明的特征和优点，而不是对本发明权利要求的限制。
本发明提供了一种PVC发泡材料，由物料熔融塑化制成，以重量份数计，所述物料包括：
Figure PCTCN2015081030-appb-000002
本发明提供的PVC发泡材料由物料熔融塑化制成，所述物料包括PVC、轻质碳酸钙、碳酸氢钠、AC发泡剂和发泡调节剂。其中，所述PVC全称为聚氯乙烯，由氯乙烯单体聚合而成。在本发明提供的一个实施例中，所述PVC的黏数为73～106mL/g；在本发明提供的另一个实施例中，所述PVC的黏数为73～86mL/g。在本发明提供的一个实施例中，所述PVC的型号为SG-6、SG-7和SG-8中的一种或多种。在本发明中，所述PVC在所述物料中的含量为600～900重量份；在本发明提供的一个实施例中，所述PVC在所述物料中的含量为700～800重量份；在本发明提供的另一个实施例中，所述PVC在所述物料中的含量为750～800重量份。
在本发明中，所述轻质碳酸钙又称沉淀碳酸钙，其沉降体积为2.4～2.8mL/g。在本发明中，所述轻质碳酸的作用为充当填料和改善PVC发泡材料的收缩性能和残余凹陷度。在本发明提供的一个实施例中，所述轻质碳酸钙的粒径为1000～1500目；在本发明提供的另一个实施例中，所述轻质碳酸钙的粒径为1200～1250目。在本发明中，所述轻质碳酸钙在所述物料中的含量为600～900重量份；在本发明提供的一个实施例中，所述轻质碳酸钙在所述物料中的含量为700～800重量份；在本发明提供的另一个实施例中，所述轻质碳酸 钙在所述物料中的含量为750～800重量份。
在本发明中，所述碳酸氢钠和AC发泡剂的作用为使物料在熔融塑化的过程中发泡。其中，所述AC发泡剂又称偶氮二甲酰胺发泡剂，其主要成分为偶氮二甲酰胺。在本发明提供的一个实施例中，所述AC发泡剂的发气量为150～200mL/g；在本发明提供的另一个实施例中，所述AC发泡剂的发气量为170～200mL/g。在本发明提供的一个实施例中，所述AC发泡剂的分解温度为170～180℃。在本发明提供的一个实施例中，所述AC发泡剂的型号为NH600。在本发明中，所述碳酸氢钠在所述物料中的含量为3～10重量份；在本发明提供的一个实施例中，所述碳酸氢钠在所述物料中的含量为5～10重量份；在本发明提供的另一个实施例中，所述碳酸氢钠在所述物料中的含量为6～8重量份。在本发明中，所述AC发泡剂在所述物料中的含量为3～5重量份；在本发明提供的一个实施例中，所述AC发泡剂在所述物料中的含量为4～5重量份；在本发明提供的另一个实施例中，所述AC发泡剂在所述物料中的含量为4～4.5重量份。
在本发明中，所述发泡调节剂的作用为调节发泡剂的发泡程度。在本发明提供的一个实施例中，所述发泡调节剂的型号K-400P、K-385、K-418、PA-40、PA-60、LP-21、LP-23、LP-40、LP-90和LP-530中的一种或多种。在本发明提供的一个实施例中，型号为K-400P、K-385和K-418的发泡调节剂由美国罗门哈斯提供，型号为PA-40和PA-60的发泡调节剂由日本钟渊提供，型号为LP-21、LP-23、LP-40、LP-90和LP-530的发泡调节剂由山东瑞丰提供。在本发明中，所述发泡调节剂在所述物料中的含量为40～80重量份；在本发明提供的一个实施例中，所述发泡调节剂在所述物料中的含量为50～70重量份；在本发明提供的另一个实施例中，所述发泡调节剂在所述物料中的含量为60～70重量份。
在本发明提供的一个实施例中，所述物料还包括稳定剂、润滑剂和抗冲改性剂中的一种或多种。
