CN107474301B

CN107474301B - Open-cell porous polymer material and preparation method thereof

Info

Publication number: CN107474301B
Application number: CN201710673273.6A
Authority: CN
Inventors: 张飞; 朱志强; 杨汇东; 韩辉升
Original assignee: Nantong Xilikang Rubber And Plastic Material Co ltd
Current assignee: Nantong Xilikang Rubber And Plastic Material Co ltd
Priority date: 2017-08-09
Filing date: 2017-08-09
Publication date: 2020-09-25
Anticipated expiration: 2037-08-09
Also published as: CN107474301A

Abstract

The invention discloses an open-cell porous polymer material and a method for preparing the same. The open cell, porous polymeric material is a blend of a plasticizable polymeric matrix, a polymer partially compatible with the polymeric matrix, and a plasticizer. The plasticizer in the blend is partially or completely extracted by the poor solvent of the polymer matrix, so that a fine open pore structure is formed in the blend, and the polymer blend has the performances of filterability, air permeability, water permeability, sound absorption and the like. An example of an application of such a polymeric material is the preparation of an artificial leather with breathability.

Description

Open-cell porous polymer material and preparation method thereof

Technical Field

The invention belongs to the field of preparation of high polymer materials, and particularly relates to an open-cell porous polymer material and a preparation method thereof.

Background

The foaming process for polymer materials is various, but whatever the foaming process is adopted, the basic process is usually as follows: introducing gas into the liquid or molten plastic to generate micropores; growing the micropores to a certain volume; the microporous structure is fixed by physical or chemical means. Common foaming methods are mechanical, physical and chemical methods, depending on the manner of introducing the gas. Mechanical methods involve the introduction of large quantities of air or other gas into a liquid polymer material by vigorous agitation, followed by physical or chemical changes to cause the material to gel and solidify into a foam. The physical method is to press inert gas, low boiling point liquid into the polymer material, then release the pressure or raise the temperature, and produce foaming effect by inert gas expansion or low boiling point liquid gasification. The chemical method is to add a chemical foaming agent which is decomposed to release gas when being heated into a polymer material, or to prepare a foaming material by utilizing the byproduct gas generated by the chemical reaction of materials in the polymerization process.

The foamed material, the foamed material or the porous material is classified into an open-cell type foamed material, a closed-cell type foamed material and a mixed-cell type foamed material. In open-cell foams, the two phases of polymeric material and gas are continuous. In the closed cell foam, only the high molecular substance is continuous, and the gas is separated, and the gas is dispersed in the high molecular substance in the form of cells. In the mixed hole type foam, a part of the gas is continuous and a part of the gas is separated.

Open-celled foams have excellent absorption and penetration properties due to the capillary action of the pores. In addition, the open-cell foam material is lightweight, has high mechanical strength, and can be mass-produced into products of arbitrary shapes. The open-cell foam material has the characteristics of open cell structure, capability of forming complex channels and allowing fluid to pass through, and is widely applied as a functional material in the aspects of filtration, water passing, ventilation, sound absorption and the like.

