Ultra-light foaming material with micropore channels and preparation method of ultra-light foaming material

Abstract

The invention relates to the technical field of thermoplastic material foaming, in particular to a preparation method of an ultralight foaming material with micropore channels. The invention relates to an ultralight foaming material with micropore channels. The ultralight foaming material comprises the following substances in parts by weight: 80-90 parts of thermoplastic matrix resin; 0.1 to 2 parts of a pore-foaming agent; 0.1 to 0.8 part of a functional auxiliary agent; 10 to 20 parts of auxiliary materials; the pore-foaming agent comprises one or a mixture of more of activated carbon, zeolite, porous ceramic and hollow glass microspheres. According to the technical scheme, the thermoplastic matrix resin is selected to be combined with the pore-forming agent, the composite material formed after foaming treatment has a good vacuum channel structure, the density of the material is effectively reduced, the porosity of the material is improved, on the basis, selection of the pore-forming agent is optimized, and the porosity of the material is improved. The prepared ultralight foaming material has different pore structures and adsorption performance, and more excellent material performance can be obtained through mixed use.

Description

Technical Field

[0001] The invention relates to the technical field of thermoplastic material foaming, in particular to a method for preparing an ultralight foaming material with microporous channels. Background Art

[0002] Although existing thermoplastic materials have shown good elasticity and plasticity in the application of foaming technology, they still face many challenges in the pursuit of lower density and higher foaming ratio. Especially after the first foaming, although the density of the material can be reduced to a certain extent by precisely controlling the process parameters such as temperature, pressure, and the type and amount of foaming agent, the increase in foaming ratio is often limited, making it difficult to meet the market demand for higher performance lightweight materials.

[0003] During the primary foaming process, when the temperature of thermoplastic materials is higher than their foaming temperature, gas molecules can be more effectively dissolved in the polymer melt. However, due to the physical properties of the material itself, such as the rigidity, crystallinity and cross-linking degree of the molecular chain, the diffusion of gas molecules and the formation of pores are limited. Even when the temperature is lowered to the foaming temperature for foaming, the growth of pores is often restricted by the internal stress and structural stability of the material, making it difficult to achieve the ideal foaming ratio.

[0004] In addition, the density reduction of the material after the first foaming is limited, which means that in the second foaming process, greater difficulties need to be overcome to achieve further density reduction and foaming ratio improvement. Secondary foaming is usually carried out on the basis of the material after the first foaming, which requires that the material after the first foaming must maintain sufficient structural integrity and stability to withstand the higher temperature and pressure changes in the second foaming process, as well as the more complex cell nucleation and growth process.

[0005] However, since a large number of pore structures have been formed inside the material after the first foaming, its mechanical properties and thermal stability tend to decline. This makes it more likely for pore merging, rupture, and gas escape to occur during the second foaming process, thereby reducing the foaming efficiency and expansion ratio. At the same time, the second foaming process also requires more precise control of process parameters such as the type and amount of the foaming agent, foaming temperature and time, in order to avoid foaming failure or poor foaming quality due to improper parameters.

[0006] Therefore, in the face of the problems that the density of existing thermoplastic materials after foaming is not low enough, the foaming ratio after one foaming is not high enough, and the secondary foaming is difficult, it is necessary to explore new foaming technologies and process parameter optimization methods to achieve a more efficient and stable foaming process, thereby promoting the application and development of thermoplastic materials in the fields of lightweight and high performance. Summary of the invention

[0007] Based on the technical problems existing in the above-mentioned prior art, the present invention provides an ultra-light foam material with microporous channels and a preparation method thereof.

[0008] In the first aspect, the present application provides an ultra-light foam material with microporous channels, which adopts the following technical solution: An ultralight foam material with microporous channels comprises the following substances in parts by weight: 80-90 parts of thermoplastic matrix resin; 0.1-2 parts of porogen; Functional additives 0.1-0.8 parts; 10-20 parts of auxiliary materials; The porogen includes a mixture of one or more of activated carbon, zeolite, porous ceramics, and hollow glass microspheres.

