CN113290977A - 一种木塑包覆的金属复合型材及其生产工艺 - Google Patents
一种木塑包覆的金属复合型材及其生产工艺 Download PDFInfo
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- CN113290977A CN113290977A CN202110489656.4A CN202110489656A CN113290977A CN 113290977 A CN113290977 A CN 113290977A CN 202110489656 A CN202110489656 A CN 202110489656A CN 113290977 A CN113290977 A CN 113290977A
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Abstract
本发明涉及一种木塑包覆的金属复合型材及其生产工艺,属于复合型材技术领域。一种木塑包覆的金属复合型材,包括金属芯材、木塑表层和设置在金属芯材与木塑表层之间的中间层,中间层包括不饱和羧酸改性聚烯烃、热塑性聚氨酯弹性体、无机填料、聚氨酯预聚体。本发明在木塑表层和金属芯材之间设置了中间层进行粘结,中间层在与金属粘结的时候具有优异的性能,同时能够在共挤时与木塑表层发生一定程度的交融,从而形成稳定的芯材‑中间层‑木塑表层结构,并且中间层具有较好的弹性和抗冲击性能,在各种环境下均能保持较好的粘结性。
Description
技术领域
本发明涉及一种木塑包覆的金属复合型材及其生产工艺,属于复合型材技术领域。
背景技术
金属型材在建筑领域是一种常见的构件,为了提高金属型材的性能,金属型材外层通常需要进行表面处理,木塑包覆处理是其中的一种方案。木塑包覆处理指的是以金属型材作为芯层,在芯层外挤出包覆木塑层,从而起到对金属外表面的保护作用,同时使型材具有木质感。木塑层的成分通常由热塑性树脂和木粉、竹粉等生物质材料以及一些其他助剂构成,其中热塑型使用的最多的是聚烯烃类高分子材料。
然而,聚烯烃类材料通常与金属之间的结合能力较弱,其中加入的木粉更是进一步降低了木塑包覆层与金属芯层之间的粘结强度,使得两者之间容易脱层,尤其是经过冷热环境变化或遇水后脱层现象更加显著。为了解决上述问题,人们开始在木塑包覆层与金属芯层之间添加胶层,通过胶层间接将包覆层与芯层进行粘结。如公开号为CN103209832B的专利文献所提供的一体挤出成型体及建筑用构件所示,该专利以α-烯烃和含环氧基的不饱和单体为原料聚合形成的共聚物作为粘结层原料来对金属芯层和木塑层进行粘结,解决木塑层与金属芯层粘结性不好的问题。然而该专利所述的粘结层主要是通过粘结层材料中的环氧基与木塑层中木粉的相互作用来提高粘结层与木塑层之间的粘结力,并未较好的解决粘结层与金属之间的粘结问题,在实际使用中粘结层容易与木塑层一同从金属芯层表面脱落,从而影响使用寿命。
发明内容
本发明提供了一种木塑包覆的金属复合型材,在木塑表层和金属芯材之间形成一层中间层,中间层分别对表层的木塑材料和金属芯材均具有较好的粘结性能,使木塑表层,尤其是聚烯烃木塑,更好地对金属芯材产生包覆效果。
具体地,本发明采用的技术方案如下:
一种木塑包覆的金属复合型材,包括金属芯材、木塑表层和设置在金属芯材与木塑表层之间的中间层,所述的中间层包括作为基体树脂的不饱和羧酸改性聚烯烃、热塑性聚氨酯弹性体和作为添加材料的无机填料、聚氨酯预聚体。
本发明上述技术方案,采用共挤工艺,以金属芯材作为基材,在金属芯材外层包覆一层主要由不饱和羧酸改性聚烯烃树脂和热塑性聚氨酯弹性体为主要成分的构成的复合高分子层,并使复合高分子层具有自粘性,最后再在中间层上挤出包覆木塑表层,待冷却定型后即可得到成品。本发明所述的共挤工艺是通过一个特殊的模具实现的,该模具具有一个轴向贯通模具自身的金属芯材通道,还具有侧向延伸至金属芯材通道的中间层流道以及木塑表层流道。金属芯材在牵引下逐渐穿过金属芯材通道,在穿过通道的过程中,中间层物料通过挤出机熔融挤出至中间层流道并包覆在金属芯材的四周,随后木塑表层物料通过挤出机熔融挤出至木塑表层流道并包覆在中间层四周,最后形成包括芯材在内的三层结构后从模具口挤出。
