CN107266899A - 一种木塑复合地板及其制备方法 - Google Patents
一种木塑复合地板及其制备方法 Download PDFInfo
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- CN107266899A CN107266899A CN201710520186.7A CN201710520186A CN107266899A CN 107266899 A CN107266899 A CN 107266899A CN 201710520186 A CN201710520186 A CN 201710520186A CN 107266899 A CN107266899 A CN 107266899A
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- parts
- wood
- plastic composite
- composite floor
- layer
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Abstract
本发明公开了一种木塑复合地板及其制备方法，属于建筑材料领域。本发明先将硅藻土与偶联剂混合球磨，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂开炼后，静置停放，得中间层，再将PVC树脂、改性聚丙烯、改性炭化稻壳料、硬脂酸锌、抗氧剂、硅烷偶联剂KH‑560和增塑剂混合均匀后，压延成片，得基体层，最后以基体层为底层，在基体层上铺设一层中间层后，再于中间层上铺设一层面层，再经热压成型和切割，即得木塑复合地板。本发明的有益效果是：本发明木塑复合地板具有较高的弯曲强度和弹性模量，说明木塑复合地板具有较好的弯曲性能，在使用过程中不易产生裂纹。
Description
技术领域
本发明涉及一种木塑复合地板及其制备方法，属于建筑材料领域。
背景技术
木塑地板是一种新型环保型木塑复合材料产品，主要材料为聚乙烯和木粉或者竹粉，经过加入助剂，高速混合后，进行造粒，再使用挤出机将粒料挤出成型材，即木塑地板。它能够克服木质地板易吸水膨胀、开裂变形以及复合木地板含有甲醛污染环境等问题。然而，通过挤出成型法制成的木塑地板会因基体层较硬、泡孔的分布与孔径大小难以控制，导致木塑地板在高温下易出现收缩翘曲的问题。此外，硬质的基体层热贴合效果差，因此在木塑地板的制造过程中，需使用胶黏剂将装饰层和耐磨层贴在基体层上，胶黏剂的引入会增大木塑地板的VOC（挥发性有机化合物）含量而引起环境污染的问题。中国专利申请号CN201310202629.X公开了一种木塑地板，该木塑地板包括基体层，所述基体层的材料包括聚氯乙烯（PVC）粉、增塑剂、植物粉及稳定剂，且所述基体层是由压延法制成；该木塑地板的基体层由PVC粉、增塑剂、植物粉及稳定剂经压延法制成，经压延制造的基体层为软质品，其可以避免现有技术中的木塑地板因采用挤出成型法制造而引起的在高温下容易收缩翘曲的问题，并且软质品的基体层具有良好的热贴合性，因此可以通过热压工艺，将装饰层及耐磨层贴合上去，从而可以避免因引入胶黏剂增大木塑地板的VOC含量而引起的污染环境的问题，但该木塑地板强度低，弯曲性能差、易产生裂纹。因此，如何实现一种弯曲性能好、不易产生裂纹的木塑地板是业内亟待解决的技术问题，不仅对木塑地板的发展具有重要的意义，也对拓宽木塑地板的应用范围具有重要的意义。
发明内容
本发明所要解决的技术问题：针对传统木塑地板弯曲性能差，易产生裂纹的弊端，提供了一种木塑复合地板及其制备方法。
为解决上述技术问题，本发明采用如下所述的技术方案是：
一种木塑复合地板，包括面层、中间层和基体层：
所述中间层是由以下重量份数的原料组成：10～30份共混橡胶，20～30份聚氨酯树脂，10～20份乙烯醋酸乙烯酯，8～10份聚甲基丙烯酸甲酯，20～30份硅藻土，8～10份偶联剂，3～5份硫磺，1～3份促进剂，1～3份防老剂，1～3份增塑剂；
所述基体层是由以下重量份数的原料组成：150～200份PVC树脂，20～30份改性聚丙烯，40～60份改性炭化稻壳料，4～6份硬脂酸锌，3～5份抗氧剂，1～3份硅烷偶联剂KH-560，1～3份增塑剂；
