A low-carbon energy-saving bio-based composite board and preparation method thereof

Abstract

The present invention discloses a low-carbon energy-saving bio-based composite board and a preparation method thereof. The structure of the composite board is a foamed bio-based reinforcement layer, a bonding layer, a bio-based polyurethane foam board, a bonding layer, and a random continuous fiber layer from top to bottom. The composite board is heated and composited into a board by a composite machine, and the gram weight is 450±20g / m 2 The foamed bio-based reinforcement layer in the low-carbon and energy-saving bio-based composite board can be foamed again under high-temperature baking, giving the parts a full surface shape during the cold mold forming process. This patent is the first to form a multi-layer composite structure by hot pressing the foamed bio-based reinforcement layer, bio-based polyurethane foam board, and random continuous fiber layer through an adhesive layer, providing a lightweight and high-strength new material structure. It uses recyclable polyester fibers, bio-based fibers, and bio-based polyurethane foam boards, making the material low-carbon, environmentally friendly, and degradable, providing a way of thinking for future low-carbon and environmentally friendly materials.

Description

Technical Field

[0001] The present invention relates to the field of automobile interior and exterior decoration, and more specifically, to a low-carbon energy-saving bio-based composite board and a preparation method thereof. Background Art

[0002] As the current automotive interior industry is increasingly moving towards lightweight, high performance, low carbon and energy-saving development trends, the requirements for automotive materials are also getting higher and higher. On the one hand, pure petroleum-based raw materials are required to be recycled as much as possible. On the other hand, bio-based materials are increasingly used as substitutes for petroleum-based materials. Bio-based materials are a new type of material made from renewable biomass or (and) raw materials obtained through biological manufacturing, through biological, chemical, physical and other means, and are green, environmentally friendly and degradable.

[0003] In patent application CN109823012A, the invention provides an ultra-light and highly sound-absorbing GMT-reinforced PU thermoplastic automotive interior composite board and its preparation method. The composite board of the invention is non-woven membrane, GMT reinforcement layer, non-woven membrane, PU foam light board, non-woven membrane, GMT reinforcement layer, non-woven membrane from top to bottom. It is obtained by bonding the 3D structure of the GMT reinforcement layer and the PU foam light board of the non-woven membrane, and then thermally compounding. It overcomes the shortcomings of the traditional dry-process PU board, such as poor rigidity of the glue glass film, full sealing without openings, and poor sound absorption, and further improves the sound absorption performance and lightweight of the PU composite board material.

[0004] The invention product has the following problems in actual use:

[0005] 1. Although the GMT reinforcement layer can present a 3D structure, it must be under a certain weight condition to meet the strength of the ceiling;

[0006] 2. The fibers in GMT are discontinuous, and the GMT is soft overall after being pressed into a thin sheet;

[0007] 3. Glue seepage and cracking are prone to occur during the molding of composite panels.

[0008] 4. Most of the materials are petroleum-based and have poor environmental friendliness.

[0009] Patent application CN110126420B proposes a manufacturing process for a hemp fiber reinforced polyurethane sandwich composite panel, in which the raw materials of each layer except the skin layer are stacked together in sequence, then heated and softened uniformly, and then the skin material is bonded, pressed into shape, cooled and solidified, cut and trimmed, and finally a hemp fiber reinforced polyurethane sandwich composite panel is formed.

[0010] The invention product has the following problems in actual use:

[0011] 1. The overall weight of the board is relatively high.

[0012] 2. The polyurethane foam in the composite layer is a petroleum-based material and has poor environmental friendliness.

[0013] In summary, in order to solve the increasingly severe environmental problems, meet the requirements of lightweight, high performance, low carbon and energy saving in the field of automotive interior decoration, and optimize the structure of traditional ceiling materials, the present invention provides a low-carbon and energy-saving bio-based composite board. At present, there are no reports on the literature and patents of low-carbon and energy-saving bio-based composite boards. The present invention further develops a new structural design for low-carbon and energy-saving bio-based composite boards. Summary of the invention

[0014] The purpose of the present invention is to solve the above-mentioned problems and provide a low-carbon energy-saving bio-based composite board to further improve the lightweight and environmental protection of the ceiling material.

[0015] The present invention is achieved through the following technical solutions:

[0016] The present invention discloses a low-carbon energy-saving bio-based composite board. The structure of the composite board is a foamed bio-based reinforcement layer, a bonding layer, a bio-based polyurethane foam board, a bonding layer, and a random continuous fiber layer from top to bottom. The composite board is heated and composited into a board by a composite machine, and the gram weight is 450±20g / m 2 .