Mechanical, physical, and chemical foaming methods can be used to prepare open-celled foamed polymeric materials. The mechanical foaming method and the physical foaming method are used for preparing the open-cell type foaming material, and a cell opening agent or certain special additives for promoting the breakage of closed cells are added in the processing engineering. For example, patent document "silicone rubber microporous material and method for producing the same" of application No. 201310598064.1 discloses a method of mixing and molding a liquid silicone rubber with a pore-forming agent, and then precipitating the pore-forming agent by washing with water to obtain an open-cell silicone rubber microporous material. The pore-forming agent used in the method is one or more of sodium chloride, sodium carbonate, sodium bicarbonate, potassium chloride, urea and potassium nitrate, and the water-soluble substances have strong polarity, are easy to agglomerate in the silicon rubber with weak polarity and have poor dispersibility, so that the silicon rubber microporous material with extremely fine pores is not easy to obtain. The patent document "open-celled rigid polyurethane foam produced from a rigid polyurethane foam-degrading liquid" of application No. 201410650782.3 discloses that liquid paraffin, polybutadiene, dimethylpolysiloxane and some specific surfactants are used as cell openers in producing the polyurethane foam. However, the addition of the cell-opening agent reduces the stability of the foam during foaming, resulting in uneven pore size distribution of the polyurethane foam produced and easy generation of large cells. Patent document No. 201310224859.6, "an open-cell polyurethane foam and a method for producing the same", discloses that an additive that thermally decomposes under a certain temperature condition to release a large amount of gas is uniformly mixed into a raw material of a polyurethane foam to prepare a closed-cell polyurethane foam, and then the closed-cell polyurethane foam is treated at a temperature of 50 to 300 ℃ for a certain period of time to expand a large amount of gas released by thermal decomposition of the additive to rupture cell walls to obtain an open-cell polyurethane foam.

It is difficult to produce a porous foam having fine cells by a mechanical method and a physical method, and it is more difficult to produce an open-cell porous foam having fine cells and uniform cells. Chemical foaming is a relatively simple process, and the cell structure formed inside the polymer tends to be uniform and the cells are relatively fine, but it is difficult to completely open-cell type foamed polymers by chemical foaming.

To this end, the skilled person prepares the open-cell porous polymer or increases the open-cell content of the foamed polymer by a combined process. For example, U.S. patent 6797738 "Open Pore Biodegradable materials" discloses a method of making an Open cell type Biodegradable material by first forming closed cells by gas foaming and then forming Open cells by leaching out leachable particles (LEACHED PARTICLES). Japanese laid-open patent publication No. 2000-318051 discloses a method for producing a polyethylene open-cell foam: the polyolefin containing blowing agent and crosslinking agent in a non-closed mould is heated to foam it and the cells are interconnected by mechanical deformation. U.S. patent application 20110098373 "Open Cell foam and manufacturing of Open Cell Products" discloses a method for producing an Open Cell foam and its Products: mixing the polymer with a foaming agent and a crosslinking agent, and keeping the obtained blend on a two-roll mill for a period of time to enable the blend to start crosslinking and start foaming to form closed pores; holding the resulting sheet at elevated temperature and pressure on a second two-roll mill having a roll gap greater than the thickness of the foam sheet to allow further crosslinking and foaming to occur; the closed cells in the crosslinked foam are then crushed to form open cells. Patent document 201210272051.0 entitled "method for opening foam sponge" discloses a method for producing an open-cell sponge by first vacuuming a foam sponge, then charging a blasting gas, and then igniting the foam sponge. Patent document No. 201310322749.3, "a method for producing a polymer foam material having an open-cell structure", discloses a method for producing a polymer foam material having an open-cell structure: the method comprises the steps of blending two or more polymers by adopting a melt blending method to obtain a polymer blend, then preparing a blank body in a certain shape by adopting vacuum mould pressing, placing the blank body in a high-pressure reaction kettle, introducing gas, heating and pressurizing to a temperature above the supercritical point of the gas to convert the gas into supercritical fluid, foaming the blend blank body of the polymers by adopting a rapid depressurization method after the supercritical fluid reaches a saturated state in the blank body, immersing the obtained polymer foaming material in proper etching liquid, enabling the etching liquid and the polymer foaming material to generate a physical or chemical reaction to enable at least one polymer in the polymer foaming material to be dissolved or degraded, forming a channel for connecting cells on the walls of the cells, and taking out the polymer foaming material after a certain time to obtain the polymer foam material with an open-cell structure. Similarly, patent document 201510392373.2 discloses a method for producing an open-cell polymer foam, which comprises extruding a mixture containing polypropylene, a nucleating agent, a vinyl-containing polyolefin and an open-cell agent by means of an extruder and foaming the mixture by means of supercritical carbon dioxide to obtain an open-cell polymer foam containing an open-cell filler, wherein the open-cell polymer foam contains a plurality of first open cells, and then immersing the open-cell filler-containing open-cell foam in an etching solution to etch the open-cell filler to form a plurality of second open cells, thereby obtaining an open-cell polymer foam having a high open-cell content and a high oil absorption rate.

