Process for producing wood-like material with multi-level grain effect and its mixture gel

Abstract

The present application is a kind of wood-like material process for producing multi-level texture effect, wherein the process can first mix a thermoplastic elastomer material, a hard segment material and a foaming agent in a mixing procedure to form a mixed glue, then perform a first foaming procedure on the mixed glue through an extruder, and expand the foaming density of the mixed glue to 10% to 20% of the density of the mixed glue, and the foaming thickness is 1mm to 4mm, to form an initial plate, then stack multiple initial plates, and perform a second foaming procedure on the initial plates through a hot-pressing mold, and expand the foaming density of the initial plates to 40% to 50% of the density of the mixed glue, to form a wood-like material, in this way, through two foaming procedures, multi-level texture effect can be formed on the wood-like material due to the difference in foaming density.

Description

Technical Field

[0001] This invention pertains to the processing of imitation wood materials, and particularly relates to a process that, after a first foaming process and a second foaming process, can naturally form a multi-layered texture effect on imitation wood materials. Background Technology

[0002] Traditional wood composite materials mostly use formaldehyde-based adhesives, which often result in problems such as free formaldehyde release during use. Therefore, in recent years, many people in this field have been mixing wood materials with plastic raw materials to create wood-plastic composites (WPC) to reduce formaldehyde release and improve material dimensional stability. At the same time, compared with plastics, WPC has better antistatic properties and elasticity. Compared with wood raw materials, WPC has better dimensional stability, insect resistance, corrosion resistance and weather resistance.

[0003] However, there are still many problems with using wood fibers (or wood flour) as reinforcing agents or fillers in plastics. The biggest problem is that the difference in surface polarity between colloids and wood fibers often hinders the chemical bond energy between them. Moreover, wood fibers in colloids can also cause poor dispersion due to hydrogen bonds between fibers.

[0004] In view of this, the inventors have developed a wood-like material technology to solve the aforementioned problems. However, in practical applications, when the final products made from wood-like materials (such as flooring, fences, exterior wall panels, window frames, and roofing materials) need to present a two-color appearance, it is often necessary to use two or more different colored boards and perform layering processing to form a multi-layered wood-like material effect. However, the aforementioned process is quite complex and lengthy. Therefore, how to effectively provide a new process to produce wood-like materials with multi-layered texture effects is an important problem of this invention. Summary of the Invention

[0005] After long-term research and experimentation, the inventors have finally developed and designed a process for producing multi-layered textured wood-like materials and its mixing colloid. It is hoped that through the proposal of this invention, multi-layered textured wood-like materials can be naturally formed.

[0006] One objective of this invention is to provide a process for producing wood-look materials with multi-layered texture effects. This process involves first mixing a thermoplastic elastomer material, a rigid structural material, and a foaming agent to form a mixed colloid. Then, the mixed colloid is subjected to a first foaming process using an extruder, causing the foam density to expand to 10% to 20% of the original density, with a foam thickness of 1 mm to 4 mm, to form an initial board. Subsequently, multiple initial boards are stacked and then subjected to a second foaming process using a hot press mold. A secondary foaming process is performed, expanding the initial boards to 40% to 50% of the density of the mixed colloid to form a wood-like material. This wood-like material exhibits a multi-layered texture with varying shades due to the different foaming densities of the outer layer near the surface and the inner layer near the center of each initial board. Thus, the process of this invention allows the initial boards to naturally form two different shades of color through differences in foaming density. These initial boards are then layered and subjected to high-temperature, high-pressure foaming to create a multi-layered texture effect on the wood-like material.

[0007] Preferably, the thermoplastic elastomer material can be a combination of polymeric compounds such as polyethylene, polyethylene-ethyl ester copolymer, styrene-butadiene block copolymer, styrene-isoprene block copolymer, styrene-based block copolymer, or any mixture of the above compounds.

[0008] Preferably, the hard segment structural material can be a combination of polymer compounds such as polystyrene, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-propylene-styrene copolymer, high-impact polystyrene, or any mixture of the above compounds.

[0009] Preferably, the thermoplastic elastomer material accounts for 10% to 90% of the weight percentage of the mixed colloid, the foaming agent accounts for 0.1% to 15% of the weight percentage of the mixed colloid, and the hard segment structural material accounts for the remaining weight percentage of the mixed colloid.

