Starch-based PP floor and preparation method thereof

Abstract

The invention discloses a starch-based PP floor and a preparation method thereof, and belongs to the technical field of plastic floors. A starch-based PP floor base material layer of the starch-based PP floor is prepared from the following components in parts by weight: 40 to 80 parts of PP resin powder, 100 to 200 parts of modified starch, 10 to 30 parts of starch-based PP floor ground powder reclaimed materials, 2 to 4 parts of CPE (Chlorinated Polyethylene), 2 to 6 parts of butylated hydroxytoluene, 1 to 5 parts of triethylhexyl phosphoric acid and 0.1 to 2 parts of PE (Polyethylene) wax. According to the invention, the starch-based material is selected to fill the PP floor components, so that the use amount of PP resin powder is reduced, the use amount of other small materials is reduced, the cost is reduced, the formula system does not have decomposed halogen and starch-based material, the decomposition speed of floor waste is greatly increased, and the environmental protection property is greatly improved.

Description

Technical Field

[0001] The invention belongs to the technical field of plastic floors, and in particular relates to a starch-based PP floor and a preparation method thereof. Background Art

[0002] Traditional ceramic floors, solid wood floors, and composite floors have problems such as being hard to the touch, easy to deform, and excessive formaldehyde. PVC floors came into being to meet people's needs; the main component of PVC floors is polyvinyl chloride. At present, the main plasticizer used in PVC floors is DOP (dioctyl phthalate). The floor contains a large amount of DOP and PVC, which decomposes in the long term to produce chlorine and benzene, which pollute the human body and the environment. PP floors came into being to replace the existing halogen-free floors. PP floors are similar to PVC in terms of process, and the content of PP resin powder is relatively high. First, the price is relatively high, and second, the waste is difficult to decompose in the natural environment, causing environmental pollution. Its formula and process need to be improved. Summary of the invention

[0003] In view of the problems existing in the prior art, one technical problem to be solved by the present invention is to provide a starch-based PP floor. Another technical problem to be solved by the present invention is to provide a method for preparing a starch-based PP floor. The use of starch-based materials to fill the PP floor components reduces the amount of PP resin powder and other small materials, thereby reducing costs. The formula system does not contain decomposition halogens, and the presence of starch-based materials greatly increases the decomposition speed of floor waste, thereby greatly improving environmental protection.

[0004] In order to solve the above problems, the technical solution adopted by the present invention is as follows:

[0005] A starch-based PP floor, which comprises, from top to bottom, a UV coating, a PP wear-resistant layer, a color film layer, and a starch-based PP floor substrate layer; wherein:

[0006] The starch-based PP floor substrate layer is composed of the following weight groups: 40-80 parts of PP resin powder (the main component of the substrate, with a density of only 0.90-0.91 g / cm 3 ), modified starch 100-200 parts (PP resin filler, reduces cost, improves performance, and promotes degradation), starch-based PP floor grinding and recycling material 10-30 parts, CPE 2-4 parts (its main function is to improve product toughness and impact resistance), dibutyl hydroxytoluene 2-6 parts (to prevent material surface oxidation), triethylhexyl phosphate 1-5 parts (to improve the dispersion and coupling between materials), PE wax 0.1-2 parts (its function is to improve the fluidity of materials and equipment barrels and molds, reduce the friction between materials and equipment, and improve the plasticization of materials).

[0007] The starch-based PP floor and the preparation method of the modified starch include the following steps:

[0008] (a) weighing rice starch, adding water, and preparing rice starch milk;

[0009] (b) adding hydrogen peroxide to the rice starch milk, heating and stirring until the solution turns white; drying and grinding to obtain oxidized starch powder; the mass of the hydrogen peroxide is 8% of the rice starch;

[0010] (c) adding an acetone solution of isocyanate methyl trimethoxy silane to the oxidized starch powder, stirring rapidly and uniformly, raising the temperature and subjecting the mixture to reflux reaction for 0.5-1.5 hours, and evaporating the acetone after the reaction is completed; the mass of the isocyanate methyl trimethoxy silane is 25% of the rice starch;

[0011] (d) adding water and stirring for gelatinization for 40-60 minutes to obtain a modified starch solution; and dehydrating, drying, crushing and screening to obtain the modified starch.

