Anti-aging non-pvc foamed wood plastic floor and preparation process thereof

Abstract

The present application relates to a kind of anti-aging non-PVC foamed wood plastic floor and its preparation process.The anti-aging non-PVC foamed wood plastic floor includes wood powder, polypropylene resin, modified anti-aging agent master batch, foaming agent, filler and maleic anhydride grafted polypropylene;Wherein the modified anti-aging agent master batch includes ultraviolet absorber, light stabilizer, coupling agent and functionalized graft polypropylene.The anti-aging non-PVC foamed wood plastic floor of the present application is effectively combined by applying modified anti-aging agent master batch, coupling agent and functionalized graft polypropylene matrix, the interfacial compatibility between anti-aging agent and matrix is enhanced, the dispersibility and stability of ultraviolet absorber and light stabilizer are significantly improved, so as to reduce the occurrence of aging effect.Through this optimal design, the anti-aging performance, tensile strength and color change performance of foamed wood plastic floor are improved.

Description

Technical Field

[0001] The invention relates to a wood plastic floor material, in particular to an anti-aging non-PVC foamed wood plastic floor and a preparation process thereof. Background Art

[0002] Wood-plastic composites (WPC) are widely used in flooring due to their environmental friendliness and excellent performance. However, non-PVC-based WPC flooring (non-PVC WPC) has become a hot topic in market research and development due to its chlorine-free and improved environmental profile. However, WPC flooring is inevitably affected by environmental factors such as ultraviolet rays, heat, and humidity over long-term use, leading to aging, discoloration, cracking, and a decrease in mechanical properties.

[0003] The addition of anti-aging agents is the primary means of improving the aging resistance of wood-plastic flooring. Existing anti-aging agents primarily include antioxidants, light stabilizers, and UV absorbers, which are typically used alone or in combination to slow the aging process of the material. However, the application of traditional anti-aging agents in polymer materials faces two major challenges: poor dispersibility and poor stability.

[0004] Poor dispersibility is due to poor compatibility between the antioxidant and the polymer matrix. This prevents the antioxidant from being evenly dispersed within the matrix, resulting in areas of high or low concentration, leading to uneven effectiveness. This not only affects the effectiveness of the antioxidant but can also cause the material to age over time. Furthermore, the antioxidant's large particle size and complex molecular structure make it prone to agglomeration during melt processing, further exacerbating the dispersion problem.

[0005] The problem of poor stability primarily manifests itself in the degradation, volatilization, and migration of antioxidants under harsh environmental conditions such as high temperature, humidity, and ultraviolet light. Some antioxidants are prone to decomposition or volatilization during high-temperature processing or prolonged use, resulting in a gradual weakening of their anti-aging effect, ultimately affecting the long-term performance of wood-plastic composites. Furthermore, some antioxidants, due to structural instability or poor compatibility with the base material, may migrate or precipitate during long-term use, further reducing their effectiveness. Therefore, improving the dispersibility and stability of antioxidants is key to enhancing the anti-aging performance of wood-plastic flooring. Summary of the Invention

[0006] The object of the present invention is to provide an anti-aging non-PVC foamed wood plastic floor and a preparation process thereof, so as to solve the problems raised in the above background technology.

[0007] The invention discloses an anti-aging non-PVC foamed wood plastic floor, comprising wood flour, polypropylene resin, modified anti-aging agent masterbatch, foaming agent, filler and maleic anhydride grafted polypropylene;

[0008] The modified anti-aging agent masterbatch comprises an ultraviolet absorber, a light stabilizer, a coupling agent and functionalized grafted polypropylene.

[0009] Preferably, the modified anti-aging agent masterbatch comprises the following raw materials in parts by weight:

[0010] 50-150 parts of ultraviolet absorber;

[0011] 50-150 parts of light stabilizer;

[0012] 5-15 parts of coupling agent;

[0013] 15-45 parts of functionalized grafted polypropylene.

[0014] The functionalized grafted polypropylene refers to a modified polymer having chemical functional groups (such as maleic anhydride, carboxyl, acrylic acid, silane, amine, maleimide, etc.) introduced into the polypropylene molecular chain.