[0010] Preferably, the foaming agent is an azo chemical foaming agent.

[0011] Preferably, the foaming agent is a physical foaming agent.

[0012] Preferably, the extrusion temperature of the first foaming process is the decomposition temperature of the foaming agent.

[0013] Preferably, the heating temperature for the second foaming process is 160 to 180 degrees Celsius, the pressure is 100 to 200 kilograms per square centimeter, and the foaming time is 10 to 30 minutes.

[0014] Preferably, the mixture further comprises a bridging agent.

[0015] Preferably, the crosslinking agent accounts for 0.01% to 2% of the weight percentage of the mixed colloid.

[0016] Preferably, the crosslinking agent can be any one of diisopropylphenyl peroxide, 2,5-peroxyterbutyl-2,5-dimethylhexane, or sulfur.

[0017] Preferably, the mixed colloid further comprises a colorant.

[0018] Preferably, the mixed colloid further contains a fire retardant.

[0019] Preferably, the mixture further comprises a foaming agent, which accounts for 0.1% to 10% of the weight percentage of the mixture.

[0020] Preferably, the foaming agent can be zinc stearate or zinc oxide.

[0021] Another object of the present invention is to provide a mixed colloid for forming a multi-layered textured effect of wood-like material, comprising a thermoplastic elastomer material, a foaming agent and a hard segment structural material, wherein the thermoplastic elastomer material accounts for 10% to 90% of the weight percentage of the mixed colloid; the foaming agent accounts for 0.1% to 15% of the weight percentage of the mixed colloid; and the hard segment structural material accounts for the remaining weight percentage of the mixed colloid.

[0022] Preferably, the mixture further includes a crosslinking agent, which accounts for 0.01% to 2% of the weight percentage of the mixture.

[0023] Preferably, the crosslinking agent is selected from any one of diisopropylphenyl peroxide, 2,5-peroxyterbutyl-2,5-dimethylhexane, or sulfur.

[0024] Preferably, the mixture further includes a foaming agent, which accounts for 0.1% to 10% of the weight percentage of the mixture.

[0025] Preferably, the foaming agent is zinc stearate or zinc oxide.

[0026] Preferably, the thermoplastic elastomer material is a combination of polymers such as polyethylene, polyethylene-ethyl ester copolymer, styrene-butadiene block copolymer, styrene-isoprene block copolymer, styrene-based block copolymer, or any mixture of the above compounds.

[0027] Preferably, the hard segment structural material is a combination of polymeric compounds selected from polystyrene, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-propylene-styrene copolymer, high-impact polystyrene, or any mixture of the above compounds.

[0028] Preferably, the mixed colloid further comprises a colorant.

[0029] Preferably, the mixed colloid further contains a fire retardant.

[0030] In order to gain a better understanding of the purpose, technical features and effects of the present invention, embodiments are provided below in conjunction with the accompanying drawings for detailed description: Attached Figure Description

[0031] Figure 1 This is a process flow diagram of the present invention;

[0032] Figure 2 This is a photographic illustration of the multi-layered texture effect on the wood-like material of this invention;

[0033] Figure 3 This is a photographic illustration of another multi-layered texture effect on the wood-like material of the present invention.

[0034] [Symbol Explanation Marking]

[0035] 101-104: Steps Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0037] Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of the present invention. Furthermore, it should be stated in advance that the accompanying drawings of the present invention are for simple illustrative purposes only and are not depictions based on actual dimensions. In addition, unless the context clearly indicates or defines it, the meanings of "a" and "the" in the present invention include multiple meanings. Moreover, the following embodiments will further describe the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention.

[0038] It should be understood that the terms used herein generally have their common meaning in the art, and in case of conflict, any definition given herein shall prevail. Since the same thing can be expressed in multiple ways, alternative words and synonyms may be used for any term discussed or described herein, and there is no particular limitation on whether a term is set forth or discussed herein. The use of one or more synonyms does not preclude other synonyms. The embodiments used anywhere in this specification, including the use of any terminology, are illustrative only and do not limit the scope or meaning of the invention or any terminology. Similarly, the invention is not limited to the various embodiments disclosed in the specification. Although the terms first, second, or third may be used herein to describe various components, each component should not be limited by the foregoing terms, which are primarily used to distinguish one component from another and should not impose any substantial limitation on any component, nor should they limit the assembly or arrangement order of the components in practical application.