所述改性炭化稻壳料为稻壳粉碎后，依次经高温炭化和氧化处理得到；
所述木塑复合地板具体制备步骤为：
（1）中间层：将硅藻土与偶联剂混合球磨，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂开炼10～15min，静置停放8～12h，得中间层；
（2）基体层：将PVC树脂、改性聚丙烯、改性炭化稻壳料、硬脂酸锌、抗氧剂、硅烷偶联剂KH-560和增塑剂混合均匀后，压延成片，得基体层；
（3）木塑复合地板：以基体层为底层，在基体层上铺设一层中间层后，再于中间层上铺设一层面层，再经热压成型和切割，即得木塑复合地板。
所述的面层是由2～4层厚度为0.6mm的竹刨切单板涂胶后，热压得到。
所述的共混橡胶是由以下重量份数的橡胶共混得到：10～20份天然橡胶，20～30份丁基橡胶，10～30份三元乙丙橡胶。
所述的偶联剂为硅烷偶联剂，钛酸酯偶联剂或铝酸酯偶联剂中的任意一种。
所述的促进剂为促进剂TMTD，促进剂M或促进剂ZDMC中的任意一种。
所述的防老剂是由以下重量份数的原料复配而成：20～40份防老剂RD，10～20份防老剂288，2～4份微晶蜡。
所述的增塑剂为邻苯二甲酸二辛酯，己二酸二辛酯或环氧硬脂酸辛酯中的任意一种。
所述改性聚丙烯为马来酸酐接枝改性聚丙烯，甲基丙烯酸接枝改性聚丙烯或衣康酸接枝改性聚丙烯中的任意一种。
所述的抗氧剂为抗氧剂1010和抗氧剂168按质量比为2:1～4:1混合而成。
步骤（3）所述的热压成型条件为：热压温度为185～200℃，热压压力为30～50MPa。
本发明与其他方法相比，有益技术效果是：
（1）本发明技术方案采用面层、中间层和基体层三层结构复合热压制得产品，面层采用竹刨切单板为主要材料，起到装饰美化作用的同时，竹纤维可有效提高产品的弯曲性能，避免产品表面在使用过程中开裂，另外采用共混橡胶、聚氨酯树脂和聚甲基丙烯酸甲酯为主要原料，以硅烷偶联剂改性的硅藻土为填料，起到增粘作用，使面层和基体层牢固结合，其中共混橡胶在常温下处于弹性态，聚甲基丙烯酸甲酯和聚氨酯树脂处于玻璃态，三者的结合可有效提高产品韧性和弯曲性能，而且聚氨酯树脂的加入，可增加橡胶分子的极性，提高体系内聚强度和表面能，从而提高最终热压过程中，中间层与面层和基体层的黏合强度，延长产品的使用寿命；
（2）本发明技术方案以氧化改性后的炭化稻壳料为木塑复合地板产品中木粉来源，稻壳自身含有一层角质化的二氧化硅层，在产品加工过程中，可起到润滑作用，另外，炭化和氧化处理后，稻壳表面的活性基团数量增多，有利于与基体层中改性聚丙烯发生化学交联，从而提高稻壳料与塑料基体的结合强度，两者结合强度的提高可有效提高产品的弯曲性能，避免在使用过程中发生开裂现象。
具体实施方式
取稻壳，置于烘箱中，于温度为105～110℃条件下干燥至恒重，得干燥稻壳，再经粉碎后过100～200目筛，得稻壳粉，并将所得稻壳粉转入炭化炉，以80～120mL/min速率向炉内通入氩气，在氩气保护状态下，于温度为1100～1200℃条件下保温炭化2～4h，随炉冷却至室温，出料，得炭化稻壳，再按重量份数计，将60～80份碳化稻壳，80～100份质量分数为20%双氧水，60～80份质量分数为20%硝酸溶液，于温度为40～50℃，转速为200～400r/min条件下，恒温搅拌反应2～4h后，过滤，得滤渣，并用去离子水洗涤所得滤渣直至洗涤液呈中性，再将洗涤后的滤渣于温度为85～90℃条件下，干燥6～8h，得改性炭化稻壳料；取2～4层厚度为0.6mm的竹刨切单板，涂抹白乳胶后，置于热压机中，于温度为120～140℃，压力为20～40MPa条件下，热压5～10min，得面层；再按重量份数计，依次取10～30份共混橡胶，20～30份聚氨酯树脂，10～20份乙烯醋酸乙烯酯，8～10份聚甲基丙烯酸甲酯，20～30份硅藻土，8～10份偶联剂，3～5份硫磺，1～3份促进剂，1～3份防老剂，1～3份增塑剂，先将硅藻土与偶联剂加入球磨罐中，球磨混合1～3h，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂转入开炼机中，开炼10～15min后，静置停放8～12h，得中间层；随后按重量份数计，在混料机中依次加入150～200份PVC树脂，20～30份改性聚丙烯，40～60份改性炭化稻壳料，4～6份硬脂酸锌，3～5份抗氧剂，1～3份硅烷偶联剂KH-560，1～3份增塑剂，于温度为55～65℃，转速为400～600r/min条件下，恒温搅拌混合3～5h，出料，得混合料，再将所得混合料转入压延机，于压延机轧辊线速度为3.5～5.0m/min，辊面温度为80～85℃条件下，压延成厚度为8～12mm的板材，得基体层；再以基体层为底层，在基体层表面覆盖一层中间层后，再于中间层上铺设一层面层，待铺设结束，得三层复合结构，随后将三层复合结构移入热压机，于热压温度为185～200℃，热压压力为30～50MPa条件下，热压处理20～30s，再经切割，即得木塑复合地板。