Acrylic artificial stone particle plate adopting mould pressing process and preparation method of acrylic artificial stone particle plate

Abstract

The invention relates to a molding process acrylic artificial stone particle plate and a preparation method thereof, and relates to the field of building materials. The particle board comprises the following components in parts by weight: 10-25 parts of PMMA resin liquid; 0.2-2 parts of an acrylic monomer; 0.1 to 1 part of a cross-linking agent; 0-1 part of a thickening agent; 0.1-1 part of a molecular weight regulator; 0.1 to 1 part of an initiator; 65-90 parts of a filler; 0-0.5 part of a functional additive; 0-2 parts of a diluting monomer; and 0-1 part of pigment color paste. According to the invention, the problems of no obvious diffusivity between particle edges and main materials, strong boundary sense of layers and unnatural appearance of the plate existing in the original traditional product are solved.

Description

Technical Field

[0001] The invention relates to the field of building materials, and more specifically to a molding process acrylic artificial stone particle board and a preparation method thereof. Background Art

[0002] The compression molding acrylic artificial stone particle board is a high-quality board made by compression molding technology, using acrylic (PMMA) particles as the main raw material, and through a specific process. Compared with conventional stone slabs, this board has many excellent properties, such as light weight, high toughness, not easy to crack and deform, fine surface texture, high gloss, bright color, etc. It is an environmentally friendly material. In the compression molding process, the acrylic particles are heated to a molten state, then pressed into shape in a mold, and the desired board is obtained after cooling and solidification.

[0003] Although the molded acrylic artificial stone particle board has many advantages, there are still some problems that need to be improved in the actual production process. Among them, the most prominent one is that there is no obvious diffusion between the edge of the particles in the board and the main material, and the layer boundary sense is strong, which makes the board look unnatural. Summary of the invention

[0004] The primary purpose of the present invention is to solve the problem that there is no obvious diffusion between the edge of the particles and the main material, the layer boundary sense is strong, and the appearance of the board appears unnatural, and to provide a molding process acrylic artificial stone particle board.

[0005] A further object of the present invention is to provide a method for preparing the above-mentioned acrylic artificial stone particle board by molding process.

[0006] The above-mentioned object of the present invention is achieved by the following technical solutions:

[0007] A molded acrylic artificial stone particle board includes the following components by weight: 10-25 parts of PMMA resin liquid; 0.2-2 parts of acrylic monomer; 0.1-1 parts of cross-linking agent; 0-1 parts of thickener; 0.1-1 parts of molecular weight regulator; 0.1-1 parts of initiator; 65-90 parts of filler; 0-0.5 parts of functional additives; 0-2 parts of diluent monomer; 0-1 parts of pigment paste. The present invention creatively solves the problems of insufficient diffusion between the edge of particles and the main material, strong sense of hierarchical boundary and unnatural appearance in current board products by carefully proportioning a series of key components. Specifically, PMMA resin liquid is used as the base material. Compared with solid PMMA particles, PMMA resin liquid has higher fluidity and permeability with its unique liquid form, and can be more fully mixed with other components in the board (such as acrylic monomer, filler, etc.) during the processing process, so that the interface between the particles and the main material is blurred, and a more natural transition and fusion is achieved. This high fluidity also promotes the uniform distribution of the crosslinking agent in the system, strengthens the chemical bonding inside the board, and thus significantly improves the overall strength and chemical resistance of the board. The addition of the crosslinking agent further enhances the overall strength and chemical resistance of the board by forming a stable chemical bond, so that the board can still maintain a stable appearance and performance in a complex environment. The filler not only provides the necessary filling effect, but also adjusts the physical properties of the board through its characteristics to make it more in line with the use requirements. In particular, the introduction of functional additives, such as shrinkage inhibitors and release agents, is used to improve the preparation process or improve other specific properties of the board, while anti-ultraviolet agents or antibacterial agents, etc., further enhance the functionality and durability of the board. The use of diluent monomers helps to adjust the viscosity of the system and facilitate processing operations without affecting the performance of the final board.

[0008] Preferably, the pigment paste is a pigment paste of corresponding colors obtained by dispersing and mixing several different pigments with a certain proportion of aliphatic unsaturated resin and grinding them, such as titanium dioxide paste, carbon black paste, iron red paste, iron yellow paste, medium yellow paste, etc.