[0039] Furthermore, the term "or" as used herein may, as appropriate, include any combination of one or more of the associated listed items. Moreover, terms such as "substantially" or "approximately" as used herein may refer to a value or the average of a range of deviations from a particular value that can be recognized or determined by one of those skilled in the art, including taking into account certain specific errors that may arise when measuring that particular value due to limitations of the measurement system or equipment. For example, a value referred to as "substantially" may include ±5%, ±3%, ±1%, ±0.5%, ±0.1%, or one or more standard deviations of that particular value.

[0040] This invention relates to a process for producing multi-layered wood-like materials and its mixing colloid, enabling the production of wood-like materials with varying shades from a single-color mixing colloid. Furthermore, this wood-like material can simulate the multi-layered texture and characteristics of real wood. In one embodiment, as... Figure 1 As shown, the process for producing this wood-like material includes the following steps:

[0041] Step (101): A composite material formed by a thermoplastic elastomer material and a hard segment structural material is mixed with a foaming agent to form a compound colloid. The thermoplastic elastomer material accounts for 10% to 90% of the weight percentage of the compound colloid, the foaming agent accounts for 0.1% to 15% of the weight percentage of the compound colloid, and the hard segment structural material accounts for the remaining weight percentage of the compound colloid. However, this is not a limitation. If the compound colloid contains other materials, the weight percentage of the hard segment structural material will also change accordingly. For example, in some embodiments of the present invention, the mixed colloid may contain a crosslinking agent, and the crosslinking agent may account for 0.01% to 2% of the weight percentage of the mixed colloid; or, the mixed colloid may contain a colorant (e.g., colored masterbatch) and / or a flame retardant, so that the final product has the color or function expected by those skilled in the art; or, the mixed colloid may contain a foaming aid, and the foaming aid may account for 0.1% to 10% of the weight percentage of the mixed colloid, to promote foaming decomposition and improve foaming efficiency, while the weight percentage of the hard segment structural material will be reduced accordingly based on the aforementioned added materials.

[0042] Furthermore, depending on the actual product and process requirements, the thermoplastic elastomer material can be selected from a combination of polymeric compounds such as polyethylene (PE), polyethylene-ethyl ester copolymer (EVA), styrene-butadiene block copolymer (SBS), styrene-isoprene block copolymer, styrene-based block copolymer, or any mixture of the above compounds; the hard segment structural material can be selected from a combination of polymeric compounds such as polystyrene (PS), acrylonitrile-styrene copolymer (SAN), acrylonitrile-butadiene-propylene-styrene copolymer (ABS), high-impact polystyrene (HIPS), or any mixture of the above compounds; the foaming agent can be a chemical foaming agent (e.g., azo chemical foaming agent) or a physical foaming agent (e.g., baking soda); the crosslinking agent can be any one of diisopropylphenyl peroxide, 2,5-peroxytributyl-2,5-dimethylhexane, or sulfur; the foaming aid can be zinc stearate or zinc oxide, but is not limited thereto. Furthermore, the thermoplastic elastomer material and the hard segment structural material are not required to be combined into a composite material before being mixed with the foaming agent. Skilled personnel can also add individual materials sequentially to the mixing machine, as long as the above components (thermoplastic elastomer material, hard segment structural material, and foaming agent) are sufficient to form the required mixed colloid.

[0043] Step (102): The mixed colloid undergoes a first foaming process (also known as an extrusion foaming process or microfoaming process) using an extruder. In this embodiment, the extrusion temperature of the first foaming process is the decomposition temperature of the foaming agent, for example, 160°C to 180°C, but not limited thereto. The operation time of this first foaming process can be adjusted by changing the extrusion speed and extrusion pressure according to the type of extruder and product requirements to change the foaming state of the mixed colloid. Furthermore, in this step, the foaming density of the mixed colloid can expand to 10% to 20% of the density of the mixed colloid, and the foaming thickness is 1 mm to 4 mm to form an initial sheet.

[0044] Step (103): Stack multiple initial boards according to the required product thickness.