[0017] As a further improvement, the foamed bio-based reinforcement layer described in the present invention is composed of bio-based fibers with reinforcement effect, polyester fibers with melt bonding effect and microsphere foaming agent that can expand at high temperature. The reinforcing bio-based fibers and polyester fibers are first opened, mixed and combed through a non-woven needle punching reinforcement process to obtain a uniform single fiber web. The microsphere foaming agent is evenly dispersed on the surface of the single fiber web through a powdering process, and then the felt is prepared through cross-laying and needle punching consolidation, and then pressed into a roll by a composite machine.

[0018] As a further improvement, the weight of the foamed bio-based reinforcement layer of the present invention is 150±10 g / m 2 The ratio of bio-based fiber to polyester fiber is 45:55-55:45. The content of microsphere foaming agent is 1wt%-10wt%, and the unexpanded microsphere foaming agent is evenly distributed in the felt obtained after the cross-laying and needle-punching consolidation process.

[0019] As a further improvement, the bio-based fiber described in the present invention is a mixture of one or two of hemp fiber, bamboo fiber and other natural fibers.

[0020] As a further improvement, the polyester fiber described in the present invention is one of recycled polyester fiber and bio-based polyester fiber, or a mixture of the two.

[0021] As a further improvement, the microsphere foaming agent of the present invention has a foaming temperature of 175-185°C and can be secondary initiated during the heating process of ceiling molding.

[0022] As a further improvement, the random continuous fiber layer described in the present invention is a continuous polyester fiber and a continuous glass fiber that are sequentially mixed through a filament complexing process to obtain a coil-shaped mixed felt with a gram weight of 100±10g / m 2 The polyester fiber can be one of recycled polyester fiber and bio-based polyester fiber, and the ratio of the polyester fiber to the glass fiber is 45:55-55:45.

[0023] As a further improvement, the bio-based polyurethane foam board of the present invention is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3 kg / m 3 , the thickness depends on the requirements of the ceiling.

[0024] As a further improvement, the adhesive layer of the present invention is a modified thermoplastic film having an adhesive effect, which is a mixture mainly composed of ethylene-vinyl acetate copolymer and has a gram weight of 20±5g / m 2 .

[0025] The present invention also discloses a method for preparing a low-carbon energy-saving bio-based composite board, which is specifically:

[0026] The composite line unwinds the foamed bio-based reinforcement layer, bonding layer, bio-based polyurethane foam board, bonding layer, and random continuous fiber layer from top to bottom in sequence, heats them to 165-175°C on a heating plate, and performs roller pressing and compounding at a pressure of 0.7-0.9MPa. The composite board is then conveyed to the cooling zone via a conveyor belt for cooling to obtain a low-carbon and energy-saving bio-based composite board with a gram weight of 450±20g / m2. The composite board can be cold-pressed after heating.

[0027] The beneficial effects of the present invention are as follows:

[0028] 1. The foamed bio-based reinforcement layer in the low-carbon and energy-saving bio-based composite board can be foamed again under high-temperature baking, giving the parts a full surface shape during the cold mold forming process.

[0029] 2. The composite of the foamed bio-based reinforcement layer and the middle bio-based polyurethane foam board layer, on the one hand, effectively reduces the surface density of the material and improves the overall strength of the molded part; on the other hand, it provides excellent sound absorption and heat insulation for the entire component after molding.

[0030] 3. The foamed bio-based reinforcement layer and the random continuous fiber layer on both sides of the low-carbon energy-saving bio-based composite board play a complementary role in the molding process and the structure of the parts. During the molding process, the ratio of bio-based fibers to polyester fibers in the foamed bio-based reinforcement layer is 45:55-55:45, the content of microsphere foaming agent is 1wt%-10wt%, the pressure in the molding cavity is appropriate, the parts have less glue infiltration, and the long fibers in the random continuous fiber layer reduce the risk of cracking of the board during the molding process. In the structure of the parts, the secondary rise of the microsphere foaming agent in the foamed bio-based reinforcement layer provides a full shape to the parts, while the random continuous fiber layer maintains good dimensional stability of the entire part through the tension of the long fibers.

[0031] 4. This patent is the first to form a multi-layer composite structure by hot pressing a foamed bio-based reinforcement layer, a bio-based polyurethane foam board, and a random continuous fiber layer through an adhesive layer, providing a new material structure that is lightweight and high-strength.

