Multifunctional wide-width PVC composite decorative film and its preparation method

Abstract

This invention provides a multifunctional wide-width PVC composite decorative film, comprising a first film layer, a second film layer, and a silica aerogel felt layer disposed between the first and second film layers; wherein the first and second film layers are PVC calendered films with identical compositions, the PVC calendered film comprising the following components in parts by weight: 100 parts PVC resin powder, 30-40 parts DOTP plasticizer, 15-30 parts hollow glass microspheres, 10-20 parts magnesium hydroxide, 2-5 parts thermally expandable microspheres, 1.5-3.0 parts calcium-zinc heat stabilizer, 0.5-3 parts acrylate processing aids, and 0.1-2 parts arsenic-free mildew inhibitor. This invention also provides a method for preparing the multifunctional wide-width PVC composite decorative film. The decorative film of this invention is extremely lightweight, has excellent thermal insulation, sound insulation, and flame retardant properties, and its low overall density further enhances the width processing capability of the film.

Description

Technical Field

[0001] This invention relates to the field of decorative film technology, and more specifically to a multifunctional wide-width PVC composite decorative film and its preparation method. Background Technology

[0002] Decorative film is a new type of decorative material made from high molecular polymer (PVC) as raw material, with the addition of various additives, through calendering and compounding. It can be compounded with substrates such as wood, plastic board, aluminum plate, and iron plate to make multi-purpose decorative materials, which are widely used in the surface decoration of household appliances and audio equipment, interior decoration, and interior decoration of airplanes, ships, and trains.

[0003] However, commonly used PVC decorative films have the following shortcomings:

[0004] (1) It has a simple structure and a single function, and can only provide conventional flame retardant properties.

[0005] (2) The width is small. Because it is filled with inorganic minerals such as calcium carbonate and flame-retardant magnesium hydroxide or aluminum hydroxide, the membrane itself has a high density. If it is made into a membrane material with a width of more than 1.5m, it will collapse due to the large weight in the middle of the membrane, resulting in defects such as printing omissions and poor adhesion.

[0006] (3) It lacks heat insulation and sound insulation functions, and its application in the field of interior decoration is not conducive to the sound insulation of the entire indoor environment. Summary of the Invention

[0007] The purpose of this invention is to address the shortcomings of existing technologies by providing a multifunctional wide-width PVC composite decorative film and its preparation method. The invention uses PVC calendered film as the top and bottom layers, respectively, and heat-bonds it with silica aerogel felt fabric with a spatial network structure as the middle layer to form a composite film. Combined with the formulation design of the PVC calendered film, the resulting decorative film is extremely lightweight, has excellent heat insulation, sound insulation and flame retardant properties, and its low overall density further enhances the width processing capability of the film.

[0008] According to a first aspect of the present invention, a multifunctional wide-width PVC composite decorative film is provided, comprising a first film layer, a second film layer, and a silica aerogel felt layer disposed between the first film layer and the second film layer;

[0009] Wherein, the first film layer and the second film layer are PVC calendered films with the same composition, and the PVC calendered film is composed of the following components in parts by weight:

[0010] 100 parts PVC resin powder, 30-40 parts DOTP plasticizer, 15-30 parts hollow glass microspheres, 10-20 parts magnesium hydroxide, 2-5 parts thermal expansion microspheres, 1.5-3.0 parts calcium zinc heat stabilizer, 0.5-3 parts acrylate processing aids, and 0.1-2 parts arsenic-free mildew inhibitor.

[0011] In an optional embodiment, the thickness of both the first and second film layers is 0.10 to 0.16 mm.

[0012] In an optional embodiment, the fabric specifications of the silica aerogel felt layer are: a thickness of 0.4–0.5 mm and a weight of 55–65 g / m². 2 .

[0013] In an optional embodiment, the thermally expanded microspheres are foamed into hollow spheres with a particle size of 50-60 μm and a maximum compressive strength of 300 MPa when heated to a temperature range of 110°C to 240°C. Their good resilience allows them to withstand multiple cycles of pressurization / depressurization without breaking.

[0014] In an optional embodiment, the hollow glass microspheres have a particle size of 10–20 μm.

[0015] According to a second aspect of the present invention, a method for preparing the aforementioned multifunctional wide-width PVC composite decorative film is provided, comprising the following steps:

[0016] S1. Weigh the corresponding weight of each component according to the weight parts of the PVC calendered film, mix the thermal expansion microspheres and DOTP plasticizer evenly to obtain the first mixture;

[0017] The first mixture is mixed evenly with PVC resin, powdered calcium-zinc stabilizer, arsenic-free mildew inhibitor, magnesium hydroxide, and acrylate processing aids to obtain the second mixture;

[0018] S2. The second mixture is extruded and granulated to obtain PVC granules containing thermally expanded microspheres;

[0019] S3. Mix the PVC granules and hollow glass microspheres evenly to obtain a third mixture;

[0020] The third mixture is pre-plasticized by intensive mixing to obtain a pre-plasticized body. The pre-plasticized body is then subjected to open milling, extrusion, and calendering to obtain a PVC calendered film with uniformly arranged thermally expanded microspheres and hollow glass microspheres inside.

[0021] S4. The PVC calendered film is used as the top layer and bottom layer, and then bonded to the middle layer of silica aerogel felt fabric in one step by heating and pressing to form a multifunctional wide-width PVC composite decorative film with a three-layer structure.

