High-strength and high-performance surface double-layer co-extrusion color pattern polystyrene foaming composite material and preparation method thereof

Abstract

The invention relates to a high-strength and high-performance surface double-layer co-extrusion color grain polystyrene foaming composite material, which is divided into a double-layer co-extrusion surface layer material and a core material, the core material is mainly prepared by the following steps: carrying out extrusion granulation on polystyrene, an antioxidant, a foaming agent and the like as raw materials, and then extruding with a reinforcing rib material by virtue of co-extrusion equipment to obtain a high-strength core material; the surface layer material is divided into a surface layer material and a bottom layer material, and then embossing and surface polishing are carried out, so that the final co-extrusion color grain polystyrene foaming composite material is obtained. According to the polystyrene foaming composite material prepared through the method, the appearance color of the surface layer has an obvious difference feeling, the surface layer has excellent comprehensive performance including halogen-free flame retardance, aging resistance, surface scratch resistance, surface pollution resistance and the like, the static bending intensity of the core material is improved to a large extent due to introduction of reinforcing ribs in the core material, and the strength of the core material is improved to a large extent. The comprehensive performance is relatively excellent.

Description

Technical Field

[0001] The invention relates to the technical field of foaming materials, and in particular to a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foaming composite material and a preparation method thereof. Background Art

[0002] Wood plastic composite materials have excellent imitation wood grain structure, and compared with pure wood, they have good moisture resistance and are not easy to rot. They have developed rapidly in recent years. However, compared with ordinary wood plastic composite materials, all-plastic foam composite materials have better water resistance, mildew resistance, outdoor durability, etc.

[0003] At present, the majority of all-plastic foam composite materials are polystyrene foam materials. Styrene all-plastic foam materials have a closed-cell structure, low water absorption, and excellent water resistance; low density, good mechanical strength, and excellent cushioning performance; good processability and easy molding; and compared with the traditional first-generation wood-plastic products, they have the characteristics of water resistance and insect resistance, and have developed rapidly in recent years. However, all-plastic polystyrene foam composite materials also have some defects, such as insufficient high temperature resistance, flame retardancy, weather resistance, and chemical resistance, and the mechanical strength is also low, the surface color is single, and the decorative effect is average. With the improvement of halogen-free flame retardant requirements, how to develop high-strength, high-performance, halogen-free flame retardant, and decorative color polystyrene foam composite materials is the focus of research in the industry.

[0004] In view of the above problems, the present invention has developed a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material and a preparation method thereof, which is divided into a double-layer co-extruded surface layer material and a core material, the core material includes a core foam material and a reinforcing rib material; the core foam material is first crushed and mixed into powder at high speed, and then extruded with the reinforcing rib material by means of a co-extrusion device to obtain a halogen-free flame-retardant high-strength core material, and finally co-extruded with two layers of fabric, wherein the surface layer material is divided into a surface layer material and a bottom layer material, and the polystyrene composite material after the double-layer co-extruded molding is subjected to surface grinding, embossing, etc. to obtain the final co-extruded color-patterned polystyrene foam composite material. Summary of the invention

[0005] The invention relates to a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material, which comprises a surface layer material and a core material; the core material comprises a foaming material and a reinforcing rib material, the foaming material is a polystyrene foaming material; the reinforcing rib material is distributed in the foaming material to play a reinforcing role; the surface layer material comprises a top layer material and a bottom layer material, the bottom layer material is compounded from raw materials including glass fiber reinforced ASA resin, polyphenylene ether, and carbon black, and the surface layer material is compounded from raw materials including ASA resin, polyvinylidene fluoride, and / or pigment; wherein the core material is sequentially composed of the bottom layer material and the top layer material outwards.

[0006] Firstly, the reinforcing rib material and the core foaming material are co-extruded to obtain a high-strength expanded polystyrene core material; then, it is used as a base material and co-extruded with a bottom layer material and a surface layer material from the inside to the outside to obtain a double-layer co-extruded layer; and then, after post-processing, a surface double-layer co-extruded colored polystyrene foam composite material is obtained.

[0007] The high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam material further comprises, in parts by mass, a foaming material composition of the core material as follows:

[0008]

[0009] Preferably, the foaming agent is ammonium carbonate, ammonium bicarbonate or a mixture of the two; the antioxidant is antioxidant 1010, and the ultraviolet absorber is ultraviolet absorber UV-9; melamine formaldehyde resin powder, fineness 80-120 mesh (for example, can be purchased from Jinan Rongguang Chemical Co., Ltd.).