[0015] Preferably, the functionalized grafted polypropylene is at least one of vinyl silane grafted polypropylene (PP-g-VS), maleimide grafted polypropylene (PP-g-MI), diphenyl carbonate grafted polypropylene (PP-g-DPC), carboxyl grafted polypropylene (PP-g-COOH), acrylic acid grafted polypropylene (PP-g-AA), alkylamine grafted polypropylene (PP-g-ALK-NH2) and maleic anhydride grafted polypropylene (PP-g-MAH).

[0016] More preferably, the functionalized grafted polypropylene is at least one of maleimide grafted polypropylene, diphenyl carbonate grafted polypropylene and maleic anhydride grafted polypropylene.

[0017] More preferably, the functionalized grafted polypropylene is a mixture of maleimide grafted polypropylene and diphenyl carbonate grafted polypropylene. Optimally, the mass ratio of maleimide grafted polypropylene to diphenyl carbonate grafted polypropylene is 10:(2-4).

[0018] The ultraviolet absorber is ultraviolet absorber UV-1577.

[0019] The light stabilizer is Tinuvin 770.

[0020] The modified anti-aging agent masterbatch is prepared by the following method: mixing an ultraviolet absorber, a light stabilizer, a coupling agent and functionalized grafted polypropylene, and then extruding the mixture.

[0021] Preferably, the anti-aging non-PVC foamed wood plastic flooring comprises the following raw materials by mass percentage:

[0022] Wood powder 40-65%;

[0023] Modified anti-aging agent masterbatch 0.5-2.5%;

[0024] Foaming agent 1-4%;

[0025] Filler 1-9%;

[0026] Maleic anhydride grafted polypropylene 1-4%;

[0027] The balance is polypropylene resin.

[0028] Preferably, the anti-aging non-PVC foamed wood-plastic floor comprises the following raw materials by mass percentage:

[0029] Wood powder 50-60%;

[0030] Modified anti-aging agent masterbatch 1-2%;

[0031] Foaming agent 1-3%;

[0032] Filler 3-7%;

[0033] Maleic anhydride grafted polypropylene 1-3%;

[0034] The balance is polypropylene resin.

[0035] Preferably, the filler is at least one of talc and calcium carbonate.

[0036] The application further discloses a preparation process of the anti-aging non-PVC foamed wood-plastic floor, comprising the following steps: mixing wood powder, polypropylene resin, modified anti-aging agent masterbatch, foaming agent, filler and maleic anhydride grafted polypropylene, and screw extruding.

[0037] The anti-aging non-PVC foamed wood-plastic floor of the application enhances the interfacial compatibility between the anti-aging agent and the matrix by effectively combining the modified anti-aging agent masterbatch, the coupling agent and the functionalized grafted polypropylene matrix, significantly improves the dispersity and stability of the ultraviolet absorber and the light stabilizer, and thus reduces the occurrence of the aging effect. Through this optimal design, the anti-aging performance, the tensile strength and the color change performance of the foamed wood-plastic floor are all significantly improved. DETAILED DESCRIPTION

[0038] Wood powder, particle size 100-200 mesh, water content 0.2%;

[0039] Calcium carbonate, powder particle size 200-300 mesh;

[0040] Polypropylene resin, polypropylene selected from Sinopec PPH-T03;

[0041] Maleic anhydride grafted polypropylene, using Honeywell propylene-maleic anhydride copolymer wax powder

[0042] Diphenyl carbonate grafted polypropylene, wherein the grafted monomer diphenyl carbonate is 3-7%. In a specific embodiment, it is prepared by the method of Example 3 of CN117844160A, and the grafted monomer maleimide is 4.3%.

[0043] Maleimide grafted polypropylene, wherein the grafted monomer maleimide is 3-7%. In a specific embodiment, it is prepared by the method of Example 5 of CN117844160A, wherein the grafted monomer maleimide is 4.9%.

[0044] Example 1

[0045] Modified anti-aging agent masterbatch, specific formula:

[0046] Ultraviolet absorber UV-1577: 1000g;

[0047] Light stabilizer Tinuvin 770: 1000 g;

[0048] Coupling agent KH-550: 100 g;

[0049] Functionalized grafted polypropylene: 300 g.