[0009] Through the above technical scheme, the technical scheme of the present application selects a thermoplastic matrix resin combined with a pore-forming agent, and the composite material formed after foaming treatment has a good vacuum channel structure, which effectively reduces the density of the material and increases the porosity of the material. On this basis, the present application optimizes the selection of the pore-forming agent. According to the material properties, pore-forming agents such as activated carbon, zeolite, porous ceramics, and hollow glass microspheres can be selected to make the prepared ultra-light foamed material have different pore structures and adsorption properties, and better material properties can be obtained by mixed use.

[0010] Furthermore, the functional additive includes a mixture of one or more of a nucleating agent, an antioxidant, a stabilizer, an antioxidant, a crosslinking agent, and a release agent; The thermoplastic matrix resin includes a mixture of one or more of TPU resin, TPEE resin, PC resin, PPE resin, PET resin, and nylon elastomer resin; The auxiliary material is an inorganic filler, and the inorganic filler includes one or a mixture of calcium carbonate, talcum powder, and clay.

[0011] Further, the nucleating agent includes a mixture of one or more of silicon dioxide powder, zinc borate, kaolin, talc, barium sulfate, and calcium carbonate; The antioxidant includes a mixture of one or more of 2,6-di-tert-butyl-p-cresol, 2,6-di-tert-butyl-4-ethylphenol, N-phenyl-1-naphthylamine, N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine, 4,4'-thiobis(6-tert-butyl-m-cresol), and tris(nonylphenyl)phosphite; The stabilizer comprises a mixture of one or more of phenolic resin, phosphite and phosphate, benzofuranone derivatives, and acryl-modified phenolic resin; The antioxidant includes a mixture of one or more of 2,6-di-tert-butyl-p-cresol (BHT), pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, tris(2,4-di-tert-butylphenyl) phosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol bis diphosphite, and pentaerythritol distearyl diphosphite; The crosslinking agent includes a mixture of one or more of diisopropyl peroxide, benzoyl peroxide, di-tert-butyl peroxide, diisopropyl hydroperoxide, diethylenetriamine, 2-ethyl-4-methylimidazole, 2-phenylimidazole, and 2-isopropylimidazole; The demoulding agent comprises a mixture of one or more of silicone oil, silicone resin, natural wax, synthetic wax, whale oil, vaseline, perfluoroalkyl compound, fluororesin powder, stearate, and mica powder.

[0012] In a second aspect, the present application provides a method for preparing an ultralight foam material having microporous channels, using the following technical solution: A method for preparing an ultralight foam material having microporous channels comprises the following preparation steps: S1, premixing the thermoplastic matrix resin, porogen, functional additive and auxiliary materials, mixing them evenly, putting them into an extruder for melt mixing, and pelletizing to obtain thermoplastic blended particles; S2, placing the thermoplastic blended particles in a reaction device, stirring and mixing, introducing a primary gas foaming agent, heating to a temperature T1 after a pressure treatment, cooling to a temperature T2 after a heat preservation treatment, and rapidly releasing the pressure after a second heat preservation and pressure treatment to obtain primary foamed particles; S3, putting the primary foamed particles into a reactor to be pressurized by air, and then putting them into a secondary foaming device, introducing a secondary gas foaming agent, and performing secondary foaming to obtain secondary foamed particles; S3, steam-forming the secondary foamed particles, and obtaining an ultra-light foamed material after curing.

[0013] Furthermore, the pressure after the pressurization treatment in step S2 is 5-20 MPa; The temperature T1 = (T2 + 10) - (T2 + 20 ° C), the temperature T1 is lower than the melting point temperature of the thermoplastic blended particles, and the heat preservation time is 5-10 minutes; The temperature T2 is the rubber state temperature of the thermoplastic blended particles, and the secondary heat preservation treatment time is 20-100 minutes; The pressure of the secondary heat preservation and pressure maintenance treatment is 10-20MPa; The rapid pressure relief speed is 1-10 MPa / s.

[0014] Through the above technical solution, the present application performs foaming by first raising the temperature to a temperature higher than the foaming temperature of the thermoplastic material for a period of time during a foaming operation, and then cooling it down to the rubber state temperature. In the high temperature stage, the molecular chains in the thermoplastic material become more active, and the molecular chains are easy to slip, which is conducive to the uniform dispersion and penetration of the subsequent foaming agent. When the temperature is reduced to the rubber state temperature, the molecular chains are relatively fixed and have a strong air encapsulation capacity. Due to the influence of the previous high temperature stage, the molecular structure inside the material has changed to a certain extent, making it easier for the foaming agent to form bubble nuclei and grow, thereby increasing the foaming ratio.