在本发明提供的一个实施例中，所述稳定剂为钙锌复合稳定剂、铅盐复合稳定剂、有机锡类稳定剂、钡锌复合稳定剂和钾锌复合稳定剂中的一种或多种。在本发明提供的一个实施例中，所述钙锌复合稳定剂中硬脂酸钙的含量为30～40wt％，硬脂酸锌的含量为30～40wt％；在本发明提供的另一个实施例中，所述钙锌复合稳定剂中硬脂酸钙的含量为35～38wt％，硬脂酸锌的含量为 30～32wt％。在本发明提供的一个实施例中，所述稳定剂在所述物料中的含量为15～50重量份；在本发明提供的另一个实施例中，所述稳定剂在所述物料中的含量为25～40重量份；在本发明提供的其他实施例中，所述稳定剂在所述物料中的含量为28～35重量份。
在本发明提供的一个实施例中，所述润滑剂包括内润滑剂和/或外润滑剂。在本发明提供的一个实施例中，所述内润滑剂的型号为G-60、G-16、G-78、GH-4、N-16和ZY-60中的一种或多种。在本发明提供的一个实施例中，型号为G-60、G-16、G-78和GH-4的内润滑剂由德国科宁提供，型号为N-16和ZY-60的内润滑剂由淄博正业提供。在本发明提供的一个实施例中，所述外润滑剂为聚乙烯蜡，又称PE蜡。在本发明提供的一个实施例中，所述聚乙烯蜡的型号为H-108和/或H-110。在本发明提供的一个实施例中，型号为H-108和H-110的聚乙烯蜡由泰国SQI公司提供。在本发明提供的一个实施例中，所述润滑剂包括内润滑剂和外润滑剂，所述润滑剂中内润滑剂和外润滑剂的质量比为5～10：1～5；在本发明提供的另一个实施例中，所述润滑剂中内润滑剂和外润滑剂的质量比为6～8：2～3；在本发明提供的其他实施例中，所述润滑剂中内润滑剂和外润滑剂的质量比为7.5～8：2.5～3。在本发明提供的一个实施例中，所述润滑剂在所述物料中的含量为5～15重量份；在本发明提供的另一个实施例中，所述润滑剂在所述物料中的含量为8～11重量份；在本发明提供的其他实施例中，所述润滑剂在所述物料中的含量为10～11重量份；在本发明提供的其他实施例中，所述润滑剂在所述物料中的含量为10～10.5重量份。
在本发明提供的一个实施例中，所述抗冲改性剂为氯化聚乙烯(CPE)、丙烯酸酯共聚物(ACR)、乙烯-醋酸乙烯共聚物(EVA)、甲基丙烯酸甲酯-丁二烯-苯乙烯三元接枝共聚物(MBS)和丙烯腈-丁二烯-苯乙烯共聚物(ABS)中的一种或多种。在本发明提供的一个实施例中，所述氯化聚乙烯的型号为CPE-130A、CPE-135A、CPE-135B、CPE-135C和CPE-140A中的一种或多种。在本发明提供的一个实施例中，型号为CPE-130A、CPE-135A、CPE-135B、CPE-135C和CPE-140A的氯化聚乙烯由山东瑞丰提供。在本发明提供的一个实施例中，所述丙烯酸酯共聚物的型号为LS-21、LS-22、LS-50、LS-51、LS-55和LS-61中的一种或多种。在本发明提供的一个实施例中，型号为LS-21、LS-22、 LS-50、LS-51、LS-55和LS-61的丙烯酸酯共聚物由山东瑞丰提供。在本发明提供的一个实施例中，所述抗冲改性剂在所述物料中的含量为30～110重量份；在本发明提供的另一个实施例中，所述抗冲改性剂在所述物料中的含量为50～90重量份；在本发明提供的其他实施例中，所述抗冲改性剂在所述物料中的含量为70～80重量份；在本发明提供的其他实施例中，所述抗冲改性剂在所述物料中的含量为70～75重量份。在本发明提供的一个实施例中，所述抗冲改性剂为氯化聚乙烯和丙烯酸酯共聚物，所述抗冲改性剂中氯化聚乙烯和丙烯酸酯共聚物的质量比为10～50：20～60；在本发明提供的另一个实施例中，所述抗冲改性剂中氯化聚乙烯和丙烯酸酯共聚物的质量比为20～40：30～50；在本发明提供的其他实施例中，所述抗冲改性剂中氯化聚乙烯和丙烯酸酯共聚物的质量比为30～35：40～45。