[0012] The starch-based PP floor comprises the following components by mass fraction in the ground powder recycled material: 70% polypropylene, 15% rice starch, 10% ethylene acrylic acid copolymer, 3% isocyanate methyl trimethoxy silane and 2% liquid paraffin.

[0013] The starch-based PP floor, the starch-based PP floor substrate layer is composed of the following components in parts by weight: 40-80 parts of PP resin powder, 100-200 parts of modified starch, 10-28 parts of starch-based PP floor milled recycled materials, 2-2.8 parts of CPE, 2-2.5 parts of butylated hydroxytoluene, 1-1.5 parts of triethylhexyl phosphate, and 0.1-0.9 parts of PE wax.

[0014] The starch-based PP floor, the UV coating is composed of the following array of parts by weight: 40-50 parts of epoxy acrylate oligomer, 26-34 parts of active diluent, 3-7 parts of photoinitiator, 1-3 parts of elastic powder, 0.2-0.6 parts of defoamer, 0.1-0.3 parts of leveling agent, 1-5 parts of wetting and dispersing agent, 8-12 parts of matting agent, 2-4 parts of filler, 0.2-0.6 parts of polymerization inhibitor; preferably, the UV coating is composed of the following array of parts by weight: 45 parts of epoxy acrylate oligomer, 30 parts of active diluent, 5 parts of photoinitiator, 2 parts of elastic powder, 0.4 parts of defoamer, 0.2 parts of leveling agent, 3 parts of wetting and dispersing agent, 10 parts of matting agent, 3 parts of filler, and 0.4 parts of polymerization inhibitor.

[0015] The UV coating makes it anti-fouling and scratch-resistant, changes the glossiness, and improves wear and scratch resistance.

[0016] The starch-based PP floor, the PP wear-resistant layer is composed of the following number of parts by weight: 100 parts of PP resin, 0-40 parts of starch-based plasticizer, 0-50 parts of flame retardant, 4 parts of aluminum oxide, 0-8.0 parts of smoke suppressant, 1.0-6.0 parts of stabilizer, and 0.5-3.0 parts of processing aid; preferably, the PP wear-resistant layer is composed of the following number of parts by weight: 100 parts of PP resin, 20 parts of starch-based plasticizer, 25 parts of flame retardant, 4 parts of aluminum oxide, 4 parts of smoke suppressant, 4 parts of stabilizer, and 2 parts of processing aid.

[0017] The PP wear-resistant layer has excellent flame retardant and smoke suppression properties by reasonably matching the amounts of plasticizers, flame retardants and smoke suppressants, which greatly improves the wear resistance.

[0018] The preparation method of the starch-based PP floor comprises the following steps:

[0019] Step A: Add PP resin powder, modified starch, CPE, butylated hydroxytoluene, triethylhexyl phosphoric acid and PE wax into a high-speed mixer, mix well and then discharge;

[0020] Step B: Cool the mixed material from step A, put it into a storage bin, and feed the mixed material into a twin-screw extruder through an automatic feeding system for extrusion processing. The mixed material enters the die through the screw, and the plate passes through the die lip to the grinding mouth, where a cooling device is provided;

[0021] Step C: After drawing the substrate, it is extruded and formed by a mold, the first and second rollers are used to adjust the thickness and shape it, the third roller is used to laminate the color film layer and the PP wear-resistant layer, the fifth roller is used to emboss and then to pull and cut;

[0022] Step D: Add UV coating to the floor surface obtained in step C by rolling, with a primer of 8g / m 3 , surface coating amount 7g / m 3 , UV lamp curing is carried out by UV energy lamp to obtain starch-based PP flooring.