[0032] 5. This patent uses recyclable polyester fibers, bio-based fibers and bio-based polyurethane foam boards, making the materials low-carbon, environmentally friendly and biodegradable, providing a way of thinking for future low-carbon and environmentally friendly materials. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic diagram of the structure of the composite board of the present invention:

[0034] In the figure, 1 is a foamed bio-based reinforcement layer, 2 is a bio-based polyurethane foam board, 3 is a random continuous fiber layer, and 4 is a bonding layer. Specific embodiments

[0035] Example 1

[0036] A low-carbon energy-saving bio-based composite board, characterized in that the structure of the composite board is, from top to bottom, a foamed bio-based reinforcement layer 1, a bonding layer 4, a bio-based polyurethane foam board 2, a bonding layer 4, and a random continuous fiber layer 3, with a gram weight of 450±20g / m 2 .

[0037] The foamed bio-based reinforcement layer 1 is made of hemp fiber and recycled PET fiber in a ratio of 45:55, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 1wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0038] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0039] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0040] The composite line unwinds the foamed bio-based reinforcement layer from top to bottom 1, 20±5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175° C. on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a low-carbon energy-saving bio-based composite board.

[0041] Example 2

[0042] A low-carbon energy-saving bio-based composite board, characterized in that the structure of the composite board is, from top to bottom, a foamed bio-based reinforcement layer 1, a bonding layer 4, a bio-based polyurethane foam board 2, a bonding layer 4, and a random continuous fiber layer 3, with a gram weight of 450±20g / m 2 .

[0043] The foamed bio-based reinforcement layer 1 is made of bamboo fiber and recycled PET fiber in a ratio of 45:55, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 1wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0044] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0045] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0046] The composite line unwinds the foamed bio-based reinforcement layer from top to bottom 1, 20±5g / m2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175° C. on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a low-carbon energy-saving bio-based composite board.

[0047] Example 3

[0048] A low-carbon energy-saving bio-based composite board, characterized in that the structure of the composite board is, from top to bottom, a foamed bio-based reinforcement layer 1, a bonding layer 4, a bio-based polyurethane foam board 2, a bonding layer 4, and a random continuous fiber layer 3, with a gram weight of 450±20g / m 2 .

[0049] The foamed bio-based reinforcement layer 1 is made of hemp fiber and recycled PET fiber in a ratio of 45:55, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 10wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0050] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0051] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0052] The composite line unwinds the foamed bio-based reinforcement layer from top to bottom 1, 20±5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175° C. on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a low-carbon energy-saving bio-based composite board.

[0053] Example 4

[0054] A low-carbon energy-saving bio-based composite board, characterized in that the structure of the composite board is, from top to bottom, a foamed bio-based reinforcement layer 1, a bonding layer 4, a bio-based polyurethane foam board 2, a bonding layer 4, and a random continuous fiber layer 3, with a gram weight of 450±20g / m 2 .

[0055] The foamed bio-based reinforcement layer 1 is made of hemp fiber and recycled PET fiber in a ratio of 55:45, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 1wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0056] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0057] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0058] The composite line unwinds the foamed bio-based reinforcement layer from top to bottom 1, 20±5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175° C. on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a low-carbon energy-saving bio-based composite board.

[0059] Example 5

[0060] A low-carbon energy-saving bio-based composite board, characterized in that the structure of the composite board is, from top to bottom, a foamed bio-based reinforcement layer 1, a bonding layer 4, a bio-based polyurethane foam board 2, a bonding layer 4, and a random continuous fiber layer 3, with a gram weight of 450±20g / m 2 .

[0061] The foamed bio-based reinforcement layer 1 is made of bamboo fiber and recycled PET fiber in a ratio of 55:45, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 1wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0062] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0063] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0064] The composite line unwinds the foamed bio-based reinforcement layer from top to bottom 1, 20±5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175° C. on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a low-carbon energy-saving bio-based composite board.

[0065] Comparative Example 1

[0066] The microsphere foaming agent is removed from the structure of the composite board.

[0067] The bio-based reinforcement layer is made of hemp fiber and recycled PET fiber in a ratio of 45:55. The fiber is opened, mixed and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. The fiber is then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine. The weight is 150±10g / m 2 .

[0068] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0069] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3, thickness 5mm.

[0070] Composite board from top to bottom is 150±10g / m 2 Bio-based reinforcement layer, 20±5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175°C on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a composite board.