本发明以碳酸氢钠和AC发泡剂作为发泡剂，同时通过调节各组分在物料中的含量，制备得到了具有良好收缩性能和较低残余凹陷度的PVC发泡材料。实验结果表明，本发明提供的PVC发泡材料的加热收缩率(80℃、6h)≤2％、残余凹陷度≤3％、加热翘曲(80℃、6h)≤2mm、吸水率≤1％、密度为0.8±0.1g/cm3。
本发明提供了一种PVC发泡材料的制备方法，包括以下步骤：
物料熔融塑化，得到PVC发泡材料；
所述物料包括600～900重量份的PVC、600～900重量份的轻质碳酸钙、3～10重量份的碳酸氢钠、3～5重量份的AC发泡剂和40～80重量份的发泡调。
在本发明提供的PVC发泡材料的制备方法中，首先将物料熔融塑化，所述物料包括PVC、轻质碳酸钙、碳酸氢钠、AC发泡剂和发泡调节剂。其中，所述PVC在物料中的含量为600～900重量份，优选为700～800重量份，更优选为750～800重量份。所述轻质碳酸钙在物料中的含量为600～900重量份，优选为700～800重量份，更优选为750～800重量份。所述碳酸氢钠在物料中的含量为3～10重量份，优选为5～10重量份，更优选为6～8重量份。所述AC发泡剂在物料中的含量为3～5重量份，优选为4～5重量份，更优选为4～4.5重量份。所述发泡调节剂在物料中的含量为40～80重量份，优选为50～70重量份，更优选为60～70重量份。
在本发明提供的一个实施例中，所述物料还包括稳定剂、润滑剂和抗冲改性剂中的一种或多种。其中，所述稳定剂在物料中的含量优选为15～50重量份，更优选为25～40重量份，最优选为28～35重量份。所述润滑剂在物料中的含量优选为5～15重量份，更优选为8～11重量份，最优选为10～11重量份。所述抗冲改性剂在物料中的含量优选为30～110重量份，更优选为50～90重量份，最优选为70～80重量份。
在本发明中，所述熔融塑化的温度优选为170～180℃；所述熔融塑化的时间优选为5～20min，更优选为10～15min。本发明对所述熔融塑化的设备没有特别限定，优选为本领域技术人员熟知的挤出机。
在本发明中，优选先将上述各物料混合均匀后，再对混合得到的混合料进行熔融塑化。本发明对所述物料进行混合的设备没有特别限定，优选为本领域技术人员熟知的高速混合机。所述混合的时间优选为15～30min。
熔融塑化结束后，定型，得到本发明提供的PVC发泡材料。
本发明提供的PVC发泡板制备方法以碳酸氢钠和AC发泡剂作为发泡剂，同时通过调节各组分在物料中的含量，制备得到了具有良好收缩性能和较低残余凹陷度的PVC发泡材料。
本发明提供了一种PVC复合板材，包括基底和设置在基底表面的半硬质PVC层；
所述基底的材料为上述技术方案所述的PVC发泡材料或上述技术方案所述方法制得的PVC发泡材料；
所述半硬质PVC层包括PVC、填料和增塑剂。
本发明提供的PVC复合板材包括基底和半硬质PVC层。其中，所述基底的材料为所述的PVC发泡材料或所述方法制得的PVC发泡材料。在本发明提供的一个实施例中，所述基底的厚度为3～5mm。
在本发明中，所述半硬质PVC层设置在所述基底表面，所述半硬质PVC层包括PVC、填料和增塑剂。
在本发明提供的一个实施例中，所述PVC的黏数为73～106mL/g；在本发明提供的另一个实施例中，所述PVC的黏数为73～86mL/g。在本发明提供的一个实施例中，所述PVC的型号为SG-6、SG-7和SG-8中的一种或多种。
在本发明提供的一个实施例中，所述填料为石粉。在本发明提供的一个实施例中，所述石粉的粒径为100～200目；在本发明提供的另一个实施例中，所 述石粉的粒径为150～200目；在本发明提供的其他实施例中，所述石粉的粒径为160～180目。