[0023] The preparation method of the starch-based PP floor comprises the following steps: adding modified starch, PP resin powder and other components into a high-speed mixer in the order of the modified starch, PP resin powder and other components; discharging the mixture when the mixture reaches 100-120° C., and placing the mixture into a storage bin when the mixture is cooled to 75° C.

[0024] In the preparation method of the starch-based PP floor, the temperature of the extruder barrel is controlled at 130° C., 150° C., 180° C., 190° C., and 170° C.

[0025] In the preparation method of the starch-based PP floor, the mold temperature is controlled at 200° C. to 220° C.; and the temperature at the grinding mouth is set at 150° C.

[0026] Beneficial effects: Compared with the existing technology, the advantages of the present invention include:

[0027] (1) Modified starch-based fillers have natural degradation properties, which is beneficial to environmental protection.

[0028] (2) Modified starch base can reduce the use of PP materials, reduce board costs and improve competitiveness.

[0029] (3) Modified starch itself contains toughening agents, which is beneficial to the rapid plasticization and molding of PP and reduces the use of toughening agents.

[0030] (4) Starch flooring itself does not contain halogen, and will not decompose chlorine in the event of a fire, which will reduce harm to the human body.

[0031] (5) The density of starch flooring is lower than that of PVC flooring, which helps to reduce transportation costs and improve product competitiveness. DETAILED DESCRIPTION

[0032] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with specific embodiments.

[0033] The preparation method of modified starch comprises the following steps:

[0034] (a) weighing rice starch, adding water, and preparing rice starch milk;

[0035] (b) adding hydrogen peroxide to the rice starch milk, heating and stirring until the solution turns white; drying and grinding to obtain oxidized starch powder; the mass of the hydrogen peroxide is 8% of the rice starch;

[0036] (c) adding an acetone solution of isocyanate methyl trimethoxy silane to the oxidized starch powder, stirring rapidly and uniformly, raising the temperature and subjecting the mixture to reflux reaction for 1 hour, and evaporating the acetone after the reaction is completed; the mass of the isocyanate methyl trimethoxy silane is 25% of the rice starch;

[0037] (d) adding water and stirring for gelatinization for 50 minutes to obtain a modified starch solution; and dehydrating, drying, crushing and sieving to obtain the modified starch.

[0038] The modified starch prepared as above is used in the preparation of starch-based PP flooring in the following examples.

[0039] In the following embodiments:

[0040] The UV coating is composed of the following components in parts by weight: 45 parts of epoxy acrylate oligomer, 30 parts of active diluent, 5 parts of photoinitiator, 2 parts of elastic powder, 0.4 parts of defoaming agent, 0.2 parts of leveling agent, 3 parts of wetting and dispersing agent, 10 parts of matting agent, 3 parts of filler and 0.4 parts of inhibitor.

[0041] The PP wear-resistant layer is composed of the following components in parts by weight: 100 parts of PP resin, 20 parts of starch-based plasticizer, 25 parts of flame retardant, 4 parts of aluminum oxide, 4 parts of smoke suppressant, 4 parts of stabilizer, and 2 parts of processing aid.

[0042] The starch-based PP floor grinding and recycling material contains the following components by mass fraction: 70% polypropylene, 15% rice starch, 10% ethylene acrylic acid copolymer, 3% isocyanate methyl trimethoxy silane, and 2% liquid paraffin.

[0043] Example 1

[0044] The formula of the starch-based PP floor substrate layer includes 40 parts of PP resin powder, 100 parts of modified starch, 10 parts of starch-based PP floor grinding and recycling materials, 2 parts of CPE, 2 parts of butylated hydroxytoluene, 1 part of triethylhexyl phosphate, and 0.1 parts of PE wax.