[0071] Comparative Example 2

[0072] The bio-based foam is removed from the structure of the composite panel.

[0073] The foamed bio-based reinforcement layer 1 is made of hemp fiber and recycled PET fiber in a ratio of 45:55, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 1wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 330±10g / m 2 .

[0074] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0075] The composite board is 330±10g / m from top to bottom 2 Foamed bio-based reinforcement layer 1, 20 ± 5g / m 2 Ethylene-vinyl acetate copolymer-based modified thermoplastic film adhesive layer 4, 100 ± 10g / m 2 Random continuous fiber layer 3, weight 450±20g / m 2 The composite board is heated to 165-175°C on a heating plate, rolled and laminated at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a composite board.

[0076] Comparative Example 3

[0077] The ratio of the random continuous fiber layer 3 in the structure of the composite board exceeds the preferred ratio.

[0078] The foamed bio-based reinforcement layer 1 is made of hemp fiber and recycled PET fiber in a ratio of 45:55, and is opened, mixed, and combed to obtain a uniform single fiber web through a non-woven needle punching reinforcement process. Then 1wt% of microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then cross-laid and needle-punched to obtain a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0079] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 40:60, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0080] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0081] Composite board from top to bottom is 150±10g / m 2 Foamed bio-based reinforcement layer 1, 20 ± 5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175°C on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a composite board.

[0082] Comparative Example 4

[0083] The bio-based fibers are replaced with glass fibers in the structure of the composite panels.

[0084] The foaming reinforcement layer is made of glass fiber and recycled PET fiber in a ratio of 45:55. Through the non-woven needle punching reinforcement process, a uniform single fiber web is obtained by opening, mixing and combing. Then 1wt% microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then it is cross-laid and needle-punched to prepare a felt, which is then pressed into a roll by a composite machine with a gram weight of 150±10g / m 2 .

[0085] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0086] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0087] Composite board from top to bottom is 150±10g / m 2 Foam reinforcement layer, 20±5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2 The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175°C on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a composite board.

[0088] Comparative Example 5

[0089] The proportion of the foamed bio-based reinforcement layer 1 in the structure of the composite board exceeds the preferred proportion.

[0090] The foamed bio-based reinforcement layer 1 is made of hemp fiber and recycled PET fiber in a ratio of 60:40, and a uniform single fiber web is obtained by opening, mixing and combing through a non-woven needle punching reinforcement process, and then 1wt% of a microsphere foaming agent is evenly dispersed on the surface of the single fiber web, and then a felt is prepared by cross-laying and needle punching consolidation, and then pressed into a roll by a composite machine, with a gram weight of 150±10g / m 2 .

[0091] The random continuous fiber layer 3 is made of recycled PET fiber and glass fiber in a ratio of 55:45, which are mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape with a gram weight of 100±10g / m 2 .

[0092] The bio-based polyurethane foam board 2 is formed by chemical foaming using a bio-based polyether combination material and a bio-based isocyanate, and its density is 30±3kg / m 3 , thickness 5mm.

[0093] Composite board from top to bottom is 150±10g / m 2 Foamed bio-based reinforcement layer 1, 20 ± 5g / m 2 Modified thermoplastic film adhesive layer based on ethylene-vinyl acetate copolymer 4, 5mm bio-based polyurethane foam board 2, 20 ± 5g / m 2The modified thermoplastic film bonding layer 4 mainly composed of ethylene-vinyl acetate copolymer and the random continuous fiber layer 3 are heated to 165-175°C on a heating plate, roll-compounded at a pressure of 0.7-0.9 MPa, and then conveyed to a cooling zone via a conveyor belt for cooling to obtain a composite board.

[0094] Table 1 Structure and performance results of the composite board of the embodiment

[0095]

[0096] Table 2 Structure and performance results of the composite board of the comparative example

[0097]

[0098] It can be seen from the above comparative cases that the performance of the composite material in the patent of the present invention has undergone a fundamental change compared with the performance of the conventional fiber reinforced skin / polyurethane foam / fiber reinforced skin composite material, and the performance of the composite board has also differed by multiples.

[0099] From the comparison of the embodiments, it is found that:

[0100] The same structure, different microsphere foaming agent dosage, the sound absorption and strength of the composite material are different: the higher the microsphere foaming agent content, the better the sound absorption effect, and the better the strength of the ceiling after the board is formed;

[0101] The same structure, the same material, the same microsphere foaming agent content, and different bio-based fibers have very little effect on sound absorption and strength;

[0102] The same structure, the same material, the same microsphere foaming agent content, and different bio-based fiber ratios (within the preferred ratio range) have very little impact on sound absorption and strength.