在本发明提供的一个实施例中所述增塑剂为对苯二甲酸二辛酯(DOTP)。在本发明提供的一个实施例中，所述半硬质PVC层中PVC、填料和增塑剂的质量比为5～20：20～60：1～6；在本发明提供的另一个实施例中，所述半硬质PVC层中PVC、填料和增塑剂的质量比为10～20：40～60：2～6；在本发明提供的其他实施例中，所述半硬质PVC层中PVC、填料和增塑剂的质量比为10～15：40～50：4～6。
在本发明提供的一个实施例中，所述半硬质PVC层还包括稳定剂。在本发明提供的一个实施例中，所述稳定剂为钙锌复合稳定剂、铅盐复合稳定剂、有机锡类稳定剂、钡锌复合稳定剂和钾锌复合稳定剂中的一种或多种。在本发明提供的一个实施例中，所述钙锌复合稳定剂中硬脂酸钙的含量为30～40wt％、硬脂酸锌的含量为30～40wt％；在本发明提供的一个实施例中，所述钙锌复合稳定剂中硬脂酸钙的含量为35～38wt％、硬脂酸锌的含量为30～32wt％。在本发明提供的一个实施例中，所述半硬质PVC层中PVC和稳定剂的质量比为50～200：1～5；在本发明提供的另一个实施例中，所述半硬质PVC层中PVC和稳定剂的质量比为100～200：2～5；在本发明提供的其他实施例中，所述半硬质PVC层中PVC和稳定剂的质量比为100～150：2～3。
在本发明提供的一个实施例中，所述半硬质PVC层的厚度为0.5～3mm；在本发明提供的另一个实施例中，所述半硬质PVC层的厚度为1～2mm；在本发明提供的其他实施例中，所述半硬质PVC层的厚度为1.5～1.65mm。
在本发明提供的一个实施例中，所述PVC复合板材还包括耐磨层，所述耐磨层设置在所述半硬质PVC层表面。在本发明提供的一个实施例中，所述耐磨层的光泽度为5～30Gs；在本发明提供的另一个实施例中，所述耐磨层的光泽度为10～20Gs；在本发明提供的其他实施例中，所述耐磨层的光泽度为15±5Gs。在本发明提供的一个实施例中，所述耐磨层的透光率为60～100％；在本发明提供的另一个实施例中，所述耐磨层的透光率为80±20％。在本发明提供的一个实施例中，所述耐磨层的断裂伸长率≥30％；在本发明提供的另一个实施例中，所述耐磨层的断裂伸长率≥50％。在本发明提供的一个实施例中，所述耐磨层的加热收缩率(100℃、30min)≤5％；在本发明提供的另一个实施例中，所述耐磨层的加热收缩率(100℃、30min)≤2％。在本发明提供的 一个实施例中，所述耐磨层的厚度为0.2～0.3mm。
在本发明提供的一个实施例中，所述PVC复合板材还包括彩膜层，所述彩膜层设置在所述半硬质PVC层与耐磨层之间，用于使PVC复合板材具有特定的花纹纹理和颜色。
在本发明提供的一个实施例中，所述PVC复合板材还包括涂料层，所述涂料层设置在所述耐磨层表面。在本发明中，所述涂料层由紫外光固化涂料固化而成。
在本发明，可以按照下述方法制备所述PVC复合板材：
上述PVC发泡材料与上述半硬质PVC层通过胶水粘合，然后压制，得到PVC复合板材。
在本发明中，首先将所述PVC发泡材料与所述半硬质PVC层通过胶水粘合。其中，所述半硬质PVC层可以采用市售的半硬质PVC板材，也可以按照下述方法制备：
原料依次经过熔融塑化、定型，得到所述半硬质PVC层；所述原料包括PVC、填料和增塑剂。
在本发明提供的一个半硬质PVC层制备方法中，首先将原料熔融塑化，所述原料包括PVC、填料和增塑剂。在本发明中，所述原料优选还包括稳定剂。所述熔融塑化的温度优选为180～190℃。
