A metallic texture spray-free material, preparation thereof and a bathroom product

Abstract

The present disclosure provides a metal texture spray-free material, a preparation method thereof and a bathroom product, the preparation method of the metal texture spray-free material comprising the following steps: mixing a metal color material, a polymer material 1 and water, and then spray granulating to obtain a composite metal color material with the surface of the metal color material wrapped by the polymer material; mixing the composite metal color material and a polymer material 2, and then melt extruding and granulating to obtain a composite granule; and using a mold to injection mold the composite granule, the inner surface of the mold being provided with a wire drawing structure, and the particle size of the composite metal color material being greater than the sum of the width and the interval of the wire drawing structure. The material prepared by using the method avoids the problem of appearance defects of turning and forming a fusion mark perpendicular to the surface when using flaky pigments in two or more melt mergings.

Description

Technical Field

[0001] This article relates to the field of new bathroom materials technology, specifically a metallic-textured paint-free material and its preparation, and a bathroom product. Background Technology

[0002] Existing gunmetal gray finish manufacturing processes mainly include electroplating silver spraying, electroplating metallic color processing, metallic color paint-free processes, methods for depositing a brushed film on a plastic substrate, and brushed plastic surface workpieces and their preparation processes. Among these, electroplating silver spraying and electroplating metallic color processing cannot achieve a brushed effect or result in appearance defects due to excessive paint layer thickness and complex processes. Chinese patent CN202210859263.2 uses in-mold brushing and rapid cooling / heating processes to obtain a plastic blank, then completes the metal film preparation through a vacuum coating process to form a plastic product with a metallic brushed texture. Chinese patent CN202110961861.6 first uses a brushing wheel to create a brushed texture on a plastic substrate, then sprays electroplated silver paint to form a brushed metallic appearance. Although some technologies can achieve a brushed effect, the processes are complex and costly. Therefore, existing gunmetal gray finish manufacturing processes still have some problems and require further improvement and innovation. Summary of the Invention

[0003] While the paint-free process for metallic colors is low-cost, it can lead to appearance defects due to the use of flake aluminum pigments. This disclosure solves the problem of flow marks and weld lines that are easily caused by injection molding of metallic colors. The solution provided in this disclosure does not produce weld lines and flow marks.

[0004] This disclosure provides a method for preparing a metallic-textured, paint-free material, the method comprising the following steps:

[0005] The metallic color material, polymer material 1 and water are mixed and then sprayed into granules to obtain a composite metallic color material with polymer material coated on the surface of the metallic color material.

[0006] The composite metallic material is mixed with polymer material 2 and then melt-extruded and granulated to obtain composite granules.

[0007] The composite granulated material is injection molded using a mold, and the inner surface of the mold is provided with a brushed texture.

[0008] The particle size of the composite metallic material is greater than the sum of the width and spacing of the brushed texture structure.

[0009] In some embodiments provided in this disclosure, the metallic material is selected from any one or more of the following: flake boron nitride with a particle size of 500 nm to 5 μm, flake aluminum powder with a particle size of 500 nm to 5 μm, nickel powder with a particle size of 50 nm to 1 μm, silver powder with a particle size of 50 nm to 1 μm, zirconium powder with a particle size of 50 nm to 1 μm, chromium powder with a particle size of 50 nm to 1 μm, and titanium powder with a particle size of 50 nm to 1 μm.

[0010] In some embodiments provided in this disclosure, the polymer material 2 is selected from any one or more of ABS, PC, PVC, PP, PA, PMMA and PS.

[0011] In some embodiments provided in this disclosure, the polymer material 1 is selected from any one or both of polyvinyl alcohol and polyethylene glycol; preferably, the polyvinyl alcohol has an oligomerization degree molecular weight of 25,000 to 35,000 and the polyvinyl alcohol has a mesomerization degree molecular weight of 120,000 to 150,000; preferably, the polyethylene glycol has a molecular weight of 8,000 to 20,000.

