Continuous fiber reinforced micro-foam profile and preparation method thereof

Abstract

The present invention discloses a continuous fiber reinforced micro-foam profile and a preparation method thereof, wherein the profile comprises a polystyrene micro-foam core layer and a continuous fiber reinforced surface layer, the core layer has a foaming ratio of 1.5-4 times, the continuous fibers are regularly arranged and distributed in the surface semicircular reinforcement ribs, the surface layer is impact-modified polystyrene, and the continuous fibers are high-strength twisted filaments with a fineness of 500-1000D. The preparation method comprises blending the raw materials of the micro-foam core layer, feeding it into a special extruder for foaming, heating and plasticizing, and micro-foaming extrusion; at the same time, the impact-modified polystyrene is fed into a co-extrusion screw extruder, heated and melted, continuous fibers are introduced through a mold, and completely coated on the micro-foam core layer for co-extrusion, cooling and shaping, and traction cutting to obtain. The present invention significantly improves the impact resistance and anti-bending performance of the profile by adopting a continuous fiber reinforcement method, and solves the problem of foam core layer pore rupture caused by the introduction of reinforcing fibers.

Description

Technical Field

[0001] The invention relates to a micro-foam profile and a preparation method thereof, and in particular to a continuous fiber reinforced micro-foam profile and a preparation method thereof. Background Art

[0002] The imitation wood, metal and marble profiles produced by polystyrene micro-foaming can be used for skirting boards, corner lines, waist lines, wall panels, shutter strips, large photo frames, mirror frames, picture frames, etc. in home decoration. They are green and environmentally friendly properties such as light weight, waterproof and moisture-proof, mildew-proof, insect-proof, and no formaldehyde release. They can replace some solid wood, metal, marble, etc., reducing the damage and waste of forest resources and mineral resources.

[0003] Polystyrene micro-foam profiles are hard and brittle, with low impact resistance. In particular, as the length of the product increases, when it is used in skirtings, wall panels, long dressing mirrors and other fields, it will appear arched and bent in the middle, which not only affects the processing and installation of the product, but also warps and breaks over time. The existing technology can improve the impact resistance and rigidity of the foam profile by using glass fiber reinforcement modification technology in the foam core layer. However, the addition of glass fiber will destroy the core layer pore structure, seriously increase the product density, and even the glass fiber will pierce the coating structure, affecting the product appearance and increasing the product defect rate. Summary of the invention

[0004] Purpose of the invention: The present invention aims to provide a polystyrene micro-foam profile which is not easy to bend and arch, has high impact resistance, low density and high strength.

[0005] Technical solution: The continuous fiber reinforced micro-foam profile of the present invention comprises a micro-foam core layer, a surface layer completely covering the micro-foam core layer, and reinforcing ribs arranged on the inner side of the surface layer, wherein continuous fibers are regularly distributed in the reinforcing ribs.

[0006] Furthermore, the reinforcing rib is a special-shaped protrusion, which is semicircular, triangular or trapezoidal, and the continuous fiber is completely wrapped inside the reinforcing rib.

[0007] Furthermore, the reinforcing rib is semicircular, and the diameter of the semicircle is 2-6 mm.

[0008] Furthermore, the material of the surface layer is impact-modified polystyrene, and the continuous fibers are one or more of polyester filaments, polyamide filaments, aromatic polyamide filaments and polyimide filaments.

[0009] Furthermore, the filament fineness of the continuous fiber is 500-2000D, the twisting mode of the continuous fiber is S twist and Z twist, and the S twist and Z twist continuous fibers are arranged alternately with an interval of 10-40mm.

[0010] Furthermore, the material of the micro-foam core layer is a polystyrene composition, and its foaming ratio is 1.5-4 times.

[0011] Furthermore, the polystyrene composition consists of the following components: by mass, 100 parts of general-purpose polystyrene, 1-30 parts of high-impact polystyrene, 1-10 parts of styrene-butadiene rubber and 1-5 parts of AC foaming agent.