在本发明中，所述原料在进行熔融塑化之前，优选先进行混合。所述混合优选在高速混合机中进行。在本发明提供的一个原料包括PVC、填料和增塑剂的实施例中，所述原料在高速混合机中混合的具体过程为：先将PVC和增塑剂混合，所述PVC和增塑剂混合的温度优选为90～100℃，所述PVC和增塑剂混合的时间优选为5～10min；然后再将PVC和增塑剂混合得到的混合料与所述填料混合，所述混合料与填料混合的温度优选为常温；所述混合料与填料混合的时间优选为8～10min。在本发明提供的一个原料包括PVC、填料、增塑剂和稳定剂的实施例中，所述原料在高速混合机中混合的具体过程为：先将PVC、增塑剂和稳定剂混合，所述PVC、增塑剂和稳定剂混合的温度优选为90～100℃，所述PVC、增塑剂和稳定剂混合的时间优选为5～10min；然后再将PVC、增塑剂和稳定剂混合得到的混合料与所述填料混合，所述混合料与填料混合的温度优选为常温；所述混合料与填料混合的时间优选为8～10min。
熔融塑化完毕后，塑化后的原料进行定型，得到所述半硬质PVC层。在 本发明中，所述原料熔融塑化和定型的具体过程为：
所述原料先在密炼机中密炼塑化，然后再开炼机中开炼塑化，最后在压延机中塑化并压延至设计厚度后冷却定型。其中，所述密炼塑化的温度优选为180～190℃；所述密炼塑化的时间优选为8～10min。所述开炼塑化的温度优选为180～190℃。本发明对所述开炼塑化的时间没有特别限定，原料开炼塑化至无明显粉料后即可进入后续流程。所述压延机辊距优选为2～3mm；所述压延机辊速优选为10～20m/min；所述压延机的压延辊温度优选为180～190℃。
在本发明，所述PVC发泡材料与所述半硬质PVC层粘合之前，优选在所述半硬质PVC层表面设置耐磨层。该过程为：
将耐磨层材料覆盖在上述制得的半硬质PVC层表面，然后压制，得到设置有耐磨层的半硬质PVC层。
其中，所述耐磨层材料的光泽度优选为5～30Gs，更优选为10～20Gs，最优选为15±5Gs；所述耐磨层材料的透光率优选为60～100％更优选为80±20％；所述耐磨层材料的断裂伸长率优选≥30％，更优选≥50％；所述耐磨层材料的加热收缩率优选(100℃、30min)≤5％，更优选≤2％。所述压制的方式优选为先进行热压，再进行冷压。所述热压的温度优选为120～140℃；所述热压的时间优选为20～30min；所述热压的压力优选为5～10mPa。所述冷压的压力优选为15～20mPa；所述冷压的时间优选为20～25min。
在本发明中，优选在半硬质PVC层和耐磨层之间设置彩膜层，该过程为：先将彩膜层覆盖在上述制得的半硬质PVC层表面，然后将耐磨层材料覆盖在所述彩膜层表面，之后进行压制。
在本发明中，优选在半硬质PVC层表面设置耐磨层之后在所述耐磨层表面设置涂料层，该过程为：将紫外光固化涂料涂覆在所述耐磨层表面，涂料固化后，所述涂料在耐磨层表面形成涂料层。
PVC发泡材料与半硬质PVC层粘合后，进行压制。所述压制的压力优选为5～10mPa；所述压制的时间优选为12～24h。压制结束后，得到本发明提供的PVC复合板材。
本发明提供的PVC复合板材采用收缩性能良好、残余凹陷度低的PVC发泡材料作为基材，表层采用半硬质PVC材料。相比于单一的半硬质PVC板材，本发明提供的复合板材的开槽和扣型强度大，密度小，具有良好的应用前景。
为更清楚起见，下面通过以下实施例进行详细说明。
实施例1
具有涂料层和耐磨层的半硬质PVC板
将100kg PVC SG-8、40kg DOTP和2kg钙锌复合稳定剂(硬脂酸钙38wt％、硬脂酸锌32wt％和余量的钙锌复合稳定剂常规助剂)在高速混合机中混合，在90～100℃下混合5min。混合得到的混合料和400kg石粉(160目，白度80)在冷混机中混合8～10min，得到混料。
