WO2022100525A1 - 聚丙烯板材及其制备方法 - Google Patents

聚丙烯板材及其制备方法 Download PDF

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WO2022100525A1
WO2022100525A1 PCT/CN2021/129029 CN2021129029W WO2022100525A1 WO 2022100525 A1 WO2022100525 A1 WO 2022100525A1 CN 2021129029 W CN2021129029 W CN 2021129029W WO 2022100525 A1 WO2022100525 A1 WO 2022100525A1
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polypropylene
parts
polypropylene resin
modified
resin
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PCT/CN2021/129029
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English (en)
French (fr)
Inventor
张小玲
肖志远
李彦辉
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常州市贝美家居科技有限公司
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Priority to EP21805341.1A priority Critical patent/EP4023714A4/en
Priority to CA3139602A priority patent/CA3139602C/en
Priority to AU2021273528A priority patent/AU2021273528B2/en
Priority to US17/527,371 priority patent/US11999846B2/en
Publication of WO2022100525A1 publication Critical patent/WO2022100525A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/14—Copolymers of propene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C08K3/346—Clay
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C08K5/098—Metal salts of carboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • C08K2003/265—Calcium, strontium or barium carbonate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/32—Phosphorus-containing compounds
    • C08K2003/321—Phosphates
    • C08K2003/328—Phosphates of heavy metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend

Definitions

  • the present invention relates to the technical field of flooring, and particularly relates to a polypropylene board and a preparation method thereof.
  • Plastic (PVC) floor is a new type of lightweight floor decoration material that is very commonly used today, also known as "lightweight floor material", which is a floor made of polyvinyl chloride materials. Specifically, using polyvinyl chloride and its copolymer resin as the main raw materials, adding fillers, plasticizers, stabilizers, colorants and other auxiliary materials, on the sheet-like continuous substrate, through the coating process or through calendering, extrusion or extrusion Produced by pressing process. At present, PVC flooring does not meet the requirements of green environmental protection due to its volatilization of toxic gases and generally contains plasticizers and other raw materials. The development of PVC and plasticizer-free flooring has very good market value.
  • Polypropylene (PP) raw materials are rich in sources, cheap in price, non-toxic, tasteless, and good in luster.
  • PP sheets cannot be fully mixed with fillers, they cannot be extruded smoothly and are prone to delamination, which also restricts the large-scale production and application of PP sheets.
  • the purpose of the present invention is to provide a polypropylene sheet, which aims to smoothly extrude the polypropylene sheet without adding a plasticizer.
  • Another object of the present invention is to provide a method for preparing a polypropylene sheet, which can prepare a plasticizer-free polypropylene sheet, and has a very good application prospect.
  • the present invention solves its technical problems by adopting the following technical solutions.
  • the present invention provides a polypropylene sheet, in parts by weight, its raw materials include 25-40 parts of modified polypropylene resin, 30-70 parts of filler, 3-10 parts of stabilizer and 1-8 parts of lubricant; , the melting mass of the modified polypropylene resin is 2-9 grams per 10 minutes.
  • the raw materials include 30-36 parts of modified polypropylene resin, 30-70 parts of filler, 5-8 parts of stabilizer and 2-5 parts of lubricant; wherein, the modified polypropylene resin
  • the melt mass is 4-7 g/10 min.
  • the modified polypropylene resin is at least one of polyolefin-modified polypropylene resin and acrylic-grafted polypropylene resin; preferably, the modified polypropylene resin includes polyolefin-modified polypropylene resin. 15-18 parts of propylene resin and 15-18 parts of acrylic-grafted polypropylene resin.
  • the filler includes at least one of calcium carbonate, kaolin and ferric oxide; preferably, the fineness of the filler is 400-800 mesh.
  • the stabilizer includes at least one of acrylic acid and zinc phosphate, preferably zinc phosphate.
  • the lubricant includes at least one of fatty acid zinc and polyethylene wax.
  • the present invention also provides a method for preparing a polypropylene sheet, comprising: mixing and extruding the raw materials of the polypropylene sheet.
  • the raw materials of the polypropylene sheet are blended, kneaded, and then extruded; preferably, the kneading temperature is 70-80° C., and the kneading time is more than 60s; preferably, the extrusion temperature is 190-200°C.
  • it also includes sequentially laminating, cooling and quenching the polypropylene substrate obtained after extrusion molding; Lamination to obtain a polypropylene color filter layer, a polypropylene wear-resistant layer and a polypropylene base material layer arranged in sequence.