[0012] On the other hand, the present invention provides a method for preparing the above-mentioned continuous fiber reinforced micro-foam profile, comprising the following steps:

[0013] (1) The raw materials of the micro-foam core layer are mixed and fed into a special extruder for foaming, heated and plasticized, and micro-foamed and extruded;

[0014] (2) At the same time, the impact-modified polystyrene is fed into the co-extrusion screw extruder, heated and melted, and continuous fibers are introduced through a die and completely covered on the micro-foam core layer for co-extrusion, cooled and shaped, and pulled and cut to complete the preparation of the continuous fiber reinforced co-extruded micro-foam profile.

[0015] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:

[0016] (1) Low density and high strength, by introducing continuous reinforcing fibers into the non-foamed layer of the profile instead of introducing continuous fibers into the foamed core layer. This method does not destroy the pore structure of the foamed core layer, avoids perforation and collapse of the pores in the foamed core layer, and maintains the mechanical strength of the foamed core layer;

[0017] (2) It is not easy to bend and has high impact resistance. Compared with discontinuous fibers, continuous fibers have higher tensile strength, bending strength and impact strength in the extrusion direction. At the same time, the S-twisted and Z-twisted fiber spacing structure can effectively prevent the foamed profile from unidirectional bending. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the structure of the continuous fiber reinforced micro-foam profile of the present invention. DETAILED DESCRIPTION

[0019] The technical solution of the present invention is further described below in conjunction with the accompanying drawings.

[0020] Example 1

[0021] like Figure 1 As shown, this embodiment provides a continuous fiber reinforced micro-foam profile, which includes a micro-foam core layer 1 and a surface layer 2 reinforced with continuous fibers, wherein the surface layer 2 completely covers the micro-foam core layer 1, and the continuous fibers 3 are regularly distributed in the reinforcing ribs 4 on the inner side of the surface layer.

[0022] The reinforcing rib 4 on the inner side of the surface layer of this embodiment is a semicircular irregular protrusion, and the continuous fiber 3 with a semicircular diameter of 3 mm is completely wrapped inside the irregular protrusion. The micro-foam core layer 1 is made of a polystyrene composition, and the foaming ratio of the micro-foam core layer 1 is 2.5 times. The material of the surface layer 2 is impact-modified polystyrene, and the continuous fiber 3 is an aromatic polyamide filament.

[0023] The filament fineness of the continuous fiber 3 of this embodiment is 500D, and the twisting modes of the continuous fiber 3 are S twist and Z twist. The S twist and Z twist continuous fibers are arranged alternately with an interval of 10 mm.

[0024] The polystyrene composition components of this embodiment (parts by mass):

[0025] Adopt chemical micro-foaming composition formula:

[0026]

[0027]

[0028] Preparation method of continuous fiber reinforced micro-foam profile in this embodiment:

[0029] (1) blending the polystyrene composition according to the formula, feeding it into a special extruder for foaming, heating and plasticizing, and extruding micro-foaming;

[0030] (2) At the same time, the impact-modified polystyrene is fed into a co-extrusion screw extruder, heated and melted, and continuous fibers are introduced through a die, and completely covered with the micro-foam core layer for co-extrusion, cooled and shaped, and pulled and cut to obtain a foamed profile.

[0031] Embodiment 2:

[0032] The present embodiment provides a continuous fiber reinforced micro-foam profile, which includes a micro-foam core layer 1 and a surface layer 2 reinforced with continuous fibers, wherein the surface layer 2 completely covers the micro-foam core layer 1, and the continuous fibers 3 are regularly distributed in the reinforcing ribs 4 on the inner side of the surface layer.