将上述混料加入密炼机，密炼塑化8～10min后，将密炼后的物料喂至开炼机继续塑化，开炼温度控制在180～190℃。待包裹在开炼机上的物料塑化均匀，无明显粉料后，送至压延机。调整压延机辊距2mm、辊速20m/min，压延辊温度控制在180～190℃。物料在压延机进一步塑化，并压延至1.65mm厚度。压延后的物料经过冷却定性、切割后，得到1280mm×990mm×1.65mm的底片。
将上述制得的底片、厚度0.05mm的彩膜和厚度0.3mm的耐磨层堆叠好，所述耐磨层的光泽度为15±5Gs、透光率为80±20％、伸长率≥50％、加热收缩率(100℃、30Min)≤2.0％。底片、彩膜和耐磨层堆叠好后，进行热压，热压的温度为120～140℃，时间为20min，压力5mPa。热压结束后，进行冷压，冷压的压力为15mPa，冷压的时间为20～25min。
将冷压得到的板材淋涂紫外光固化涂料(湖南恒兴，HX5A01)，涂料固化后，得到半硬质PVC板。
本实施例制得的半硬质PVC板的尺寸为：1228×950×2mm，密度为1.7g/cm3。对该半硬质PVC板进行性能测试，其性能符合标准GB/T4085-2005半硬质聚氯乙烯块状地板的要求。
实施例2
PVC发泡板材
将750g PVC SG-8、750g轻质碳酸钙(1250目，沉降体积2.4～2.8mL/g)、28g钙锌复合稳定剂(硬脂酸钙38wt％、硬脂酸锌32wt％和余量的钙锌复合稳定剂常规助剂)、7.5g内润滑剂(德国科宁、G-60)、60g发泡调节剂(山东瑞丰、LP-90)、40g ACR(山东瑞丰、LS-21)、2.5g PE蜡(泰国SQI、H-110)、4.5gAC发泡剂(杰上杰化工、NH600)、30g氯化聚乙烯(山东瑞丰、CPE-135A)和6g碳酸氢钠在高速混合机中混合15min，得到混合料。
上述混合料在170℃条件在挤出机中熔融塑化10min，并通过模头挤出至真 空定型装置中。挤出料在真空定型装置中定型后进行切割，得到低发泡PVC板。
本实施例制得的低发泡PVC板的尺寸为：1230mm×50mm×3mm。对该PVC发泡材料进行加热收缩性能、残余凹陷度、吸水率和密度测试，其中，加热收率参照GB/T 4085-2005、加热翘曲参照GB/T 4085-2005、残余凹陷度参照GB/T 4085-2005中6.7的规定、吸水率参照GBT 17657-1999，测试结果为：加热收缩率(80℃、6h)≤1.5％，加热翘曲(80℃、6h)≤2mm，残余凹陷度≤2％、吸水率≤1％、密度为0.8±0.1g/cm3。由上述测试数据可知，本实施例制得PVC发泡材料具有较低的加热收缩率和加热翘曲，说明该PVC发泡材料具有良好的收缩性能；同时，本实施例制得PVC发泡材料的残余凹陷度≤2％，残余凹陷度较低。
对本实施例制得的PVC发泡板材进行耐冷热性能测试：
(1)测试原理
确定试件抵抗温度反复变化的能力。
(2)仪器和工具
空气对流干燥箱，恒温灵敏度±1℃，温度范围40℃-200℃；
低温箱，恒温灵敏度±1℃，温度可达-40℃；
游标卡尺，精度0.02mm；
(3)试验步骤
a)、用脱脂纱布蘸少许乙醇将3块本实施例提供的低发泡PVC板表面擦净晾干。在每块低发泡PVC板上画出平行于长度方向的中心线，并测量中心线长度L1，精确至0.02mm。
b)、分别对3块低发泡PVC板进行高低温周期试验，每个高低温周期的温度和时间设置如下所示:
温度：(23±2)℃→(-40±2)℃→(23±2)℃→(80±2)℃
时间：1h 6h 1h 16h
然后，在(23±2)℃温度下放置6h以上，于自然光线下目测试件外观，并测量中心线长度L2，精确至0.02mm。
(4)结果和表示
记录低发泡PVC板表面是否有龟裂、鼓泡等情况。