[0022] In an optional embodiment, in step S1, a pneumatic ink mixer is used to thoroughly stir the mixture at a speed of 400-600 rpm for 6-8 minutes to obtain a first mixture; a high-speed mixer is used to thoroughly stir the mixture at a speed of 1200-1500 rpm for 3-5 minutes to obtain a second mixture.

[0023] In an optional embodiment, in step S2, the conditions for the twin-screw extruder are: temperature 110–140°C, speed 180–220 rpm, and loading current 100–120 amp; the conditions for the single-screw extruder are: temperature 90–115°C, speed 25–35 rpm, and loading current 35–45 amp; and the conditions for the pelletizer are: speed 15–30 rpm.

[0024] In an optional embodiment, in step S3, a high-speed mixer is used to thoroughly stir the mixture at a speed of 1000-1200 rpm for 3-5 minutes to obtain a third mixture;

[0025] The conditions for intensive mixing are: rotor speed 50-60 rpm, motor loading current 200-600 A;

[0026] The conditions for starting the refining process are: temperature 155℃~170℃, speed 22~35rpm;

[0027] The extrusion conditions are: temperature 160℃~175℃, single screw speed 20~30rpm;

[0028] The calendering conditions are as follows: the temperature of the four-roll calender is set sequentially along the feeding to discharging direction as follows: R1: 172℃~182℃, R2: 175℃~185℃, R3: 177℃~188℃, R4: 160℃~170℃.

[0029] The rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 15-25 rpm, R2: 20-28 rpm, R3: 25-35 rpm, R4: 36-49 rpm.

[0030] In an optional implementation, in step S4,

[0031] Unwinding conditions: speed 6-12 rpm, tension 5-10 N;

[0032] Preheating conditions are: temperature 110~125℃, speed 8~12rpm;

[0033] Pre-bonding conditions are: temperature 105~130℃, speed 8~12rpm;

[0034] The embossing conditions are: temperature 40-80℃, pressure 0-20 bar, and speed 8-12 rpm.

[0035] Compared with the prior art, the significant advantages of the present invention are as follows:

[0036] 1. The multifunctional wide-width PVC composite decorative film of the present invention can produce PVC decorative film with a width of over 3 meters. Compared with traditional PVC decorative film, this decorative film is extremely lightweight, which makes it easier to avoid missing prints and weak bonding strength in the middle of the film during subsequent printing and lamination.

[0037] 2. In the multifunctional wide-width PVC composite decorative film of the present invention, all three layers of materials have excellent thermal insulation, sound insulation and flame retardant properties. On the basis of ensuring sound insulation and flame retardant properties, the low thermal conductivity of the materials further improves the overall flame retardant effect of the composite film.

[0038] 3. The multifunctional wide-width PVC composite decorative film of the present invention uses a PVC calendered film to first uniformly disperse thermally expandable microspheres in the PVC system to form a film system with high compressive strength, ensuring that the hollow glass microspheres will not be damaged by high pressure during the second step of filling hollow glass microspheres during calendering; in addition, it can make the hollow glass microspheres with smaller particle size uniformly dispersed in the gaps between the thermally expandable microspheres, so that the two materials with low thermal conductivity and sound insulation complement each other and give full play to their high efficiency performance. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of the multifunctional wide-width PVC composite decorative film of the present invention.

[0040] Figure 2 This is a schematic diagram of the internal structure distribution of the PVC calendered film used in the multifunctional wide-width PVC composite decorative film of the present invention.

[0041] Figure 3 This is a structural diagram of the silica aerogel felt layer used in the multifunctional wide-width PVC composite decorative film of the present invention. Detailed Implementation

[0042] To better understand the technical content of the present invention, specific embodiments are described below in conjunction with the accompanying drawings.

[0043] Various aspects of the invention are described in this disclosure with reference to the accompanying drawings, in which numerous illustrative embodiments are shown. The embodiments of this disclosure are not necessarily intended to encompass all aspects of the invention. It should be understood that the various concepts and embodiments described above, as well as those described below in more detail, can be implemented in any of a number of ways.

[0044] Combination Figure 1 As shown, in an exemplary embodiment of the present invention, a multifunctional wide-width PVC composite decorative film is provided, which consists of a first film layer 1, a second film layer 2, and a silica aerogel felt layer 3 disposed between the first film layer and the second film layer.

[0045] Wherein, the first film layer 1 and the second film layer 2 are PVC calendered films with the same composition, and the PVC calendered film is composed of the following components in parts by weight:

[0046] 100 parts PVC resin powder, 30-40 parts DOTP plasticizer, 15-30 parts hollow glass microspheres, 10-20 parts magnesium hydroxide, 2-5 parts thermal expansion microspheres, 1.5-3.0 parts calcium zinc heat stabilizer, 0.5-3 parts acrylate processing aids, and 0.1-2 parts arsenic-free mildew inhibitor.

[0047] like Figure 2 As shown, the thermally expandable microspheres 11 in the PVC calendered film foam into hollow spheres when heated, dispersing in the PVC system. Simultaneously, hollow glass microspheres 12 fill the gaps between the thermally expandable microspheres, while the thermally expandable microspheres support the hollow glass microspheres from being crushed. The entire interior of the PVC calendered film is fully and uniformly filled by the complementary and synergistic interaction of the thermally expandable microspheres and hollow glass microspheres. Both the hollow glass microspheres and the thermally expandable microspheres have low thermal conductivity and vacuum characteristics inside the spheres, which can further improve the flame retardant performance of the PVC calendered film based on ordinary flame retardant additives. This gives the PVC calendered film excellent heat insulation, sound insulation, and flame retardant effects. Furthermore, the low density of the hollow glass microspheres and the foamed structure of the thermally expandable microspheres result in an extremely low density PVC calendered film.