[0009] Preferably, the pigment content of the pigment paste is 10-60%wt, preferably 30%wt.

[0010] Preferably, the PMMA resin liquid is PMMA dissolved in MMA, the weight fraction thereof is 15-40%, and the PMMA molecular weight is 30-120 kg / mol.

[0011] Preferably, the acrylic acid monomer is one or more of methacrylic acid and acrylic acid.

[0012] Preferably, the crosslinking agent is a difunctional or trifunctional acrylate or methacrylate crosslinking agent, preferably one or more of trimethylolpropane tris(TMPTMA), ethylene glycol dimethacrylate (EGDMA), 1,4-butanediol diacrylate (BDDA), and 1,6-hexanediol dimethacrylate (HDDMA).

[0013] Preferably, the thickener is a metal oxide and a metal base, preferably one or more of calcium oxide, calcium hydroxide, magnesium oxide and magnesium hydroxide.

[0014] Preferably, the molecular weight regulator is a mercapto organic compound, preferably one or more of ethylene glycol bis(thioglycolate) (GDMA), 3-mercaptopropionic acid (MPA), and tert-dodecyl mercaptan (TDM).

[0015] Preferably, the initiator is an organic peroxide, preferably one or more of tert-butyl peroxy(2-ethylhexanoate), tert-amyl peroxy-2-ethylhexanoate, tert-butyl peroxyisobutyrate, and tert-butyl peroxymaleate.

[0016] Preferably, the filler is an inorganic filler, preferably one or more of aluminum hydroxide, aluminum oxide, and calcium carbonate.

[0017] Preferably, the diluent monomer is an acrylate or methacrylate, preferably one or more of methyl methacrylate, glycidyl methacrylate, cyclohexyl methacrylate, isobornyl methacrylate, and isobornyl acrylate.

[0018] Preferably, the board is made of prefabricated particles in a reactive gel state by hot pressing and curing, and the prefabricated particles include the following components by weight: 10-25 parts of PMMA resin liquid; 0.2-2 parts of acrylic monomer; 0.1-1 parts of crosslinking agent; 0-1 parts of thickener; 0.1-1 parts of molecular weight regulator; 0.1-1 parts of initiator; 75-80 parts of filler; 0-0.5 parts of functional additives; 0-2 parts of diluent monomer; 0-1 parts of pigment color paste. In addition, by flexibly adjusting the amount of thickener, molecular weight regulator and initiator, the physical state of the prefabricated particles is further optimized, ensuring that the combination between the prefabricated particles in the subsequent hot pressing process is more compact and natural.

[0019] A method for preparing a molded acrylic artificial stone particle board comprises the following steps:

[0020] Step 1: Weigh the raw materials by weight, fully mix the PMMA resin liquid, acrylic monomer, crosslinking agent, thickener, molecular weight regulator, initiator, filler, functional additive, diluent monomer, and pigment paste, stir evenly to obtain a mixture, and prepare corresponding prefabricated particles according to the different colors of the plate;

[0021] Step 2: Mix, mold and compact the prefabricated particles;

[0022] Step 3: Use a hot compression molding process to cure the plate to obtain a compression molding acrylic artificial stone particle board.

[0023] In the above-mentioned preparation method, the inventor prepared corresponding prefabricated particles according to the different color requirements of the board. These prefabricated particles are not only uniform in color, but also, through a specific formula design, achieve good diffusion and fusion between the components of each particle during the hot molding process, effectively avoiding the problem of poor diffusion between the edge of the particle and the main material in the traditional process. The use of prefabricated particles also makes the boundary between the particles and the main material more blurred during the subsequent molding process of the board, and the transition between the layers is more natural, which significantly weakens the sense of boundary between the layers.

[0024] The above-mentioned molded acrylic artificial stone particle board is composed of at least 2 prefabricated particles of different colors, preferably 2 to 6 prefabricated particles of different colors. When the proportion of a single prefabricated particle reaches at least 40%, a continuous phase can be formed, and the molded board obtained is equivalent to particles of other colors distributed in the continuous phase of the single color.