Patent document No. 03126866.8, "a method for preparing breathable artificial leather", describes a method for preparing breathable artificial leather by needling flat artificial leather with a plurality of heated needles, and also provides a concept for preparing open-cell type materials.

In summary, it is a challenging technical problem to obtain an open-cell porous polymer material with fine and uniform cells in the prior art. The invention provides a new way for preparing the open-cell porous polymer, in particular for preparing the open-cell porous polymer with fine and uniform cells.

Disclosure of Invention

The purpose of the invention is as follows: in order to solve the defects of the prior art, the invention provides an open-cell porous polymer material and a preparation method thereof.

The technical scheme is as follows: an open-cell porous polymer material is prepared by extracting part or all of plasticizer from a polymer blend D consisting of a polymer matrix material A which can be plasticized by plasticizer, a polymer B which is partially compatible with the matrix polymer, a plasticizer C which can be extracted partially or completely, and other auxiliary agents and additives required in the formula by poor solvent so as to form voids or holes after drying; the open-cell type porous polymer material is in an open-cell structure or a mixed structure of open cells and closed cells. The average pore size of the open or closed pores in the open-cell porous polymer material is between 0.001 and 100 μm, and typically the average pore size of the open or closed pores is between 0.1 and 10 μm. The size of the average pore size will depend on such factors as the type of polymer used in the blend, the type of plasticizer used in the blend, the solvent used for the extraction, the extraction temperature and time.

As described above, an open cell porous polymeric material can be made from polymer blend D. The composite of the polymer blend D and the metal material or the nonmetal material can also be prepared into the composite of the open-cell porous polymer material and the metal material or the nonmetal material by poor solvent extraction. The metal material or the nonmetal material can be used as a bottom layer, a surface layer or an intermediate layer of the open-cell porous polymer material.

In the present invention, the polymer base material is a polymer which can be plasticized with a plasticizer, such as a vinyl chloride homopolymer or copolymer, chlorinated polyvinyl chloride, chlorinated polyethylene, polyvinylidene chloride, polyvinyl acetate, polyvinyl alcohol, an ABS resin, a cellulose resin or the like.

Extraction of a material consisting of a single polymer containing a plasticizer does not result in a cellular foam. After the plasticizer is extracted from the material, the material only shrinks and becomes smaller, and no holes are generated in the material. Therefore, we must select a suitable polymer partially compatible with the polymer matrix to be paired with the polymer matrix to form a blend which is not fully compatible with the polymer matrix and not fully incompatible with the polymer matrix material, or else, the polymer blends containing plasticizers produced therefrom will undergo volume shrinkage after the plasticizer is partially or fully extracted, forming a polymeric material which is still dense without creating the fine voids we need to create.

For example, when polyvinyl acetate is selected as the matrix material, polyvinyl nitrate cannot be selected as the partner because the two polymers are completely compatible. When polyvinyl chloride is used as the base material, it is not possible to use a copolymer of alpha-methylstyrene-methacrylonitrile-ethyl acrylate (monomer weight ratio 58:40:2) in combination with the polyvinyl chloride, also because the two polymers are completely compatible. It is also not possible to choose a polyethylene to pair with polyvinyl chloride because the two polymers are completely incompatible. The two completely incompatible polymers are mixed together, so that the mechanical property of the mixture is poor, and a porous material with fine and uniform pores cannot be formed.