[0015] Specifically, the present application helps the foaming agent to dissolve and disperse better in the thermoplastic melt by first raising the temperature to a level higher than the foaming temperature of the thermoplastic material during the primary foaming, thereby forming more bubble nucleation points. When the temperature is lowered to the rubber state temperature, these nucleation points will quickly grow into bubbles, thereby obtaining a foamed material with finer and more uniform pores, effectively improving the pore structure; On this basis, the present invention can affect the growth speed and direction of bubbles through appropriate temperature changes, making the shape of the cells more regular and reducing the generation of irregular cells. This helps to improve the structural stability and mechanical properties of the foamed thermoplastic material, avoid the degradation of material properties caused by poor cell shape, and effectively optimize the cell morphology.

[0016] Secondly, the present application can effectively disperse stress through a uniform and fine cell structure, thereby improving the mechanical properties of the foamed thermoplastic material, such as tensile strength, compressive strength, and impact toughness. At the same time, a good cell structure can also reduce the anisotropy of the material, making the performance of the material in different directions more balanced, further enhancing the mechanical properties; Finally, by optimizing the pore structure, the surface of the foamed thermoplastic material can be made smoother and flatter, surface defects and flaws can be reduced, and the appearance quality of the material can be improved.

[0017] Furthermore, the cooling to temperature T2 in step S2 is staged cooling, and specifically adopts the following cooling steps: Start cooling from T1, cool down by 3-5℃ within 1-2min, then keep warm for 1-2min, then cool down by 3-5℃ within 1-2min again, then keep warm for 1-2min, repeat the above cooling and keeping process until the temperature drops to T2.

[0018] Through the above technical solution, the process of cooling from T1 to T2 in this application is a staged cooling, which can better lock the air, that is, during the foaming process, a certain stress will be generated inside the material. If the temperature changes too quickly, it will cause uneven stress distribution, which is easy to cause cracking or deformation of the material. Staged cooling can gradually release stress and reduce stress concentration, thereby improving the strength and stability of the product and reducing the phenomenon of stress concentration; At the same time, this technical solution also helps to form a closed-cell foam material through an appropriate cooling rate, which has better thermal insulation, sound insulation and mechanical properties. Staged cooling can optimize the size, shape and distribution of the pores by regulating temperature changes to meet different application requirements, thereby effectively optimizing the pore structure; Finally, this technical solution can reduce temperature fluctuations and energy consumption in the production process and improve production efficiency through reasonable staged cooling. At the same time, since the pore structure is more uniform and stable, it can also reduce the scrap rate and rework rate in subsequent processing, thereby effectively improving production efficiency.

[0019] Furthermore, in step S3, the pressure in the reactor is negative pressure, the air is hot air, and the air pressure-carrying time is 1-10 min.

[0020] Furthermore, the foaming conditions of the secondary foaming in step S3 are: pressure of 1-3 bar, time of 5-20 min.

[0021] Furthermore, the primary gas foaming agent includes one of CO2, N2, and a rare gas, and the secondary gas foaming agent includes saturated water vapor.

[0022] Through the above technical solution, the pressure in the pressure-carrying kettle is set to negative pressure, hot air is used as air, and the air pressure-carrying time is 1-10 minutes. The pore-forming agent is used to make the surface of the primary foaming particles have uniform channels. Under negative pressure conditions, the primary gas foaming agent in the primary foaming particles exchanges with the hot air more quickly, thereby improving production efficiency.

[0023] Furthermore, the molar ratio of the primary foaming agent to the thermoplastic blended particles in step S2 is (1-5):100, and the molar ratio of the secondary gas foaming agent to the primary foamed particles in step S3 is (1-5):100.

[0024] In summary, this application has the following beneficial effects: First, the technical solution of this application selects a thermoplastic matrix resin combined with a pore-forming agent, and the composite material formed after foaming treatment has a good vacuum channel structure, which effectively reduces the density of the material and increases the porosity of the material. On this basis, this application optimizes the selection of the pore-forming agent. According to the material properties, pore-forming agents such as activated carbon, zeolite, porous ceramics, and hollow glass microspheres can be selected to make the prepared ultra-light foamed material have different pore structures and adsorption properties. By mixing and using, better material properties can be obtained.