  • the overall thickness of the polypropylene sheet is 5-6 mm; the thickness of the polypropylene base material layer is 4-8 mm, preferably 4-6 mm; the thickness of the polypropylene color filter layer is 0.02-0.08 mm mm, preferably 0.06-0.08; the thickness of the polypropylene wear-resistant layer is 0.15-0.8mm, preferably 0.35-0.55mm; the haze of the polypropylene wear-resistant layer is less than 10%, and the light transmittance is greater than 92%.
  • the embodiment of the present invention provides a beneficial effect of a polypropylene sheet: through the improvement of the raw material formula, the modified polypropylene resin, filler, stabilizer and lubricant are used as raw materials, and the melting quality of the modified polypropylene resin is specially regulated to be 2-9 grams per 10 minutes, and adjusting the dosage of each component, it can be extruded without adding plasticizer, and there will be no delamination.
  • the embodiment of the present invention also provides a method for preparing a polypropylene sheet.
  • the PP sheet can be extruded and formed without delamination, especially without adding a plasticizer. Complete the forming process.
  • the embodiment of the present invention provides a polypropylene sheet, in parts by weight, its raw materials include 25-40 parts of modified polypropylene resin, 30-70 parts of filler, 3-10 parts of stabilizer and 1-8 parts of lubricant ; Among them, the melting mass of the modified polypropylene resin is 2-9 g/10 minutes.
  • PP materials are non-polar materials in terms of molecular structure, and the entire molecule is generally a symmetrical structure, which is not conducive to electron transfer. Due to the poor degree of electron transfer, the energy transfer effect is not good, so that the mixing effect of PP molecules and powder (filler) is poor and cannot be fully mixed, and the powder and PP resin will be delaminated after extrusion.
  • the melting mass is greater than 9 g/10 minutes, the modified PP material is easy to flow out and cannot be formed; when the melting mass is less than 2 g/10 minutes, it is not easy to shear, and the mixing uniformity is poor; and the melting mass is 2-9 g/10 minutes. In the range of 10 minutes, the modified PP material is melted and mixed evenly and is easy to form.
  • the raw material formula of the polypropylene sheet provided by the embodiment of the present invention does not contain plasticizer, fully meets the requirements of green environmental protection, and has a very good market application prospect.
  • the inventor further optimized the dosage of each component.
  • the raw materials of the polypropylene sheet include 30-36 parts of modified polypropylene resin, 30-70 parts of filler, 5-8 parts of stabilizer and 2-5 parts of lubricant;
  • the melt mass of the polypropylene resin is 4-7 grams per 10 minutes.
  • the modified polypropylene resin is at least one of polyolefin modified polypropylene resin and acrylic grafted polypropylene resin; preferably, the modified polypropylene resin includes 15-18 parts of polyolefin modified polypropylene resin and 15-18 parts of acrylic grafted polypropylene resin.
  • the polyolefin-modified polypropylene resin can choose the product model VM3588, and its degree of polymerization is approximately 800-1000.
  • Acrylic acid grafted polypropylene resin can choose the product model VM3980, and its molecular weight is roughly 850-1200.
  • the filler includes at least one of calcium carbonate, kaolin, and ferric oxide, and the above inorganic fillers are more conducive to mixing with the modified polypropylene resin evenly to improve the molding effect.
  • the fineness of filler is controlled to 400-800 mesh.
  • the stabilizer includes at least one of acrylic acid and zinc phosphate, preferably zinc phosphate.
  • the addition of zinc phosphate can increase the stability of the mixed system and improve the stability of product quality.
  • the lubricant includes at least one of fatty acid zinc and polyethylene wax.
  • the lubricant is a commercially available product, and its addition can further improve the mixing uniformity of each component, which is beneficial to improve the forming effect of the sheet.
  • fillers, stabilizers and lubricants are not limited to the above, and are not listed here.
  • the embodiment of the present invention also provides a preparation method of a polypropylene sheet, which includes: mixing and extruding the raw materials of the polypropylene sheet.
  • the polypropylene sheet is extruded and formed under the premise of the agent, and a product that fully meets the requirements of green environmental protection is prepared.
  • the raw materials of the polypropylene sheet are blended, kneaded, and then extruded; by adding a kneading step before extrusion molding, the mixing uniformity of each component is higher.