[0025] Preferably, in step 1, the prefabricated particles are irregular spherical particles in a tackified state with reactive gel state prepared by agglomeration granulation method. The granulation method is agglomeration granulation method, and a mixing granulator designed by creatively applying the turbulent three-dimensional mixing granulation principle can complete the process of material mixing, slurry thickening, and ball granulation in the same device, so as to reduce the process and reduce the difficulty of operation.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows: the acrylic artificial stone particle board produced by the molding process of the present invention has a comfortable sense of layering of edge color gradient between particles of different colors, which visually becomes more natural and beautiful, and closer to real granite-like stone. At the same time, ultra-thin acrylic artificial stone boards can be prepared by the molding process. It can be widely used in the design and manufacture of artificial stone application fields such as artificial stone furniture facings, commercial housing interior decoration, and commercial building interior design. DETAILED DESCRIPTION

[0027] In order to more clearly and completely describe the technical scheme of the present invention, the present invention is further described in detail by specific examples below. It should be understood that the specific examples described herein are only used to explain the present invention and are not used to limit the present invention. Various changes can be made within the scope of the rights of the present invention. The experimental reagents and instruments designed for the implementation and comparative examples of the present invention are all commonly used ordinary reagents and instruments, unless otherwise specified, and can be obtained from commercial channels. In the implementation and comparative examples, the experimental methods used are conventional methods unless otherwise specified; and unless otherwise specified, the raw materials used in parallel experiments are the same batch of raw materials.

[0028] The equipment and raw materials used in the embodiments and comparative examples are described below, but are not limited to these options:

[0029] Mixing granulator: Sentai Electromechanical Technology Co., Ltd.: SIMT25-P granulator

[0030] Pigment: Dongguan Baoxu Chemical Technology Co., Ltd.

[0031] PMMA: Evonik Degussa

[0032] MMA: Sinopec Corporation;

[0033] MAA: LG, South Korea;

[0034] EGDMA: Evonik Degussa;

[0035] GDMA: Shanghai Youpeng Chemical Co., Ltd.;

[0036] Aliphatic unsaturated resin: Zhejiang Tianhe Resin Co., Ltd.

[0037] Tert-butyl peroxyisobutyrate: LQ-TBPI of Lanzhou Additive Factory Co., Ltd.

[0038] Stearic acid release agent: Guangzhou Jinglong Technology Co., Ltd.;

[0039] Aluminum hydroxide powder: Zhongzhou Chalco New Materials H-WF-25B-SP;

[0040] Calcium oxide: Shijiazhuang Xunhua Mineral Products Co., Ltd.

[0041] Examples 1 to 3

[0042] Embodiment 1:

[0043] A molded acrylic artificial stone particle board, the particle colors of which are mainly brick red, gray white, gray black, and cream yellow, of which the brick red particles account for 50%, and the finished product has a relatively continuous phase after molding. The specific preparation method is as follows:

[0044] Preparation: Prepare the raw materials according to the formula ratio;

[0045] Granulation: Color A prefabricated particles (brick red) are mixed, dispersed, thickened and granulated using a mixing granulator. The specific method is as follows: 160g of PMMA resin liquid (a solution of PMMA with a molecular weight of about 80kg / mol dissolved in MMA, with a weight fraction of 22%wt), 810g of aluminum hydroxide powder, and 5g of color A pigment paste are added to the mixing granulator barrel in sequence, and the material cover is tightly closed. Start the mixing granulator, adjust the speed to 200r / min, mix for 10min, then add 5gMAA, 4gEGDMA, 2gGDMA, 2g tert-butyl peroxyisobutyrate, 3g stearic acid release agent, and 1gMMA in sequence at the feed port, and continue mixing and stirring for 5 to 10min. Then, after stirring 8g of calcium oxide at the feed port for 1min, the system begins to thicken. After continuing to stir for 30 to 60min, start the granulation function of the equipment and start granulation. After granulation, color A prefabricated particles are obtained. Similarly, color B prefabricated particles (cream yellow), color C particles (gray white), and color D particles (gray black) are prepared in sequence. The preparation method is the same as the preparation procedure of color A particles (brick red), the difference is that the color of the pigment paste in the formula is different.