[0025] Second, the present application adopts a high-temperature pretreatment method. During the foaming process of the thermoplastic material, the activation of the molecular chain is promoted by heating it to a temperature higher than the foaming temperature, the slippage of the molecular chain is increased, and the uniform dispersion and penetration of the foaming agent are facilitated. Subsequently, in the stage of cooling to the rubber state temperature, the solidification state of the molecular chain and the molecular structure change in the pretreatment stage are utilized to promote the formation and growth of the bubble nucleus and improve the foaming ratio. This process optimizes the pore structure, reduces the generation of irregular pores, and helps to improve the structural stability and mechanical properties of the material. At the same time, the small and uniform pore structure can effectively disperse stress, improve the mechanical properties of the material and reduce anisotropy. Finally, through the optimization of the pore structure, the surface quality is improved, the appearance of the material is made smoother and flatter, and the overall appearance quality is improved.

[0026] Third, this technical solution adopts a staged cooling strategy, gradually reducing from T1 to T2, so as to more effectively lock the gas inside the material and help release the stress generated inside the material. Compared with rapid cooling, staged cooling can gradually release stress, reduce the concentrated distribution of stress, improve the strength and stability of the product, and avoid cracks and deformation problems caused by stress concentration. In addition, through an appropriate cooling rate, it is helpful to form a foam material with a closed-cell structure, which has excellent thermal insulation, sound insulation and mechanical properties. By regulating temperature changes, the characteristics of the pores, such as size, shape and distribution, can be optimized to meet the needs of different application fields and achieve fine regulation of the pore structure. Finally, a reasonable staged cooling strategy can reduce temperature fluctuations and energy consumption in the production process and improve production efficiency; at the same time, because the pore structure is more uniform and stable, it can also reduce the scrap rate and rework rate in the subsequent processing process, thereby effectively improving the overall production efficiency and product quality. DETAILED DESCRIPTION

[0027] The present application is further described in detail below with reference to the embodiments.

[0028] In the examples of the present application, the raw materials and instruments used are as follows, but not limited thereto. Raw materials not otherwise specified are of analytical grade.

[0029] Among them, the TPU material used is TPU S60 (BASF, Germany).

[0030] Example 1 An ultra-light foam material with microporous channels, the formula of which is shown in Table 1 below; A method for preparing an ultralight foam material having microporous channels comprises the following preparation steps: S1, placing the thermoplastic matrix resin, porogen, functional additive and auxiliary materials in a high-speed mixer at 3500r / min for premixing, mixing evenly and then putting them into an extruder for melt mixing, and underwater pelletizing to obtain thermoplastic blended particles; S2, placing the thermoplastic blended particles in a reaction device, stirring and mixing, and introducing a primary gas foaming agent, pressurizing to 5 MPa, then heating to temperature T1, and heat preservation for 5 minutes, cooling to temperature T2, wherein the process of cooling from T1 to T2 is a staged cooling, specifically: cooling from T1, cooling by 5°C within 2 minutes, then heat preservation for 2 minutes, then cooling by 5°C within 2 minutes, then heat preservation for 2 minutes, and then cooling by 5°C within 2 minutes to T2; the speed of rapid pressure relief is 10 MPa / s, after secondary heat preservation and pressure treatment at 10 MPa for 20 minutes, the pressure is rapidly released at a pressure relief speed of 1 MPa / s to obtain primary foamed particles; S3, putting the primary foamed particles into a reactor to be pressurized by air, and then putting them into a secondary foaming device, introducing a secondary gas foaming agent, and performing secondary foaming at a pressure of 1 bar and keeping the temperature for 10 minutes to obtain secondary foamed particles; S3, steam-forming the secondary foamed particles, and obtaining an ultra-light foamed material after curing.