  • the kneading temperature is 70-80°C
  • the kneading time is more than 60s
  • the extrusion temperature is 190-200°C.
  • the method further includes sequentially laminating, cooling and quenching the polypropylene substrate obtained after extrusion molding; In order to obtain a polypropylene color filter layer, a polypropylene wear-resistant layer and a polypropylene base material layer arranged in sequence.
  • a polypropylene color filter layer obtained after extrusion molding
  • a polypropylene wear-resistant layer obtained after extrusion molding
  • a polypropylene base material layer obtained after extrusion molding
  • the polypropylene color film layer and the polypropylene wear-resistant layer are the existing materials. After extrusion, the film is covered while hot to realize the three-in-one of the PP color film, the PP wear-resistant layer and the PP substrate.
  • the overall thickness of the polypropylene sheet is 5-6mm; the thickness of the polypropylene base material layer is 4-8mm, preferably 4-6mm; the thickness of the polypropylene color filter layer is 0.02-0.08mm, preferably 0.06-0.08 ;
  • the thickness of the polypropylene wear-resistant layer is 0.15-0.8mm, preferably 0.35-0.55mm; the haze of the polypropylene wear-resistant layer is less than 10%, and the light transmittance is greater than 92%.
  • the preparation method of the polypropylene sheet proposed in the embodiment of the present invention has the following advantages: (1) it does not contain any plasticizers, antioxidants, lubricants, vulcanizing agents, colorants and other auxiliaries, and the produced PP floor does not contain Carcinogens, do not affect human health, more environmentally friendly; (2) without adding plasticizers, the stability of PP materials is easier to control, and the uniformity is better; (3) PP materials are used as raw materials for each layer of PP flooring, which has It is non-toxic and tasteless, and does not volatilize toxic gases; (4) The scrapped floor and the waste generated in the production process can be reused, and the performance is attenuated very little during secondary use.
  • This embodiment provides a polypropylene sheet, whose raw materials include 25 parts by weight of modified polypropylene resin, 30 parts of calcium carbonate, 3 parts of zinc phosphate and 1 part of polyethylene wax; wherein, the modified polypropylene resin The melting mass of 2 g/10 minutes; the modified polypropylene resin is a polyolefin modified polypropylene resin.
  • the present embodiment provides a method for preparing a polypropylene sheet, which is prepared with the raw material formula of the polypropylene sheet provided in this embodiment, including:
  • the thickness of the polypropylene base material layer is controlled to be 4mm, the thickness of the polypropylene color filter layer is 0.02mm, the thickness of the polypropylene wear-resistant layer is 0.15mm, the haze of the polypropylene wear-resistant layer is less than 10%, and the light transmittance is greater than 92 %.
  • This embodiment provides a polypropylene sheet, in parts by weight, its raw materials include 40 parts of modified polypropylene resin, 70 parts of kaolin, 10 parts of acrylic acid and 8 parts of fatty acid zinc; wherein, the melting mass of the modified polypropylene resin is It is 9 grams/10 minutes; the modified polypropylene resin is acrylic acid grafted polypropylene resin.
  • the present embodiment provides a method for preparing a polypropylene sheet, which is prepared with the raw material formula of the polypropylene sheet provided in this embodiment, including:
  • the thickness of the polypropylene substrate layer to be 8mm
  • the thickness of the polypropylene color filter layer to be 0.08mm
  • the thickness of the polypropylene wear-resistant layer to be 0.8mm
  • the haze of the polypropylene wear-resistant layer to be less than 10%
  • the light transmittance to be greater than 92 %.
  • This embodiment provides a polypropylene sheet, in parts by weight, its raw materials include 30 parts of modified polypropylene resin, 30 parts of calcium carbonate, 5 parts of zinc phosphate and 2 parts of polyethylene wax; wherein, the modified polypropylene resin The melting mass of the acrylic resin is 4 g/10 minutes; the modified polypropylene resin is 15 parts of polyolefin modified polypropylene resin and 15 parts of acrylic acid grafted polypropylene resin.
  • the present embodiment provides a method for preparing a polypropylene sheet, which is prepared with the raw material formula of the polypropylene sheet provided in this embodiment, including:
  • the thickness of the polypropylene substrate layer is controlled to be 4mm, the thickness of the polypropylene color filter layer is 0.06mm, the thickness of the polypropylene wear-resistant layer is 0.35mm, the haze of the polypropylene wear-resistant layer is less than 10%, and the light transmittance is greater than 92 %.