所述的共混橡胶是由以下重量份数的橡胶共混得到：10～20份天然橡胶，20～30份丁基橡胶，10～30份三元乙丙橡胶。所述的偶联剂为硅烷偶联剂，钛酸酯偶联剂或铝酸酯偶联剂中的任意一种。所述的促进剂为促进剂TMTD，促进剂M或促进剂ZDMC中的任意一种。所述的防老剂是由以下重量份数的原料复配而成：20～40份防老剂RD，10～20份防老剂288，2～4份微晶蜡。所述的增塑剂为邻苯二甲酸二辛酯，己二酸二辛酯或环氧硬脂酸辛酯中的任意一种。所述改性聚丙烯为马来酸酐接枝改性聚丙烯，甲基丙烯酸接枝改性聚丙烯或衣康酸接枝改性聚丙烯中的任意一种。所述的抗氧剂为抗氧剂1010和抗氧剂168按质量比为2:1～4:1混合而成。
实例1
取稻壳，置于烘箱中，于温度为105℃条件下干燥至恒重，得干燥稻壳，再经粉碎后过100目筛，得稻壳粉，并将所得稻壳粉转入炭化炉，以80mL/min速率向炉内通入氩气，在氩气保护状态下，于温度为1100℃条件下保温炭化2h，随炉冷却至室温，出料，得炭化稻壳，再按重量份数计，将60份碳化稻壳，80份质量分数为20%双氧水，60份质量分数为20%硝酸溶液，于温度为40℃，转速为200r/min条件下，恒温搅拌反应2h后，过滤，得滤渣，并用去离子水洗涤所得滤渣直至洗涤液呈中性，再将洗涤后的滤渣于温度为85℃条件下，干燥6h，得改性炭化稻壳料；取2层厚度为0.6mm的竹刨切单板，涂抹白乳胶后，置于热压机中，于温度为120℃，压力为20MPa条件下，热压5min，得面层；再按重量份数计，依次取10份共混橡胶，20份聚氨酯树脂，10份乙烯醋酸乙烯酯，8份聚甲基丙烯酸甲酯，20份硅藻土，8份偶联剂，3份硫磺，1份促进剂，1份防老剂，1份增塑剂，先将硅藻土与偶联剂加入球磨罐中，球磨混合1h，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂转入开炼机中，开炼10min后，静置停放8h，得中间层；随后按重量份数计，在混料机中依次加入150份PVC树脂，20份改性聚丙烯，40份改性炭化稻壳料，4份硬脂酸锌，3份抗氧剂，1份硅烷偶联剂KH-560，1份增塑剂，于温度为55℃，转速为400r/min条件下，恒温搅拌混合3h，出料，得混合料，再将所得混合料转入压延机，于压延机轧辊线速度为3.5m/min，辊面温度为80℃条件下，压延成厚度为8mm的板材，得基体层；再以基体层为底层，在基体层表面覆盖一层中间层后，再于中间层上铺设一层面层，待铺设结束，得三层复合结构，随后将三层复合结构移入热压机，于热压温度为185℃，热压压力为30MPa条件下，热压处理20s，再经切割，即得木塑复合地板。所述的共混橡胶是由以下重量份数的橡胶共混得到：10份天然橡胶，20份丁基橡胶，10份三元乙丙橡胶。所述的偶联剂为硅烷偶联剂。所述的促进剂为促进剂TMTD。所述的防老剂是由以下重量份数的原料复配而成：20份防老剂RD，10份防老剂288，2份微晶蜡。所述的增塑剂为邻苯二甲酸二辛酯。所述改性聚丙烯为马来酸酐接枝改性聚丙烯。所述的抗氧剂为抗氧剂1010和抗氧剂168按质量比为2:1混合而成。
实例2