[0033] The reinforcing rib 4 on the inner side of the surface layer of this embodiment is a semicircular irregular protrusion, and the continuous fiber 3 with a semicircular diameter of 4 mm is completely wrapped inside the irregular protrusion. The material of the micro-foam core layer 1 is a polystyrene composition, and the foaming ratio of the micro-foam core layer 1 is 2.5 times. The material of the surface layer 2 is impact-modified polystyrene, and the continuous fiber 3 is an aromatic polyamide filament.

[0034] The filament fineness of the continuous fiber 3 in this embodiment is 1000D, and the twisting modes of the continuous fiber 3 are S twist and Z twist. The S twist and Z twist continuous fibers are arranged alternately with an interval of 10 mm.

[0035] The polystyrene composition components of this embodiment (parts by mass):

[0036] Adopt chemical micro-foaming composition formula:

[0037]

[0038] Preparation method of continuous fiber reinforced micro-foam profile in this embodiment:

[0039] (1) blending the polystyrene composition according to the formula, feeding it into a special extruder for foaming, heating and plasticizing, and extruding micro-foaming;

[0040] (2) At the same time, the impact-modified polystyrene is fed into a co-extrusion screw extruder, heated and melted, and continuous fibers are introduced through a die, and completely covered with the micro-foam core layer for co-extrusion, cooled and shaped, and pulled and cut to obtain a foamed profile.

[0041] Embodiment 3:

[0042] The present embodiment provides a continuous fiber reinforced micro-foam profile, which includes a micro-foam core layer 1 and a surface layer 2 reinforced with continuous fibers, wherein the surface layer 2 completely covers the micro-foam core layer 1, and the continuous fibers 3 are regularly distributed in the reinforcing ribs 4 on the inner side of the surface layer.

[0043] The reinforcing rib 4 on the inner side of the surface layer of this embodiment is a semicircular irregular protrusion, and the continuous fiber 3 with a semicircular diameter of 5 mm is completely wrapped inside the irregular protrusion. The material of the micro-foam core layer 1 is a polystyrene composition, and the foaming ratio of the micro-foam core layer 1 is 3 times. The material of the surface layer 2 is impact-modified polystyrene, and the continuous fiber 3 is an aromatic polyamide filament.

[0044] The filament fineness of the continuous fiber 3 in this embodiment is 2000D, and the twisting modes of the continuous fiber 3 are S twist and Z twist. The S twist and Z twist continuous fibers are arranged alternately with an interval of 10 mm.

[0045] The polystyrene composition components of this embodiment (parts by mass):

[0046] Adopt chemical micro-foaming composition formula:

[0047]

[0048] Preparation method of continuous fiber reinforced micro-foam profile in this embodiment:

[0049] (1) blending the polystyrene composition according to the formula, feeding it into a special extruder for foaming, heating and plasticizing, and extruding micro-foaming;

[0050] (2) At the same time, the impact-modified polystyrene is fed into a co-extrusion screw extruder, heated and melted, and continuous fibers are introduced through a die, and completely covered with the micro-foam core layer for co-extrusion, cooled and shaped, and pulled and cut to obtain a foamed profile.

[0051] Table 1 Performance comparison of continuous fiber reinforced micro-foam profiles

[0052]

[0053] The performance of the continuous fiber reinforced micro-foamed profiles prepared in Examples 1-3 was tested, and the results are shown in Table 3. The same type of foamed profile as in Example 1 but without continuous fiber reinforcement was taken as a control sample for comparison. As can be seen from Table 1, compared with the control sample without continuous fiber reinforcement, the continuous fiber reinforced micro-foamed profiles of each embodiment have significantly improved tensile strength, flexural strength and impact strength.

[0054] Example 4

[0055] This embodiment provides a continuous fiber reinforced micro-foam profile, which has the same structure as that of Embodiment 1, except that the material of the micro-foam core layer 1 and the continuous fiber 3 is that the material of the micro-foam core layer 1 is a polystyrene composition with a foaming ratio of 1.5; the material of the continuous fiber 3 is polyester filament.