[0010] The high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam material as described above, wherein the reinforcing rib material is made of medium-long fibers; the fiber material is carbon fiber, glass fiber, or a mixture of the two;

[0011] Among them, the length of medium and long fibers is controlled to be 5-10cm;

[0012] Preferably, the mass of the fibers used accounts for 3-8% of the total mass of the core foaming material.

[0013] The reinforcing ribs are arranged at the center of the polystyrene foam core material; that is, the reinforcing ribs are arranged at the center of the polystyrene foam core material (e.g., 10-20 cm in width); for example, when viewed from the side, the reinforcing ribs are located at the intersection of the diagonal lines of the rectangular side (width direction) of the polystyrene foam composite material. Figure 3 It can also be seen that the reinforcement rib is located in the center of the side.

[0014] The fiber orientation of the reinforcing rib material is consistent with the length direction of the polystyrene foam composite material. The corresponding preparation process of the present invention is: the core material foaming premix powder is added to the main machine of the parallel twin-screw profile extruder, and the auxiliary machine synchronously pulls and pushes out the reinforcing rib material and the core material foam material in the main machine for co-extrusion molding to obtain a high-strength foamed polystyrene core material. The length of the polystyrene foam composite material is continuously extruded from the main machine of the parallel twin-screw profile extruder, and then cut to length as required. In addition to removing the texture and specific design shape, the main body of the polystyrene foam composite material can be, for example, a structure similar to a rectangular parallelepiped, and the length after cutting is generally more than 30cm (it is a continuous length before cutting, which can also be understood as infinite length), the width is, for example, 10-20cm, and the height is, for example, 3-5cm, so the length of the fiber is consistent with the length direction of the board.

[0015] The width of the polystyrene foam composite material can be set as required, for example, it can be 10-20 cm, preferably 15-20 cm; since the length direction of the fiber is consistent with the length direction of the board, it is equivalent to containing a reinforcing rib in each polystyrene composite material.

[0016] As described above, a high-strength, high-performance surface double-layer co-extruded colored polystyrene foam material is provided, wherein in the surface layer, the bottom layer material is obtained by compounding glass fiber reinforced ASA resin, polyphenylene ether and carbon black, the glass fiber reinforced ASA resin is 15% glass fiber reinforced ASA resin (for example, it can be purchased from Qingdao Zhongxin Huamei Plastic Co., Ltd.); the polyphenylene ether is black flame retardant polyphenylene ether (for example, the model is 130P-BK, purchased from Guangdong Junlong New Materials Technology Co., Ltd.); the mass ratio of 15% glass fiber reinforced ASA resin: polyphenylene ether: carbon black is 87-91:8-12:0.3-1; the raw materials of the surface layer material may contain or not contain pigments; the mass ratio of ASA resin, polyvinylidene fluoride and pigment in the surface layer material is 70-78:22-29:0-1; the pigment may be red iron oxide, yellow iron oxide or other weather-resistant pigments. For example, the ASA resin model PW-997S was purchased from Taiwan Chi Mei Industrial Co., Ltd.; the polyvinylidene fluoride resin was purchased from Shanghai San Ai Fu New Materials Co., Ltd.

[0017] As described above, the high-strength, high-performance surface double-layer co-extruded colored polystyrene foam material preferably has a bottom layer material mass of 4-7% of the total core foam material mass, and a surface layer material mass of 3-4% of the total core foam material mass.

[0018] As described above, a high-strength, high-performance surface double-layer co-extruded colored polystyrene foam material is provided, wherein the preparation method of the double-layer co-extruded bottom layer premix is ​​as follows: dry 15% glass fiber reinforced ASA resin particles, polyphenylene ether, and carbon black are first mixed uniformly in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed, and granulated by a twin-screw extruder to obtain a bottom layer premix for standby use; wherein the twin-screw extrusion temperature is 280-295°C, and the screw speed is 150-200rpm.

[0019] As described above, a high-strength, high-performance surface double-layer co-extruded colored polystyrene foam material, the preparation method of the double-layer co-extruded surface premix is: dry ASA resin particles, polyvinylidene fluoride, and pigment are first mixed uniformly in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain a surface premix for standby use; wherein the twin-screw extrusion temperature is 230-245°C, and the screw speed is 220-250rpm.