[0046] Molding: Weigh 100g, 40g, 40g and 20g of the prepared color A particles (brick red), color B particles (cream yellow), color C particles (gray white) and color D particles (gray black) in a mass ratio of 5:2:2:1, respectively, mix and pour into the mold frame (pre-place a 200×200mm mirror stainless steel plate as the lower mold, and then place a 3mm thick and 10mm wide hollow square frame), then cover with a 200×200mm mirror stainless steel plate as the upper mold, and vibrate and compact.

[0047] Molding: Place the loaded mold in a molding machine (preheated to 120°C), start pressing, adjust the pressure to 10MPa, hot press and keep warm for 15 minutes, and demold after cooling to room temperature to obtain a molded acrylic artificial stone particle board with a thickness of 3mm.

[0048] Embodiment 2:

[0049] A molded acrylic artificial stone particle board, the particle color of which is mainly composed of two colors: earth yellow and white, of which the amount of white particles reaches 80%, and the finished product after molding has a relatively continuous phase. The specific preparation method is as follows:

[0050] Preparation: Prepare the raw materials according to the formula ratio;

[0051] Granulation: Color E particles (khaki) and color F particles (white) are prepared in sequence. The preparation method is the same as the preparation procedure of color A particles (brick red) in Example 1, except that the colors of the pigment paste in the formula are different.

[0052] Molding: Weigh 80g and 320g of the prepared color E particles (khaki) and color F particles (white) in a mass ratio of 2:8 respectively, mix and pour into the mold frame (pre-place a 200×200mm mirror stainless steel plate as the lower mold, and then place a 6mm thick and 10mm wide hollow square frame), then cover with a 200×200mm mirror stainless steel plate as the upper mold, and vibrate and compact.

[0053] Molding: Place the loaded mold in a molding machine (preheated to 120°C), start pressing, adjust the pressure to 10MPa, hot press and keep warm for 15 minutes, and demold after cooling to room temperature to obtain a molded acrylic artificial stone particle board with a thickness of 3mm.

[0054] Embodiment 3:

[0055] A molding process acrylic artificial stone particle board, which is different from Example 1 in that the composition of the prefabricated particles is different: 250g of PMMA resin liquid (a solution of PMMA with a molecular weight of about 80kg / mol dissolved in MMA, with a weight fraction of 22%wt), 900g of aluminum hydroxide powder, and 10g of color A pigment paste are added to the mixing granulator barrel in sequence, and the material cover is tightly closed. The mixing granulator is started, the speed is adjusted to 200r / min, and mixed for 10min. Then, 12gMAA, 8gEGDMA, 6gGDMA, 6gtert-butyl peroxyisobutyrate, 3g stearic acid release agent, and 6gMMA are added in sequence at the feed port, and the mixing and stirring is continued for 5-10min. Then, 3g of calcium oxide is stirred at the feed port for 1min, and the system begins to thicken.

[0056] Comparative Example 1:

[0057] A process acrylic artificial stone particle board is produced by using pre-cured mechanically crushed solid particles to produce the artificial stone particle board, which is a traditional particle board manufacturing method.

[0058] Performance Test:

[0059] The sense of appearance boundary is determined by using an electron microscope to observe the range of color diffusion gradient between the edge of the particles and the main body of the artificial stone. The larger the diffusion range, the more natural the layering, and the closer it is to the effect of natural minerals.

[0060] Chemical resistance: Prepare a plate with a size of 10cm*10cm*3mm, refer to JC / T 908-2013: Test method for chemical resistance of solid surface materials. Observe whether there are cracks on the surface of the sample.

[0061] The performance test results are shown in Table 1.

[0062] Table 1

[0063]

[0064] In the component system of the technical solution of the present invention, the prefabricated particles of Examples 1-3 use reactive gel-state irregular spherical particles in a tackified state to prepare the board. The PMMA resin liquid has higher fluidity and permeability than solid PMMA particles due to its unique liquid form, and can be more fully mixed with other components in the board (such as acrylic monomers, fillers, etc.) during the processing process, so that the interface between the particles and the main material is blurred, and a more natural transition and fusion is achieved. The thickener in the component can better adjust the viscosity of the prefabricated particles before hot pressing. The reactive activity of the prefabricated particles comes from the monomers and cross-linking agents in the component, which further ensures that the bonding force between the prefabricated particles after fusion during the hot pressing process is stronger, thereby improving the mechanical level of the particle board.