[0012] In some embodiments provided in this disclosure, the spray granulation method includes: dissolving the polymer material 1 in hot water, stirring until uniform, adding a metallic color material, stirring until uniform, and then spray granulating.

[0013] The weight ratio of the polymer material 1, the metallic color material, and the hot water is 5 to 20:100:333 to 2000.

[0014] In some embodiments provided in this disclosure, the temperature of the hot water is 60°C to 90°C.

[0015] In some embodiments provided in this disclosure, the polymer material 1 is mixed and stirred with hot water for 10 to 30 minutes.

[0016] In some embodiments provided in this disclosure, the polymer material 1, hot water, and metallic color material are mixed and stirred for 1 to 3 hours.

[0017] In some embodiments provided in this disclosure, the spray drying temperature is 150°C to 250°C, and the spray drying feed rate is 100 ml / h to 2 L / h.

[0018] In some embodiments provided in this disclosure, the particle size of the composite metallic material is from 20 μm to 100 μm.

[0019] In some embodiments provided in this disclosure, the weight ratio of the composite metallic material to the polymer material 2 is (1 to 8):100.

[0020] In some embodiments provided in this disclosure, the composite metallic color material is mixed with the polymer material 2 for 30 min to 45 min.

[0021] In some embodiments provided in this disclosure, the screw speed of the melt extrusion granulation is 230 r / min to 280 r / min, and the output rate is 300 kg / h to 450 kg / h.

[0022] In some embodiments provided in this disclosure, the extruder has at least nine temperature zones, and the temperatures of the at least nine temperature zones extending from the distal end of the extruder outlet to the extruder outlet direction include at least 40°C to 90°C, 90°C to 140°C, 140°C to 170°C, 170°C to 200°C, 200°C to 270°C, 200°C to 270°C, 200°C to 270°C, and 200°C to 270°C.

[0023] In some embodiments provided in this disclosure, the width of the brushed texture is 0.5 to 2 μm.

[0024] In some embodiments provided in this disclosure, the depth of the brushed texture is from 5 μm to 50 μm.

[0025] In some embodiments provided in this disclosure, the spacing of the brushed texture is from 2 μm to 10 μm.

[0026] In some embodiments provided in this disclosure, the injection molding process includes: a material temperature of 250°C to 270°C; an injection speed of 10% to 95% (when the injection speed is 100%, the specific injection speed value is 99 mm / s); an injection pressure of 10 bar to 60 bar; and a mold temperature of 170°C to 250°C.

[0027] In another aspect, this disclosure provides a method for preparing the above-described metallic-textured paint-free material, resulting in a metallic-textured paint-free material.

[0028] In another aspect, this disclosure provides a brushed metal-textured bathroom product, which includes the aforementioned metal-textured paint-free material.

[0029] Beneficial Effects: This disclosure provides a metallic-textured paint-free material, its preparation, and a bathroom product. As an additive to a granulated material, when injection molded using a brushed mold, the composite metallic material, being more loosely distributed than the resin matrix, breaks upon passing through the sharp peaks of the brushed texture. It then arranges itself along the brushed texture, reflecting light, and further arranges itself in an orderly manner at high mold temperatures, enhancing light reflection and giving the final brushed injection molded product a strong metallic effect. Because the composite metallic material is granulated into near-spherical shapes, it avoids the problem of weld lines formed when flake pigments flip perpendicular to the surface during the fusion of two or more melt streams, resulting in an unsightly appearance.

[0030] Other features and advantages of this disclosure will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the disclosure. Other advantages of this disclosure may be realized and obtained by means of the methods described in the description and the accompanying drawings. Attached Figure Description

[0031] The accompanying drawings are used to provide an understanding of the technical solutions of this disclosure and form part of the specification. They are used together with the embodiments of this disclosure to explain the technical solutions of this disclosure and do not constitute a limitation on the technical solutions of this disclosure.

[0032] Figure 1 This is a schematic diagram illustrating the appearance defects caused by the reduced reflection of the flake aluminum pigment in Comparative Example 1.