Taking polyvinyl chloride, chlorinated polyethylene or chlorinated polyvinyl chloride as an example, the polymer partially compatible with the matrix polymer can be selected from one or more of ethylene-vinyl acetate copolymer, ethylene-vinyl acetate-carbon monoxide copolymer, chlorinated polyethylene, chlorosulfonated polyethylene, methyl methacrylate-butadiene-styrene terpolymer, acrylonitrile-butadiene-styrene copolymer, acrylate copolymer, butadiene-acrylonitrile rubber and chloroprene rubber. Generally, in preparing the polymer blend, the ratio of polymer matrix to partially compatible polymer with the polymer matrix is in the range of 100:2.5 to 100: 100.

In any event, the solubility parameter of the polymeric substrate and the solubility parameter of the polymer to which it is mated should not be the same or very similar, and the difference between the solubility parameters should be greater than 0.2. Generally, we choose a polymer matrix material having a solubility parameter greater than the solubility parameter of the polymer with which it is paired.

The plasticizer selected must be one that can be extracted with a solvent. Generally, these plasticizers are low molecular weight plasticizers or low molecular weight plasticizers such as phthalic acid esters, phosphoric acid esters, polyols, dibasic fatty acid esters, benzenepolycarboxylic acid esters, citric acid esters, polyol esters, epoxidized vegetable oils, epoxidized oleic acid esters, chlorine-containing compounds, camphor and the like. The phthalate plasticizers include phthalate, terephthalate and isophthalate plasticizers, such as DBP, DOP and the like, and the plasticizers have good compatibility with polymer matrixes, such as polyvinyl chloride, chlorinated polyethylene and the like, are cheap and easy to obtain and can be preferably selected.

Of course, in addition to controlling the extraction time, non-extractable polymeric plasticizers, reactive plasticizers, polymeric tougheners or polymeric modifiers may be added to the formulation in order to control the hardness of the polymeric material or to enhance the softness or other properties of the polymeric material. The migration rate of the polymeric plasticizer is low and, in general, it is not extracted by the poor solvent of the polymer matrix. Reactive plasticizers, such as diallyl benzoate, are reactive plasticizers that polymerize upon heating or in the presence of a catalyst, either by themselves to form a polymeric plasticizer, or by reacting with a polymeric matrix to bond to the macromolecular chains of the matrix polymer.

As a special example, the open-cell porous polymer material is a blend of chlorinated polyethylene with a chlorine content of 40-72 wt% as a polymer matrix material and chlorinated polyethylene with a chlorine content of 16-45 wt% as a polymer matrix material part compatible, and the difference of the chlorine contents of the two chlorinated polyethylenes in the blend is not less than 7.5 wt%. If the difference between the chlorine contents of the two chlorinated polyethylenes is too small, a two-phase polymer blend cannot be formed, but only one homogeneous polymer blend can be formed. Plasticizer extraction of a homogeneous polymer blend containing plasticizer results in only volumetric shrinkage of the polymer blend without the formation of voids in the polymer blend, and thus an open cell porous polymer cannot be obtained. The polymer blend contains a significant amount of plasticizer, such as 60 wt% dioctyl phthalate, prior to solvent extraction of the plasticizer-containing polymer. The plasticizer contained in the blend is partially or completely extracted, so that the prepared open-cell porous polymer material contains no more than 30 wt% of the plasticizer. The more plasticizer is extracted, the greater the porosity in the resulting open-celled porous polymer.

As another specific example, the open cell porous polymeric material is prepared from a blend of polyvinyl chloride as the polymeric matrix material and chlorinated polyethylene having a chlorine content of 20 to 48 wt% as partially compatible with the polymeric matrix material. The plasticizer in the blend may be partially or completely extracted, such that the resulting open-celled porous polymeric material contains no extractable low molecular weight plasticizer, or at most 30 wt% low molecular weight plasticizer. In addition, the blend may also contain 0 to 30 weight percent of a polymeric plasticizer and 0 to 45 weight percent of a polymeric modifier. Commonly used polymer modifiers for polyvinyl chloride are crosslinked or uncrosslinked nitrile rubber, ethylene-vinyl acetate or ethylene-vinyl acetate-carbon monoxide copolymers, and the like.