计算低发泡PVC板的尺寸变化率，精确至0.01％。
L＝(l2一l1)/100l1
式中:
L——试件的尺寸变化率；
l2——试件在试验后的尺寸，单位为毫米(mm)；
l1——试件在试验前的尺寸，单位为毫米(mm)。
分别计算出3块低发泡PVC板的尺寸变化率后，取平均值，即为本实施例提供的低发泡PVC板的尺寸变化率，精确至0.02mm。
本实施例提供的PVC发泡板材的耐冷热性能测试结果如表1所示：
表1 实施例2制得的PVC发泡板耐冷热性能测试结果
表面外观 无龟裂、无鼓泡、无脱胶
尺寸变化％ ≤0.28％
通过表1可以看出，本实施例提供的PVC发泡材料具有优良的耐冷热性能。
实施例3
PVC发泡板材
将800g PVC SG-8、750g轻质碳酸钙(1000目，沉降体积2.4～2.8mL/g)、35g钙锌复合稳定剂(硬脂酸钙38wt％、硬脂酸锌32wt％和余量的钙锌复合稳定剂常规助剂)、8g内润滑剂(德国科宁、G-60)、60g发泡调节剂(山东瑞丰、LP-90)、40g ACR(山东瑞丰、LS-21)、2.5g PE蜡(泰国SQI、H-110)、4gAC发泡剂(杰上杰化工、NH600)、35g氯化聚乙烯(山东瑞丰、CPE-135A)和8g碳酸氢钠在高速混合机中混合15min，得到混合料。
上述混合料在170℃条件在挤出机中熔融塑化10min，并通过模头挤出至真空定型装置中。挤出料在真空定型装置中定型后进行切割，得到低发泡PVC板。
本实施例得到的低发泡PVC板的尺寸为：1230mm×50mm×3mm。对该PVC发泡材料进行加热收缩性能、残余凹陷度、吸水率和密度测试，其中，加热收率参照GB/T 4085-2005、加热翘曲参照GB/T 4085-2005、残余凹陷度参照GB/T 4085-2005中6.7的规定、吸水率参照GBT 17657-1999，测试结果为：加热收缩(80℃、6h)≤1.8％，加热翘曲(80℃、6h)≤2mm，残余凹陷≤2.5％、吸水率≤1％、密度为0.8±0.1g/cm3。
由上述测试数据可知，本实施例制得PVC发泡材料具有较低的加热收缩率和加热翘曲，说明该PVC发泡材料具有良好的收缩性能；同时，本实施例制得PVC发泡材料的残余凹陷度≤2.5％，残余凹陷度较低。
参照实施例2的方法对本实施例制得的PVC发泡板材进行耐冷热性能测 试。测试结果如表2所示：
表2 实施例3制得的PVC发泡板耐冷热性能测试结果
表面外观 无龟裂、无鼓泡、无脱胶
尺寸变化％ ≤0.3％
通过表2可以看出，本实施例提供的PVC发泡材料具有优良的耐冷热性能。
实施例4
PVC发泡板材
将750g PVC SG-8、800g轻质碳酸钙(1500目，沉降体积2.4～2.8mL/g)、28g钙锌复合稳定剂(硬脂酸钙38wt％、硬脂酸锌32wt％和余量的钙锌复合稳定剂常规助剂)、7.5g内润滑剂(德国科宁、G-60)、70g发泡调节剂(山东瑞丰、LP-90)、45g ACR(山东瑞丰、LS-21)、3g PE蜡(泰国SQI、H-110)、4.5gAC发泡剂(杰上杰化工、NH600)、30g氯化聚乙烯(山东瑞丰、CPE-135A)和6g碳酸氢钠在高速混合机中混合15min，得到混合料。
上述混合料在170℃条件在挤出机中熔融塑化10min，并通过模头挤出至真空定型装置中。挤出料在真空定型装置中定型后进行切割，得到低发泡PVC板。
本实施例得到的低发泡PVC板的尺寸为：1230mm×50mm×3mm。对该PVC发泡材料进行加热收缩性能、残余凹陷度、吸水率和密度测试，其中，加热收率参照GB/T 4085-2005、加热翘曲参照GB/T 4085-2005、残余凹陷度参照GB/T 4085-2005中6.7的规定、吸水率参照GBT 17657-1999，测试结果为：加热收缩(80℃、6h)≤1.7％，加热翘曲(80℃、6h)≤2mm，残余凹陷≤2.8％、吸水率≤1％、密度0.8±0.1g/cm3。