[0048] like Figure 3 As shown, the middle layer uses aerogel felt fabric with a spatial mesh structure, which is lightweight and has the functions of heat insulation, sound insulation and flame retardancy. It is bonded to the PVC calendered film with heat and pressure to form a sandwich structure composite film material.

[0049] The finished composite film of this invention consists of three lightweight materials, making it much lighter than traditional PVC-filled decorative films. This allows for the production of films exceeding 3 meters in width. Furthermore, during subsequent printing and lamination, the film will not collapse in the center due to its weight, preventing defects such as missed prints and weak adhesion. When traditional PVC-filled decorative films are made up to 2 meters wide, their weight causes the center to collapse during subsequent printing and lamination, making it difficult to align with the sides. This results in missed prints and weak adhesion during heat lamination.

[0050] In addition, in the composite film of the present invention, the hollow glass microspheres and thermally expanded microspheres in the bottom PVC film of the surface layer have good thermal insulation and sound insulation effects, and the aerogel fabric in the middle layer also has thermal insulation and sound insulation properties. When this composite film is applied to interior decoration materials, it brings excellent thermal insulation and sound insulation effects.

[0051] In an optional embodiment, the thickness of both the first and second film layers is 0.10 to 0.16 mm.

[0052] In an optional embodiment, the fabric specifications of the silica aerogel felt layer are: a thickness of 0.4–0.5 mm and a weight of 55–65 g / m². 2 .

[0053] In an optional embodiment, the particle size of the thermally expanded microspheres after foaming during heating is larger than that of the hollow glass microspheres, so that the thermally expanded microspheres can support the hollow glass microspheres from being crushed, and the hollow glass microspheres can fill the gaps between the thermally expanded microspheres.

[0054] In an optional embodiment, the thermally expanded microspheres are foamed into hollow spheres with a particle size of 50-60 μm and a maximum compressive strength of 300 MPa when heated to a temperature range of 110°C to 240°C. Their good resilience allows them to withstand multiple cycles of pressurization / depressurization without breaking.

[0055] In an optional embodiment, the hollow glass microspheres have a particle size of 10–20 μm.

[0056] It is understandable that PVC resin powder, DOTP plasticizer, magnesium hydroxide, calcium zinc heat stabilizer, acrylate processing aids, and arsenic-free mildew inhibitors are common components in this field, and no further limitations are made here.

[0057] In another preferred embodiment of the present invention, thermally expanded microspheres with larger particle size and higher compressive strength after being heated and foamed are first mixed with other materials in the PVC system except for hollow glass microspheres and granulated. Then, the hollow glass microspheres and granules are blended and calendered to obtain the top layer and bottom layer PVC film. Finally, the PVC film is heated and laminated with the middle aerogel felt fabric layer to obtain the composite film.

[0058] The preparation method of the aforementioned multifunctional wide-width PVC composite decorative film according to an exemplary embodiment of the present invention includes the following steps:

[0059] S1. Weigh the corresponding weight of each component according to the weight parts of the PVC calendered film, mix the thermal expansion microspheres and DOTP plasticizer evenly to obtain the first mixture;

[0060] The first mixture is mixed evenly with PVC resin, powdered calcium-zinc stabilizer, arsenic-free mildew inhibitor, magnesium hydroxide, and acrylate processing aids to obtain the second mixture;

[0061] S2. The second mixture is extruded and granulated to obtain PVC granules containing thermally expanded microspheres;

[0062] S3. Mix the PVC granules and hollow glass microspheres evenly to obtain a third mixture;

[0063] The third mixture is pre-plasticized by intensive mixing to obtain a pre-plasticized body. The pre-plasticized body is then subjected to open milling, extrusion, and calendering to obtain a PVC calendered film with uniformly arranged thermally expanded microspheres and hollow glass microspheres inside.

[0064] S4. The PVC calendered film is used as the top layer and bottom layer, and then bonded to the middle layer of silica aerogel felt fabric in one step by heating and pressing to form a multifunctional wide-width PVC composite decorative film with a three-layer structure.

[0065] In an optional embodiment, in step S1, a pneumatic ink mixer is used to thoroughly stir the mixture at a speed of 400-600 rpm for 6-8 minutes to obtain a first mixture; a high-speed mixer is used to thoroughly stir the mixture at a speed of 1200-1500 rpm for 3-5 minutes to obtain a second mixture.

[0066] The preparation of PVC film involves first uniformly dispersing thermally expandable microspheres in a PVC system to form a high compressive strength system that protects the hollow glass microspheres from being crushed during calendering. Then, the hollow glass microspheres are filled into the PVC system and calendered into a PVC film, ensuring that the entire interior of the PVC film is fully filled by the complementary and synergistic interaction of the thermally expandable microspheres and the hollow glass microspheres.

[0067] In an optional embodiment, in step S2, the conditions for the twin-screw extruder are: temperature 110–140°C, speed 180–220 rpm, and loading current 100–120 amp; the conditions for the single-screw extruder are: temperature 90–115°C, speed 25–35 rpm, and loading current 35–45 amp; and the conditions for the pelletizer are: speed 15–30 rpm.