The preparation method of the open-cell porous polymer material comprises the following steps: mixing a polymer matrix material A, a polymer B partially compatible with the matrix polymer, a plasticizer C capable of being partially or completely extracted and other auxiliary agents and additives required in the formula together, preparing a blend in the form of a film, a sheet, a plate, a tube or a profile by a mixing, calendering, injection, blow molding, mould pressing, pouring, extrusion, casting, slush molding, sintering or casting process, or combining the blend comprising the polymer matrix material A, the polymer B partially compatible with the matrix polymer, the plasticizer C capable of being partially or completely extracted and other auxiliary agents and additives required in the formula with a metal material or a non-metal material by a mode of superposition, mould pressing, injection, calendering, extrusion, transfer printing, silk screening, brush coating, roller coating, knife coating, spray coating, dip coating, curtain coating or pump coating, the method comprises the steps of preparing a composite of a blend and a metal material or a non-metal material, extracting the blend or the composite by using a poor solvent of a polymer matrix material, partially or completely extracting the contained plasticizer, and removing the poor solvent in the blend by drying or vacuum drying to prepare the polymer blend with an open pore structure or a mixed structure of open pores and closed pores or the composite of the polymer blend and the metal material or the non-metal material, namely the open pore type porous polymer material disclosed by the invention.

The metal material or the nonmetal material is a material with certain mechanical strength, and can be compounded together as the polymer blend D to be used as a bottom layer, a surface layer or an intermediate layer of the polymer blend D. The metal material can be selected from metal sheets or metal plates, metal wire nets, metal plate nets, metal foams, metal fiber sintered felts, metal pipes, metal profiles and the like, and the non-metal material can be selected from various cloth materials, non-woven fabrics, glass fiber cloth, carbon fiber woven cloth, asbestos cloth, paper, plastic films, plastic sheets, rubber sheets, plastic nets, plastic pipes, plastic profiles, glass, ceramics, wood, bamboo, stone, gypsum boards, cement, concrete, tiles and the like. Of course, metal or non-metal composite materials, such as glass fiber reinforced plastic materials, metal-plastic laminates, may also be used. The mechanical strength of the open-cell porous polymer is usually significantly improved by using these metallic or non-metallic materials. The open-cell porous polymer is compounded with concrete, brick and tile and other material to make concrete and brick and tile possess excellent sound absorbing effect.

Extraction of some or all of the plasticizer from the polymer blend is a critical step in the present invention for the preparation of open cell porous polymeric materials. The plasticizer-containing blend can optionally be extracted with water or surfactant-containing aqueous solutions, hydrocarbon solvents or alcohol solvents, the solvent selected being a poor solvent for the polymer matrix material and not capable of dissolving or eroding the polymer matrix material during the extraction process. With large amounts of water, the plasticizer in the blend can be extracted. The extraction of the plasticizer with an aqueous solution containing a surfactant is more efficient than pure water.

The hydrocarbon solvent can be solvent gasoline, petroleum ether, white electric oil, kerosene, hydrocarbon cleaning agent, etc., and the alcohol solvent can be methanol, ethanol, propanol and isopropanol.

Incidentally, the boiling point of the organic solvent or water used for the extraction in the present invention is greatly different from that of the plasticizer. For example, n-hexane, the solvent used for the extraction, has a boiling point of 69 ℃ and a boiling point of 80-120 ℃ at atmospheric pressure for solvent gasoline 120, whereas DNOP, the plasticizer, has a boiling point of 340 ℃ and DOA, the plasticizer, has a boiling point of 374.4 ℃ at 760 mmHg. The solvent and the plasticizer in the extract can be easily separated by methods such as fractional distillation, so that the solvent and the plasticizer can be recycled to protect the environment.

Has the advantages that: the invention provides a new method for preparing an open-cell porous polymer material, which has uniformly distributed open-cell micropores and has good performances of filterability, air permeability, water permeability, sound absorption and the like. The polymer material is suitable for preparing breathable artificial leather. Such polymeric materials may also be used to prepare sound absorbing materials. The polymer material is compounded with gypsum board to increase the sound absorption effect of gypsum board, and the gypsum board is used in building.

