Polystyrene foam board and production process and equipment thereof

Abstract

The invention relates to the field of polystyrene foam advertisement boards, in particular to a polystyrene foam board and a production process and equipment thereof, and the process comprises the following steps: 1) foam board core compounding: thermally compounding upper and lower layers of polystyrene foam board cores together by using a first thermal compounding roller; (2) groove pressing, wherein an exhaust groove channel is pressed in the surface of the foam board core through a line pressing roller; (3) surface film compounding is conducted, specifically, the surface film is attached to the surface of the groove-pressed foam board core again through a second thermal compounding roller, so that the attached surface film is only in contact with the top plane of the exhaust groove channel, and then an exhaust channel is formed by the attached surface film and the exhaust groove channel; according to the method, the mode of firstly pressing grooves and then laminating is adopted, concave-convex marks cannot be seen on the surface of the polystyrene foam board, the appearance of the polystyrene foam board is flat and smooth, and the polystyrene foam board is high in strength and not prone to bending deformation.

Description

Technical Field

[0001] The invention relates to the field of polystyrene foam advertising boards (KT boards for short), and in particular to a polystyrene foam board and a production process and equipment thereof. Background Art

[0002] Polystyrene foam advertising board (KT board for short) is a new type of material made of polystyrene (PS) PS particles through foaming to form a board core, and then coated and pressed on the surface. The board is crisp, light, and not easy to deteriorate. It can be directly screen-printed (silk-screen printing board), painted (the adaptability of the paint needs to be tested), mounted with adhesive-backed images, and spray-painted. It is widely used in advertising display promotions, aircraft models, architectural decoration, culture and art, and packaging.

[0003] However, since the ordinary KT board on the market is a foam composite PS mask, and the PS mask has a worse barrier property to foaming gas than the spray film used for mounting, bubbles are inevitable after mounting. In a few hours at the fastest and three or four months at the slowest, the foaming gas will be slowly released and accumulate on the back of the spray film mounted on the KT board surface, forming local pressure to tear off the self-adhesive sticker of the mounted painting, forming bubbles.

[0004] In order to solve this problem, a blocking method has been adopted in recent years. PVC film or thermal composite PVC / PS double-layer film is applied to the foam board surface with curing glue, which has a good blocking effect on gas release. However, after the introduction of PVC material, the recycling of inferior waste, scraps and used board bodies becomes very difficult; PVC and PS cannot be recycled without separation. If they are to be separated, the separation cost far exceeds the recycling value, and white pollution is inevitable. Therefore, these existing methods not only increase the manufacturing cost (increase in processes and materials), but also have a bad impact on the recycling cycle, causing white pollution.

[0005] The inventor has previously designed an anti-bubbling foam advertising board and its preparation method, see the Chinese invention patent application with publication number CN105751652A, the foam advertising board includes a foam board body mainly composed of a foam substrate and a mask covering it, and a mesh-shaped groove exhaust mechanism is provided on the foam board body; the exhaust mechanism is to use an embossing roller with continuous mesh convex ribs to press mesh grooves on the board surface after the foam substrate is produced and pasted with the mask before it is cooled, so that the board surface is divided into multiple supporting board surfaces, and the grooves surround the supporting board surfaces to form exhaust channels. The invention can discharge the gas released in the board through the exhaust channel, solve the defects of introducing new materials for blocking, and also meet the use requirements of preventing large-area gas accumulation and preventing the mounting of paintings from bulging; however, the setting of the exhaust channel will make the strength and flatness of the foam advertising board worse. Summary of the invention

[0006] The purpose of the present invention is to provide a polystyrene foam board with better product strength and flatness and a production process and equipment thereof, so as to at least provide a beneficial choice or create conditions for solving one or more technical problems in the prior art.

[0007] To achieve the above objectives, the present invention adopts the following technical solutions.