由上述测试数据可知，本实施例制得PVC发泡材料具有较低的加热收缩率和加热翘曲，说明该PVC发泡材料具有良好的收缩性能；同时，本实施例制得PVC发泡材料的残余凹陷度≤2.8％，残余凹陷度较低。
参照实施例2的方法对本实施例制得的PVC发泡板材进行耐冷热性能测试，测试结果如表3所示：
表3 实施例4制得的PVC发泡板耐冷热性能测试结果
表面外观 无龟裂、无鼓泡、无脱胶
尺寸变化％ ≤0.29％
通过表3可以看出，本实施例提供的PVC发泡材料具有优良的耐冷热性能。
实施例5
PVC复合板材
使用贴合机将以75g/m2的用量将热固性胶水(深圳德固、CY1003:CY6008＝1:1(g/g)混合胶水)均匀的涂在实施例2制备的低发泡PVC材料表面，将实施例1制得半硬质PVC板与涂有胶水的低发泡PVC材料压贴在一起，得到半硬质PVC/低发泡PVC板。
将贴合好的半硬质PVC/低发泡PVC板进行冷压，压力为5.0mPa，时间为12h。冷压结束后，板材冲切、开槽，得到PVC复合板材。
对本实施例制得的PVC复合板材进行性能测试，结果如表4所示：
表4 实施例5制得的PVC复合板材性能测试结果
Figure PCTCN2015081030-appb-000003
通过表4可以看出，本实施例制得的PVC复合板材的热翘曲和加热收缩率较低，说明该板材具有良好的收缩性能，同时该PVC复合板材具有较低的残余凹陷度和吸水率，密度适中，耐磨性能良好。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (10)

  1. 一种PVC发泡材料，由物料熔融塑化制成，以重量份数计，所述物料包括：
    Figure PCTCN2015081030-appb-100001
  2. 根据权利要求1所述的发泡材料，其特征在于，所述轻质碳酸钙的粒径为1000～1500目。
  3. 根据权利要求1所述的发泡材料，其特征在于，所述AC发泡剂的发气量为150～200mL/g。
  4. 根据权利要求1所述的发泡材料，其特征在于，所述AC发泡剂的分解温度为170～180℃。
  5. 根据权利要求1所述的发泡材料，其特征在于，所述发泡调节剂的型号为K-400P、K-385、K-418、PA-40、PA-60、LP-21、LP-23、LP-40、LP-90和LP-530中的一种或多种。
  6. 根据权利要求1所述的发泡材料，其特征在于，所述PVC的黏数为73～106mL/g。
  7. 根据权利要求1所述的发泡材料，其特征在于，所述物料还包括稳定剂、润滑剂和抗冲改性剂中的一种或多种。
  8. 一种PVC发泡材料的制备方法，包括以下步骤：
    物料熔融塑化，得到PVC发泡材料；
    所述物料包括600～900重量份的PVC、600～900重量份的轻质碳酸钙、3～10重量份的碳酸氢钠、3～5重量份的AC发泡剂和40～80重量份的发泡调节剂。
  9. 一种PVC复合板材，包括基底和设置在基底表面的半硬质PVC层；
    所述基底的材料为权利要求1～7任一项所述的PVC发泡材料或权利要求8所述方法制得的PVC发泡材料；
    所述半硬质PVC层包括PVC、填料和增塑剂。
  10. 根据权利要求9所述的复合板材，其特征在于，所述半硬质PVC层中PVC、填料和增塑剂的质量比为5～20：20～60：1～6。
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