Drawings

FIG. 1 is a schematic illustration of the preparation of an open cell porous polymeric material.

Fig. 2 is a schematic diagram of the preparation of a composite of an open cell porous polymeric material and a metallic or non-metallic material.

Detailed Description

The present invention will be further described with reference to the following specific examples.

Example 1

Preparing a blend, which comprises the following components in parts by weight: 70 parts of chlorinated polyethylene with the chlorine content of 46 wt%, 30 parts of chlorinated polyethylene with the chlorine content of 25 wt%, 30 parts of dioctyl adipate (DOA) serving as a plasticizer, 1 part of calcium stearate, 3 parts of barium stearate, 5 parts of epoxidized soybean oil, 1 part of phosphite ester and 15 parts of light calcium carbonate. The blend was kneaded uniformly and then pressed into a sheet of 0.5mm thickness. And (3) putting the sheet in No. 120 solvent gasoline for 30 minutes to extract the plasticizer in the sheet from the No. 120 solvent gasoline, taking out and drying to obtain the breathable polymer material with fine pores, wherein the pore diameter of the pores is less than 2.5 mu. And (3) putting the sheet into fresh No. 120 solvent gasoline for multiple times for extraction until the polymer material is dried and has constant weight, thereby obtaining the breathable polymer material with the plasticizer completely extracted.

The content of DOA in the formula is increased from 30 parts to 60 parts or 90 parts, and the breathable polymer material with fine pores and higher porosity can be prepared by the same method.

Example 2

In order to increase the elasticity of the blend and to reduce the permanent set, 3 parts of peroxide crosslinking agent DCP and 3 parts of co-crosslinking agent TAC were added to the formulation of example 1. All the components were mixed uniformly and vulcanized at 160 ℃ for 30 minutes to prepare a sheet having a thickness of 0.5 mm. And (3) putting the thin sheet in No. 120 solvent gasoline for 30 minutes, taking out and drying to obtain the breathable polymer material with fine pores. The compression set (70 ℃ C.. times.22 h) of the porous material prepared in example 1 was 59%, whereas the compression set (70 ℃ C.. times.22 h) of the porous material prepared in this example was greatly reduced to 28%.

Example 3

65 parts of polyvinyl chloride (SG-2 with the average polymerization degree of 1500), 35 parts of chlorinated polyethylene with the chlorine content of 36 wt%, 70 parts of plasticizer dioctyl phthalate (DNOP), 5 parts of Epoxidized Soybean Oil (ESO), 2 parts of di-n-octyl tin dilaurate and 1 part of Ca-Zn composite stabilizer. The materials are put into a kneader to be stirred for 10min, then an internal mixer is used for mixing, and then the materials are put into a three-roll calender to be pressed into sheets, wherein the calendering speed is 1.5m/min, the roll temperature is 170-. And soaking the blend sheet prepared by calendering in petroleum ether or n-hexane for different times, and controlling the amount of DNOP and ESO extracted according to the length of the soaking time, thereby controlling the porosity and hardness of the sheet. When the soaking time is prolonged to 2h, the porosity of the sheet is changed from 0 to 40% initially, and the Shore A hardness is changed from 45 to 98 initially.

The petroleum ether or n-hexane extract containing the plasticizer is fractionated to separate the plasticizer and the extraction solvent, and the plasticizer and the extraction solvent are reused.

An appropriate amount of a peroxide crosslinker system (e.g., DCP and TAIC, or DCP and TAC) can also be added to the formulation of this example to crosslink the chlorinated polyethylene in the blend, thereby reducing the compression set of the blend.

The blend sheet has excellent air permeability and is suitable for making artificial leather.