  • This embodiment provides a polypropylene sheet, whose raw materials, in parts by weight, include 36 parts of modified polypropylene resin, 70 parts of calcium carbonate, 8 parts of zinc phosphate and 5 parts of polyethylene wax; wherein, the modified polypropylene resin The melting mass of the acrylic resin is 7 g/10 minutes; the modified polypropylene resin is 18 parts of polyolefin modified polypropylene resin and 18 parts of acrylic acid grafted polypropylene resin.
  • the present embodiment provides a method for preparing a polypropylene sheet, which is prepared with the raw material formula of the polypropylene sheet provided in this embodiment, including:
  • the thickness of the polypropylene base material layer is controlled to be 6mm, the thickness of the polypropylene color filter layer is 0.08mm, the thickness of the polypropylene wear-resistant layer is 0.55mm, the haze of the polypropylene wear-resistant layer is less than 10%, and the light transmittance is greater than 92 %.
  • This comparative example provides a polypropylene sheet, the raw material of which differs from Example 1 only in that the melting mass of the modified polypropylene resin is 1 g/10 minutes.
  • This comparative example provides a method for preparing a polypropylene sheet, which is prepared with the raw material formula of the polypropylene sheet provided in this comparative example, and the specific steps refer to Example 1.
  • This comparative example provides a polypropylene sheet, the raw material of which differs from that of Example 1 only in that the melting mass of the modified polypropylene resin is 10 g/10 minutes.
  • This comparative example provides a method for preparing a polypropylene sheet, which is prepared with the raw material formula of the polypropylene sheet provided in this comparative example, and the specific steps refer to Example 1.