[0045] Extrusion process

[0046] Step A: Add PP resin powder, modified starch, CPE, antioxidant, dispersant and external lubricant into a high-speed mixer, add modified starch, PP resin powder and other small materials into the mixing tank in order, and discharge the mixture when the mixture reaches 110°C;

[0047] Step B: When the mixed material from step A is cooled to 75°C, it is placed in a storage bin, and the mixed material is fed into a twin-screw extruder for extrusion processing through an automatic feeding system. The barrel temperature is controlled at 130°C, 150°C, 180°C, 190°C, and 170°C. The mixed material enters the mold through the screw, and the mold temperature is controlled at 210°C. The plate passes through the die lip to the grinding mouth, and a cooling device is provided at the grinding mouth, and the temperature is set to 150°C;

[0048] Step C: After drawing the substrate, it is extruded and formed by a mold, the first and second rollers are used to adjust the thickness and shape it, the third roller is used to laminate the color film layer and the PP wear-resistant layer, the fifth roller is used to emboss and then to pull and cut;

[0049] Step D: Add UV coating to the floor surface obtained in step C by rolling, with a primer of 8g / m 3 , surface coating amount 7g / m 3 , UV lamp curing is carried out by UV energy lamp to obtain starch-based PP flooring.

[0050] Example 2

[0051] The formula of the starch-based PP floor substrate layer includes 45 parts of PP resin powder, 120 parts of modified starch, 15 parts of starch-based PP floor grinding and recycling materials, 2.2 parts of CPE, 2 parts of butylated hydroxytoluene, 1 part of triethylhexyl phosphate, and 0.3 parts of PE wax.

[0052] The extrusion process of the starch-based PP floor is the same as that in Example 1.

[0053] Example 3

[0054] The formula of the starch-based PP floor substrate layer includes 50 parts of PP resin powder, 150 parts of modified starch, 20 parts of starch-based PP floor grinding and recycling materials, 2.5 parts of CPE modifier, 2.1 parts of butylated hydroxytoluene, 1.3 parts of triethylhexyl phosphate, and 0.5 parts of PE wax.

[0055] The extrusion process of the starch-based PP floor is the same as that in Example 1.

[0056] Example 4

[0057] The formula of the starch-based PP floor substrate layer includes 60 parts of PP resin powder, 180 parts of modified starch, 24 parts of starch-based PP floor grinding and recycling materials, 2.6 parts of CPE, 2.3 parts of butylated hydroxytoluene, 1.4 parts of triethylhexyl phosphate, and 0.7 parts of PE wax.

[0058] The extrusion process of the starch-based PP floor is the same as that in Example 1.

[0059] Example 5

[0060] The formula of the starch-based PP floor substrate layer includes 80 parts of PP resin powder, 200 parts of modified starch, 28 parts of starch-based PP floor grinding and recycling materials, 2.8 parts of CPE, 2.5 parts of butylated hydroxytoluene, 1.5 parts of triethylhexyl phosphate, and 0.9 parts of PE wax.

[0061] The extrusion process of the starch-based PP floor is the same as that in Example 1.

[0062] Table 1 Performance test results of starch-based PP flooring in Examples 1-5

[0063]

Claims

1. A starch-based PP floor, characterized in that: From top to bottom, they are UV coating, PP wear-resistant layer, color film layer, and starch-based PP floor substrate layer; The starch-based PP floor substrate layer is composed of the following components in parts by weight: 40-80 parts of PP resin powder, 100-200 parts of modified starch, 10-30 parts of starch-based PP floor milled recycled material, 2-4 parts of CPE, 2-6 parts of butylated hydroxytoluene, 1-5 parts of triethylhexyl phosphate, and 0.1-2 parts of PE wax.