[0033] Figure 2 A top-sprayed housing prepared using the gunmetal gray metallic paint-free material obtained in Example 1 of this disclosure.

[0034] Figure 3 The top spray shell was prepared using a gunmetal gray metallic paint-free material for Comparative Example 1.

[0035] Figure 4 This is a schematic diagram of the process of drawing a brushed texture through a mold during injection molding of a metallic paint-free material according to an embodiment of this disclosure.

[0036] Figure 5 The top spray shell prepared from the gunmetal gray non-coating material used in Comparative Example 2 has weld lines as an appearance defect.

[0037] Figure 6 The top spray shell prepared from the gunmetal gray non-coating material of Comparative Example 3 has a weld line appearance defect. Detailed Implementation

[0038] This disclosure includes and contemplates combinations of features known to those skilled in the art. The embodiments and features disclosed in this disclosure can also be combined with any conventional features to form a unique inventive scheme as defined by the claims. Any feature of any embodiment can also be combined with features from other inventive schemes to form another unique inventive scheme as defined by the claims. Therefore, it should be understood that any feature shown and / or discussed in this disclosure can be implemented individually or in any suitable combination. Therefore, the embodiments are not limited except by the limitations imposed by the appended claims and their equivalents. Furthermore, various modifications and changes can be made within the scope of the appended claims.

[0039] Example 1

[0040] Take 500g of polyvinyl alcohol (PVA) (oligomeric molecular weight of 25,000 to 35,000) and 5kg of flake aluminum powder (average particle size of 2μm). Dissolve the PVA in 20kg of water at 80℃ and stir for 20min. Then add the flake aluminum powder and stir for 3h. Next, spray dry while stirring at 200℃ and a feed rate of 600ml / h to obtain a composite metallic material with an average particle size of 35μm. A composite metallic material (2 wt% by weight of ABS resin) was added to a high-speed mixer and mixed for 30 minutes, followed by extrusion granulation to obtain composite granules. The screw speed for melt extrusion granulation was 230 r / min, and the output rate was 300 kg / h. The extruder had nine temperature zones, with temperatures of 60℃, 120℃, 160℃, 200℃, 250℃, 250℃, 250℃, 250℃, and 250℃ respectively, extending from the far end of the extruder outlet to the outlet direction. The inner surface of the mold had a brushed texture with a width of 2 μm, a depth of 20 μm, and a spacing of 4 μm. Next, the shower head product was injection molded. Injection molding process: material temperature 250℃, injection speed 30%, injection pressure 20 bar. Electromagnetic induction heating technology was used to heat the mold temperature to 180℃. After cooling, the product was demolded. The shower head had a smooth, glossy appearance with a metallic texture and no weld lines.

[0041] Example 2:

[0042] Take 250g of polyvinyl alcohol (PVA) (molecular weight of 25,000 to 35,000), 500g of polyethylene glycol (PEG) (molecular weight of 8,000), 3kg of flake aluminum powder (average particle size of 5μm), 1.5kg of flake boron nitride (average particle size of 2μm), 200g of nickel powder (average particle size of 500nm), and 300g of silver powder (average particle size of 500nm). Dissolve PVA and PEG in 20kg of water at 90℃ and stir for 15min. Then add the metallic powder and stir for 3h. Next, spray dry while stirring at 250℃ and a feed rate of 1.5L / h to obtain a composite metallic material with an average particle size of 60μm. A composite metallic material (3 wt% by weight of ABS resin) was added to a high-speed mixer and mixed for 30 minutes. The mixture was then melt-extruded and granulated to obtain composite granules. The screw speed for melt extrusion granulation was 250 r / min, and the output rate was 380 kg / h. The extruder had nine temperature zones, with temperatures of 60℃, 130℃, 170℃, 200℃, 260℃, 260℃, 260℃, 260℃, and 260℃ respectively, extending from the far end of the extruder outlet to the outlet direction. The inner surface of the mold was decorated with a brushed texture, 1.5 μm wide, 30 μm deep, and 8 μm spaced. Next, the shower head was injection molded. Injection molding process: material temperature 260℃, injection speed 50%, injection pressure 30 bar. Electromagnetic induction heating technology was used to heat the mold to 200℃. After cooling, the product was demolded. The shower head had a smooth, glossy appearance with a metallic texture and no weld lines.