上述金属芯材可由铝、铁、铜或包含多种金属合金制成,例如铝合金、不锈钢、镀锌钢等,从实际应用和加工角度来看,金属型材在建筑领域的应用过程中需要考虑到施工难易程度以及型材自重对结构受力的影响,因此通常需要更加轻质的材料,而型材之所以具有多种功能,是因为其截面具有多种形状,可以与多种结构发生连接关系,因此在加工过程中对精密度要求较高,需要可塑性强的材料,综合以上几点来看铝合金作为金属芯材为优选。在本发明中,金属芯材并不限定于截面为矩形等具有规则几何形状的结构,其截面可以为中空形状、U形、L形等特殊形状,具体的形状根据其具体用途进行设计,在对特殊形状的金属芯材共挤包覆时,模具的金属芯材通道也需要相应地改动以适应金属芯材的形状。
在金属芯材进行包覆之前,优选地可以对其进行表面处理,表面处理包括化学处理和物理处理两种。
化学处理指的是在铝合金表面形成一层氧化膜,具体的形成方法通常是阳极氧化法,即将铝合金芯材连通至电源的阳极,电源的阴极连接一导电体,将铝合金芯材和导电体置入电解溶液中并通电,此时铝合金表面层的铝接受电解液中的氧原子被氧化形成氧化铝,阴极区域一些具有氧化性的物质接受电子被还原,这些具有氧化性的物质以氢离子为例,被还原后生产氢气。为了实现上述过程,电解液中需要存在较多的氢离子,因此电解液可以是磷酸溶液、硫酸溶液、草酸溶液等。由于阴极连接的导电体不参与反应,因此可以选用多种材料,优选地为了便于氢离子的还原,可以采用比表面较大的电极材料,例如石墨电极等。在进行表面氧化后,铝合金表层即可得到一层较为致密的氧化铝薄膜,此时的氧化铝薄膜表面微观上实际上是一种凹凸不平且带有孔洞结构的结构,在常规的工艺中,铝合金氧化膜形成后需要对其表面进行封孔处理(通常是利用封孔剂进行处理),防止其表面以孔洞为基点发生腐蚀,而在本发明中,铝合金表面因为将受到包覆层的隔离保护,并不需要进行封孔处理,反而其表面的孔隙结构可以增加中间层与铝合金芯材之间的接触面积以及形成微观上的嵌合结构,从而增大中间层与铝合金芯材之间的粘结力。不过对于并非完全包覆的铝合金芯材,例如具有中空结构的铝合金芯材,其具有与包覆层接触的外表面和构成中空结构轮廓的内表面,由于内表面暴露于外,理论上应当对内表面进行局部封孔处理。不过在芯材应用过程中内表面分为两种情况,其中一种是中空结构与外界相通,此时内表面存在接触到腐蚀物的可能,另一种是在芯材安装完成后中空结构形成封闭结构,此时内表面不会接触到外界的腐蚀物;对于前者,优选地应当对内表面进行封孔处理,若实际生产中局部封孔技术难度较大,可以对芯材进行全封孔处理,由于本发明的中间层改性对金属的粘结力已经足以达到使用标准,封孔后对金属的粘结力不会产生较大影响,对于后者可以不进行封孔处理。
物理处理指的是在铝合金芯材受木塑层包覆的外表面上加工形成沿长度方向的沟槽,沟槽的作用是在宏观结构上与中间层形成嵌合结构,并提高中间层与铝合金芯材的接触面积,从而提高粘结强度。这里的沿长度方向并不限定于直线,也可以是曲线状的沟槽,只要其大致走向是沿着铝合金芯材的长度方向即可,优选地形成规整的直线状沟槽。之所以将沟槽设计成沿长度方向,存在两个原因。第一个原因是虽然复杂形状的沟槽能够提高中间层与金属芯材的结合力,但这种结合力的提高是有限的,且并不明显,更重要的是沿长度方向形成沟槽相较于沿其他的方向形成沟槽,在加工难度上明显更低,并且所需要形成沟槽的总条数也更少,需要的加工部件也更加简单;另一原因是,在该设计下铝合金芯材是沿着沟槽的走向移动进入模具内并被包覆的,在受到包覆时沟槽内的气体可以顺着沟槽沿与铝合金芯材运动相反的方向排出,不会在沟槽内产生气孔,若沿其他方向设置沟槽(如宽度方向),则气体无法排出,会残留在中间层与铝合金芯材之间形成空泡。沟槽的截面应当设计成从槽口至槽底槽宽不断减小的形状,例如倒三角形、圆弧形等,以便于中间层物料进入槽内。优选地,铝合金芯材首先通过物理处理形成沟槽,再进行化学处理形成氧化膜,以免沟槽加工时对氧化膜造成破坏。沟槽的形成可以是铝合金芯材在挤出成型时通过模具的作用直接形成,也可以是对铝合金芯材进行二次加工处理。