[0020] The method for preparing a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises the following steps:

[0021] A. Add the fully dried core foaming material into a high-speed pulverizer according to the formula, and then pulverize and mix it to a particle size of 50-100 mesh to obtain a core foaming premix powder;

[0022] B. Add the core foam premix powder into the main machine of the parallel twin-screw profile extruder, and the auxiliary machine simultaneously pulls out the reinforcing rib material and co-extrudes it with the core foam material in the main machine to obtain a high-strength expanded polystyrene core material;

[0023] C. The high-strength expanded polystyrene core material obtained in B is used as a substrate, and is passed through a stage I co-extrusion die with a co-extruded bottom layer fabric (premix) and a stage II co-extrusion die with a co-extruded surface layer fabric (premix) in a channel to obtain double-layer co-extruded layers respectively; then, after embossing, cooling and forming, surface grinding, and fixed-length cutting, a surface double-layer co-extruded color-patterned polystyrene foam composite material is obtained.

[0024] As described above, a method for preparing a high-strength, high-performance surface double-layer co-extruded colored polystyrene foam composite material, preferably, in step B, the extrusion temperature of the parallel twin-screw profile extruder is 195-205°C, and the screw speed is 15-25rpm; in step C, the temperature of the co-extrusion mold in section I is 280-295°C; the temperature of the co-extrusion mold in section II is 240-245°C, and the screw speed of the co-extrusion molds in sections I and II and the speed of the core material extruder are both 15-25rpm.

[0025] Beneficial Effects

[0026] The polystyrene foam composite material obtained by the technical solution adopts double-layer co-extrusion, and the colors of the double-layer co-extrusion layers can be different. After polishing in the polishing process, a small part of the surface co-extrusion layer will be worn away due to the polishing effect in some positions to expose the bottom co-extrusion layer. Since the bottom co-extrusion layer and the surface co-extrusion layer are different in color, a blended color appears on the surface of the composite material, and the color layering is excellent, and the decorative effect is good. In addition, the double-layer co-extruded surface has excellent weather resistance, high temperature resistance, halogen-free flame retardant properties, etc. At the same time, the introduction of reinforcing ribs in the core material and the use of melamine formaldehyde resin in the foamed core material greatly improve the static bending strength and flame retardant properties of the core material, and finally have better comprehensive performance.

[0027] Specifically, from the core material, the addition of melamine formaldehyde resin in the foam core material, after the foaming material is crushed into powder, the melamine formaldehyde resin itself will undergo partial cross-linking and curing during the foaming molding process. On the one hand, the strength of the foam core material is enhanced. On the other hand, the melamine formaldehyde resin itself is a halogen-free flame retardant ingredient, which also provides the foam core material with halogen-free flame retardant capability; and the co-extrusion layer molding of fiber reinforcement ribs greatly improves the mechanical strength of the core material.

[0028] From the surface layer, the high-strength raw materials used in the bottom layer, such as 15% glass fiber reinforced ASA resin, black flame-retardant polyphenylene ether and carbon black, not only provide the performance of the co-extruded bottom layer, but also provide the basis for the color after surface polishing. The surface layer is made of ASA resin, polyvinylidene fluoride and pigment. The surface color layering and decorativeness of the polystyrene composite material after polishing are good. More importantly, the surface after double-layer co-extrusion uses ASA resin, polyphenylene ether, polyvinylidene fluoride and other plastics, so the surface wear resistance, chemical resistance, weather resistance and flame retardancy of the final polystyrene foam composite material are excellent.

[0029] The present invention has been described in detail above, but the above embodiments are only illustrative in nature and are not intended to limit the present invention. In addition, this article is not limited by any theory described in the above prior art or invention content or the following examples. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a front view of an exemplary product of the present invention after polishing;

[0031] Figure 2 A side view of an exemplary product of the present invention;

[0032] Figure 3 This is a schematic side view of a sample according to Embodiment 1 of the present invention;

[0033] The black part is the reinforcement rib, and the light yellow part is the polystyrene foam core material. DETAILED DESCRIPTION

[0034] The present invention is further described below in conjunction with examples. It should be noted that the following examples are provided for illustrative purposes only and do not constitute a limitation on the scope of protection claimed for the present invention.

[0035] Among them, in the foaming material, general-purpose polystyrene and high-impact polystyrene are both ordinary products on the market, purchased from Ningbo Liwan New Materials Co., Ltd.; melamine formaldehyde resin powder, fineness 80-120 mesh, purchased from Jinan Rongguang Chemical Co., Ltd.; in the base material, glass fiber reinforced ASA resin is 15% glass fiber reinforced ASA resin, purchased from Qingdao Zhongxin Huamei Plastic Co., Ltd.; polyphenylene ether is black flame retardant polyphenylene ether, model 130P-BK, purchased from Guangdong Junlong New Materials Technology Co., Ltd.; in the surface material, ASA resin model PW-997S, purchased from Taiwan Chi Mei Industrial Co., Ltd.; polyvinylidene fluoride resin was purchased from Shanghai San Ai Fa New Materials Co., Ltd.