[0068] In an optional embodiment, in step S3, a high-speed mixer is used to thoroughly stir the mixture at a speed of 1000-1200 rpm for 3-5 minutes to obtain a third mixture;

[0069] The conditions for intensive mixing are: rotor speed 50-60 rpm, motor loading current 200-600 A;

[0070] The conditions for starting the refining process are: temperature 155℃~170℃, speed 22~35rpm;

[0071] The extrusion conditions are: temperature 160℃~175℃, single screw speed 20~30rpm;

[0072] The calendering conditions are as follows: the temperature of the four-roll calender is set sequentially along the feeding to discharging direction as follows: R1: 172℃~182℃, R2: 175℃~185℃, R3: 177℃~188℃, R4: 160℃~170℃.

[0073] The rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 15-25 rpm, R2: 20-28 rpm, R3: 25-35 rpm, R4: 36-49 rpm.

[0074] In an optional implementation, in step S4,

[0075] Unwinding conditions: speed 6-12 rpm, tension 5-10 N;

[0076] Preheating conditions are: temperature 110~125℃, speed 8~12rpm;

[0077] Pre-bonding conditions are: temperature 105~130℃, speed 8~12rpm;

[0078] The embossing conditions are: temperature 40-80℃, pressure 0-20 bar, and speed 8-12 rpm.

[0079] Interior decorative films often face the challenge of achieving high flame retardancy. The PVC composite decorative film of this invention addresses this issue. Firstly, the hollow glass microspheres and thermally expanding microspheres in the top and bottom layers possess low thermal conductivity and internal vacuum characteristics, further enhancing the flame retardant properties of the PVC film beyond that of ordinary flame retardant additives. Secondly, the middle layer is a composite film made of ultra-low thermal conductivity aerogel felt fabric thermally bonded together. These two measures further strengthen the flame retardant effect of the PVC film. The low thermal conductivity of the three materials also provides the composite film with excellent thermal insulation properties.

[0080] Ordinary PVC decorative wallpaper film, in order to meet flame retardant requirements, is filled with a large amount of high-density magnesium hydroxide or aluminum hydroxide inorganic minerals, resulting in an excessively high density. If the film is made into a width exceeding 1.5m or even 2m, its weight causes it to collapse in the middle during printing and lamination, resulting in unevenness and making processing impossible. The film material of this invention, however, is lightweight and can be made into wider films. While maintaining overall flatness, it also avoids multiple splicing steps, simplifying construction time.

[0081] In current building materials, sound insulation of floors and interior spaces is one of the important indicators of decorative materials. Ordinary PVC wallpaper film has no sound insulation effect. In the PVC composite decorative film of this invention, the surface layer and bottom layer both utilize the noise reduction and sound absorption properties of thermally expanding microspheres and hollow glass microspheres, and then use complementary filling of different sizes to work together and complement each other to prepare a PVC film with better thermal insulation and sound insulation effect. In addition, the porous mesh structure of the aerogel felt fabric in the middle layer also has excellent sound insulation and noise reduction properties. Combining the advantages of the three layers of materials, a PVC composite film with excellent sound insulation and noise reduction performance is prepared.

[0082] The present invention will be further illustrated by the following examples. Unless otherwise specified, the materials in the examples are prepared according to existing methods or purchased directly from the market.

[0083] The raw materials used in the following embodiments are:

[0084] The PVC resin is sourced from Suzhou Huasu Plastics Co., Ltd., specifically the HS-1000 type PVC resin.

[0085] DOTP plasticizer is sourced from Jiangsu Hongxin Chemical Co., Ltd.

[0086] The powdered calcium-zinc stabilizer is sourced from Yafeng Industrial Co., Ltd., specifically the CZ-180A type calcium-zinc stabilizer.

[0087] Acrylic ester processing aids are derived from Zhongyuan Chemical's PA 40 type processing aids.

[0088] Arsenic-free mildew inhibitor is sourced from Tangyanlian (Shanghai) Trading Co., Ltd., specifically the DW 30 type mildew inhibitor.

[0089] Magnesium hydroxide is sourced from Kunshan Runshi Chemical Co., Ltd., specifically type A8 magnesium hydroxide.

[0090] Hollow glass microspheres are sourced from Zhengzhou Shenglete Hollow Microsphere New Material Co., Ltd., specifically the HS70 type hollow microspheres.

[0091] The thermal expansion microspheres are derived from the F-230D type thermal expansion microspheres of Matsumoto Chemical Co., Ltd., Japan.

[0092] The aerogel felt fabric is sourced from Nano Technology Co., Ltd., with a thickness of 0.5mm and a weight of 65g / m². 2

[0093] The equipment manufacturers and models used are as follows:

[0094] Calender: IHI, Adhesive tape machine

[0095] Internal mixer: Taisheng Precision Machinery Industrial Co., Ltd., V-IM-0760

[0096] Mixer: Chia Tai Iron Works Co., Ltd., Taiwan, 300L

[0097] Extrusion Filter: Yangding Machinery Industry Co., Ltd. Filter

[0098] Open mill: Taisheng Precision Machinery Industrial Co., Ltd. type

[0099] Medium winding machine: Somatec, ATW-800 / 2400I

[0100] Granulating Twin-Screw Extruder: Coperon (Nanjing) Machinery Co., Ltd.

[0101] Granulation Single Screw Extruder: Coperon (Nanjing) Machinery Co., Ltd.

[0102] Pelletizer: Coperon (Nanjing) Machinery Co., Ltd.