  • This comparative example provides a polypropylene sheet, the raw material of which differs from Example 1 only in that: adding 2 parts of plasticizer, the effect of speed increase is not very obvious, because a group of plasticization degrees without adding plasticizer can also be achieved requirements, the flow rate is basically unchanged.
  • Examples 1-4 can be extruded sequentially without delamination, and the molding effect of Examples 3-4 is better; Comparative Examples 1-2 cannot be sequentially molded.
  • the polypropylene sheet provided by the present invention uses modified polypropylene resin, filler, stabilizer and lubricant as raw materials through the improvement of the raw material formula, and the melting quality of the modified polypropylene resin is specially regulated as follows: 2-9 grams per 10 minutes, and adjusting the dosage of each component, it can be extruded without adding plasticizer, and there will be no delamination.
  • the present invention also provides a method for preparing a polypropylene sheet, which can make the PP sheet extruded through the improvement of the raw material formula without delamination, especially without adding a plasticizer. forming process.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
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  • Compositions Of Macromolecular Compounds (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明公开了聚丙烯板材及其制备方法，涉及地板技术领域。聚丙烯板材，其原料包括改性聚丙烯树脂25-40份、填料30-70份、稳定剂3-10份和润滑剂1-8份；其中，改性聚丙烯树脂的熔融质量为2-9克/10分钟。聚丙烯板材的制备方法，其通过原料配方的改进，利用改性聚丙烯树脂、填料、稳定剂和润滑剂为原料，特别调控改性聚丙烯树脂的熔融质量为2-9克/10分钟，能够在不添加增塑剂的前提下挤出成型，且不会产生分层现象，符合绿色环保的要求。

Description

聚丙烯板材及其制备方法 技术领域
本发明涉及地板技术领域，且特别涉及聚丙烯板材及其制备方法。
背景技术
塑胶(PVC)地板是当今应用非常普遍的一种新型轻体地面装饰材料，也称为"轻体地材"，其是采用聚氯乙烯材料生产的地板。具体地，以聚氯乙烯及其共聚树脂为主要原料，加入填料、增塑剂、稳定剂、着色剂等辅料，在片状连续基材上，经涂敷工艺或经压延、挤出或挤压工艺生产而成。目前，PVC地板由于其挥发有毒气体，且一般含有增塑剂等原料，不满足绿色环保的要求，开发不含PVC和增塑剂的地板具有非常好的市场价值。
聚丙烯(PP)原料来源丰富、价格便宜，且无毒无味、光泽性好。但是，PP板材由于其与填充料不能充分混合，无法顺利挤出成型、容易产生分层现象，这也制约了PP板材的大规模生产和应用。
发明内容
本发明的目的在于提供一种聚丙烯板材，旨在不添加增塑剂的条件下，使聚丙烯板材顺利挤出成型。
本发明的另一目的在于提供一种聚丙烯板材的制备方法，其能够制备形成不含增塑剂的聚丙烯板材，具有非常好的应用前景。
本发明解决其技术问题是采用以下技术方案来实现的。
本发明提出了一种聚丙烯板材，按重量份数计，其原料包括改性聚丙烯树脂25-40份、填料30-70份、稳定剂3-10份和润滑剂1-8份；其中，改性聚 丙烯树脂的熔融质量为2-9克/10分钟。