[0036] Except for those explicitly stated above, other raw materials are commercially available.

[0037] Example 1

[0038] A high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises a surface layer material and a core material; the core material comprises a foaming material and a reinforcing rib material, and the foaming material is a polystyrene foaming material; the surface layer material comprises a top layer material and a bottom layer material, the bottom layer material is compounded by glass fiber reinforced ASA resin, polyphenylene ether, and carbon black, and the surface layer material is compounded by ASA resin, polyvinylidene fluoride, and pigment.

[0039] Wherein, the foaming material of the core material is composed as follows:

[0040]

[0041] The foaming agent is a mixture of ammonium carbonate and ammonium bicarbonate; the antioxidant is antioxidant 1010, and the ultraviolet absorber is ultraviolet absorber UV-9;

[0042] The reinforcement material is a medium-long mixed fiber; the fiber material is a mixed fiber of carbon fiber and glass fiber, in which the mass ratio of carbon fiber to glass fiber is 5:5; the length of the fiber is controlled to be 5-10cm;

[0043] The mass of the fiber used accounts for 5% of the total mass of the core foam material;

[0044] In the surface layer, the bottom layer material is obtained by compounding glass fiber reinforced ASA resin, polyphenylene ether and carbon black, and the mass ratio of 15% glass fiber reinforced ASA resin: polyphenylene ether: carbon black is 87:12:1; the mass ratio of ASA resin, polyvinylidene fluoride and pigment in the surface layer material is 70:29:1; the pigment is red iron oxide;

[0045] Among them, the mass of the bottom layer of the double-layer co-extrusion layer accounts for 5% of the total mass of the core foam material; the surface layer material accounts for 4% of the total mass of the core foam material;

[0046] The preparation method of the double-layer co-extrusion bottom layer premix is ​​as follows: dry 15% glass fiber reinforced ASA resin particles, polyphenylene ether, and carbon black are first mixed uniformly in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed, and granulated by a twin-screw extruder to obtain the bottom layer premix, which is then used for standby; wherein the twin-screw extrusion temperature is 295°C and the screw speed is 200rpm;

[0047] The preparation method of the double-layer co-extrusion surface premix is ​​as follows: dry ASA resin particles, polyvinylidene fluoride, and pigment are uniformly mixed in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain the surface premix for standby use; wherein the twin-screw extrusion temperature is 245°C and the screw speed is 250rpm;

[0048] The preparation method of the high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises the following steps:

[0049] A. Add the fully dried core foaming material into a high-speed pulverizer according to the formula, and then pulverize and mix it to a particle size of 50-100 mesh to obtain a core foaming premix powder;

[0050] B. Add the core foam premix powder into the main machine of the parallel twin-screw profile extruder, and the auxiliary machine simultaneously pulls out the reinforcing rib material and co-extrudes it with the core foam material in the main machine to obtain a high-strength expanded polystyrene core material;

[0051] C. The high-strength expanded polystyrene core material obtained in B is used as a substrate, and is passed through a stage I co-extrusion die with a co-extruded bottom layer fabric (premix) and a stage II co-extrusion die with a co-extruded surface layer fabric (premix) in a channel to obtain double-layer co-extruded layers respectively; then, after embossing, cooling and forming, surface grinding, and fixed-length cutting, a surface double-layer co-extruded color-patterned polystyrene foam composite material is obtained.

[0052] Among them, in step B, the extrusion temperature of the parallel twin-screw profile extruder is 200°C and the screw speed is 25rpm; in step C, the temperature of the co-extrusion die in section I is 290°C; the temperature of the co-extrusion die in section II is 242°C, and the screw speed of the co-extrusion dies in sections I and II and the speed of the core material extruder are both 25rpm.

[0053] Example 2

[0054] A high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises a surface layer material and a core material; the core material comprises a foaming material and a reinforcing rib material, and the foaming material is a polystyrene foaming material; the surface layer material comprises a top layer material and a bottom layer material, the bottom layer material is compounded by glass fiber reinforced ASA resin, polyphenylene ether, and carbon black, and the surface layer material is compounded by ASA resin, polyvinylidene fluoride, and pigment.