取稻壳，置于烘箱中，于温度为108℃条件下干燥至恒重，得干燥稻壳，再经粉碎后过150目筛，得稻壳粉，并将所得稻壳粉转入炭化炉，以100mL/min速率向炉内通入氩气，在氩气保护状态下，于温度为1150℃条件下保温炭化3h，随炉冷却至室温，出料，得炭化稻壳，再按重量份数计，将70份碳化稻壳，90份质量分数为20%双氧水，70份质量分数为20%硝酸溶液，于温度为45℃，转速为300r/min条件下，恒温搅拌反应3h后，过滤，得滤渣，并用去离子水洗涤所得滤渣直至洗涤液呈中性，再将洗涤后的滤渣于温度为88℃条件下，干燥7h，得改性炭化稻壳料；取3层厚度为0.6mm的竹刨切单板，涂抹白乳胶后，置于热压机中，于温度为130℃，压力为30MPa条件下，热压8min，得面层；再按重量份数计，依次取20份共混橡胶，25份聚氨酯树脂，15份乙烯醋酸乙烯酯，9份聚甲基丙烯酸甲酯，25份硅藻土，9份偶联剂，4份硫磺，2份促进剂，2份防老剂，2份增塑剂，先将硅藻土与偶联剂加入球磨罐中，球磨混合2h，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂转入开炼机中，开炼13min后，静置停放10h，得中间层；随后按重量份数计，在混料机中依次加入170份PVC树脂，25份改性聚丙烯，50份改性炭化稻壳料，5份硬脂酸锌，4份抗氧剂，2份硅烷偶联剂KH-560，2份增塑剂，于温度为60℃，转速为500r/min条件下，恒温搅拌混合4h，出料，得混合料，再将所得混合料转入压延机，于压延机轧辊线速度为4.2m/min，辊面温度为83℃条件下，压延成厚度为10mm的板材，得基体层；再以基体层为底层，在基体层表面覆盖一层中间层后，再于中间层上铺设一层面层，待铺设结束，得三层复合结构，随后将三层复合结构移入热压机，于热压温度为192℃，热压压力为40MPa条件下，热压处理25s，再经切割，即得木塑复合地板。所述的共混橡胶是由以下重量份数的橡胶共混得到：15份天然橡胶，25份丁基橡胶，20份三元乙丙橡胶。所述的偶联剂为钛酸酯偶联剂。所述的促进剂为促进剂M。所述的防老剂是由以下重量份数的原料复配而成：30份防老剂RD，15份防老剂288，3份微晶蜡。所述的增塑剂为己二酸二辛酯。所述改性聚丙烯为甲基丙烯酸接枝改性聚丙烯。所述的抗氧剂为抗氧剂1010和抗氧剂168按质量比为3:1混合而成。
实例3
取稻壳，置于烘箱中，于温度为110℃条件下干燥至恒重，得干燥稻壳，再经粉碎后过200目筛，得稻壳粉，并将所得稻壳粉转入炭化炉，以120mL/min速率向炉内通入氩气，在氩气保护状态下，于温度为1200℃条件下保温炭化4h，随炉冷却至室温，出料，得炭化稻壳，再按重量份数计，将80份碳化稻壳，100份质量分数为20%双氧水，80份质量分数为20%硝酸溶液，于温度为50℃，转速为400r/min条件下，恒温搅拌反应4h后，过滤，得滤渣，并用去离子水洗涤所得滤渣直至洗涤液呈中性，再将洗涤后的滤渣于温度为90℃条件下，干燥8h，得改性炭化稻壳料；取4层厚度为0.6mm的竹刨切单板，涂抹白乳胶后，置于热压机中，于温度为140℃，压力为40MPa条件下，热压10min，得面层；再按重量份数计，依次取30份共混橡胶，30份聚氨酯树脂，20份乙烯醋酸乙烯酯，10份聚甲基丙烯酸甲酯，30份硅藻土，10份偶联剂，5份硫磺，3份促进剂，3份防老剂，3份增塑剂，先将硅藻土与偶联剂加入球磨罐中，球磨混合3h，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂转入开炼机中，开炼15min后，静置停放12h，得中间层；随后按重量份数计，在混料机中依次加入200份PVC树脂，30份改性聚丙烯，60份改性炭化稻壳料，6份硬脂酸锌，5份抗氧剂，3份硅烷偶联剂KH-560，3份增塑剂，于温度为65℃，转速为600r/min条件下，恒温搅拌混合5h，出料，得混合料，再将所得混合料转入压延机，于压延机轧辊线速度为5.0m/min，辊面温度为85℃条件下，压延成厚度为12mm的板材，得基体层；再以基体层为底层，在基体层表面覆盖一层中间层后，再于中间层上铺设一层面层，待铺设结束，得三层复合结构，随后将三层复合结构移入热压机，于热压温度为200℃，热压压力为50MPa条件下，热压处理30s，再经切割，即得木塑复合地板。所述的共混橡胶是由以下重量份数的橡胶共混得到：20份天然橡胶，30份丁基橡胶，30份三元乙丙橡胶。所述的偶联剂为铝酸酯偶联剂。所述的促进剂为促进剂ZDMC。所述的防老剂是由以下重量份数的原料复配而成：40份防老剂RD，20份防老剂288，4份微晶蜡。所述的增塑剂为环氧硬脂酸辛酯。所述改性聚丙烯为衣康酸接枝改性聚丙烯。所述的抗氧剂为抗氧剂1010和抗氧剂168按质量比为4:1混合而成。
对照例：江苏某公司生产的木塑复合地板。
将上述实施例所得木塑复合地板与对照例的木塑复合地板进行检测，具体检测如下：