对于木塑表层,其组成基质是热塑性树脂以及天然植物纤维粉,特别地,所述的热塑性树脂为烯烃类单体聚合得到的高分子材料,例如乙烯、丙烯、丁烯等,具体的聚合方式可以是单一的单体进行聚合,例如聚乙烯、聚丙烯,也可以是多种单体进行共聚,例如以乙烯和丙烯作为原料聚合得到的聚乙丙烯。需要说明的是,本发明所述的烯烃类聚合物所描述的是高分子的主链结构是通过碳碳双键的加成反应得到的,并不限定单体为只具有碳碳双键官能团的烯烃,单体除了碳碳双键以外还可以存在其他的官能团,例如丙烯酸、丁烯酸乙酯等。
木塑表层中除了热塑性树脂以及天然植物纤维粉以外,还包括一些常用于制品的其他的功能性助剂,例如补强剂、着色剂、抗氧剂、抗紫外线剂、无机填料等,以增强木塑的理化性能,如抗氧化性、紫外稳定性等。
进一步地,木塑表层中还包含有不饱和羧酸改性聚烯烃,这里的不饱和羧酸指的是存在一个或以上不饱和键的羧酸或酸酐或羧酸衍生物,优选地,该不饱和键为分子末端的碳碳双键,例如:丙烯酸、甲基丙烯酸、丁烯酸等不饱和一元酸和马来酸、马来酸酐、邻苯二甲酸等二元酸以及上述不饱和羧酸的衍生物,例如羧酸与醇缩合形成的酯类化合物、羧酸的羟基被取代后形成的酰类化合物等。羧酸及其衍生物改性树脂其侧链具有羰基、羟基等含氧基团,而木粉中的纤维素也具有大量的羟基,因此两者之间可以产生氢键等弱作用键,同时不饱和羧酸改性树脂的羧基可以与纤维素中的羟基发生一定程度上的缩合,产生强作用键,因此不饱和羧酸及其衍生物改性聚烯烃与木粉具有较好的相容性,同时由于其与聚烯烃树脂也具有很好的相容性,因此木粉可以随着不饱和羧酸改性树脂在聚烯烃树脂中的流动而在木塑材料中分散均匀。
所述的不饱和羧酸改性树脂的改性形式可以是共混、共聚、接枝等多种形式,共混指的是将单种或多种不饱和羧酸通过聚合反应得到以不饱和羧酸为单体的聚合物,例如聚丙烯酸、聚丁烯酸、聚丙烯酸与聚丁烯酸共聚物等,加入到原有的木塑表层材料中,熔融共混得到改性后的木塑表层材料,在该改性方法中,不饱和羧酸与木塑表层中的聚烯烃树脂不发生直接反应,仅进行物理方式的混合(不考虑高分子链之间的交联情况);共聚指的是在聚烯烃树脂的合成过程中就加入不饱和羧酸,得到烯烃类单体和不饱和羧酸单体的共聚物,例如乙烯-乙烯-聚丙烯-乙烯-乙烯等链状结构;接枝指的是在聚烯烃树脂合成完成后,对高分子链进行接枝反应,为高分子链添加侧链结构,使高分子额外获得基团,例如马来酸酐接枝聚乙烯。
对于木塑表层,并不限定于仅存在单一的木塑层状结构,在木塑的外侧面上还可进行其他层状结构的复合,由于实际使用过程中有着种种需求,因此木塑表层上有时会存在其他层状复合物,例如在木塑表层的外侧面上贴合印刷层、涂覆耐磨层等,本发明旨在对木塑表层内侧面的粘结强度进行改性,因此外侧面的其他加工行为并不在本发明的讨论范围,本发明也不对其产生限定。
中间层是由不饱和羧酸改性聚烯烃树脂、热塑性聚氨酯弹性体、无机填料、聚氨酯预聚体构成的复合高分子层,其中羧酸改性聚烯烃树脂和热塑性聚氨酯弹性体的共混体系构成中间层的基质成分,赋予中间层低于弹性体但又高于普通热塑性聚烯烃树脂的弹性和韧性,同时赋予中间层作为黏合过渡层而必要的刚性,以免在外层遭受到意外的暴力作用时,因力传递而导致的中间层的破坏。中间层的无机填料用于调节中间层的硬度,聚氨酯预聚体使中间层相对于金属基材具有良好的自粘性,而不必要使用额外的胶黏剂。