[0045] Step (104): The initial boards are subjected to a second foaming process using a hot press mold. In this embodiment, the heating temperature for the second foaming process is 160°C to 180°C, and the pressure is 100 kg / cm² to 200 kg / cm². 2 The foaming time is 10 to 30 minutes, but not limited to this. In other embodiments of the present invention, the operating values ​​of the above procedure can be adjusted according to product requirements. Furthermore, in this step, the foaming density of the initial boards can expand to 40% to 50% of the density of the mixed colloid to form a wood-like material.

[0046] Furthermore, continue as Figure 1 As shown, through the process of this invention, in the first foaming process, only the initial board is micro-foamed, mainly to give the initial board slightly different shades of color. Specifically, because the foaming density of the two outer surfaces of the initial board is higher during foaming, its color is darker, while the foaming density of the inner layer near the center is lower, resulting in a lighter color. This naturally creates two different shades of color (referring to the visual effect of the same color due to different shades). Subsequently, in the second foaming process, after multiple layers of initial boards are foamed under high temperature and pressure, the colors of each initial board do not fuse together, thus allowing the wood-like material to exhibit a natural, multi-layered texture effect, such as... Figure 2 and Figure 3 The image shown is a schematic diagram of the wood-like material.

[0047] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A process for producing imitation wood materials with multi-layered texture effects, characterized in that, include: A thermoplastic elastomer material, a rigid segment structural material, and a foaming agent are mixed in a process to form a compound colloid. The mixture is subjected to a first foaming process using an extruder, and the foam density of the mixture is expanded to 10% to 20% of the density of the mixture, with a foam thickness of 1 mm to 4 mm, to form an initial sheet. Multiple initial boards are stacked together; and The initial boards are subjected to a second foaming process using a hot press mold, and the foaming density of the initial boards is expanded to 40% to 50% of the density of the mixed colloid to form a wood-like material. The wood-like material will form a multi-layered texture with varying shades of color as a whole due to the different foaming densities of the outer layer near the surface and the inner layer near the center of each initial board.

2. The wood-imitation material process according to claim 1, characterized in that, The thermoplastic elastomer material can be a combination of polymers such as polyethylene, polyethylene-ethyl ester copolymer, styrene-butadiene block copolymer, styrene-isoprene block copolymer, styrene-based block copolymer, or any mixture of the aforementioned compounds.

3. The wood-imitation material process according to claim 2, characterized in that, The hard segment structural material can be selected from a combination of polymer compounds such as polystyrene, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-propylene-styrene copolymer, high-impact polystyrene, or any mixture of the aforementioned compounds.

4. The wood-imitation material process according to claim 1, characterized in that, The thermoplastic elastomer material accounts for 10% to 90% of the weight percentage of the mixed colloid, the foaming agent accounts for 0.1% to 15% of the weight percentage of the mixed colloid, and the hard segment structural material accounts for the remaining weight percentage of the mixed colloid.

5. The wood-imitation material process according to claim 1, characterized in that, The foaming agent is an azo chemical foaming agent.

6. The wood-imitation material process according to claim 1, characterized in that, This foaming agent is a physical foaming agent.

7. The wood-imitation material process according to claim 1, characterized in that, The extrusion temperature of the first foaming process is the decomposition temperature of the foaming agent.

8. The wood-imitation material process according to claim 7, characterized in that, The heating temperature for the second foaming process is 160 to 180 degrees Celsius, the pressure is 100 to 200 kilograms per square centimeter, and the foaming time is 10 to 30 minutes.

9. The wood-imitation material process according to any one of claims 1 to 8, characterized in that, The mixture also contains a bridging agent.

10. The wood-imitation material process according to claim 9, characterized in that, The crosslinking agent accounts for 0.01% to 2% of the weight of the mixed colloid.

11. The wood-imitation material process according to claim 10, characterized in that, The crosslinking agent can be any one of diisopropylphenyl peroxide, 2,5-peroxyterbutyl-2,5-dimethylhexane, or sulfur.

12. The wood-imitation material process according to any one of claims 1 to 8, characterized in that, The mixed colloid also contains a colorant.

13. The wood-imitation material process according to any one of claims 1 to 8, characterized in that, The mixture also contains a fire retardant.

14. The wood-imitation material process according to any one of claims 1 to 8, characterized in that, The mixture also contains a foaming agent, which accounts for 0.1% to 10% of the weight percentage of the mixture.

15. The wood-imitation material process according to claim 14, characterized in that, The foaming agent can be zinc stearate or zinc oxide.

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