Example 4

The formula is as follows: 78 portions of PVC resin (average polymerization degree is 1000) for paste, 22 portions of chlorinated polyethylene with 30 weight percent of chlorine content, 50 portions of plasticizer DBP, 40 portions of plasticizer DBP, 30 portions of polyester plasticizer (viscosity is 5 Pa.s at 25 ℃), 4.3 portions of tribasic lead sulfate, 2.9 portions of dibasic lead phosphite and 2 portions of high-color carbon black.

Adding the paste materials such as PVC resin, chlorinated polyethylene, plasticizer, stabilizer, pigment and the like into a kneader according to the formula for stirring, wherein the steam pressure used by the kneader is 0.186MPA, the stirring speed is 60r/min, the stirring time is 5 minutes, and then grinding the prepared paste into slurry by a three-roll grinder. The mixed slurry is ready to use after being prepared, and is used up in one time within 1 h. The slurry is coated on a 120-mesh nylon wire mesh treated by an adhesion promoter by scraping, then the slurry enters an oven with the temperature of about 100 ℃ for continuous preplastication for 30min, then the slurry is placed in an oven with the temperature of 160-165 ℃ for 10-15 min for complete plasticization, and the mixture is cooled to room temperature, thus obtaining the compound of the blend and the nylon wire mesh. The compound is soaked in an aqueous solution containing 2 wt% of sodium dodecyl benzene sulfonate and 5 wt% of sodium carbonate for 24 hours at room temperature, and then is respectively washed by tap water and pure water and dried to prepare a sheet with the thickness of about 0.25 mm. The sheet has good air permeability and water resistance due to the polymer in the sheet having an open-cell foam structure with fine pores.

Example 5

5 parts of an adhesion promoter were added to the formulation of example 4. The adhesion promoter used is polyvinyl butyral (molecular weight 20000), which promotes adhesion between the PVC paste and the metal. The nylon wire mesh used in example 4 was replaced with a 80-mesh stainless wire mesh, and a composite sheet of the stainless wire mesh and the open-cell porous polymer material having good strength and good air permeability was obtained by the process of example 4.

Example 6

The PVC slurries shown in example 4 were prepared. The surface of the gypsum board is coated by dipping to form a layer of slurry with a thickness of 0.1-1.0 mm. The gypsum board used is a 9mm or 12mm thick perforated gypsum board with 23% perforation diameter of 2-10mm and a perforation rate of 15-30%. The perforated gypsum board coated with the PVC slurry was baked at 160-175 ℃ for 15-30min to completely plasticize the PVC slurry. The gypsum board was then extracted with the aqueous solution of example 5 for 24 hours or with petroleum ether having a boiling range of 60-90 c for 1 hour to produce a gypsum board having an open-celled, porous polymeric material on the surface. The purpose of adding a layer of open-cell porous polymer material to the surface of the gypsum board is to further improve the sound absorption of the perforated gypsum board.

The present invention is not limited to the above-mentioned preferred embodiments, and any other products in various forms can be obtained by anyone in the light of the present invention, but any changes in the shape or structure thereof, which have the same or similar technical solutions as those of the present application, fall within the protection scope of the present invention.

Claims

1. An open cell, porous polymeric material characterized by: the open-cell porous polymer material is prepared by a polymer blend D which consists of a polymer matrix A plasticized by a plasticizer, a polymer B compatible with the polymer matrix part, a plasticizer C capable of being partially or completely extracted, and other auxiliary agents and additives required in the formula, and gaps or holes formed by partially or completely extracting the plasticizer contained in the polymer blend D; the open-cell type porous polymer material is in an open-cell structure or an open-cell and closed-cell mixed structure; the average pore diameter of open pores or closed pores in the open-pore type porous polymer material is between 0.001 and 100 mu m; the open-cell porous polymer material is prepared from a polymer blend D or a composite of the polymer blend D and a metallic material or a non-metallic material;

the polymer matrix A which can be plasticized by the plasticizer is vinyl chloride homopolymer or copolymer, chlorinated polyethylene; the polymer B compatible with the polymer matrix A part is chlorinated polyethylene or chlorosulfonated polyethylene; the ratio of polymer matrix A and polymer B which is partially compatible with the polymer matrix is in the range of 100:2.5 to 100: 100;

the solubility parameter of the polymer matrix A is greater than the solubility parameter of the polymer B which is partially compatible with the polymer matrix A.