[0056] The polystyrene composition consists of the following components: by mass, 100 parts of general-purpose polystyrene, 30 parts of high-impact polystyrene, 10 parts of styrene-butadiene rubber and 5 parts of AC foaming agent.

[0057] The preparation method of the continuous fiber reinforced co-extruded micro-foam profile is the same as that of Example 1, and the prepared continuous fiber reinforced co-extruded micro-foam profile has similar performance to that of Example 1.

[0058] Example 5

[0059] This embodiment provides a continuous fiber reinforced micro-foam profile, which has the same structure as that of Embodiment 1, except for the composition of the material of the micro-foam core layer 1, which is a polystyrene composition with a foaming ratio of 4; and the continuous fiber 3 is made of polyamide filaments.

[0060] The polystyrene composition consists of the following components: by mass, 100 parts of general-purpose polystyrene, 1 part of high-impact polystyrene, 1 part of styrene-butadiene rubber and 1 part of AC foaming agent.

[0061] The preparation method of the continuous fiber reinforced micro-foam profile is the same as that of Example 1, and the prepared continuous fiber reinforced co-extruded micro-foam profile has similar performance to that of Example 1.

[0062] The continuous fiber 3 in Example 5 may also be made of polyimide filaments. The performance of the continuous fiber reinforced co-extruded micro-foam profile prepared using the polyimide filaments is similar to that of Example 5.

[0063] The present invention is different from the traditional method of introducing continuous fibers into the foam core layer. By introducing continuous reinforcing fibers into the non-foamed layer of the profile, the cell structure of the foam core layer will not be destroyed, the perforation and collapse of the cells of the foam core layer will be avoided, and the mechanical strength of the foam core layer will be maintained. In addition, compared with non-continuous fibers, continuous fibers have higher tensile strength, bending strength and impact strength in the extrusion direction, and the S-twisted and Z-twisted fiber spacing arrangement structure can effectively prevent the foam profile from unidirectional bending.

Claims

1. A continuous fiber reinforced micro-foam profile, characterized in that: It comprises a micro-foam core layer (1), a surface layer (2) completely covering the micro-foam core layer (1), and reinforcing ribs (4) arranged on the inner side of the surface layer (2), wherein continuous fibers (3) are regularly distributed in the reinforcing ribs (4); The material of the surface layer (2) is impact-modified polystyrene, and the material of the micro-foam core layer (1) is a polystyrene composition, which is composed of the following components: by mass, 100 parts of general-purpose polystyrene, 10 parts of high-impact polystyrene, 5 parts of styrene-butadiene rubber and 1 part of AC foaming agent; the reinforcing rib (4) is a special-shaped protrusion, which is semicircular, triangular or trapezoidal, and the continuous fiber (3) is completely wrapped inside the reinforcing rib (4); wherein the reinforcing rib (4) is semicircular, the diameter of the semicircle is 2-6 mm, and the continuous fiber (3) is one or more of polyester filament, aromatic polyamide filament and polyimide filament; the filament fineness of the continuous fiber (3) is 500-2000D, and the twisting method of the continuous fiber (3) is S twist and Z twist, and the S twist and Z twist continuous fibers are arranged alternately, with an interval of 10-40 mm.

2. The continuous fiber reinforced micro-foam profile according to claim 1, characterized in that: The foaming ratio of the material of the micro-foam core layer (1) is 1.5-4 times.

3. A method for preparing a continuous fiber reinforced micro-foam profile according to any one of claims 1-2, characterized in that: The following steps are involved: (1) The raw materials of the micro-foam core layer are mixed and fed into a special foaming extruder, heated and plasticized, and micro-foamed; (2) At the same time, the impact-modified polystyrene is fed into the co-extrusion screw extruder, heated and melted, and the continuous fibers are introduced through the die and completely covered with the micro-foam core layer for co-extrusion, cooled and shaped, and pulled and cut to complete the preparation of the continuous fiber reinforced co-extruded micro-foam profile.

Images