[0031] Example 2 An ultra-light foam material with microporous channels, the formula of which is shown in Table 1 below; A method for preparing an ultralight foam material having microporous channels comprises the following preparation steps: S1, placing the thermoplastic matrix resin, porogen, functional additive and auxiliary materials in a high-speed mixer at 3500r / min for premixing, mixing evenly and then putting them into an extruder for melt mixing, and underwater pelletizing to obtain thermoplastic blended particles; S2, placing the thermoplastic blended particles in a reaction device, stirring and mixing, and introducing a primary gas foaming agent, pressurizing to 12 MPa, then heating to temperature T1, and heat preservation for 8 minutes, cooling to temperature T2, wherein the process of cooling from T1 to T2 is a staged cooling, specifically: cooling from T1, cooling by 5°C within 2 minutes, then heat preservation for 2 minutes, then cooling by 5°C within 2 minutes, then heat preservation for 2 minutes, and then cooling by 5°C within 2 minutes to T2; the speed of rapid pressure relief is 10 MPa / s, after secondary heat preservation and pressure treatment at 15 MPa for 60 minutes, rapid pressure relief is performed at a pressure relief speed of 5 MPa / s to obtain primary foamed particles; S3, putting the primary foamed particles into a reactor to be pressurized by air, and then putting them into a secondary foaming device, introducing a secondary gas foaming agent, and performing secondary foaming at a pressure of 2 bar and keeping the temperature for 10 minutes to obtain secondary foamed particles; S3, steam-forming the secondary foamed particles, and obtaining an ultra-light foamed material after curing.

[0032] Example 3 An ultra-light foam material with microporous channels, the formula of which is shown in Table 1 below; A method for preparing an ultralight foam material having microporous channels comprises the following preparation steps: S1, placing the thermoplastic matrix resin, porogen, functional additive and auxiliary materials in a high-speed mixer at 3500r / min for premixing, mixing evenly and then putting them into an extruder for melt mixing, and underwater pelletizing to obtain thermoplastic blended particles; S2, placing the thermoplastic blended particles in a reaction device, stirring and mixing, and introducing a primary gas foaming agent, pressurizing to 20 MPa, then heating to temperature T1, and heat preservation for 10 minutes, cooling to temperature T2, wherein the process of cooling from T1 to T2 is a staged cooling, specifically: cooling from T1, cooling by 5°C within 2 minutes, then heat preservation for 2 minutes, then cooling by 5°C within 2 minutes, then heat preservation for 2 minutes, and then cooling by 5°C within 2 minutes to T2; the speed of rapid pressure relief is 10 MPa / s, after secondary heat preservation and pressure treatment at 20 MPa for 100 minutes, the pressure is rapidly released at a pressure relief speed of 10 MPa / s to obtain primary foamed particles; S3, putting the primary foamed particles into a reactor to be pressurized by air, and then putting them into a secondary foaming device, introducing a secondary gas foaming agent, and performing secondary foaming at a pressure of 3 bar and keeping the temperature for 10 minutes to obtain secondary foamed particles; S3, steam-forming the secondary foamed particles, and obtaining an ultra-light foamed material after curing.

[0033] It should be noted that the functional additives used in the present application include a mixture of one or more of a nucleating agent, an antioxidant, a stabilizer, an antioxidant, a crosslinking agent, and a release agent; The thermoplastic matrix resin includes a mixture of one or more of TPU resin, TPEE resin, PC resin, PPE resin, PET resin, and nylon elastomer resin; The auxiliary material is an inorganic filler, and the inorganic filler includes one or a mixture of calcium carbonate, talcum powder, and clay.

[0034] Further, the nucleating agent includes a mixture of one or more of silicon dioxide powder, zinc borate, kaolin, talc, barium sulfate, and calcium carbonate; The antioxidant includes a mixture of one or more of 2,6-di-tert-butyl-p-cresol, 2,6-di-tert-butyl-4-ethylphenol, N-phenyl-1-naphthylamine, N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine, 4,4'-thiobis(6-tert-butyl-m-cresol), and tris(nonylphenyl)phosphite; The stabilizer comprises a mixture of one or more of phenolic resin, phosphite and phosphate, benzofuranone derivatives, and acryl-modified phenolic resin; The antioxidant includes a mixture of one or more of 2,6-di-tert-butyl-p-cresol (BHT), pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, tris(2,4-di-tert-butylphenyl) phosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol bis diphosphite, and pentaerythritol distearyl diphosphite; The crosslinking agent includes a mixture of one or more of diisopropyl peroxide, benzoyl peroxide, di-tert-butyl peroxide, diisopropyl hydroperoxide, diethylenetriamine, 2-ethyl-4-methylimidazole, 2-phenylimidazole, and 2-isopropylimidazole; The demoulding agent comprises a mixture of one or more of silicone oil, silicone resin, natural wax, synthetic wax, whale oil, vaseline, perfluoroalkyl compound, fluororesin powder, stearate, and mica powder.