[0043] Example 3:

[0044] Take 500g of polyvinyl alcohol (PVA) (oligomeric molecular weight of 25,000 to 35,000) and 5kg of flake aluminum powder (average particle size of 2μm). Dissolve the PVA in 20kg of water at 80℃ and stir for 20min. Then add the flake aluminum powder and stir for 3h. Next, spray dry while stirring at 200℃ and a feed rate of 600ml / h to obtain a composite metallic material with an average particle size of 35μm. A composite metallic material (2 wt% by weight of PP resin) was added to a high-speed mixer and mixed for 30 minutes, followed by extrusion granulation to obtain composite granules. The screw speed for melt extrusion granulation was 230 r / min, and the output rate was 300 kg / h. The extruder had nine temperature zones, with temperatures of 60℃, 110℃, 150℃, 180℃, 200℃, 210℃, 210℃, 210℃, and 205℃, respectively, from the far end of the extruder outlet to the outlet direction. The inner surface of the mold had a brushed texture with a width of 2 μm, a depth of 20 μm, and a spacing of 4 μm. Next, the shower head product was injection molded. Injection molding process: material temperature 230℃, injection speed 30%, injection pressure 20 bar. Electromagnetic induction heating technology was used to heat the mold to 180℃. After cooling, the product was demolded. The shower head had a smooth, glossy appearance with a metallic texture and no weld lines.

[0045] Example 4:

[0046] Take 500g of polyvinyl alcohol (PVA) (oligomeric molecular weight of 25,000 to 35,000) and 5kg of flake aluminum powder (average particle size of 2μm). Dissolve the PVA in 20kg of water at 80℃ and stir for 20min. Then add the flake aluminum powder and stir for 3h. Next, spray dry while stirring at 200℃ and a feed rate of 600ml / h to obtain a composite metallic material with an average particle size of 35μm. A composite metallic material (2 wt% by weight of PC resin) was added to a high-speed mixer and mixed for 30 minutes, followed by extrusion granulation to obtain composite granules. The screw speed for melt extrusion granulation was 230 r / min, and the output rate was 300 kg / h. The extruder had nine temperature zones, with temperatures of 60℃, 110℃, 150℃, 180℃, 200℃, 260℃, 260℃, 260℃, and 260℃ respectively, extending from the far end of the extruder outlet to the outlet direction. The inner surface of the mold had a brushed texture with a width of 2 μm, a depth of 20 μm, and a spacing of 4 μm. Next, the shower head product was injection molded. Injection molding process: material temperature 280℃, injection speed 30%, injection pressure 20 bar. Electromagnetic induction heating technology was used to heat the mold temperature to 220℃. After cooling, the product was demolded. The shower head had a smooth, glossy appearance with a metallic texture and no weld lines.

[0047] Example 5:

[0048] Take 250g of polyvinyl alcohol (PVA) (molecular weight 25,000 to 35,000), 500g of polyethylene glycol (PEG) (molecular weight 8,000), 2kg of flake aluminum powder (average particle size 5μm), 2kg of flake boron nitride (average particle size 500nm), 200g of nickel powder (average particle size 50nm), 200g of zirconium powder (average particle size 50nm), 300g of silver powder (average particle size 50nm), and 300g of titanium powder (average particle size 50nm). Dissolve PVA and PEG in 20kg of water at 90℃ and stir for 15min. Then add the metallic powder and stir for 3h. Next, spray dry while stirring at 250℃ and a feed rate of 1.5L / h to obtain a composite metallic material with an average particle size of 60μm. A composite metallic material (7 wt% by weight of ABS resin) was mixed with ABS resin in a high-speed mixer for 30 minutes, followed by melt extrusion granulation to obtain composite granules. The screw speed for melt extrusion granulation was 250 r / min, and the output rate was 380 kg / h. The extruder had nine temperature zones, with temperatures of 60℃, 130℃, 170℃, 200℃, 260℃, 260℃, 260℃, 260℃, and 260℃ respectively, extending from the far end of the extruder outlet to the outlet direction. The inner surface of the mold was decorated with a brushed texture, with a width of 1.5 μm, a depth of 30 μm, and a spacing of 8 μm. Next, the shower head product was injection molded. Injection molding process: material temperature 260℃, injection speed 50%, injection pressure 30 bar. Electromagnetic induction heating technology was used to heat the mold temperature to 200℃. After cooling, the product was demolded. The shower head had a smooth, glossy appearance with a metallic texture and no weld lines.