2. An open cell, porous polymeric material according to claim 1, wherein: the plasticizer C is one or more of phthalic acid esters, phosphoric acid esters, polyols, dibasic fatty acid esters, benzene polyacid esters, citric acid esters, polyol esters, epoxidized vegetable oil, epoxidized oleic acid esters and chlorine-containing compounds.

3. An open cell, porous polymeric material according to claim 1, wherein: the polymer blend D also contains non-extractable polymer plasticizer, reactive plasticizer, polymer toughening agent or polymer modifier.

4. An open cell, porous polymeric material according to claim 1, wherein: the open-cell porous polymer material is a blend consisting of chlorinated polyethylene A with the chlorine content of 40-72 wt% as a polymer matrix and chlorinated polyethylene B with the chlorine content of 16-45 wt% compatible with the polymer matrix part, and the difference of the chlorine contents of the two types of chlorinated polyethylene in the blend is not less than 7.5 wt%; the open-cell porous polymer material contains no more than 30 wt% of ester plasticizer or aromatic hydrocarbon plasticizer C.

5. An open cell, porous polymeric material according to claim 1, wherein: the open-cell porous polymer material is a blend of polyvinyl chloride serving as a polymer matrix and chlorinated polyethylene with the chlorine content of 20-48 wt% compatible with the polymer matrix part; the open-cell porous polymer material contains 0-30 wt% of ester plasticizer or aromatic hydrocarbon plasticizer C, 0-30 wt% of polymer plasticizer and 0-45 wt% of polymer modifier; the polymer modifier is nitrile rubber, ethylene-vinyl acetate copolymer or ethylene-vinyl acetate-carbon monoxide copolymer.

6. A method of making an open cell, porous polymeric material according to claim 1, wherein: mixing a polymer matrix A, a polymer B partially compatible with a matrix polymer, a plasticizer C capable of being partially or completely extracted and other auxiliary agents and additives required in a formula together, and preparing a polymer blend D in a film shape, a sheet shape, a plate shape, a tubular shape or a special-shaped material shape by a forming process of mixing, calendering, injection, blow molding, mould pressing, pouring, extrusion, casting, slush molding, sintering or salivation; or, the polymer blend D containing the polymer matrix A, the polymer B compatible with the polymer part of the matrix, the plasticizer C capable of being partially or completely extracted and other auxiliary agents required in the formula are combined with a metal material or a nonmetal material by the modes of laminating, molding, injecting, calendaring, extruding, pad printing, silk-screen printing, brush coating, roller brush coating, knife coating, spray coating, dip coating, curtain coating and pump coating to prepare a composite of the polymer blend D and the metal material or the nonmetal material; then, extracting the polymer blend D or the compound of the polymer blend D and the metal material or the nonmetal material by using the poor solvent of the polymer matrix A, partially or completely extracting the plasticizer contained in the polymer blend D, and removing the poor solvent in the polymer D by drying or vacuum drying to prepare the open-cell type porous polymer material with an open-cell structure or a mixed structure of open cells and closed cells; the metal material is metal sheet, metal wire mesh, metal plate mesh, metal foam, metal fiber sintered felt, metal pipe and metal section, and the non-metal material is cloth, non-woven fabric, glass fiber cloth, carbon fiber woven cloth, asbestos cloth, paper, plastic film, plastic sheet, rubber sheet, plastic mesh, plastic pipe, plastic section, glass, ceramic, wood, bamboo, stone, gypsum board, cement, concrete and tile, or a compound of metal material and non-metal material.

7. The method of making an open cell, porous polymeric material of claim 6, wherein: the poor solvent is water or water solution containing surfactant, hydrocarbon solvent or alcohol solvent.