2. The starch-based PP floor according to claim 1, characterized in that: The preparation method of the modified starch comprises the following steps: (a) weighing rice starch, adding water, and preparing rice starch milk; (b) adding hydrogen peroxide to the rice starch milk, heating and stirring until the solution turns white; drying and grinding to obtain oxidized starch powder; the mass of the hydrogen peroxide is 8% of the rice starch; (c) adding an acetone solution of isocyanate methyl trimethoxy silane to the oxidized starch powder, stirring rapidly and uniformly, raising the temperature and subjecting the mixture to reflux reaction for 0.5-1.5 hours, and evaporating the acetone after the reaction is completed; the mass of the isocyanate methyl trimethoxy silane is 25% of the rice starch; (d) adding water and stirring for gelatinization for 40-60 minutes to obtain a modified starch solution; and dehydrating, drying, crushing and screening to obtain the modified starch.

3. The starch-based PP floor according to claim 1, characterized in that: The starch-based PP floor grinding and recycling material contains the following components by mass fraction: 70% of polypropylene, 15% of rice starch, 10% of ethylene acrylic acid copolymer, 3% of isocyanate methyl trimethoxy silane and 2% of liquid paraffin.

4. The starch-based PP floor according to claim 1, characterized in that: The starch-based PP floor substrate layer is composed of the following components in parts by weight: 40-80 parts of PP resin powder, 100-200 parts of modified starch, 10-28 parts of starch-based PP floor milled recycled material, 2-2.8 parts of CPE, 2-2.5 parts of butylated hydroxytoluene, 1-1.5 parts of triethylhexyl phosphate, and 0.1-0.9 parts of PE wax.

5. The starch-based PP floor according to claim 1, characterized in that: The UV coating is composed of the following components in parts by weight: 40-50 parts of epoxy acrylate oligomer, 26-34 parts of active diluent, 3-7 parts of photoinitiator, 1-3 parts of elastic powder, 0.2-0.6 parts of defoamer, 0.1-0.3 parts of leveling agent, 1-5 parts of wetting and dispersing agent, 8-12 parts of matting agent, 2-4 parts of filler and 0.2-0.6 parts of inhibitor.

6. The starch-based PP floor according to claim 1, characterized in that: The PP wear-resistant layer is composed of the following components in parts by weight: 100 parts of PP resin, 0-40 parts of starch-based plasticizer, 0-50 parts of flame retardant, 4 parts of aluminum oxide, 0-8.0 parts of smoke suppressant, 1.0-6.0 parts of stabilizer, and 0.5-3.0 parts of processing aid.

7. The method for preparing the starch-based PP floor according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step A: Add PP resin powder, modified starch, CPE, butylated hydroxytoluene, triethylhexyl phosphoric acid and PE wax into a high-speed mixer, mix well and then discharge; Step B: Cool the mixed material from step A, put it into a storage bin, and feed the mixed material into a twin-screw extruder through an automatic feeding system for extrusion processing. The mixed material enters the die through the screw, and the plate passes through the die lip to the grinding mouth, where a cooling device is provided; Step C: After drawing the substrate, it is extruded and formed by a mold, the first and second rollers are used to adjust the thickness and shape, the third roller is used to laminate the color film layer and the PP wear-resistant layer, the fifth roller is used to emboss and then to pull and cut; Step D: Add UV coating to the floor surface obtained in step C by rolling, and then perform UV lamp curing by UV energy lamp to obtain starch-based PP floor.

8. The method for preparing the starch-based PP floor according to claim 7, characterized in that: The materials added to the high-speed mixer are modified starch, PP resin powder, and other components in order; the mixture is discharged when it reaches 100-120°C, and the materials are placed in the storage bin when they are cooled to 75°C.

9. The method for preparing starch-based PP flooring according to claim 7, characterized in that: The extruder barrel temperature is controlled at 130°C, 150°C, 180°C, 190°C, and 170°C.

10. The method for preparing starch-based PP flooring according to claim 7, characterized in that: The mold temperature is controlled at 200℃~220℃; the temperature at the grinding mouth is set at 150℃.

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