[0055] Wherein, the foaming material of the core material is composed as follows:

[0056]

[0057] Wherein, the foaming agent is ammonium carbonate; the antioxidant is antioxidant 1010, and the ultraviolet absorber is ultraviolet absorber UV-9;

[0058] The reinforcement material is made of medium and long fibers; the fiber material is carbon fiber; the fiber length is controlled to be 5-10cm;

[0059] The fiber mass used accounts for 4% of the total mass of the core foam material;

[0060] In the surface layer, the bottom layer material is obtained by compounding glass fiber reinforced ASA resin, polyphenylene ether and carbon black, and the mass ratio of 15% glass fiber reinforced ASA resin: polyphenylene ether: carbon black is 90:9:1; the mass ratio of ASA resin, polyvinylidene fluoride and pigment in the surface layer material is 75:24:1; the pigment is iron oxide yellow;

[0061] Among them, the mass of the bottom layer of the double-layer co-extrusion layer accounts for 7% of the total mass of the core foam material; the surface layer material accounts for 3% of the total mass of the core foam material;

[0062] The preparation method of the double-layer co-extrusion bottom layer premix is ​​as follows: dry 15% glass fiber reinforced ASA resin particles, polyphenylene ether, and carbon black are uniformly mixed in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed, and granulated by a twin-screw extruder to obtain the bottom layer premix, which is then used for standby; wherein the twin-screw extrusion temperature is 280°C and the screw speed is 150rpm;

[0063] The preparation method of the double-layer co-extrusion surface premix is ​​as follows: dry ASA resin particles, polyvinylidene fluoride, and pigment are uniformly mixed in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain the surface premix for standby use; wherein the twin-screw extrusion temperature is 230°C and the screw speed is 220rpm;

[0064] The preparation method of the high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises the following steps:

[0065] A. Add the fully dried core foaming material into a high-speed pulverizer according to the formula, and then pulverize and mix it to a particle size of 50-100 mesh to obtain a core foaming premix powder;

[0066] B. Add the core foam premix powder into the main machine of the parallel twin-screw profile extruder, and the auxiliary machine simultaneously pulls out the reinforcing rib material and co-extrudes it with the core foam material in the main machine to obtain a high-strength expanded polystyrene core material;

[0067] C. The high-strength expanded polystyrene core material obtained in B is used as a substrate, and is passed through a stage I co-extrusion die with a co-extruded bottom layer fabric (premix) and a stage II co-extrusion die with a co-extruded surface layer fabric (premix) in a channel to obtain double-layer co-extruded layers respectively; then, after embossing, cooling and forming, surface grinding, and fixed-length cutting, a surface double-layer co-extruded color-patterned polystyrene foam composite material is obtained.

[0068] Among them, in step B, the extrusion temperature of the parallel twin-screw profile extruder is 195°C and the screw speed is 15rpm; in step C, the temperature of the co-extrusion die in section I is 280°C; the temperature of the co-extrusion die in section II is 240°C, and the screw speeds of the co-extrusion dies in sections I and II and the speed of the core material extruder are both 15rpm.

[0069] Example 3

[0070] A high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises a surface layer material and a core material; the core material comprises a foaming material and a reinforcing rib material, and the foaming material is a polystyrene foaming material; the surface layer material comprises a top layer material and a bottom layer material, the bottom layer material is compounded by glass fiber reinforced ASA resin, polyphenylene ether, and carbon black, and the surface layer material is compounded by ASA resin, polyvinylidene fluoride, and pigment.

[0071] Wherein, the foaming material of the core material is composed as follows:

[0072]

[0073] Wherein, the foaming agent is ammonium bicarbonate; the antioxidant is antioxidant 1010, and the ultraviolet absorber is ultraviolet absorber UV-9;

[0074] The reinforcement material uses medium and long fibers; the fiber material is glass fiber; the fiber length is controlled to be 5-10cm;

[0075] The mass of the fiber used accounts for 8% of the total mass of the core foam material;

[0076] In the surface layer, the bottom layer material is obtained by compounding glass fiber reinforced ASA resin, polyphenylene ether and carbon black, and the mass ratio of 15% glass fiber reinforced ASA resin: polyphenylene ether: carbon black is 87:12:1; the mass ratio of ASA resin, polyvinylidene fluoride and pigment in the surface layer material is 70:29:1; the pigment is red iron oxide;

[0077] Among them, the mass of the bottom layer of the double-layer co-extrusion layer accounts for 6% of the total mass of the core foam material; the surface layer material accounts for 4% of the total mass of the core foam material;