[0035] Comparative Example 1 Compared with Example 1, this comparative example 1 performs a foaming treatment at 70° C., and the remaining steps and formula are the same as those of Example 1.

[0036] Comparative Example 2 Compared with Example 1, no pore-forming agent was added in Comparative Example 2, and the rest of the preparation scheme and formula were the same as those in Example 1.

[0037] Table 1 Parameter ratio table of Example 1-Example 3, Comparative Example 1-Comparative Example 2

[0038] Performance Testing The ultra-light foam materials with microporous channels prepared in Examples 1 to 3 and Comparative Examples 1 to 2 were subjected to performance testing: the specific test methods and test results are shown in Table 2 below: Table 2 Performance test table

[0039] From the above-mentioned Example 1-Example 3 and Comparative Example 1-Comparative Example 2, combined with the test results of Table 1, it can be found that: By selecting a thermoplastic matrix resin combined with a pore-forming agent, the composite material formed after foaming has a good vacuum channel structure, which effectively reduces the density of the material and increases the porosity of the material. The high-temperature pretreatment method is adopted to promote the activation of the molecular chain by raising the temperature to a temperature higher than the foaming temperature during the foaming process of the thermoplastic material, increase the slippage of the molecular chain, and facilitate the uniform dispersion and penetration of the foaming agent. The strategy of staged cooling is adopted, gradually decreasing from T1 to T2, so as to more effectively lock the gas inside the material and help release the stress generated inside the material. Compared with rapid cooling, staged cooling can gradually release stress, reduce the concentrated distribution of stress, improve the strength and stability of the product, and avoid cracks and deformation problems caused by stress concentration.

[0040] The present invention has been described in detail above in conjunction with specific implementations and exemplary examples, but these descriptions cannot be understood as limiting the present invention. Those skilled in the art understand that, without departing from the spirit and scope of the present invention, a variety of equivalent substitutions, modifications or improvements may be made to the technical solution of the present invention and its implementation methods, all of which fall within the scope of the present invention. The scope of protection of the present invention shall be subject to the attached claims.

[0041] All publications, patent applications, patents and other references mentioned in this specification are incorporated herein by reference. Unless otherwise defined, all technical and scientific terms used in this specification have the meanings conventionally understood by those skilled in the art. In the event of a conflict, the definition in this specification shall prevail.

[0042] When this specification uses the prefix "well-known to those skilled in the art", "prior art" or similar terms to introduce materials, substances, methods, steps, devices or components, etc., the objects introduced by the prefix cover those commonly used in the art when this application is filed, but also include those that are not commonly used at present but will become recognized in the art as being suitable for similar purposes.

[0043] In the context of the present specification, any matters or items not mentioned are directly applicable to those known in the art without any changes except those explicitly stated.

Claims

1. An ultralight foam material with microporous channels, characterized in that: The composition includes the following materials in parts by weight: 80-90 parts of thermoplastic matrix resin; 0.1-2 parts of porogen; Functional additives 0.1-0.8 parts; 10-20 parts of auxiliary materials; The porogen includes a mixture of one or more of activated carbon, zeolite, porous ceramics, and hollow glass microspheres.

2. The ultralight foam material with microporous channels according to claim 1, characterized in that: The functional additives include a mixture of one or more of a nucleating agent, an antioxidant, a stabilizer, an antioxidant, a crosslinking agent, and a release agent; The thermoplastic matrix resin includes a mixture of one or more of TPU resin, TPEE resin, PC resin, PPE resin, PET resin, and nylon elastomer resin; The auxiliary material is an inorganic filler, which includes one or a mixture of calcium carbonate, talcum powder, and clay.