在本发明较佳的实施例中，其原料包括改性聚丙烯树脂30-36份、填料30-70份、稳定剂5-8份和润滑剂2-5份；其中，改性聚丙烯树脂的熔融质量为4-7克/10分钟。
在本发明较佳的实施例中，改性聚丙烯树脂为聚烯烃改性聚丙烯树脂和丙烯酸接枝聚丙烯树脂中的至少一种；优选地，改性聚丙烯树脂包括聚烯烃改性聚丙烯树脂15-18份和丙烯酸接枝聚丙烯树脂15-18份。
在本发明较佳的实施例中，填料包括碳酸钙、高岭土和三氧化二铁中的至少一种；优选地，填料的细度为400-800目。
在本发明较佳的实施例中，稳定剂包括丙烯酸和磷酸锌中的至少一种，优选为磷酸锌。
在本发明较佳的实施例中，润滑剂包括脂肪酸锌和聚乙烯蜡中的至少一种。
本发明还提供了一种聚丙烯板材的制备方法，包括：将上述聚丙烯板材的原料混合挤出。
在本发明较佳的实施例中，将聚丙烯板材的原料共混、捏合，然后再挤出成型；优选地，捏合温度为70-80℃，捏合时间大于60s；优选地，挤出温度为190-200℃。
在本发明较佳的实施例中，还包括对挤出成型后得到的聚丙烯基材依次进行覆膜、冷却和淬火；优选地，覆膜是进行聚丙烯彩膜和聚丙烯耐磨层的贴合，以得到依次设置的聚丙烯彩膜层、聚丙烯耐磨层和聚丙烯基材层。
在本发明较佳的实施例中，聚丙烯板材的整体厚度为5-6mm；聚丙烯基 材层的厚度为4-8mm，优选为4-6mm；聚丙烯彩膜层的厚度为0.02-0.08mm，优选为0.06-0.08；聚丙烯耐磨层的厚度为0.15-0.8mm，优选为0.35-0.55mm；聚丙烯耐磨层的雾度小于10％，透光率大于92％。
本发明实施例提供一种聚丙烯板材的有益效果是：其通过原料配方的改进，利用改性聚丙烯树脂、填料、稳定剂和润滑剂为原料，特别调控改性聚丙烯树脂的熔融质量为2-9克/10分钟，并调控各组分的用量，能够在不添加增塑剂的前提下挤出成型，且不会产生分层现象。
本发明实施例还提供一种聚丙烯板材的制备方法，其通过原料配方的改进，能够使PP板材挤出成型，且不会产生分层现象，特别还能够在不添加增塑剂的情况下完成成型的工艺。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将对本发明实施例中的技术方案进行清楚、完整地描述。实施例中未注明具体条件者，按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
下面对本发明实施例提供的聚丙烯板材及其制备方法进行具体说明。
本发明实施例提供了一种聚丙烯板材，按重量份数计，其原料包括改性聚丙烯树脂25-40份、填料30-70份、稳定剂3-10份和润滑剂1-8份；其中，改性聚丙烯树脂的熔融质量为2-9克/10分钟。
需要说明的是，传统PP材料从分子结构上看，属于非极性材料，整个分子总体上看都是对称结构，这种结构不利于电子转移。由于电子转移程度差，导致能量传递效果不好，使PP分子与粉料(填充料)混合效果很差，无法充分混合，挤出后粉料与PP树脂会出现分层。
发明人发现，通过有效调控改性聚丙烯树脂的熔融质量，选择熔融质量为2-9克/10分钟的改性聚丙烯树脂，成型效果较好。当熔融质量大于9克/10分钟时，改性PP材料容易流出不成型；当熔融质量小于2克/10分钟时，不容易剪切，混合的均匀性差；而熔融质量在2-9克/10分钟范围内改性PP材料其熔融后混合均匀易于成型。
特别强调的是，本发明实施例所提供的聚丙烯板材的原料配方，其不含有增塑剂，完全符合绿色环保的要求，具有非常好的市场应用前景。
为了获得更好的成型效果，发明人对各组分的用量做了进一步优化。在本发明较佳的实施例中，聚丙烯板材的原料包括改性聚丙烯树脂30-36份、填料30-70份、稳定剂5-8份和润滑剂2-5份；其中，改性聚丙烯树脂的熔融质量为4-7克/10分钟。
进一步地，改性聚丙烯树脂为聚烯烃改性聚丙烯树脂和丙烯酸接枝聚丙烯树脂中的至少一种；优选地，改性聚丙烯树脂包括聚烯烃改性聚丙烯树脂15-18份和丙烯酸接枝聚丙烯树脂15-18份。聚烯烃改性聚丙烯树脂可以选择型号为VM3588的产品，其聚合度大致为800-1000。丙烯酸接枝聚丙烯树脂可以选择型号为VM3980的产品，其分子量大致为850-1200。
在本发明较佳的实施例中，填料包括碳酸钙、高岭土和三氧化二铁中的至少一种，以上几种无机填料更有利于和改性聚丙烯树脂混合均匀，提升成型的效果。为增加填料和改性聚丙烯树脂混合的均匀性，填料的细度控制为400-800目。
在本发明较佳的实施例中，稳定剂包括丙烯酸和磷酸锌中的至少一种，优选为磷酸锌。磷酸锌的加入能够增加混合体系的稳定性能，提升产品品质的稳定性。
在本发明较佳的实施例中，润滑剂包括脂肪酸锌和聚乙烯蜡中的至少一种。润滑剂均位市购产品，其的加入可以进一步提升各组分混合的均匀度，有利于提升板材的成型效果。