虽然上面已经给出了中间层的构成成分。但实际上,跨越材料进行粘结是不容易的。尤其是金属和热塑性聚烯烃。
基于申请人的研究,有机高分子材料对金属的粘结通常出于两种机理。一种是有机物分子或有机物分子的某些基团与金属表面之间形成的物理吸附;另一种是有机物分子的某些基团与金属表面的金属原子形成配位键等化学键而增强吸附强度,其中后者的吸附强度要远高于前者。金属作为典型的缺电子物质,通常与能提供电子对的多电子有机物能形成化学键而产生较强的粘结作用。而聚烯烃,尤其是聚乙烯的结构为一条不带支链的低极性高分子,因为缺乏提供电子的基团,无法与金属之间形成配位作用,因此与金属之间粘结强度很低,同理,其他具有类似结构的高分子,如聚丙烯、乙丙橡胶等也难以粘结在金属上,而实际生产过程中也确实出现了上述现象。
中间层材料对木塑表层的粘结根据制备工艺的不同会具有一定的差异,本发明采用的是共挤工艺,中间层先挤出包覆至金属芯材,然后木塑表层挤出包覆至中间层。当木塑表层对中间层进行包覆时,中间层还未完全冷却硬化,因此木塑表层与中间层在接触面上会发生交融形成一体化的结构,而结构的一体化程度取决于两者之间的相容性。
构成本发明中间层的复合高分子主要是不饱和羧酸改性的聚烯烃和热塑性聚氨酯的共混体系,该体系中,高分子链的侧链上具有羧基、酯基等基团,一方面使高分子链的极性增强,高分子与金属表面的物理吸附作用提高,另一方面这些多电子基团可以与金属表面的金属离子发生配合作用,进一步提高对金属的粘结。因此,复合高分子层能与金属表面产生良好粘结。
而复合高分子层和木塑层的界面,由于都是以聚烯烃为基形成的树脂体系,因此中间层与木塑表层具有良好的相容性,并且中间层的聚烯烃改性是不饱和羧酸改性;在木塑表层中,聚烯烃的不饱和羧酸改性甚至是提高植物纤维粉与聚烯烃相容性的最有效途径。因此,中间层的不饱和羧酸改性树脂不仅能与木塑表层的聚烯烃成分具有良好的相容性,还与木塑表层的木粉成分也具有良好的相容性。从另一个角度来说,中间层与木塑表层粘合时,木塑表层的相接面从微观角度分析主要具有以下几种相对独立的组成相:聚烯烃树脂相、不饱和羧酸改性聚烯烃相、木粉相;中间层的热塑性聚烯烃弹性体与上述几种相的相容性不足,当热塑性聚烯烃弹性体中也具不饱和羧酸改性聚烯烃时,能够通过局部相融来提高整体的融合程度,中间层的不饱和羧酸改性聚烯烃由于具有非极性的主链部分和极性的侧链部分,其主链部分能够与木塑表层中的聚烯烃产生较好的交融,侧链部分能与木塑表层中的不饱和羧酸改性聚烯烃以及木粉相融合。也就是说,在产品的形成过程中,木塑表层与中间层在接触面上会发生交融,形成良好的一体化结构。
作为上述技术方案的优选,所述的复合高分子层还包括异氰酸酯。
本申请的一个方面是致力于研究提高木塑表层与金属基材之间的粘结性。当在中间层的复合高分子体系中添加适量的异氰酸酯时,能够显著提高体系的酯基含量,这对于提高与金属的粘结性的作用是显著的。也就是说能够显著提高中间层基于金属芯材的自粘性。
作为上述技术方案的优选,所述的中间层的厚度为0.5~5.0mm。
作为上述技术方案的优选,所述的中间层包括与金属芯材贴合的第一中间层和与木塑表层贴合的第二中间层;所述的第一中间层组成包括以下质量份的组分:不饱和羧酸改性聚烯烃树脂40~60、热塑型聚氨酯弹性体20~30、聚氨酯预聚体5~15、异氰酸酯1~5、无机填料5~10;所述的第二中间层组成为:聚烯烃树脂30~50、不饱和羧酸改性聚烯烃树脂10~20、聚乙烯醇缩丁醛树脂20~30、无机填料5~10。
本申请的一个方面是致力于研究在即时性极限载荷破坏下的木塑包覆型材的自我保护能力。因此,申请人并不满足于复合中间层与金属芯材具有良好的粘结性。因为传统的胶粘层仅能提供胶黏性,而胶黏性的稳定是有条件的。当木塑表层或者复合高分子层出现氧化、老化等情况时,胶黏性就会出现问题;只是这个问题的解决相对简单,通常在木塑表层中添加适量的功能助剂,如紫外吸收助剂、抗氧剂等。胶黏性的稳定的其他方面,如在遭受意外冲击等机械应力时,胶粘层是否仍能提供其应有功能是工程师们密切关注的。