[0078] The preparation method of the double-layer co-extrusion bottom layer premix is ​​as follows: dry 15% glass fiber reinforced ASA resin particles, polyphenylene ether, and carbon black are first mixed uniformly in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed, and granulated by a twin-screw extruder to obtain the bottom layer premix, which is then used for standby; wherein the twin-screw extrusion temperature is 290°C and the screw speed is 200rpm;

[0079] The preparation method of the double-layer co-extrusion surface premix is ​​as follows: dry ASA resin particles, polyvinylidene fluoride, and pigment are uniformly mixed in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain the surface premix for standby use; wherein the twin-screw extrusion temperature is 245°C and the screw speed is 250rpm;

[0080] The preparation method of the high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises the following steps:

[0081] A. Add the fully dried core foaming material into a high-speed pulverizer according to the formula, and then pulverize and mix it to a particle size of 50-100 mesh to obtain a core foaming premix powder;

[0082] B. Add the core foam premix powder into the main machine of the parallel twin-screw profile extruder, and the auxiliary machine simultaneously pulls out the reinforcing rib material and co-extrudes it with the core foam material in the main machine to obtain a high-strength expanded polystyrene core material;

[0083] C. The high-strength expanded polystyrene core material obtained in B is used as a substrate, and is passed through a stage I co-extrusion die with a co-extruded bottom layer fabric (premix) and a stage II co-extrusion die with a co-extruded surface layer fabric (premix) in a channel to obtain double-layer co-extruded layers respectively; then, after embossing, cooling and forming, surface grinding, and fixed-length cutting, a surface double-layer co-extruded color-patterned polystyrene foam composite material is obtained.

[0084] Among them, in step B, the extrusion temperature of the parallel twin-screw profile extruder is 200°C and the screw speed is 20rpm; in step C, the temperature of the co-extrusion mold in section I is 290°C; the temperature of the co-extrusion mold in section II is 242°C, and the screw speed of the co-extrusion molds in sections I and II and the speed of the core material extruder are both 20rpm.

[0085] Example 4

[0086] A high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises a surface layer material and a core material; the core material comprises a foaming material and a reinforcing rib material, and the foaming material is a polystyrene foaming material; the surface layer material comprises a top layer material and a bottom layer material, the bottom layer material is compounded by glass fiber reinforced ASA resin, polyphenylene ether, and carbon black, and the surface layer material is compounded by ASA resin, polyvinylidene fluoride, and pigment.

[0087] Wherein, the foaming material of the core material is composed as follows:

[0088] General purpose polystyrene 76 parts;

[0089] High impact polystyrene 16 parts;

[0090] 7 parts of melamine formaldehyde resin powder;

[0091] 1.2 parts of foaming agent;

[0092] 1 part antioxidant;

[0093] 0.5 parts of ultraviolet absorber;

[0094] The foaming agent is a mixture of ammonium carbonate and ammonium bicarbonate; the antioxidant is antioxidant 1010, and the ultraviolet absorber is ultraviolet absorber UV-9;

[0095] The reinforcement material is made of medium and long fibers; the fiber material is a mixed fiber of carbon fiber and glass fiber, where the mass ratio of carbon fiber to glass fiber is 3:7; the length of the medium and long fibers is controlled to be 5-10cm;

[0096] The fiber mass used accounts for 7% of the total mass of the core foam material;

[0097] In the surface layer, the bottom layer material is obtained by compounding glass fiber reinforced ASA resin, polyphenylene ether and carbon black, and the mass ratio of 15% glass fiber reinforced ASA resin: polyphenylene ether: carbon black is 90:9:1; the mass ratio of ASA resin, polyvinylidene fluoride and pigment in the surface layer material is 75:24:1; the pigment is red iron oxide;

[0098] Among them, the mass of the bottom layer of the double-layer co-extrusion layer accounts for 7% of the total mass of the core foam material; the surface layer material accounts for 4% of the total mass of the core foam material;

[0099] The preparation method of the double-layer co-extrusion bottom layer premix is ​​as follows: dry 15% glass fiber reinforced ASA resin particles, polyphenylene ether, and carbon black are first mixed uniformly in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed, and granulated by a twin-screw extruder to obtain the bottom layer premix, which is then used for standby; wherein the twin-screw extrusion temperature is 295°C and the screw speed is 200rpm;

[0100] The preparation method of the double-layer co-extrusion surface premix is ​​as follows: dry ASA resin particles, polyvinylidene fluoride, and pigment are uniformly mixed in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain the surface premix for standby use; wherein the twin-screw extrusion temperature is 245°C and the screw speed is 250rpm;