1、弹性模量：按照GB/T 11718《中密度纤维板》，采用三点加载法进行测定；
2、弯曲强度：按ASTM D790-2007，采用RGT-20A微机控制电子万能试验机进行测定；
3、表面胶合强度：按照GB/T 15104《装饰单板贴面人造板》，采用力学实验机进行测定。
结果如表一所示。
表一：
由上表可知，本发明木塑复合地板具有较高的弯曲强度和弹性模量，说明木塑复合地板具有较好的弯曲性能，同时具有较高的表面胶合强度，值得推广与使用。
Claims (10)
1.一种木塑复合地板，包括面层、中间层和基体层，其特征在于：
所述中间层是由以下重量份数的原料组成：10～30份共混橡胶，20～30份聚氨酯树脂，10～20份乙烯醋酸乙烯酯，8～10份聚甲基丙烯酸甲酯，20～30份硅藻土，8～10份偶联剂，3～5份硫磺，1～3份促进剂，1～3份防老剂，1～3份增塑剂；
所述基体层是由以下重量份数的原料组成：150～200份PVC树脂，20～30份改性聚丙烯，40～60份改性炭化稻壳料，4～6份硬脂酸锌，3～5份抗氧剂，1～3份硅烷偶联剂KH-560，1～3份增塑剂；
所述改性炭化稻壳料为稻壳粉碎后，依次经高温炭化和氧化处理得到；
所述木塑复合地板具体制备步骤为：
（1）中间层：将硅藻土与偶联剂混合球磨，得球磨料，再将球磨料、共混橡胶、聚氨酯树脂、乙烯醋酸乙烯酯、聚甲基丙烯酸甲酯、硫磺、促进剂、防老剂和增塑剂开炼10～15min，静置停放8～12h，得中间层；
（2）基体层：将PVC树脂、改性聚丙烯、改性炭化稻壳料、硬脂酸锌、抗氧剂、硅烷偶联剂KH-560和增塑剂混合均匀后，压延成片，得基体层；
（3）木塑复合地板：以基体层为底层，在基体层上铺设一层中间层后，再于中间层上铺设一层面层，再经热压成型和切割，即得木塑复合地板。
2.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的面层是由2～4层厚度为0.6mm的竹刨切单板涂胶后，热压得到。
3.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的共混橡胶是由以下重量份数的橡胶共混得到：10～20份天然橡胶，20～30份丁基橡胶，10～30份三元乙丙橡胶。
4.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的偶联剂为硅烷偶联剂，钛酸酯偶联剂或铝酸酯偶联剂中的任意一种。
5.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的促进剂为促进剂TMTD，促进剂M或促进剂ZDMC中的任意一种。
6.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的防老剂是由以下重量份数的原料复配而成：20～40份防老剂RD，10～20份防老剂288，2～4份微晶蜡。
7.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的增塑剂为邻苯二甲酸二辛酯，己二酸二辛酯或环氧硬脂酸辛酯中的任意一种。
8.根据权利要求1所述的一种木塑复合地板，其特征在于：所述改性聚丙烯为马来酸酐接枝改性聚丙烯，甲基丙烯酸接枝改性聚丙烯或衣康酸接枝改性聚丙烯中的任意一种。
9.根据权利要求1所述的一种木塑复合地板，其特征在于：所述的抗氧剂为抗氧剂1010和抗氧剂168按质量比为2:1～4:1混合而成。
10.根据权利要求1所述的一种木塑复合地板，其特征在于：步骤（3）所述的热压成型条件为：热压温度为185～200℃，热压压力为30～50MPa。
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| JP2025047645A (ja) * | 2023-09-21 | 2025-04-03 | イー・トップ株式会社 | 吸水率の低い天然素材配合熱可塑性樹脂複合体 |
| JP7770655B2 (ja) | 2023-09-21 | 2025-11-17 | イー・トップ株式会社 | 吸水率の低い天然素材配合熱可塑性樹脂複合体 |
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