[0103] Laminating Machine: Yangding Machinery Industry Co., Ltd. Four-layer Laminating Machine

[0104] Example 1

[0105] 100 parts PVC resin; 34 parts DOTP plasticizer; 2 parts powdered calcium-zinc stabilizer; 3 parts thermally expandable microspheres; 15 parts magnesium hydroxide; 1 part arsenic-free mildew inhibitor; 2 parts acrylate processing aids; 15 parts hollow glass microspheres. At room temperature, the thermally expandable microspheres were placed in the DOTP plasticizer and thoroughly stirred for 8 minutes at 600 rpm using a pneumatic ink mixer to ensure complete and uniform dispersion of the microspheres in the plasticizer. Then, the PVC resin, plasticizer, stabilizer, magnesium hydroxide, arsenic-free mildew inhibitor, and processing aids were thoroughly stirred for 4 minutes at 1200 rpm in a high-speed mixer to obtain a homogeneous first mixture.

[0106] The first mixture was processed through a twin-screw extruder, a single-screw extruder, and a pelletizer to obtain PVC granules containing thermally expanded microspheres. These granules were then mixed with hollow glass microspheres in a high-speed mixer at 1000 rpm for 4 minutes to obtain a homogeneous second mixture. This second mixture was then kneaded in an internal mixer for 2 minutes to obtain a pre-plasticized melt. The melt was then passed through an open mill, an extruder, and finally a four-roll calender to obtain a PVC film with a thickness of approximately 0.15 mm and a width of 3.04 m.

[0107] The twin-screw extruder has four zones with temperatures of 115, 125, 130, and 135°C, a rotation speed of 220 rpm, and a current of 110 amps; the single-screw extruder has two zones with temperatures of 95 and 105°C, a rotation speed of 30 rpm, and a current of 40 rpm; the pelletizing conditions are: cutter rotation speed of 20 rpm.

[0108] The conditions for intensive mixing are: rotor speed 50 rpm, motor loading current 400A, and mixing time 2 min;

[0109] The conditions for starting the refining process are: temperature 160℃, rotation speed 26.2 rpm;

[0110] The conditions for filtration and extrusion are: temperature 170℃, single screw speed 25rpm;

[0111] The calendering conditions are as follows: the temperatures of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 175℃, R2: 180℃, R3: 185℃, R4: 165℃; the rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 19.2 rpm, R2: 23.8 rpm, R3: 29.9 rpm, R4: 45.2 rpm.

[0112] Large rolls of film are placed on the laminating machine's feeding rack in the order of surface PVC film, middle aerogel felt fabric, and bottom PVC film. Through preheating, pre-lamination, and embossing stages, they are heated and pressed to form a composite film with a width of 3m.

[0113] The unwinding conditions were: speed 8.9 rpm, tension 9.1 N;

[0114] Preheating conditions: temperature 112℃, speed 9.8 rpm;

[0115] Pre-bonding conditions are: temperature 125℃, speed 10.1 rpm;

[0116] The embossing conditions were: temperature 45℃, pressure 5 bar, and speed 10.1 rpm.

[0117] Example 2

[0118] 100 parts PVC resin; 40 parts DOTP plasticizer; 3 parts powdered calcium-zinc stabilizer; 5 parts thermally expandable microspheres; 20 parts magnesium hydroxide; 2 parts arsenic-free mildew inhibitor; 3 parts acrylate processing aids; 30 parts hollow glass microspheres. At room temperature, the thermally expandable microspheres were placed in the DOTP plasticizer and thoroughly stirred for 8 minutes at 600 rpm using a pneumatic ink mixer to ensure complete and uniform dispersion of the microspheres in the plasticizer. Then, the PVC resin, plasticizer, stabilizer, magnesium hydroxide, arsenic-free mildew inhibitor, and processing aids were thoroughly stirred for 4 minutes at 1200 rpm in a high-speed mixer to obtain a homogeneous first mixture.

[0119] The first mixture was processed through a twin-screw extruder, a single-screw extruder, and a pelletizer to obtain PVC granules containing thermally expanded microspheres. These granules were then mixed with hollow glass microspheres in a high-speed mixer at 1000 rpm for 4 minutes to obtain a homogeneous second mixture. This second mixture was then kneaded in an internal mixer for 2 minutes to obtain a pre-plasticized melt. The melt was then passed through an open mill, an extruder, and finally a four-roll calender to obtain a PVC film with a thickness of approximately 0.15 mm and a width of 3.04 m.

[0120] The twin-screw extruder has four zones with temperatures of 115, 125, 130, and 135°C, a rotation speed of 220 rpm, and a current of 110 amps; the single-screw extruder has two zones with temperatures of 95 and 105°C, a rotation speed of 30 rpm, and a current of 40 rpm; the pelletizing conditions are: cutter rotation speed of 20 rpm.

[0121] The conditions for intensive mixing are: rotor speed 50 rpm, motor loading current 400A, and mixing time 2 min;

[0122] The conditions for starting the refining process are: temperature 160℃, rotation speed 26.2 rpm;

[0123] The conditions for filtration and extrusion are: temperature 170℃, single screw speed 25rpm;

[0124] The calendering conditions are as follows: the temperatures of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 175℃, R2: 180℃, R3: 185℃, R4: 165℃; the rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 19.2 rpm, R2: 23.8 rpm, R3: 29.9 rpm, R4: 45.2 rpm.

[0125] Large rolls of film are placed on the laminating machine's feeding rack in the order of surface PVC film, middle aerogel felt fabric, and bottom PVC film. Through preheating, pre-lamination, and embossing stages, they are heated and pressed to form a composite film with a width of 3m.