[0050] The functionalized grafted polypropylene is maleic anhydride grafted polypropylene.

[0051] The preparation process of the modified anti-aging agent masterbatch:

[0052] The ultraviolet absorber UV-1577 and the light stabilizer Tinuvin770 are mixed, and then the coupling agent KH-550 is added, and the stirring is continued. Then, the functionalized grafted polypropylene is added and mixed, and the mixture is sent into a twin-screw extruder for extrusion to obtain the modified anti-aging agent masterbatch.

[0053] An anti-aging non-PVC foamed wood plastic floor, the specific formula is:

[0054] 54.5 kg of wood flour;

[0055] 35 kg of polypropylene resin;

[0056] 1.5 kg of modified anti-aging agent masterbatch;

[0057] AC foaming agent 2 kg;

[0058] 5 kg of calcium carbonate;

[0059] 2 kg of maleic anhydride grafted polypropylene.

[0060] The preparation process of the foamed wood plastic floor:

[0061] The wood flour, polypropylene resin and calcium carbonate were dry mixed, then modified anti-aging agent masterbatch, maleic anhydride grafted polypropylene and AC foaming agent were added and mixed uniformly.

[0062] The mixture was sent into a twin-screw extruder for extrusion. After cooling, the floor with a thickness of 8 mm corresponding to the size was cut and prepared for subsequent testing and packaging.

[0063] Example 2:

[0064] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:1.

[0065] Example 3:

[0066] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:2.

[0067] Example 4:

[0068] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:3.

[0069] Example 5:

[0070] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:4.

[0071] Example 6:

[0072] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:5.

[0073] Example 7:

[0074] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:5.

[0075] Example 8:

[0076] The difference from Example 1 is that the functionalized grafted polypropylene is a mixture of diphenyl carbonate grafted polypropylene and maleimide grafted polypropylene with a mass ratio of 10:5.

[0077] Comparative Example 1:

[0078] Non-PVC foamed wood plastic flooring, specific formula:

[0079] Wood flour: 55 kg

[0080] Polypropylene resin: 35 kg

[0081] AC foaming agent: 2 kg

[0082] Calcium carbonate: 5 kg

[0083] Maleic anhydride grafted polypropylene: 2 kg

[0084] The preparation process of the foamed wood plastic floor:

[0085] The wood flour, polypropylene resin and calcium carbonate are dry-mixed, and then maleic anhydride grafted polypropylene and AC foaming agent are added and continued to mix evenly.

[0086] The mixture is fed into a twin-screw extruder for extrusion, cooled, and cut into corresponding 8mm thick floor panels for subsequent testing and packaging.

[0087] Comparative Example 2:

[0088] Non-PVC foamed wood plastic flooring, specific formula:

[0089] Wood flour: 54.5 kg;

[0090] Polypropylene resin: 35 kg;

[0091] AC foaming agent: 2 kg;

[0092] Calcium carbonate: 5 kg;

[0093] Ultraviolet absorber UV-1577: 625g;

[0094] Light stabilizer Tinuvin 770: 625 g;

[0095] Maleic anhydride grafted polypropylene: 2 kg.

[0096] The preparation process of the foamed wood plastic floor:

[0097] The wood flour, polypropylene resin and calcium carbonate are dry-mixed, and then ultraviolet absorber UV-1577, light stabilizer Ti nuvin770, maleic anhydride grafted polypropylene and AC foaming agent are added and continued to mix evenly.

[0098] The mixture is fed into a twin-screw extruder for extrusion, cooled, and cut into corresponding 8mm thick floor panels for subsequent testing and packaging.

[0099] Test example:

[0100] After gamma ray treatment at a dose of 35 kGy, wood-plastic foam flooring (20 cm × 20 cm × 8 mm) was tested for color difference ΔE, yellowness index, and tensile strength. Color difference ΔE was determined according to CIEDE 2000, yellowness index according to GB / T 2409-1980, and tensile strength according to GB / T 1040.2-2022.