[0101] The preparation method of the high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material comprises the following steps:

[0102] A. Add the fully dried core foaming material into a high-speed pulverizer according to the formula, and then pulverize and mix it to a particle size of 50-100 mesh to obtain a core foaming premix powder;

[0103] B. Add the core foam premix powder into the main machine of the parallel twin-screw profile extruder, and the auxiliary machine simultaneously pulls out the reinforcing rib material and co-extrudes it with the core foam material in the main machine to obtain a high-strength expanded polystyrene core material;

[0104] C. The high-strength expanded polystyrene core material obtained in B is used as a substrate, and is passed through a stage I co-extrusion die with a co-extruded bottom layer fabric (premix) and a stage II co-extrusion die with a co-extruded surface layer fabric (premix) in a channel to obtain double-layer co-extruded layers respectively; then, after embossing, cooling and forming, surface grinding, and fixed-length cutting, a surface double-layer co-extruded color-patterned polystyrene foam composite material is obtained.

[0105] Among them, in step B, the extrusion temperature of the parallel twin-screw profile extruder is 205°C and the screw speed is 25rpm; in step C, the temperature of the co-extrusion die in section I is 295°C; the temperature of the co-extrusion die in section II is 245°C, and the screw speed of the co-extrusion dies in sections I and II and the speed of the core material extruder are both 25rpm.

[0106] Product performance test:

[0107] Finally, the polystyrene foam composite material board was tested for relevant performances according to the standard of GB17657-2013. Among them, the aging resistance test was carried out according to Section 4.26 of GB17657-2013 for 10 cycles, and the performance of the sample was observed and tested; the static bending strength was carried out according to Section 4.7; the high temperature resistance test was carried out according to Section 4.29; the light fastness test was carried out according to Section 4.30, and the xenon arc lamp was irradiated for 6000 hours; the cold and hot cycle resistance was carried out according to Section 4.38; the surface scratch resistance was carried out according to Section 4.39; the surface cigarette burn resistance test was carried out according to Section 4.45; the surface pollution resistance test was carried out according to Section 4.40; the flame retardant performance test adopted the oxygen index test method, and was tested according to GB / T 2406.2-2009 "Determination of Combustion Behavior of Plastics by Oxygen Index Method".

[0108] Table 1 Performance data of examples 1-4 1

[0109]

[0110]

[0111] Table 2 Performance data of examples 1-4 2

[0112]

[0113] It can be seen from the performance tables 1-2 of the above embodiments that the present invention adopts a specific double-layer co-extrusion and a combination molding with a special foam core material and reinforcement ribs; the high strength and excellent comprehensive performance of the co-extruded polystyrene foam composite material are achieved. The embossing and polishing after the double-layer co-extrusion achieves a layered sense of double-layer color, and the decorative effect is outstanding. At the same time, the use of melamine formaldehyde resin and medium and long fibers in the core material as reinforcement ribs not only improves the mechanical properties, so that the static bending strength of the foamed polystyrene composite material reaches more than 54Mpa, but also the use of special fabrics polyvinylidene fluoride and polyphenylene ether for double-layer co-extrusion also achieves halogen-free flame retardancy, and the oxygen index is basically above 36%. Moreover, the combination of special fabrics and processes makes the final polystyrene foam composite material have better comprehensive performance, such as excellent light color fastness, high temperature resistance, boiling water resistance, cold and hot cycle resistance, aging resistance, surface scratch resistance, surface cigarette burn resistance and surface pollution resistance, etc. These are performance advantages that the currently prepared polystyrene foam materials cannot have at the same time. Therefore, the product of the present invention also has excellent mechanical properties and application performance, and has better market application value.

[0114] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that the technical solutions described in the above embodiments may be modified, or some or all of the technical features thereof may be replaced by equivalents, without departing from the spirit and essence of the claims of the present invention; and these modifications or replacements are still within the scope defined by the claims of the present invention.

Claims

1. A high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material, characterized by: It includes an outer surface material and an inner core material; the core material includes a core foam material and a reinforcing rib material, and the foam material is a polystyrene foam material; The surface layer material includes a surface layer material and a bottom layer material, the bottom layer material is compounded from raw materials including glass fiber reinforced ASA resin, polyphenylene ether, and carbon black, and the surface layer material is compounded from raw materials including ASA resin, polyvinylidene fluoride, and / or pigment; Firstly, the reinforcing rib material and the core foaming material are co-extruded to obtain a high-strength foamed polystyrene core material; then, it is used as a base material and co-extruded with a bottom layer material and a surface layer material in sequence to obtain a double-layer co-extruded layer; and then, after post-processing, a surface double-layer co-extruded colored polystyrene foam composite material is obtained.