[0126] The unwinding conditions were: speed 8.9 rpm, tension 9.1 N;

[0127] Preheating conditions: temperature 112℃, speed 9.8 rpm;

[0128] Pre-bonding conditions are: temperature 125℃, speed 10.1 rpm;

[0129] The embossing conditions were: temperature 45℃, pressure 5 bar, and speed 10.1 rpm.

[0130] Example 3

[0131] 100 parts PVC resin; 30 parts DOTP plasticizer; 1.5 parts powdered calcium-zinc stabilizer; 2 parts thermally expandable microspheres; 10 parts magnesium hydroxide; 0.1 parts arsenic-free mildew inhibitor; 0.5 parts acrylate processing aids; 20 parts hollow glass microspheres. At room temperature, the thermally expandable microspheres were placed in the DOTP plasticizer and thoroughly stirred for 8 minutes at 600 rpm using a pneumatic ink mixer to ensure complete and uniform dispersion of the microspheres in the plasticizer. Then, the PVC resin, plasticizer, stabilizer, magnesium hydroxide, arsenic-free mildew inhibitor, and processing aids were thoroughly stirred for 4 minutes at 1200 rpm in a high-speed mixer to obtain a homogeneous first mixture.

[0132] The first mixture was processed through a twin-screw extruder, a single-screw extruder, and a pelletizer to obtain PVC granules containing thermally expanded microspheres. These granules were then mixed with hollow glass microspheres in a high-speed mixer at 1000 rpm for 4 minutes to obtain a homogeneous second mixture. This second mixture was then kneaded in an internal mixer for 2 minutes to obtain a pre-plasticized melt. The melt was then passed through an open mill, an extruder, and finally a four-roll calender to obtain a PVC film with a thickness of approximately 0.15 mm and a width of 3.04 m.

[0133] The twin-screw extruder has four zones with temperatures of 115, 125, 130, and 135°C, a rotation speed of 220 rpm, and a current of 110 amps; the single-screw extruder has two zones with temperatures of 95 and 105°C, a rotation speed of 30 rpm, and a current of 40 rpm; the pelletizing conditions are: cutter rotation speed of 20 rpm.

[0134] The conditions for intensive mixing are: rotor speed 50 rpm, motor loading current 400A, and mixing time 2 min;

[0135] The conditions for starting the refining process are: temperature 160℃, rotation speed 26.2 rpm;

[0136] The conditions for filtration and extrusion are: temperature 170℃, single screw speed 25rpm;

[0137] The calendering conditions are as follows: the temperatures of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 175℃, R2: 180℃, R3: 185℃, R4: 165℃; the rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 19.2 rpm, R2: 23.8 rpm, R3: 29.9 rpm, R4: 45.2 rpm.

[0138] Large rolls of film are placed on the laminating machine's feeding rack in the order of surface PVC film, middle aerogel felt fabric, and bottom PVC film. Through preheating, pre-lamination, and embossing stages, they are heated and pressed to form a composite film with a width of 3m.

[0139] The unwinding conditions were: speed 8.9 rpm, tension 9.1 N;

[0140] Preheating conditions: temperature 112℃, speed 9.8 rpm;

[0141] Pre-bonding conditions are: temperature 125℃, speed 10.1 rpm;

[0142] The embossing conditions were: temperature 45℃, pressure 5 bar, and speed 10.1 rpm.

[0143] Comparative Example 1

[0144] Ordinary PVC calendered film in the prior art

[0145] The raw materials used are:

[0146] The PVC resin is sourced from Suzhou Huasu Plastics Co., Ltd., specifically the HS-1000 type PVC resin.

[0147] DOTP plasticizer is sourced from Jiangsu Hongxin Chemical Co., Ltd.

[0148] The powdered calcium-zinc stabilizer is sourced from Yafeng Industrial Co., Ltd., specifically the CZ-180A type calcium-zinc stabilizer.

[0149] Acrylic ester processing aids are derived from Zhongyuan Chemical's PA 40 type processing aids.

[0150] Arsenic-free mildew inhibitor is sourced from Tangyanlian (Shanghai) Trading Co., Ltd., specifically the DW 30 type mildew inhibitor.

[0151] Magnesium hydroxide is sourced from Kunshan Runshi Chemical Co., Ltd., specifically type A8 magnesium hydroxide.

[0152] Calcium carbonate is sourced from Jiangsu Qunxin Powder Technology Co., Ltd.

[0153] Preparation process:

[0154] 100 parts PVC resin; 34 parts DOTP plasticizer; 2 parts powdered calcium-zinc stabilizer; 15 parts magnesium hydroxide; 1 part arsenic-free mildew inhibitor; 2 parts acrylate processing aids; 40 parts calcium carbonate. The PVC resin, plasticizer, stabilizer, mildew inhibitor, calcium carbonate, magnesium hydroxide, and processing aids were thoroughly mixed in a high-speed mixer at 1300 rpm for 4 minutes to obtain a homogeneous mixture.

[0155] The mixture is kneaded in an internal mixer for 2.5 minutes to obtain a pre-plasticized melt. The melt is then passed through an open mill, an extruder, and finally a four-roll calender to obtain a PVC film with a thickness of about 0.30 mm.

[0156] The conditions for intensive mixing are: rotor speed 50 rpm, motor loading current 400A, and mixing time 2.5 min.