在其他实施例中，填料、稳定剂和润滑剂不限于以上几种，在此不做一一列举。
本发明实施例还提供了一种聚丙烯板材的制备方法，包括：将上述聚丙烯板材的原料混合挤出，本实施例中所提出的制备方法通过原料配方的改进，可以在不添加增塑剂的前提下使聚丙烯板材挤出成型，制备得到完全符合绿色环保要求的产品。
在本发明较佳的实施例中，将聚丙烯板材的原料共混、捏合，然后再挤出成型；通过在挤出成型之前增加捏合的步骤，使各组分混合的均匀度更高。优选地，捏合温度为70-80℃，捏合时间大于60s；挤出温度为190-200℃。通 过进一步控制操作温度使改性PP材料的熔融效果更好，流动性也更好，更容易挤出。
在本发明较佳的实施例中，还包括对挤出成型后得到的聚丙烯基材依次进行覆膜、冷却和淬火；覆膜是进行聚丙烯彩膜和聚丙烯耐磨层的贴合，以得到依次设置的聚丙烯彩膜层、聚丙烯耐磨层和聚丙烯基材层。通过在成型之后增加覆膜、冷却和淬火等过程，以制备形成地板成品，以上过程的具体工艺可以参照现有技术，在此不做过多赘述。聚丙烯彩膜层、聚丙烯耐磨层为现有材料，挤出后趁热覆膜，实现PP彩膜、PP耐磨层和PP基材三合一。
进一步地，聚丙烯板材的整体厚度为5-6mm；聚丙烯基材层的厚度为4-8mm，优选为4-6mm；聚丙烯彩膜层的厚度为0.02-0.08mm，优选为0.06-0.08；聚丙烯耐磨层的厚度为0.15-0.8mm，优选为0.35-0.55mm；聚丙烯耐磨层的雾度小于10％，透光率大于92％。通过进一步控制聚丙烯基材层、聚丙烯耐磨层和聚丙烯彩膜层的厚度，使层与层之间的同步效果较好、便于安装和运输。
需要补充的是，若聚丙烯板材的整体厚度大于6mm，整体重量较大不便于安装和运输。基材层越厚、耐磨层越薄，层与层之间的同步效果越好，从而稳定性越好。
本发明实施例所提出的聚丙烯板材的制备方法具备以下优点：(1)不含有任何增塑剂、抗氧化剂、润滑剂、硫化剂、着色剂等其它助剂，所生产的PP地板不含致癌物质，不影响人体健康，更加环保；(2)不添加增塑剂使PP材料的稳定性更容易控制，均一性更好；(3)PP地板每一层均使用PP材料作为原 料，具有无毒无味特性，不挥发有毒气体；(4)可以将报废后的地板以及生产过程中产生的废料重复利用，二次利用时性能衰减很小。
以下结合实施例对本发明的特征和性能作进一步的详细描述。
实施例1
本实施例提供一种聚丙烯板材，按重量份数计，其原料包括改性聚丙烯树脂25份、碳酸钙30份、磷酸锌3份和聚乙烯蜡1份；其中，改性聚丙烯树脂的熔融质量为2克/10分钟；改性聚丙烯树脂为聚烯烃改性聚丙烯树脂。
本实施例提供一种聚丙烯板材的制备方法，其以本实施例中所提供的聚丙烯板材的原料配方进行制备，包括：
将各组分混合之后，在70℃下结合2min，然后在190℃的条件下挤出成型。挤出后趁热覆膜，实现PP彩膜、PP耐磨层和PP基材三合一，再冷却、淬火。控制聚丙烯基材层的厚度为4mm，聚丙烯彩膜层的厚度为0.02mm，聚丙烯耐磨层的厚度为0.15mm，聚丙烯耐磨层的雾度小于10％，透光率大于92％。
实施例2
本实施例提供一种聚丙烯板材，按重量份数计，其原料包括改性聚丙烯树脂40份、高岭土70份、丙烯酸10份和脂肪酸锌8份；其中，改性聚丙烯树脂的熔融质量为9克/10分钟；改性聚丙烯树脂为丙烯酸接枝聚丙烯树脂。
本实施例提供一种聚丙烯板材的制备方法，其以本实施例中所提供的聚丙烯板材的原料配方进行制备，包括：
将各组分混合之后，在70℃下结合2min，然后在190℃的条件下挤出成型。挤出后趁热覆膜，实现PP彩膜、PP耐磨层和PP基材三合一，再冷却、淬火。控制聚丙烯基材层的厚度为8mm，聚丙烯彩膜层的厚度为0.08mm，聚丙烯耐磨层的厚度为0.8mm，聚丙烯耐磨层的雾度小于10％，透光率大于92％。
实施例3
本实施例提供一种聚丙烯板材，按重量份数计，其原料包括改性聚丙烯树脂30份、碳酸钙30份、磷酸锌5份和聚乙烯蜡2份；其中，改性聚丙烯树脂的熔融质量为4克/10分钟；改性聚丙烯树脂为聚烯烃改性聚丙烯树脂15份、丙烯酸接枝聚丙烯树脂15份。
本实施例提供一种聚丙烯板材的制备方法，其以本实施例中所提供的聚丙烯板材的原料配方进行制备，包括：
将各组分混合之后，在70℃下结合2min，然后在190℃的条件下挤出成型。挤出后趁热覆膜，实现PP彩膜、PP耐磨层和PP基材三合一，再冷却、淬火。控制聚丙烯基材层的厚度为4mm，聚丙烯彩膜层的厚度为0.06mm，聚丙烯耐磨层的厚度为0.35mm，聚丙烯耐磨层的雾度小于10％，透光率大于92％。
实施例4
本实施例提供一种聚丙烯板材，按重量份数计，其原料包括改性聚丙烯树脂36份、碳酸钙70份、磷酸锌8份和聚乙烯蜡5份；其中，改性聚丙烯树脂的熔融质量为7克/10分钟；改性聚丙烯树脂为聚烯烃改性聚丙烯树脂18份、丙烯酸接枝聚丙烯树脂18份。