[0008] A polystyrene foam board production process, the steps of which are as follows: 1) secondary foaming compounding, including a first layer and a second layer of foaming compounding, using a first hot compounding roller to foam and compound the upper and lower layers of polystyrene (PS) foam board core together; 2) grooving, using a line pressing roller to press an exhaust groove on the surface of the foam board core; 3) mask compounding, using a second hot compounding roller to paste a mask on the surface of the foam board core after the grooving, so that the pasted mask only contacts the top plane of the exhaust groove and forms an exhaust channel with the exhaust groove; 4) cooling, cooling the foam board body compounded with the mask; 5) cutting, cutting the cooled foam board body compounded with the mask to obtain a polystyrene foam board.

[0009] More preferably, in step 1) the secondary foaming and compounding step, there is a preheating step, in which secondary foaming is achieved by preheating to thicken the core of the board, and after preheating, thermal compounding is performed by a first hot compounding roller.

[0010] More preferably, in step 2) the groove pressing step, one or more groups of pressing rollers arranged up and down are used to press out mesh exhaust channels on the surface of the foam board core.

[0011] More preferably, in step 2) the grooving step, corresponding exhaust channels are pressed on the upper and lower surfaces or one side of the foam board core, and during subsequent lamination, facial masks are laminated on both the upper and lower surfaces of the foam board core.

[0012] More preferably, in step 3), the stretching ratio of the mask is controlled by using a film-releasing speed roller group, and the mask is stretched and pressed at the same time during the mask lamination, so that the thickness of the mask can be flexibly controlled.

[0013] More preferably, in step 4), cooling is achieved by using several cooling roller groups.

[0014] More preferably, a pulling roller is used to pull the cooled polystyrene foam board.

[0015] On the other hand, the present invention provides a polystyrene foam board production device, which is used to implement the polystyrene foam board production process as described above.

[0016] More preferably, the polystyrene foam board production equipment comprises a foam board core barrel, a guide roller, a secondary foaming heating device, a first hot composite roller, a groove pressing roller group, a mask barrel, a film release speed roller, a second hot composite roller, a cooling roller group, a traction roller and a cutting mechanism, the foam board core barrel is two (or one, if the single layer is thick enough to meet the demand, only one layer of foam board core can be used), which are respectively used to store the upper and lower layers of foam board core, the guide roller is used to guide the upper and lower layers of foam board core to the secondary foaming heating device for secondary foaming and heating, and at the same time introduce them into the first hot composite roller for hot pressing and composite, the secondary foaming The thermal device is arranged upstream of the first hot composite roller and is used to heat and foam the composite foam board core. The groove pressing roller group includes two groups of pressing rollers arranged front and back and is used to press out a mesh exhaust groove on the surface of the foam board core. The mask barrel is used to store the upper and lower layers of masks. The film release speed roller is used to control the release speed of the upper and lower layers of masks. The second hot composite roller is used to thermally composite the upper and lower layers of masks on the upper and lower surfaces of the foam board core. The cooling roller group is used to cool the foam board core composited with the mask. The traction roller is used to pull the cooled foam board. The cutting mechanism is used to cut the cooled foam board.

[0017] On the other hand, the present invention also provides a polystyrene foam board, which is produced by the polystyrene foam board production process as described above.

[0018] The present invention has at least the following beneficial effects.

[0019] 1. The present invention provides a polystyrene foam board production process, which adopts the method of first pressing grooves and then laminating, so that the surface of the polystyrene foam board has no concave and convex marks and has a smooth appearance; and after pressing grooves and then laminating, the film can effectively improve the strength of the final product by pulling the foam board core. In addition, under the same thickness, the strength of the double-layer foam board core is much greater than that of the single-layer foam board core; the polystyrene foam board finally obtained is not easy to bend and deform.