[0157] The conditions for starting the refining process are: temperature 165℃, rotation speed 26.4 rpm;

[0158] The extrusion conditions were: temperature 172℃, single screw speed 25.6 rpm;

[0159] The calendering conditions are as follows: the temperatures of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 175℃, R2: 185℃, R3: 185℃, R4: 170℃; the rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 20.1 rpm, R2: 25.6 rpm, R3: 28.4 rpm, R4: 44.6 rpm.

[0160] Large rolls of film are placed on the laminating machine's feeding rack in the order of surface PVC film, middle aerogel felt fabric, and bottom PVC film. Through preheating, pre-lamination, and embossing stages, they are heated and pressed to form a composite film with a width of 3m.

[0161] The unwinding conditions were: speed 8.9 rpm, tension 9.1 N;

[0162] Preheating conditions: temperature 112℃, speed 9.8 rpm;

[0163] Pre-bonding conditions are: temperature 125℃, speed 10.1 rpm;

[0164] The embossing conditions were: temperature 45℃, pressure 5 bar, and speed 10.1 rpm.

[0165] Comparative Example 2

[0166] PVC calendered film filled only with hollow glass microspheres

[0167] The raw materials used are:

[0168] The PVC resin is sourced from Suzhou Huasu Plastics Co., Ltd., specifically the HS-1000 type PVC resin.

[0169] DOTP plasticizer is sourced from Jiangsu Hongxin Chemical Co., Ltd.

[0170] The powdered calcium-zinc stabilizer is sourced from Yafeng Industrial Co., Ltd., specifically the CZ-180A type calcium-zinc stabilizer.

[0171] Acrylic ester processing aids are derived from Zhongyuan Chemical's PA 40 type processing aids.

[0172] Arsenic-free mildew inhibitor is sourced from Tangyanlian (Shanghai) Trading Co., Ltd., specifically the DW 30 type mildew inhibitor.

[0173] Magnesium hydroxide is sourced from Kunshan Runshi Chemical Co., Ltd., specifically type A8 magnesium hydroxide.

[0174] Hollow glass microspheres are sourced from Zhengzhou Shenglete Hollow Microsphere New Material Co., Ltd., specifically the HS70 type hollow microspheres.

[0175] Preparation process:

[0176] 100 parts PVC resin; 34 parts DOTP plasticizer; 2 parts powdered calcium-zinc stabilizer; 15 parts magnesium hydroxide; 1 part arsenic-free mildew inhibitor; 2 parts acrylate processing aids; 15 parts hollow glass microspheres. The PVC resin, plasticizer, stabilizer, mildew inhibitor, hollow glass microspheres, magnesium hydroxide, and processing aids were thoroughly mixed in a high-speed mixer at 1300 rpm for 4 minutes to obtain a homogeneous mixture.

[0177] The mixture is kneaded in an internal mixer for 2.5 minutes to obtain a pre-plasticized melt. The melt is then passed through an open mill, an extruder, and finally a four-roll calender to obtain a PVC film with a thickness of about 0.30 mm.

[0178] The conditions for intensive mixing are: rotor speed 50 rpm, motor loading current 400A, and mixing time 2.5 min.

[0179] The conditions for starting the refining process are: temperature 165℃, rotation speed 26.4 rpm;

[0180] The extrusion conditions were: temperature 172℃, single screw speed 25.6 rpm;

[0181] The calendering conditions are as follows: the temperatures of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 175℃, R2: 185℃, R3: 185℃, R4: 170℃; the rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 20.1 rpm, R2: 25.6 rpm, R3: 28.4 rpm, R4: 44.6 rpm.

[0182] Large rolls of film are placed on the laminating machine's feeding rack in the order of surface PVC film, middle aerogel felt fabric, and bottom PVC film. Through preheating, pre-lamination, and embossing stages, they are heated and pressed to form a composite film with a width of 3m.

[0183] The unwinding conditions were: speed 8.9 rpm, tension 9.1 N;

[0184] Preheating conditions: temperature 112℃, speed 9.8 rpm;

[0185] Pre-bonding conditions are: temperature 125℃, speed 10.1 rpm;

[0186] The embossing conditions were: temperature 45℃, pressure 5 bar, and speed 10.1 rpm.

[0187] Performance testing

[0188] The PVC decorative films obtained in Example 1, Comparative Example 1, and Comparative Example 2 were used to test their sound insulation and thermal conductivity. The specific test standards and results are shown in the table below:

[0189]

[0190]

[0191] The test results above show that the PVC composite decorative film of this invention has excellent sound insulation and heat preservation properties, while further improving the flame retardant effect compared to ordinary flame-retardant PVC film. Furthermore, while meeting the requirements of multifunctionality, the film has a lower basis weight, making it lighter than traditional PVC decorative film. This makes it suitable not only for downstream wide-width printing and lamination processing but also a potential lightweight building decoration material.

[0192] The oxygen index of ordinary PVC film containing flame-retardant filler is around 27.5%. The oxygen index is improved to a certain extent after hollow glass microspheres replace calcium carbonate. The oxygen index of the PVC composite decorative film of the present invention is significantly improved, indicating that the decorative film of the present invention has a better flame-retardant effect.

[0193] The sound insulation performance was tested in a noise environment with a sound pressure level of 90dB and a frequency range of 100-3150Hz. The sound insulation of ordinary PVC film is less than 18dB. The sound insulation performance of PVC filled with hollow glass microspheres is improved to a certain extent. The sound insulation performance of the PVC composite decorative film of the present invention has been significantly improved.