[0103] From the comparison between the embodiment and the comparative example:

[0104] The bio-based fibers and / or bio-based foams that have been removed from the structure will reduce the proportion of bio-based (recycled) materials in the entire structure;

[0105] When the microsphere foaming agent is removed from the structure, the launching height of the bio-based reinforced fiber layer is obviously lower than that of the embodiment, resulting in the overall softness of the ceiling;

[0106] When the bio-based foam is removed from the structure, the sandwich structure loses its supporting layer, the ceiling becomes soft, and the sound absorption becomes poor;

[0107] When glass fiber is used to replace bio-based fiber in the structure, the overall performance is similar, indicating that bio-based fiber can be equivalent to glass fiber in this structure. When bio-based fiber is used in the structure, the proportion of bio-based (recycled material) in the entire structure can be increased.

[0108] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the core technical features of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

[0109] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the core technical features of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A low-carbon energy-saving bio-based composite board, characterized in that: The structure of the composite board is, from top to bottom, a foamed bio-based reinforcement layer (1), a bonding layer (4), a bio-based polyurethane foam board (2), a bonding layer (4), and a random continuous fiber layer (3). The composite board is heated and composited into a board by a composite machine, and the gram weight is 450±20g / m 2 The foamed bio-based reinforcement layer (1) is composed of bio-based fibers with reinforcement effect, polyester fibers with melt bonding effect and microsphere foaming agent capable of high temperature expansion. The reinforcing bio-based fibers and polyester fibers are firstly opened, mixed and combed through a non-woven needle punching reinforcement process to obtain a uniform single fiber web. The microsphere foaming agent is evenly dispersed on the surface of the single fiber web through a powdering process, and then a felt is prepared through cross-laying and needle punching consolidation, and then pressed into a coil by a composite machine. The gram weight of the foamed bio-based reinforcement layer (1) is 150±10g / m 2 The ratio of bio-based fiber to polyester fiber is 45:55-55:45, the content of microsphere foaming agent is 1wt%-10wt%, and the unexpanded microsphere foaming agent is evenly distributed in the felt obtained after the cross-laying and needle-punching consolidation process; the random continuous fiber layer (3) is a continuous polyester fiber and a continuous glass fiber mixed in sequence through a filament complexing process to obtain a mixed felt in a coil shape, and the gram weight is 100±10g / m 2 The polyester fiber is one of recycled polyester fiber and bio-based polyester fiber, and the ratio of the polyester fiber to the glass fiber is 45:55-55:

45.

2. The low-carbon energy-saving bio-based composite board according to claim 1, characterized in that: The bio-based fiber is one or a mixture of two of hemp fiber, bamboo fiber and other natural fibers.

3. The low-carbon energy-saving bio-based composite board according to claim 1 or 2, characterized in that: The polyester fiber is one of recycled polyester fiber and bio-based polyester fiber or a mixture of the two.

4. The low-carbon energy-saving bio-based composite board according to claim 1 or 2, characterized in that: The microsphere foaming agent has a foaming temperature of 175-185° C. and is secondary initiated during the ceiling molding heating process.

5. The low-carbon energy-saving bio-based composite board according to claim 1 or 2, characterized in that: The bio-based polyurethane foam board (2) is formed by chemical foaming using a bio-based polyether composite material and a bio-based isocyanate, and has a density of 30±3 kg / m 3 , the thickness depends on the requirements of the ceiling.

6. The low-carbon energy-saving bio-based composite board according to claim 1, characterized in that: The adhesive layer (4) is a modified thermoplastic film having an adhesive effect, which is a mixture mainly composed of ethylene-vinyl acetate copolymer and has a gram weight of 20±5g / m 2 .

7. The method for preparing a low-carbon energy-saving bio-based composite board according to claim 1, characterized in that: Specifically: The composite line unwinds a foamed bio-based reinforcement layer (1), an adhesive layer (4), a bio-based polyurethane foam board (2), an adhesive layer (4), and a random continuous fiber layer (3) in sequence from top to bottom, heats the board to 165-175° C. on a heating plate, performs roller pressing and composites at a pressure of 0.7-0.9 MPa, and then conveys the board to a cooling zone via a conveyor belt for cooling, thereby obtaining a low-carbon energy-saving bio-based composite board having a gram weight of 450±20 g / m2. The composite board is heated and cold-pressed.

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