[0020] 2. The polystyrene foam board production equipment provided by the present invention can produce polystyrene foam board products with internal exhaust channels, smooth appearance and greater strength. It not only solves the bubbling problem of KT board after mounting paintings from the root, but also avoids the problem of insufficient product strength and uneven surface caused by grooving on the surface of the foam board core. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 Shown is a schematic diagram of the groove pressing process in the present invention.

[0022] Figure 2 Shown is a schematic diagram of the foam board core surface after grooving.

[0023] Figure 3Shown is a schematic diagram of the foam core surface of the mask composite.

[0024] Figure 4 Shown is a schematic structural diagram of the polystyrene foam board production equipment in the present invention.

[0025] Figure 5 Shown is a schematic structural diagram of the polystyrene foam board of the present invention.

[0026] Description of Figure Numbers.

[0027] 101: foam board core barrel, 102: guide roller, 103: secondary foaming heating device, 104: first hot composite roller, 105: groove pressing roller group, 1051 / 1052: groove pressing roller, 106: facial mask barrel, 107: film releasing speed roller, 108: second hot composite roller, 109: cooling roller group, 110: traction roller, 111: cutting mechanism.

[0028] 201: foam board core, 202: upper film layer, 203: lower film layer, 204: exhaust channel. DETAILED DESCRIPTION

[0029] The following is a further description of the specific implementation of the present invention in conjunction with the drawings of the specification, so that the technical solution and its beneficial effects of the present invention are clearer and more explicit. The following description of the embodiments with reference to the drawings is exemplary and intended to explain the present invention, but cannot be understood as limiting the present invention.

[0030] Additional aspects and advantages of the present invention will become apparent from the following description or may be learned by practice of the present invention.

[0031] A polystyrene foam board production process, the steps of which are as follows: 1) secondary foaming compounding, including a first layer and a second layer of foaming compounding, using a first hot compounding roller to foam and compound the upper and lower layers of polystyrene (PS) foam board core together; 2) grooving, using a line pressing roller to press an exhaust groove on the surface of the foam board core; 3) mask compounding, using a second hot compounding roller to paste a mask on the surface of the foam board core after the grooving, so that the pasted mask only contacts the top plane of the exhaust groove; 4) cooling, cooling the foam board body compounded with the mask; 5) cutting, cutting the cooled foam board body compounded with the mask to obtain a polystyrene foam board.

[0032] Compared with the prior art, the polystyrene foam board production process provided in this embodiment adopts the method of first pressing grooves and then laminating, which can make the surface of the polystyrene foam board have no concave and convex marks and have a smooth appearance; and after pressing grooves and then laminating, the surface of the foam board core forms a three-dimensional thickened mesh root groove and the surface film to form a closed hollow reinforcement rib, which can effectively improve the strength of the final product. In addition, under the same thickness, the strength of the double-layer foam board core is also much greater than that of the single-layer foam board core; the polystyrene foam board finally obtained is not easy to bend and deform.

[0033] It should be noted that in the above-mentioned polystyrene foam board production process, before the upper and lower polystyrene foam board cores are thermally laminated together by the first thermal laminating roller, there is also a preheating step. After preheating and foaming, the first thermal laminating roller is used to perform thermal lamination to improve the thermal lamination effect and product yield. Among them, the preheating step is achieved by using a preheating lamp. Obviously, those skilled in the art can adopt other forms of preheating methods that are currently known or can be realized in the future according to different actual needs, as long as they can meet the corresponding preheating requirements, and are not limited to this embodiment.

[0034] Reference Figure 1 As shown, in step 2) the grooving step, it is preferred to use two groups of crimping rollers 1051 and 1052 arranged up and down to press out a mesh exhaust channel on the surface of the foam board core. Here, the advantage of using two groups of crimping rollers to press the mesh exhaust channel is that not only the production cost of the rollers is low, but also the depth and width of the exhaust channels obtained by pressing are more uniform, ensuring the exhaust effect of the product. In some embodiments, the front and rear two groups of crimping rollers can also be replaced by a single embossing roller with a mesh pattern. Accordingly, the depth and width uniformity of the exhaust channels and the exhaust performance are also slightly worse. The surface of the foam board core after grooving is as shown in Figure 2.