[0101] Color difference ΔE Yellow Index Tensile strength retention, % Example 1 4.9 6.4 90.7 Example 2 3.5 4.9 93.4 Example 3 2.8 3.8 94.2 Example 4 2.9 3.7 94.0 Example 5 2.4 3.2 95.1 Example 6 1.8 2.6 96.5 Example 7 2.1 3.0 95.3 Example 8 3.0 4.1 93.8 Comparative Example 1 18.6 23.4 82.3 Comparative Example 2 6.4 9.7 87.5

[0102] Comparison of Examples 1-8 with Comparative Example 2 demonstrates that optimizing the dosage and formulation of the modified antioxidant masterbatch significantly enhances the anti-aging properties of the wood-plastic flooring. The use of the modified antioxidant masterbatch effectively improves the dispersibility and stability of the UV absorber UV-1577 and the light stabilizer Tinuvin 770. Furthermore, the effective integration of the coupling agent KH-550 with the functionalized grafted polypropylene matrix enhances interfacial compatibility between the antioxidant and the matrix, thereby reducing the effects of material aging. Compared to Comparative Example 2, Examples 1-8 demonstrate significant improvements in anti-aging properties, tensile strength, and color change performance.

[0103] Comparing Examples 1-3, it can be seen that the maleimide-grafted polypropylene used in Example 3 outperforms the maleic anhydride-grafted polypropylene in Example 1 and the diphenyl carbonate-grafted polypropylene in Example 2 in terms of aging resistance. Example 3 performs particularly well in terms of high-temperature resistance, moisture resistance, and interfacial adhesion. By improving the interfacial compatibility of the polymer with the wood powder and polypropylene matrix, maleimide-grafted polypropylene significantly enhances the material's UV absorption and thermal aging resistance, effectively slowing the aging process of the wood-plastic flooring and improving its long-term durability.

[0104] Examples 5-7 demonstrate the synergistic effect of diphenyl carbonate-grafted polypropylene and maleimide-grafted polypropylene at specific mass ratios. By optimizing the mass ratio, the combination optimizes dispersibility and interfacial adhesion, enhancing overall anti-aging performance. In contrast, Examples 4 and 8 failed to achieve the expected synergistic effect, indicating that the ratio and combination of the two significantly influences the results. Therefore, an appropriate grafted polypropylene ratio is crucial for improving the durability and performance of foamed wood-plastic flooring.

Claims

1. An anti-aging non-PVC foamed wood plastic floor, characterized in that: The anti-aging non-PVC foamed wood plastic flooring comprises the following raw materials by mass percentage: Wood flour 40-65%; Modified anti-aging agent masterbatch 0.5-2.5%; Foaming agent 1-4%; Filler 1-9%; Maleic anhydride grafted polypropylene 1-4%; The balance is polypropylene resin; The modified anti-aging agent masterbatch comprises the following raw materials in parts by weight: 50-150 parts of ultraviolet absorber; 50-150 parts of light stabilizer; 5-15 parts of coupling agent; 15-45 parts of functionalized grafted polypropylene; The functionalized grafted polypropylene is a mixture of maleimide grafted polypropylene and diphenyl carbonate grafted polypropylene, and the mass ratio of maleimide grafted polypropylene to diphenyl carbonate grafted polypropylene is 10:(2-4).

2. The anti-aging non-PVC foamed wood plastic flooring according to claim 1, characterized in that: The ultraviolet absorber is ultraviolet absorber UV-1577.

3. The anti-aging non-PVC foamed wood plastic flooring according to claim 1, characterized in that: The light stabilizer is Tinuvin 770.

4. The anti-aging non-PVC foamed wood plastic flooring according to any one of claims 1 to 3, characterized in that: The anti-aging non-PVC foamed wood plastic flooring comprises the following raw materials by mass percentage: Wood flour 50-60%; Modified anti-aging agent masterbatch 1-2%; Foaming agent 1-3%; Filler 3-7%; Maleic anhydride grafted polypropylene 1-3%; The balance is polypropylene resin.

5. The anti-aging non-PVC foamed wood plastic flooring according to claim 4, characterized in that: The filler is at least one of talc and calcium carbonate.

6. The preparation process of the anti-aging non-PVC foamed wood plastic flooring according to any one of claims 1 to 5, characterized in that: The method comprises the following steps: mixing wood powder, polypropylene resin, modified anti-aging agent master batch, foaming agent, filler and maleic anhydride grafted polypropylene, and screw extruding.