[0194] Typically, highly filled PVC films have higher thermal conductivity than unfilled PVC films because the inorganic fillers have certain thermal conductivity. A thermal conductivity of less than 0.2 W / (m·K) is defined as a thermal insulation material. The PVC composite decorative film of this invention has a thermal conductivity as low as 0.042 W / (m·K), exhibiting excellent thermal insulation performance.

[0195] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A multifunctional wide-width PVC composite decorative film, characterized in that, It consists of a first film layer, a second film layer, and a silica aerogel felt layer disposed between the first film layer and the second film layer; Wherein, the first film layer and the second film layer are PVC calendered films with the same composition, and the PVC calendered film is composed of the following components in parts by weight: 100 parts PVC resin powder, 30-40 parts DOTP plasticizer, 15-30 parts hollow glass microspheres, 10-20 parts magnesium hydroxide, 2-5 parts thermal expansion microspheres, 1.5-3.0 parts calcium zinc heat stabilizer, 0.5-3 parts acrylate processing aids, and 0.1-2 parts arsenic-free mildew inhibitor. The PVC calendered film is prepared by first uniformly dispersing thermally expanded microspheres in a PVC system to form granules, then heating the thermally expanded microspheres to a temperature range of 110℃~240℃ to foam them into hollow spheres with a particle size of 50~60μm and a maximum compressive strength of 300Mpa, and then filling the hollow glass microspheres into the PVC system and calendering them into a PVC calendered film. The width of the PVC composite decorative film exceeds 1.5m.

2. The multifunctional wide-width PVC composite decorative film according to claim 1, characterized in that, The thickness of both the first and second films is 0.10~0.16 mm.

3. The multifunctional wide-width PVC composite decorative film according to claim 1, characterized in that, The fabric specifications of the silica aerogel felt layer are: thickness of 0.4~0.5mm, and weight of 55~65 g / m². 2 .

4. The multifunctional wide-width PVC composite decorative film according to claim 1, characterized in that, The hollow glass microspheres have a particle size of 10~20μm.

5. A method for preparing a multifunctional wide-width PVC composite decorative film according to any one of claims 1-4, characterized in that, Includes the following steps: S1. Weigh the corresponding weight of each component according to the weight parts of the PVC calendered film, mix the thermal expansion microspheres and DOTP plasticizer evenly to obtain the first mixture; The first mixture is mixed evenly with PVC resin, powdered calcium-zinc heat stabilizer, arsenic-free mildew inhibitor, magnesium hydroxide, and acrylate processing aids to obtain the second mixture; S2. The second mixture is extruded and granulated to obtain PVC granules containing thermally expanded microspheres; S3. Mix the PVC granules and hollow glass microspheres evenly to obtain a third mixture; The third mixture is pre-plasticized by intensive mixing to obtain a pre-plasticized body. The pre-plasticized body is then subjected to open milling, extrusion, and calendering to obtain a PVC calendered film with uniformly arranged thermally expanded microspheres and hollow glass microspheres inside. S4. The PVC calendered film is used as the top layer and bottom layer, and then bonded to the middle layer of silica aerogel felt fabric in one step by heating and pressing to form a multifunctional wide-width PVC composite decorative film with a three-layer structure.

6. The preparation method according to claim 5, characterized in that, In step S1, a pneumatic ink mixer is used to stir the mixture thoroughly at a speed of 400-600 rpm for 6-8 minutes to obtain a first mixture; a high-speed mixer is used to stir the mixture thoroughly at a speed of 1200-1500 rpm for 3-5 minutes to obtain a second mixture.

7. The preparation method according to claim 5, characterized in that, In step S2, the conditions for the twin-screw extruder are: temperature 110~140℃, speed 180~220rpm, and loading current 100~120amp; the conditions for the single-screw extruder are: temperature 90~115℃, speed 25~35rpm, and loading current 35~45amp; and the conditions for the pelletizer are: speed 15~30rpm.

8. The preparation method according to claim 5, characterized in that, In step S3, a high-speed mixer is used to thoroughly stir the mixture at a speed of 1000~1200 rpm for 3~5 minutes to obtain the third mixture; The conditions for intensive mixing are: rotor speed 50~60 rpm, motor load current 200~600A; The conditions for starting the refining process are: temperature 155℃~170℃, speed 22~35rpm; The extrusion conditions are: temperature 160℃~175℃, single screw speed 20~30 rpm; The calendering conditions are as follows: the temperature of the four-roll calender is set sequentially along the feeding to discharging direction as follows: R1: 172℃~182℃, R2: 175℃~185℃, R3: 177℃~188℃, R4: 160℃~170℃. The rotational speeds of the four-roll calender are set sequentially along the feeding to discharging direction as follows: R1: 15~25 rpm, R2: 20~28 rpm, R3: 25~35 rpm, R4: 36~49 rpm.

9. The preparation method according to claim 5, characterized in that, In step S4, the large roll of film is placed on the laminating machine's feeding rack in the order of the top layer PVC calendered film, the middle layer aerogel felt fabric, and the bottom layer PVC calendered film. The composite film is then bonded together through preheating, pre-lamination, and embossing stages under heat and pressure. The unwinding conditions are: speed 6~12 rpm, tension 5~10N; Preheating conditions are: temperature 110~125℃, speed 8~12rpm; Pre-bonding conditions are: temperature 105~130℃, speed 8~12rpm; The embossing conditions are: temperature 40~80℃, pressure 0~20bar, and speed 8~12rpm.

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