本实施例提供一种聚丙烯板材的制备方法，其以本实施例中所提供的聚丙烯板材的原料配方进行制备，包括：
将各组分混合之后，在70℃下结合2min，然后在190℃的条件下挤出成型。挤出后趁热覆膜，实现PP彩膜、PP耐磨层和PP基材三合一，再冷却、淬火。控制聚丙烯基材层的厚度为6mm，聚丙烯彩膜层的厚度为0.08mm，聚丙烯耐磨层的厚度为0.55mm，聚丙烯耐磨层的雾度小于10％，透光率大于92％。
对比例1
本对比例提供一种聚丙烯板材，其原料与实施例1的区别仅在于：改性聚丙烯树脂的熔融质量为1克/10分钟。
本对比例提供一种聚丙烯板材的制备方法，其以本对比例中所提供的聚丙烯板材的原料配方进行制备，具体步骤参照实施例1。
对比例2
本对比例提供一种聚丙烯板材，其原料与实施例1的区别仅在于：改性聚丙烯树脂的熔融质量为10克/10分钟。
本对比例提供一种聚丙烯板材的制备方法，其以本对比例中所提供的聚丙烯板材的原料配方进行制备，具体步骤参照实施例1。
对比例3
本对比例提供一种聚丙烯板材，其原料与实施例1的区别仅在于：加入增塑剂2份，增速效果不是很明显，因为没有加增塑剂的一组塑化程度也可以达到要求，流动速度基本没有变化。
试验例
测试实施例1-4和对比例1-2中的聚丙烯板材挤出成型的效果，结果显示：
实施例1-4中的聚丙烯板材均可以顺序挤出成型，均没有出现分层现象，且实施例3-4的成型效果更好；对比例1-2均不能顺序成型。
综上所述，本发明提供的一种聚丙烯板材，其通过原料配方的改进，利用改性聚丙烯树脂、填料、稳定剂和润滑剂为原料，特别调控改性聚丙烯树脂的熔融质量为2-9克/10分钟，并调控各组分的用量，能够在不添加增塑剂的前提下挤出成型，且不会产生分层现象。
本发明还提供的一种聚丙烯板材的制备方法，其通过原料配方的改进，能够使PP板材挤出成型，且不会产生分层现象，特别还能够在不添加增塑剂的情况下完成成型的工艺。
以上所描述的实施例是本发明一部分实施例，而不是全部的实施例。本发明的实施例的详细描述并非旨在限制要求保护的本发明的范围，而是仅仅 表示本发明的选定实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。

Claims (10)

  1. 一种聚丙烯板材，其特征在于，按重量份数计，其原料包括改性聚丙烯树脂25-40份、填料30-70份、稳定剂3-10份和润滑剂1-8份；其中，所述改性聚丙烯树脂的熔融质量为2-9克/10分钟。
  2. 根据权利要求1所述的聚丙烯板材，其特征在于，包括改性聚丙烯树脂30-36份、填料30-70份、稳定剂5-8份和润滑剂2-5份；其中，所述改性聚丙烯树脂的熔融质量为4-7克/10分钟。
  3. 根据权利要求1或2所述的聚丙烯板材，其特征在于，所述改性聚丙烯树脂为聚烯烃改性聚丙烯树脂和丙烯酸接枝聚丙烯树脂中的至少一种；
    优选地，所述改性聚丙烯树脂包括聚烯烃改性聚丙烯树脂15-18份和丙烯酸接枝聚丙烯树脂15-18份；
    优选地，聚烯烃改性聚丙烯树脂的型号为VM3588，丙烯酸接枝聚丙烯树脂的型号为VM3980。
  4. 根据权利要求1或2所述的聚丙烯板材，其特征在于，所述填料包括碳酸钙、高岭土和三氧化二铁中的至少一种；
    优选地，所述填料的细度为400-800目。
  5. 根据权利要求1或2所述的聚丙烯板材，其特征在于，所述稳定剂包括丙烯酸和磷酸锌中的至少一种，优选为磷酸锌。
  6. 根据权利要求1或2所述的聚丙烯板材，其特征在于，所述润滑剂包括脂肪酸锌和聚乙烯蜡中的至少一种。
  7. 一种聚丙烯板材的制备方法，其特征在于，包括：将权利要求1-6中任一项所述聚丙烯板材的原料混合挤出。
  8. 根据权利要求7所述的制备方法，其特征在于，将所述聚丙烯板材的 原料共混、捏合，然后再挤出成型；
    优选地，捏合温度为70-80℃，捏合时间大于60s；
    优选地，挤出温度为190-200℃。
  9. 根据权利要求8所述的制备方法，其特征在于，还包括对挤出成型后得到的聚丙烯基材依次进行覆膜、冷却和淬火；
    优选地，所述覆膜是进行聚丙烯彩膜和聚丙烯耐磨层的贴合，以得到依次设置的聚丙烯彩膜层、聚丙烯耐磨层和聚丙烯基材层。
  10. 根据权利要求9所述的制备方法，其特征在于，所述聚丙烯板材的整体厚度为5-10mm；
    优选地，聚丙烯基材层的厚度为4-8mm，更优选为4-6mm；
    优选地，所述聚丙烯彩膜层的厚度为0.02-0.08mm，更优选为0.06-0.08；
    优选地，所述聚丙烯耐磨层的厚度为0.15-0.8mm，更优选为0.35-0.55mm；
    更优选地，所述聚丙烯耐磨层的雾度小于10％，透光率大于92％。
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