[0049] Comparative Example 1

[0050] Flake aluminum powder (average particle size 2μm), accounting for 2wt% of the weight of ABS resin, was mixed with ABS resin in a high-speed mixer for 30 minutes, followed by extrusion granulation to obtain composite granules. The inner surface of the mold was then wire-brushed, with the brushed texture being 2μm wide, 20μm deep, and 4μm spaced. Next, the shower head product was injection molded. The injection molding process was as follows: material temperature 250℃, injection speed 30%, injection pressure 20 bar. Electromagnetic induction heating technology was used to heat the mold temperature to 180℃. After cooling, the product was demolded. The shower head had a smooth and glossy appearance with a metallic texture, but exhibited weld lines and other surface defects.

[0051] Comparative Example 2

[0052] The only difference between this comparative example and Example 1 is that the width of the brushed texture is 30 μm and the spacing is 50 μm. That is, the sum of the width and spacing of the brushed texture is greater than the particle size of the composite metallic material (35 μm). In this case, the weld lines on the resulting product are more obvious. Figure 5 As shown.

[0053] Comparative Example 3

[0054] The only difference between this comparative example and Example 2 is that the width of the brushed texture is 70 μm and the spacing is 100 μm. That is, the sum of the width and spacing of the brushed texture is greater than the particle size of the metallic material (60 μm). In this case, the weld lines on the resulting product are more obvious. Figure 6 As shown.

[0055] It is evident that when the sum of the width and spacing of the brushed texture structure is greater than the particle size of the composite metallic pigment, weld lines will inevitably be generated. The applicant unexpectedly discovered that when the sum of the width and spacing of the brushed texture structure is less than the particle size of the composite metallic pigment, weld lines can be avoided. This avoids the problem of weld lines forming an appearance defect when two or more melts converge and flip perpendicular to the surface.

[0056] This disclosure describes several embodiments, but these descriptions are exemplary and not limiting, and it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the scope of the embodiments described herein. Although many possible combinations of features are shown in the drawings and discussed in the detailed description, many other combinations of the disclosed features are also possible. Unless specifically limited, any feature of any embodiment may be used in combination with any other feature in any other embodiment, or may substitute for any other feature in any other embodiment.

[0057] Furthermore, in describing representative embodiments, the specification may have presented methods and / or processes as a specific sequence of steps. However, the method or process should not be limited to the specific order of steps described herein, to the extent that the method or process does not depend on the specific order of steps described herein. As will be understood by those skilled in the art, other sequences of steps are also possible. Therefore, the specific order of steps set forth in the specification should not be construed as a limitation of the claims. Moreover, the claims relating to the method and / or process should not be limited to the steps performed in the order written, and those skilled in the art will readily understand that these orders can be varied and still remain within the spirit and scope of the embodiments disclosed herein.

Claims

1. A method for preparing a metallic-textured, paint-free material, characterized in that, The preparation method includes the following steps: The metallic color material, polymer material 1 and water are mixed and then sprayed into granules to obtain a composite metallic color material with polymer material coated on the surface of the metallic color material. The composite metallic material is mixed with polymer material 2 and then melt-extruded and granulated to obtain composite granules. The composite granulated material is injection molded using a mold, and the inner surface of the mold is provided with a brushed texture. The particle size of the composite metallic material is greater than the sum of the width and spacing of the brushed texture structure; The polymer material 1 is selected from any one or both of polyvinyl alcohol and polyethylene glycol; The polymer material 2 is selected from any one or more of ABS, PC, PVC, PP, PA, PMMA and PS.