[0035] In step 2) the grooving step, preferably, corresponding exhaust channels are pressed on the upper and lower surfaces of the foam board core, and during the subsequent lamination, a mask is applied to the upper and lower surfaces of the foam board core. The mask material is preferably high-impact polystyrene (HIPS). High-impact polystyrene is a kind of impact-resistant polystyrene product produced by adding polybutyl rubber particles to polystyrene. This polystyrene product will add micron-sized rubber particles and connect the polystyrene and rubber particles together by grafting. When impacted, the tip stress of the crack extension will be released by the relatively soft rubber particles. Therefore, the expansion of the crack is hindered and the impact resistance is improved. In some embodiments, according to different actual needs, exhaust channels can be pressed on one side of the foam board core, and the mask can also use other PS materials that are currently known or can be realized in the future; it is not limited to this embodiment.

[0036] In step 3) the mask is compounded, preferably the film unwinding speed and stretching ratio of the mask are controlled by a film unwinding speed roller group, and a process of laminating while stretching is adopted to ensure that the applied mask is only in contact with the top plane of the exhaust channel and the entire board surface is flat, thereby ensuring the strength of the final polystyrene foam board. Figure 3 Obviously, according to different actual needs, those skilled in the art can use other methods that are currently known or can be realized in the future to control the stretching ratio of the mask; it is not limited to this embodiment.

[0037] In step 4), it is preferred to use several cooling roller groups to achieve cooling. In this way, a certain traction force can be provided during cooling to facilitate the foam board core and the mask to be drawn out from the corresponding barrel. Furthermore, the traction roller is also used to pull the cooled polystyrene foam board.

[0038] Reference Figure 4 As shown, the present invention also provides an apparatus for implementing the above-mentioned polystyrene foam board production process, including a foam board core barrel 101, a guide roller 102, a secondary foaming heating secondary foaming device 103, a first hot composite roller 104, a groove pressing roller group 105, a mask barrel 106, a film release speed roller 107, a second hot composite roller 108, a cooling roller group 109, a traction roller 110 and a cutting mechanism 111, the foam board core barrel 101 is two, respectively used to store the upper and lower layers of foam board core, the guide roller 102 is used to guide the upper and lower layers of foam board core to the first hot composite roller 104 for hot pressing and composite, and the preheating device 103 is arranged at the The upstream of the first hot composite roller 104 is used to preheat the foam board core to be composited. The groove pressing roller group 105 includes two groups of pressing rollers arranged front and back, which are used to press out mesh exhaust grooves on the surface of the foam board core. The mask barrel 106 is used to store the upper and lower layers of masks. The film release speed roller 107 is used to control the release speed of the upper and lower layers of masks. The second hot composite roller 108 is used to thermally composite the upper and lower layers of masks on the upper and lower surfaces of the foam board core. The cooling roller group 109 is used to cool the foam board core composited with the mask. The traction roller 110 is used to traction the cooled foam board. The cutting mechanism 111 is used to cut the cooled foam board.

[0039] It should be noted that the specific structural designs of the foam board core barrel 101, the guide roller 102, the secondary foaming heating device 103, the first hot composite roller 104, the groove pressing roller group 105, the mask barrel 106, the film release speed roller 107, the second hot composite roller 108, the cooling roller group 109, the traction roller 110, and the cutting mechanism 111 are common technical knowledge mastered by those skilled in the art. The innovation of the polystyrene foam board production equipment of the present invention does not lie in the improvement of the component structure, but in the new production line formed after the components are combined.