3. The ultra-light foam material with microporous channels according to claim 2, characterized in that: The nucleating agent includes a mixture of one or more of silicon dioxide powder, zinc borate, kaolin, talc, barium sulfate, and calcium carbonate; The antioxidant includes a mixture of one or more of 2,6-di-tert-butyl-p-cresol, 2,6-di-tert-butyl-4-ethylphenol, N-phenyl-1-naphthylamine, N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine, 4,4'-thiobis(6-tert-butyl-m-cresol), and tris(nonylphenyl)phosphite; The stabilizer comprises a mixture of one or more of phenolic resin, phosphite and phosphate, benzofuranone derivatives, and acryl-modified phenolic resin; The antioxidant includes a mixture of one or more of 2,6-di-tert-butyl-p-cresol (BHT), pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, tris(2,4-di-tert-butylphenyl) phosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol bis diphosphite, and pentaerythritol distearyl diphosphite; The crosslinking agent includes a mixture of one or more of diisopropyl peroxide, benzoyl peroxide, di-tert-butyl peroxide, diisopropyl hydroperoxide, diethylenetriamine, 2-ethyl-4-methylimidazole, 2-phenylimidazole, and 2-isopropylimidazole; The demoulding agent comprises a mixture of one or more of silicone oil, silicone resin, natural wax, synthetic wax, whale oil, vaseline, perfluoroalkyl compound, fluororesin powder, stearate, and mica powder.

4. A method for preparing an ultralight foam material having microporous channels according to any one of claims 1 to 3, characterized in that: The method comprises the following preparation steps: S1, premixing the thermoplastic matrix resin, porogen, functional additive and auxiliary materials, mixing them evenly, putting them into an extruder for melt mixing, and pelletizing to obtain thermoplastic blended particles; S2, placing the thermoplastic blended particles in a reaction device, stirring and mixing, introducing a primary gas foaming agent, heating to a temperature T1 after a pressure treatment, cooling to a temperature T2 after a heat preservation treatment, and rapidly releasing the pressure after a second heat preservation and pressure treatment to obtain primary foamed particles; S3, putting the primary foamed particles into a reactor to be pressurized by air, and then putting them into a secondary foaming device, introducing a secondary gas foaming agent, and performing secondary foaming to obtain secondary foamed particles; S3, steam-forming the secondary foamed particles, and obtaining an ultra-light foamed material after curing.

5. The method for preparing an ultralight foam material having microporous channels according to claim 4, characterized in that: The pressure after the pressurization treatment in step S2 is 5-20 MPa; The temperature T1 = (T2 + 10) - (T2 + 20 ° C), the temperature T1 is lower than the melting point temperature of the thermoplastic blended particles, and the heat preservation time is 5-10 minutes; The temperature T2 is the rubber state temperature of the thermoplastic blended particles, and the secondary heat preservation treatment time is 20-100 minutes; The pressure of the secondary heat preservation and pressure maintenance treatment is 10-20MPa; The rapid pressure relief speed is 1-10 MPa / s.

6. The method for preparing an ultralight foam material having microporous channels according to claim 5, characterized in that: The cooling to temperature T2 in step S2 is staged cooling, and specifically adopts the following cooling steps: Start cooling from T1, cool down by 3-5℃ within 1-2min, then keep warm for 1-2min, then cool down by 3-5℃ within 1-2min again, then keep warm for 1-2min, repeat the above cooling and keeping process until the temperature drops to T2.

7. The method for preparing an ultralight foam material having microporous channels according to claim 4, characterized in that: In step S3, the pressure in the reactor is negative pressure, the air is hot air, and the air pressure-carrying time is 1-10 min.

8. The method for preparing an ultralight foam material having microporous channels according to claim 4, characterized in that: The foaming conditions of the secondary foaming in step S3 are: pressure of 1-3 bar and time of 5-20 min.

9. The method for preparing an ultralight foam material having microporous channels according to claim 4, characterized in that: The primary gas foaming agent includes one of CO2, N2, and a rare gas, and the secondary gas foaming agent includes saturated water vapor.

10. The method for preparing an ultralight foam material having microporous channels according to claim 9, characterized in that: The molar ratio of the primary foaming agent to the thermoplastic blended particles in step S2 is (1-5):100, and the molar ratio of the secondary gas foaming agent to the primary foamed particles in step S3 is (1-5):100.

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