在解决上述问题时,本申请提供了另一个保护方案。该方案是,所述的中间层包括与金属芯材贴合的第一中间层和与木塑表层贴合的第二中间层;所述的第一中间层组成包括以下质量份的组分:不饱和羧酸改性聚烯烃树脂40~60、热塑型聚氨酯弹性体20~30、聚氨酯预聚体5~15、异氰酸酯1~5、无机填料5~10;所述的第二中间层组成为:聚烯烃树脂30~50、不饱和羧酸改性聚烯烃树脂10~20、聚乙烯醇缩丁醛树脂20~30、无机填料5~10。
在上述方案中,第一中间层提供与金属芯材的粘结性。第二中间层与第一中间层形成一体,复合在第一中间层的表面,从而提供抗冲保护作用。第二中间层,以聚烯烃树脂和聚乙烯醇缩丁醛树脂的共混体系形成,其中不饱和羧酸改性聚烯烃树脂作为增溶剂提高聚烯烃树脂和聚乙烯醇缩丁醛树脂的相容性,使聚烯烃树脂和聚乙烯醇缩丁醛树脂产生局部相容,在这个体系中,相对的,聚烯烃树脂相提供刚性和硬度,聚乙烯醇缩丁醛树脂相提供一定的柔韧度。基于此,机械力在作用到第一中间层前,首先被第二中间层予以平衡,由于第二中间层具有良好的柔韧性,能够平衡较大部分的机械力作用。从结构组成上来看,第二中间层的刚性和柔韧性都介于木塑表层和第一中间层之间;如此,在机械外力作用时,能够起到良好的缓冲作用。
此外,第二中间层相较于第一中间层,去除了聚氨酯弹性体,由于木塑表层中不具有聚氨酯弹性体成分,因此将其去除还可以提高第二中间层与木塑表层的交融程度。从整体上来看,双层结构相较于单层结构具有更好的抗冲保护作用,也具有更强的层间粘结效果。由于木塑层包覆在金属芯材上的稳定度更多地取决于中间层与金属的粘合,因此第一中间层应当厚度大于或等于第二中间层,使第一中间层更好地发挥作用。优选地,第一中间层和第二中间层的厚度之和为0.5~5.0mm。
本发明在制备过程中,木塑表层、第一中间层、第二中间层的物料应当分别预先混炼、造粒之后再进行使用,以免各组分分散不均匀对质量产生影响。
作为上述技术方案的优选,所述的木塑表层中含有不饱和羧酸改性聚烯烃。
作为上述技术方案的优选,所述的无机填料为硅烷偶联剂预处理后的表面活化无机填料。
作为上述技术方案的优选,所述的金属芯材为铝制芯材,其表面具有氧化膜。
作为上述技术方案的优选,所述的金属芯材与中间层贴合的至少一侧外表面形成沿金属芯层长度方向的深度为0.03~1.0mm的沟槽。
需要说明的是,虽然本发明是基于实际使用中更为常见的金属芯材的外表面全包覆情况来进行分析和描述的,但是对金属芯材进行部分外表面的包覆也应当包含在本发明的范围内,例如对截面为矩形的金属芯材的两个长边侧面进行包覆,使两个短边侧面暴露于外。
本发明的另一个目的是,提供上述木塑包覆的金属复合型材的生产工艺。
木塑包覆的金属复合型材生产工艺,包括以下步骤:
(1)将预处理的金属芯材通过牵引导入至模具中;
(2)将中间层物料通过挤出机以熔融态挤出至模具中,并通过模具的中间层流道使中间层熔融体包覆在金属芯材的周向表面形成中间层包覆的金属芯材;
(3)将木塑表层物料通过另一挤出机以熔融态挤出至模具中,并通过模具的表层流道使木塑熔融体包覆在中间层的外表面;
(4)将包覆完成的金属复合型材冷却定型后得到成品。
作为上述技术方案的优选,步骤(2)中所述的中间层包括第一中间层和第二中间层,第一中间层物料通过第一挤出机包覆至金属芯材外表面,第二中间层物料通过第二挤出机包覆至第一中间层外表面。所述的第一中间层组成包括以下质量份的组分:不饱和羧酸改性聚烯烃树脂40~60、热塑型聚氨酯弹性体20~30、聚氨酯预聚体5~15、异氰酸酯1~5、无机填料5~10;所述的第二中间层组成为:聚烯烃树脂30~50、不饱和羧酸改性聚烯烃树脂10~20、聚乙烯醇缩丁醛树脂20~30、无机填料5~10。
综上所述,本发明具有以下有益效果:
本发明使用以聚烯烃木塑为代表的木塑表层包覆金属芯材来制备金属复合型材,由于聚烯烃木塑中的聚烯烃成分和木粉成分与金属芯材均具有较差的粘结性能,本发明在两者之间设置了中间层进行粘结,中间层在与金属粘结的时候具有优异的性能,同时能够在共挤时与木塑表层发生一定程度的交融,从而形成稳定的芯材-中间层-木塑表层结构,并且中间层具有较好的弹性和抗冲击性能,在各种环境下均能保持较好的粘结性。进一步地,本发明还将中间层分为第一中间层和第二中间层,第一中间层中去除与金属粘结性差的聚烯烃,第二中间层去除了与木塑表层粘结性差的聚氨酯弹性体,使中间层对金属芯材和木塑表层的粘结强度同时得到提高,进一步增强粘结效果。
具体实施方式
下面通过实施例和对比例来对本发明的实施方式和性能进行进一步说明。
为了便于比较各实施例与对比例的性能,在各对比例和实施例中的金属芯材统一选用规格为200mm*200mm*3000mm的立方结构铝合金芯材,铝合金芯材内部具有截面为方形的空腔,芯材的外表面与内表面之间所夹的铝合金厚度为3mm。在对金属芯材包覆之前首先进行预处理,预处理过程包括:
(1)滚花处理:沿着芯材的长度方向使用滚花工艺在芯材的外表面上形成多条深度为0.3mm的v形沟槽;
(2)表面氧化处理:将(1)中带沟槽的芯材通过阳极氧化处理得到一层氧化铝膜(不进行封孔处理)。
此外,在将芯材牵引导入至模具中之间,还需对芯材进行预热处理,加热至约100℃。
木塑包覆型材的制法如下:
将经过预处理的铝合金芯材导入共挤模具的主通道内,在穿过通道的过程中,中间层物料通过挤出机熔融挤出至中间层流道并包覆在金属芯材的四周,随后表层物料通过挤出机熔融挤出至表层流道并包覆在中间层四周,最后形成包括芯材在内的三层结构后从模具口挤出。本实施例中,中间层物料为具有自粘性的复合高分子层。
实施例1
木塑表层物料:聚乙烯45份、植物纤维粉60份、滑石粉6.25份、炭黑0.07份、铁红0.38份、抗氧剂0.6份、抗紫外吸收剂1.2份、润滑剂1.5份作为原料;将上述物料经过混料机混合,并通过挤出机造粒得到木塑表层物料颗粒。
中间层物料:聚乙烯15份、马来酸酐接枝聚乙烯25份、热塑性聚氨酯弹性体20份、碳酸钙10份、聚氨酯预聚体10份作为原料;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将聚乙烯、马来酸酐接枝聚乙烯、热塑性聚氨酯弹性体、聚氨酯预聚体和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到中间层物料颗粒。
实施例2
木塑表层物料:聚乙烯45份、植物纤维粉60份、滑石粉6.25份、炭黑0.07份、铁红0.38份、抗氧剂0.6份、抗紫外吸收剂1.2份、润滑剂1.5份作为原料;将上述物料经过混料机混合,并通过挤出机造粒得到木塑表层物料颗粒。
中间层物料:马来酸酐接枝聚乙烯40份、热塑性聚氨酯弹性体20份、碳酸钙10份、聚氨酯预聚体10份作为原料;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将马来酸酐接枝聚乙烯、热塑性聚氨酯弹性体、聚氨酯预聚体和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到中间层物料颗粒。
实施例3
木塑表层物料:聚乙烯45份、植物纤维粉60份、滑石粉6.25份、炭黑0.07份、铁红0.38份、抗氧剂0.6份、抗紫外吸收剂1.2份、润滑剂1.5份作为原料;将上述物料经过混料机混合,并通过挤出机造粒得到木塑表层物料颗粒。
中间层物料:马来酸酐接枝聚乙烯40份、热塑性聚氨酯弹性体20份、碳酸钙10份、聚氨酯预聚体10份、异氰酸酯5份作为原料;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将马来酸酐接枝聚乙烯、聚氨酯弹性体、聚氨酯预聚体和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到中间层物料颗粒。