2. The method for preparing the metallic-textured, spray-free material according to claim 1, characterized in that, The metallic material is selected from any one or more of the following: flake boron nitride with a particle size of 500 nm to 5 μm, flake aluminum powder with a particle size of 500 nm to 5 μm, nickel powder with a particle size of 50 nm to 1 μm, silver powder with a particle size of 50 nm to 1 μm, zirconium powder with a particle size of 50 nm to 1 μm, chromium powder with a particle size of 50 nm to 1 μm, and titanium powder with a particle size of 50 nm to 1 μm. The polyvinyl alcohol has an oligomerization degree of molecular weight of 25,000 to 35,000 or a mesomerization degree of molecular weight of 120,000 to 150,000; the polyethylene glycol has a molecular weight of 8,000 to 20,000.

3. The method for preparing the metallic-textured, spray-free material according to claim 1 or 2, characterized in that, The spray granulation method includes: dissolving the polymer material 1 in hot water, stirring until uniform, adding the metallic color material, stirring until uniform, and then spray granulating. The weight ratio of the polymer material 1, the metallic color material, and the hot water is 5 to 20: 100: 333 to 2000; The temperature of the hot water is between 60°C and 90°C.

4. The method for preparing the metallic-textured, spray-free material according to claim 3, characterized in that, The polymer material 1 is mixed and stirred with hot water for 10 to 30 minutes; and / or, The polymer material 1, hot water, and metallic color material are mixed and stirred for 1 to 3 hours; and / or, The spray drying temperature is 150°C to 250°C, and the spray drying feed rate is 100 ml / h to 2 L / h; and / or, The particle size of the composite metallic material is 20 μm to 100 μm.

5. The method for preparing a metallic-textured, spray-free material according to claim 1 or 2, characterized in that, The weight ratio of the composite metallic material to the polymer material 2 is (1 to 8):

100.

6. The method for preparing the metallic-textured, spray-free material according to claim 5, characterized in that, The weight ratio of the composite metallic material to the polymer material 2 is (1 to 5):

100.

7. The method for preparing the metallic-textured, paint-free material according to claim 5, characterized in that, The composite metallic material is mixed with polymer material 2 for 30 to 45 minutes; and / or, The screw speed of the melt extrusion granulation is 230 r / min to 280 r / min, and the output rate is 300 kg / h to 450 kg / h.

8. The method for preparing the metallic-textured, spray-free material according to claim 7, characterized in that, The extruder has at least nine temperature zones, and the temperatures of the at least nine temperature zones extending from the far end of the extruder outlet to the extruder outlet direction include at least 40°C to 90°C, 90°C to 140°C, 140°C to 170°C, 170°C to 200°C, 200°C to 270°C, 200°C to 270°C, 200°C to 270°C, and 200°C to 270°C.

9. The method for preparing a metallic-textured, paint-free material according to claim 1 or 2, characterized in that, The width of the brushed texture is 0.5 to 2 μm.

10. The method for preparing a metallic-textured, paint-free material according to claim 9, characterized in that, The depth of the brushed texture is 5 μm to 50 μm.

11. The method for preparing the metallic-textured, spray-free material according to claim 10, characterized in that, The spacing of the brushed texture is 2μm to 10μm.

12. The method for preparing a metallic-textured, spray-free material according to claim 9, characterized in that, Injection molding process includes: material temperature 250℃ to 270℃; injection speed 10% to 95%; injection pressure 10 bar to 60 bar; mold temperature 170℃ to 250℃.

13. A metallic-textured paint-free material prepared by the method for preparing a metallic-textured paint-free material according to any one of claims 1 to 12.

14. A brushed metallic bathroom product, characterized in that, The brushed metallic bathroom product includes the metallic paint-free material as described in claim 13.

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