[0065] Therefore, from the comparison of the above examples and comparative data, it can be seen that the diffusion range of the appearance boundary sense of the particle board prepared by the present invention is 0.5-1.5mm, which is far better than the diffusion range of the traditional particle board of 0.05-0.2mm. The gradient of the color of the particle edge is comfortable and natural, and the particles with large particle size also show the effect of particles in particles, making the board visually more real and smart, and closer to the real granite-like stone. In addition, the particle board prepared by the present invention is less likely to crack under the influence of the penetration of chemical reagents due to the smaller gaps in the microstructure than the traditional particle board, and has better chemical resistance.

[0066] The acrylic artificial stone particle board product prepared by the molding process can be widely used in the design and manufacture of artificial stone application fields such as artificial stone furniture facings, commercial housing interior decoration, commercial building interior design, etc.

[0067] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A molded acrylic artificial stone particle board, characterized in that: The invention comprises the following components by weight: 10-25 parts of PMMA resin liquid; 0.2-2 parts of acrylic acid monomer; 0.1-1 parts of crosslinking agent; 0-1 parts of thickener; 0.1-1 parts of molecular weight regulator; 0.1-1 parts of initiator; 65-90 parts of filler; 0-0.5 parts of functional additive; 0-2 parts of diluent monomer; Pigment paste 0-1 part.

2. The molded acrylic artificial stone particle board according to claim 1, characterized in that: The PMMA resin liquid is PMMA dissolved in MMA, with a weight fraction of 15-40% and a PMMA molecular weight of 30-120 kg / mol.

3. The molded acrylic artificial stone particle board according to claim 1, characterized in that: The acrylic acid monomer is one or more of methacrylic acid and acrylic acid.

4. The molded acrylic artificial stone particle board according to claim 1, characterized in that: The thickener is one or more of calcium oxide, calcium hydroxide, magnesium oxide and magnesium hydroxide.

5. The molded acrylic artificial stone particle board according to claim 1, characterized in that: The molecular weight regulator is one or more of ethylene glycol bis(thioglycolate), 3-mercaptopropionic acid, and tert-dodecyl mercaptan.

6. The molded acrylic artificial stone particle board according to claim 1, characterized in that: The initiator is one or more of tert-butyl peroxide (2-ethylhexanoate), tert-pentyl peroxide-2-ethylhexanoate, tert-butyl peroxide isobutyrate, and tert-butyl peroxide maleate.

7. The polypropylene composition according to claim 1, characterized in that: The diluent monomer is one or more of methyl methacrylate, glycidyl methacrylate, cyclohexyl methacrylate, isobornyl methacrylate, and isobornyl acrylate.

8. The molded acrylic artificial stone particle board according to claim 1, characterized in that: The board is made of prefabricated particles in a reactive gel state that are cured by hot pressing; The prefabricated particles include the following components by weight: 10-25 parts of PMMA resin liquid; 0.2-2 parts of acrylic acid monomer; 0.1-1 parts of crosslinking agent; 0-1 parts of thickener; 0.1-1 parts of molecular weight regulator; 0.1-1 parts of initiator; 75-80 parts of filler; 0-0.5 parts of functional additives; 0-2 parts of diluent monomer; Pigment paste 0-1 part.

9. A method for preparing a molded acrylic artificial stone particle board, characterized in that: The steps include: Step 1: Weigh the raw materials by weight, fully mix the PMMA resin liquid, acrylic monomer, crosslinking agent, thickener, molecular weight regulator, initiator, filler, functional additive, diluent monomer, and pigment paste, stir evenly to obtain a mixture, and prepare corresponding prefabricated particles according to the different colors of the plate; Step 2: mixing, molding and compacting the prefabricated particles; Step 3: Use a hot compression molding process to cure the plate to obtain a compression molding acrylic artificial stone particle board.

10. The preparation method according to claim 9, characterized in that: In step 1, the prefabricated particles are reactive irregular spherical particles in a viscous state prepared by agglomeration granulation method.

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