实施例4
木塑表层物料:聚乙烯45份、植物纤维粉60份、滑石粉6.25份、炭黑0.07份、铁红0.38份、抗氧剂0.6份、抗紫外吸收剂1.2份、润滑剂1.5份作为原料;将上述物料经过混料机混合,并通过挤出机造粒得到木塑表层物料颗粒。
第一中间层物料:马来酸酐接枝聚乙烯40份、热塑性聚氨酯弹性体20份、碳酸钙10份、聚氨酯预聚体10份作为原料;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将马来酸酐接枝聚乙烯、聚氨酯弹性体、聚氨酯预聚体和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到第一中间层物料颗粒。
第二中间层物料:聚乙烯35份、马来酸酐接枝聚乙烯15份、聚乙烯醇缩丁醛树脂25份、碳酸钙10份;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将聚乙烯、马来酸酐接枝聚乙烯、聚乙烯醇缩丁醛树脂和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到第二中间层物料颗粒。
实施例5
木塑表层物料:聚乙烯45份、植物纤维粉60份、滑石粉6.25份、炭黑0.07份、铁红0.38份、抗氧剂0.6份、抗紫外吸收剂1.2份、润滑剂1.5份作为原料;将上述物料经过混料机混合,并通过挤出机造粒得到木塑表层物料颗粒。
第一中间层物料:马来酸酐接枝聚乙烯40份、热塑性聚氨酯弹性体20份、碳酸钙10份、聚氨酯预聚体10份、异氰酸酯5份作为原料;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将马来酸酐接枝聚乙烯、聚氨酯弹性体、聚氨酯预聚体、异氰酸酯和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到第一中间层物料颗粒。
第二中间层物料:聚乙烯35份、马来酸酐接枝聚乙烯15份、聚乙烯醇缩丁醛树脂25份、碳酸钙10份;首先将碳酸钙使用乙烯基三过氧化叔丁基硅烷溶液进行预处理,随后将聚乙烯、马来酸酐接枝聚乙烯、聚乙烯醇缩丁醛树脂和处理后的碳酸钙通过混料机混合,并通过挤出机造粒得到第二中间层物料颗粒。
对比例1
中间层物料:聚氨酯热熔胶;
木塑表层物料:与实施例1中相同。
对比例2
中间层物料:马来酸酐接枝聚乙烯热熔胶;
木塑表层物料:与实施例1中相同。
将实施例1~4和对比例1和2通过以下方法制备得到木塑包覆的金属复合型材:
对采用实施例1~4和对比例1和2原料制备得到的产品的评价方法:
(1)内胶合强度性能测试
内胶合强度是试件表面承受均匀分布的拉力,直至破坏时的抗拉能力测定。内胶合强度是垂直与试件表面的最大破坏拉力和试件面积之比;参照GB/T 17657-2013测定。
将样品在70℃、相对湿度为95%的环境下保存30天后,使用HY-914快速胶黏剂将尺寸为20mm*20mm的钢制卡头黏贴在产品上,并沿着钢制卡头的轮廓割断胶黏层,待粘合牢固后,用拉力计沿与板材平面垂直的方向向上拉起钢制卡头,或将钢制卡头朝下放置在钢制卡头上悬挂重物并记录重物的重力大小,记录下热熔胶与铝合金板材脱层前的最大拉力(N)或最大重力,记为F,则内胶合强度大小为P=F/S,其中S为钢制卡头的面积。
上述测试结果中脱落的测试格数量如下表所示,表格中记录数据为粘结强度(MPa),若在进行测试之前木塑表层和中间层已经从金属芯材上发生剥离、浮起、开裂等现象,则数据记为0,表示产品不合格。
(2)耐冷热粘结性能测试
参照LY/T-2565-2015之5.3.10方法进行测定,参照GB/T24508-2009之6.5.9的标准结果进行评判。