[0040] Reference Figure 5 As shown, a polystyrene foam board made by using the above-mentioned polystyrene foam board production process and equipment includes a foam board core 201, an upper film layer 202 and a lower film layer 203. The foam board core 201 is a double-layer structure composed of an upper and lower layer of polystyrene (PS) foam board cores. Exhaust channels 204 are respectively formed on the upper and lower surfaces of the foam board core 201. The upper film layer 202 is attached to the upper surface of the foam board core 201, and together with the exhaust channels 204 on the upper surface, forms an upper exhaust channel for exhausting air on all sides. The lower film layer 203 is attached to the lower surface of the foam board core 201, and together with the exhaust channels 204 on the lower surface, forms a lower exhaust channel for exhausting air on all sides.

[0041] In this embodiment, the upper film layer 202 and the lower film layer 203 are both high-impact polystyrene (HIPS) film layers, and the upper exhaust channel and the lower exhaust channel are both mesh-shaped, continuous channels. The bubbles in the foam board core 201 will release butane gas when the pressure is released. The gas can enter the exhaust channel nearby and be diverted to the edges of the board core through the exhaust channel network. The pressure is released in time before the butane gas penetrates into the mask, and it no longer gathers on the board surface, thereby avoiding bubbling.

[0042] In this embodiment, the exhaust channel 204 is preferably a triangular groove cavity that is wide outside and narrow inside, the depth of the triangular groove cavity is preferably 0.5mm, and the outer width of the triangular groove cavity is preferably 0.5mm. In some embodiments, the exhaust channel 204 can be a trapezoidal channel, a circular arc channel, or an elliptical arc channel that is wide outside and narrow inside, the depth of the exhaust channel 204 can be appropriately selected between 0.2-1.0mm, the outer width of the exhaust channel 204 can be appropriately selected between 0.1-0.5mm, and the maximum distance between the exhaust channels 204 is appropriately selected between 5-20mm. While ensuring that the exhaust channel is continuous and not blocked, the narrower and shallower the better, which can make the subsequent heat-bonding easier. Because the process of stretching and pressing at the same time is adopted during the heat-bonding process, any obvious depression or defect in the foam board embryo is likely to cause film breakage and surface inequality.

[0043] In order to better reflect the advancement of the present invention, the present invention also conducted the following two comparative tests.

[0044] Comparative Test 1: A polystyrene foam board, the structure of which is Figure 2 The polystyrene foam board shown has a substantially identical structure, except that no groove structure is formed.

[0045] Comparative Test 2: A polystyrene foam board, the structure of which is Figure 2The structure of the polystyrene foam board shown is basically the same, except that the shapes of the upper film layer 202 and the lower film layer 203 are consistent with the surface shape of the foam board core, and no exhaust channel is formed between the exhaust channel 204.

[0046] Performance testing.

[0047] A polystyrene foam board having a thickness of 6 mm was taken and formed into a sample strip having a length×width of 300 mm×25 mm.

[0048] The test method is: fix one end of the sample strip along the length direction, suspend the other end, and test the sagging distance of the other end. The test results are shown in Table 1.

[0049] Table 1. Performance test comparison The present invention Comparative test 1 ordinary board Comparative test 2: surface grooved board The other end droop distance (mm) 5 8 15 .

[0050] It can be seen from Table 1 that the polystyrene foam board prepared by the present invention can significantly improve the strength of the product.

[0051] It should also be noted that, in the description of the present invention, directional words such as the terms "center", "lateral", "longitudinal", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", etc., indicating directions and positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of narrating the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and cannot be understood as limiting the specific scope of protection of the present invention.

[0052] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features. Therefore, the definition of "first" and "second" features can explicitly or implicitly include one or more of the features. In the description of the present invention, "at least" means one or more, unless otherwise clearly and specifically defined.