2. According to claim 1, a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material, characterized in that: The foaming material of the core material is composed of the following parts by mass: 72-82 parts of general-purpose polystyrene; High impact polystyrene 10-20 parts; 5-9 parts of melamine formaldehyde resin powder; 0.8-1.5 parts of foaming agent; Antioxidant 0.5-1 part; 0.2-0.5 parts of ultraviolet absorber; Wherein, the foaming agent is ammonium carbonate, ammonium bicarbonate or a mixture of the two.

3. According to claim 2, a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material, characterized in that: The reinforcement material is made of medium and long fibers; the fiber material is carbon fiber, glass fiber or a mixture of the two; The length of the fiber is controlled to be 5-10 cm; the mass of the fiber used accounts for 3-8% of the total mass of the core foaming material.

4. A high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material according to any one of claims 1 to 3, characterized in that: In the surface layer material, the bottom layer material is obtained by compounding glass fiber reinforced ASA resin, polyphenylene ether and carbon black, wherein the glass fiber reinforced ASA resin is 15% glass fiber reinforced ASA resin; the polyphenylene ether is black flame retardant polyphenylene ether; the mass ratio of 15% glass fiber reinforced ASA resin: polyphenylene ether: carbon black is 87-91:8-12:0.3-1; the raw materials of the surface layer material may contain or not contain pigments; the mass ratio of the surface layer material ASA resin, polyvinylidene fluoride and pigment is 70-78:22-29:0-1; the pigment may be red iron oxide, yellow iron oxide and / or other weather-resistant pigments.

5. The high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material according to claim 1, characterized in that: The mass of the bottom layer material of the double-layer co-extrusion layer accounts for 4-7% of the total mass of the core foam material; the mass of the surface layer material accounts for 3-4% of the total mass of the core foam material.

6. The high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material according to claim 1, characterized in that: The preparation method of the double-layer co-extruded bottom layer premix is ​​as follows: dry 15% glass fiber reinforced ASA resin particles, polyphenylene ether and carbon black are first mixed uniformly in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain the bottom layer premix for standby use; wherein the twin-screw extrusion temperature is 280-295°C and the screw speed is 150-200rpm.

7. The high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material according to claim 1, characterized in that: The preparation method of the double-layer co-extrusion surface premix is ​​as follows: dry ASA resin particles, polyvinylidene fluoride, and / or pigment are uniformly mixed in a high-speed mixer according to the mass ratio, and then melt-extruded, mixed and granulated by a twin-screw extruder to obtain the surface premix for standby use; wherein the twin-screw extrusion temperature is 230-245°C, and the screw speed is 220-250rpm.

8. A method for preparing a high-strength, high-performance surface double-layer co-extruded color-patterned polystyrene foam composite material according to any one of claims 1 to 7, characterized in that: The following steps are involved: A. Add the fully dried core foaming material into a high-speed pulverizer according to the formula, and then pulverize and mix it to a particle size of 50-100 mesh to obtain a core foaming premix powder; B. Add the core foam premix powder into the main machine of the parallel twin-screw profile extruder, and the auxiliary machine simultaneously pulls out the reinforcing rib material and co-extrudes it with the core foam material in the main machine to obtain a high-strength expanded polystyrene core material; C. The high-strength expanded polystyrene core material obtained in B is used as a substrate, and is passed through a stage I co-extrusion die with a co-extruded bottom layer fabric and a stage II co-extrusion die with a co-extruded surface layer fabric in a channel in turn to obtain double-layer co-extruded layers respectively; then, after embossing, cooling and forming, surface grinding, and fixed-length cutting, a surface double-layer co-extruded color-patterned polystyrene foam composite material is obtained.

9. A method for preparing a high-strength, high-performance surface double-layer co-extruded colored polystyrene foam composite material as claimed in claim 8, further characterized in that in step B, the extrusion temperature of the parallel twin-screw profile extruder is 195-205°C, and the screw speed is 15-25rpm.

10. A method for preparing a high-strength, high-performance surface double-layer co-extruded colored polystyrene foam composite material as described in claim 8, further characterized in that, in step C, the temperature of the co-extrusion mold in section I is 280-295°C; the temperature of the co-extrusion mold in section II is 240-245°C, and the screw speed of the co-extrusion molds in sections I and II and the speed of the core material extruder are both 15-25rpm.

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