取样品置于60℃水浴环境中12H,紧接着把试样放在温度为-35℃的超低温冰箱中24H冷冻,这个过程组成一个周期,循环五个周期后将其置于23℃±2℃的常温下2H并进行干燥处理;随后对样品按照(1)中方法进行测试。检测要求:表面外观无龟裂、无鼓泡;尺寸变化≤0.5mm。
测定结果
按照LY/T-2565-2015之6.进行抽样,任意12块试样为一组,每一试件全部性能均要求达到标准规定要求,该批产品物理力学性能判为合格,否则为不合格。
Claims (10)
1.一种木塑包覆的金属复合型材,包括金属芯材、木塑表层和设置在金属芯材与木塑表层之间的中间层,其特征在于:所述的中间层为复合高分子层,包括作为基体树脂的不饱和羧酸改性聚烯烃树脂、热塑性聚氨酯弹性体和作为添加材料的无机填料、聚氨酯预聚体。
2.根据权利要求1所述的一种木塑包覆的金属复合型材,其特征在于:所述的复合高分子层还包括异氰酸酯。
3.根据权利要求2所述的一种木塑包覆的金属复合型材,其特征在于:所述的中间层包括与金属芯材贴合的第一中间层和与木塑表层贴合的第二中间层;所述的第一中间层组成包括以下质量份的组分:不饱和羧酸改性聚烯烃树脂40~60、热塑型聚氨酯弹性体20~30、聚氨酯预聚体5~15、异氰酸酯1~5、无机填料5~10;所述的第二中间层组成为:聚烯烃树脂30~50、不饱和羧酸改性聚烯烃树脂10~20、聚乙烯醇缩丁醛树脂20~30、无机填料5~10。
4.根据权利要求1所述的一种木塑包覆的金属复合型材,其特征在于:所述的中间层的厚度为0.5~5.0mm。
5.根据权利要求1或2所述的一种木塑包覆的金属复合型材,其特征在于:所述的木塑表层中含有不饱和羧酸改性聚烯烃。
6.根据权利要求1或2所述的一种木塑包覆的金属复合型材,其特征在于:所述的无机填料为硅烷偶联剂预处理后的表面活化无机填料。
7.根据权利要求1所述的一种木塑包覆的金属复合型材,其特征在于:所述的金属芯材为铝制芯材,其表面具有氧化膜。
8.根据权利要求1所述的一种木塑包覆的金属复合型材,其特征在于:所述的金属芯材与中间层贴合的至少一侧外表面形成沿金属芯层长度方向的深度为0.03~1.0mm的沟槽。
9.一种木塑包覆的金属复合型材生产工艺,包括以下步骤:
(1)将预处理的金属芯材通过牵引导入至模具中;
(2)将中间层物料通过挤出机以熔融态挤出至模具中,并通过模具的中间层流道使中间层熔融体包覆在金属芯材的周向表面形成中间层包覆的金属芯材;
(3)将木塑表层物料通过另一挤出机以熔融态挤出至模具中,并通过模具的表层流道使木塑熔融体包覆在中间层的外表面;
(4)将包覆完成的金属复合型材冷却定型后得到成品。
10.根据权利要求9所述的一种木塑包覆的金属复合型材生产工艺,其特征在于:步骤(2)中所述的中间层包括第一中间层和第二中间层,第一中间层物料通过第一挤出机包覆至金属芯材外表面,第二中间层物料通过第二挤出机包覆至第一中间层外表面。
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CN114293732A (zh) * | 2021-12-14 | 2022-04-08 | 安徽森泰木塑科技地板有限公司 | 一种复合地板及其生产工艺 |
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CN115491049B (zh) * | 2022-10-20 | 2024-01-12 | 北京林业大学 | 一种聚氨酯基阻燃型木塑复合材料及其制备方法 |
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US20220355524A1 (en) | 2022-11-10 |
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