[0053] In the present invention, unless otherwise specified and limited, the terms "assemble", "connect", and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can also be a mechanical connection; it can be directly connected, or it can be connected through an intermediate medium, or the two elements can be internally connected. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0054] In the invention, unless otherwise specified and limited, a first feature being “above” or “below” a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being “above”, “below”, and “above” a second feature includes that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “above”, “below”, and “below” a second feature includes that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0055] Through the description of the above structure and principle, those skilled in the art should understand that the present invention is not limited to the above specific implementations, and improvements and substitutions based on the present invention using the known technology in the art fall within the protection scope of the present invention, and the protection scope of the present invention should be defined by the claims and their equivalents. Parts not described in the specific implementations are prior art or common knowledge.

Claims

1. A polystyrene foam board production process, It is characterized in that The steps are as follows: 1) secondary foaming and compounding, including one layer and two layers of foaming and compounding, using a first hot compounding roller to foam and compound the upper and lower layers of polystyrene (PS) foam board core together; 2) grooving, using a line pressing roller to press the exhaust groove on the surface of the foam board core; 3) mask compounding, using a second hot compounding roller to paste the mask on the surface of the foam board core after the grooving, so that the pasted mask only contacts the top plane of the exhaust groove and forms an exhaust channel with the exhaust groove; 4) cooling, cooling the foam board body compounded with the mask; 5) cutting, cutting the cooled foam board body compounded with the mask to obtain a polystyrene foam board.

2. A polystyrene foam board production process according to claim 1, It is characterized in that In step 1) the secondary foaming and compounding step, there is a preheating step, in which secondary foaming is achieved by preheating to thicken the core of the board, and after preheating, thermal compounding is performed by a first hot compounding roller.

3. A polystyrene foam board production process according to claim 1, It is characterized in that In step 2) the groove pressing step, one or more sets of pressing rollers arranged up and down are used to press out mesh exhaust grooves on the surface of the foam board core.

4. A polystyrene foam board production process according to claim 1, It is characterized in that In step 2) the groove pressing step, corresponding exhaust channels are pressed on the upper and lower surfaces or one side of the foam board core, and during subsequent lamination, the upper and lower surfaces of the foam board core are both laminarly pasted.

5. A polystyrene foam board production process according to claim 1, It is characterized in that In step 3) the mask is compounded, the stretching ratio of the mask is controlled by using the film-releasing speed roller group, and the mask is stretched and pressed at the same time during the mask compounding.

6. A polystyrene foam board production process according to claim 1, It is characterized in that In step 4), cooling is achieved using several cooling roller sets.

7. A polystyrene foam board production process according to claim 1, It is characterized in that The cooled polystyrene foam board is also pulled by a pulling roller.

8. A polystyrene foam board production equipment, It is characterized in that Used to realize a polystyrene foam board production process as described in any one of claims 1-7.

9. A polystyrene foam board production equipment according to claim 8, It is characterized in that It includes a foam board core barrel, a guide roller, a secondary foaming heating device, a first hot composite roller, a groove pressing roller group, a mask barrel, a film release speed roller, a second hot composite roller, a cooling roller group, a traction roller and a cutting mechanism. The foam board core barrel is used to store the foam board core to be secondary foamed, the guide roller is used to guide the foam board core to the secondary foaming heating, and at the same time introduce the first hot composite roller for hot pressing and compounding, the preheating device is arranged upstream of the first hot composite roller, and is used to perform surface heating on the foam board core to be compounded, the groove pressing roller group includes one or more groups of pressing rollers arranged up and down, and is used to press a mesh exhaust channel on the surface of the foam board core, the mask barrel is used to store upper and lower layers of masks, the film release speed roller is used to control the release speed of the upper and lower layers of masks, the second hot composite roller is used to thermally compound the upper and lower layers of masks on the upper and lower surfaces of the foam board core, the cooling roller group is used to cool the foam board core compounded with the mask, the traction roller is used to pull the cooled foam board, and the cutting mechanism is used to cut the cooled foam board.

10. A polystyrene foam board, It is characterized in that The polystyrene foam board is produced by a polystyrene foam board production process as described in any one of claims 1 to 7.

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