Aba in-mold composite panel and processing method thereof

Abstract

The application discloses an ABA in-mold composite board and a processing method thereof, and belongs to the technical field of composite board processing. The ABA in-mold composite board comprises a surface layer and an intermediate layer, and the intermediate layer is tightly wrapped by the surface layer on both sides. The surface layer is prepared from 950-1000 parts of general polystyrene resin and 25-50 parts of light diffusion master batch, and the intermediate layer is prepared from 890-980 parts of general polystyrene resin, 1-60 parts of foaming master batch and 5-100 parts of light diffusion master batch. The ABA in-mold composite board prepared by the method has excellent light diffusion performance, durability, strength and heat insulation and sound absorption.

Description

Technical Field

[0001] This invention belongs to the field of ABA in-mold composite material preparation technology, specifically relating to ABA in-mold composite materials and their processing methods. Background Technology

[0002] The demands for environmental protection and resource conservation have driven continuous exploration of low-energy, high-efficiency material preparation and processing methods. The preparation process of ABA in-mold composite sheets often achieves efficient material utilization, reduces waste generation, and aligns with the concept of green manufacturing. Meanwhile, the increasingly diverse demands for material performance in high-end fields such as aerospace, automotive manufacturing, and architectural decoration make composite sheets, with their strong designability and adjustable performance, an indispensable material choice for these fields.

[0003] In terms of processing methods, ABA in-mold composite sheets utilize various advanced manufacturing technologies, such as laser processing, electrical discharge machining, and CNC machining. These technologies not only improve processing accuracy and efficiency but also reduce production costs, promoting the large-scale production and application of composite sheets. Furthermore, composite mold processing technology is a crucial link in the ABA in-mold composite sheet processing process, and its design and manufacturing level directly affects the performance and quality of the final product.

[0004] Patent CN 216100868 U discloses a composite board, comprising: a substrate layer, a surface layer disposed on at least one side of the substrate layer, the surface layer being a breathable material, and an adsorption layer disposed between the surface layer and the substrate layer, the adsorption layer comprising activated carbon, the activated carbon being grafted with amino acid substances; by using coconut shell carbon to graft amino acid-containing substances to form a novel adsorption and degradation material, and combining it with an outer panel of polypropylene material and an inner panel of polyester fiber to form a novel composite board. Interior parts made from the composite board prepared by this method can achieve the effect of purifying the air inside the car and improving the odor quality inside the car. However, there is still room for improvement in the heat insulation and sound absorption performance, strength, light diffusion performance, and durability of the composite board prepared by this method. Summary of the Invention

[0005] The purpose of this invention is to provide ABA in-mold composite materials and their processing methods to solve the technical problems of poor heat insulation and sound absorption, strength, light diffusion performance and durability of composite materials in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides an ABA in-mold composite board, comprising a surface layer and an intermediate layer, wherein the intermediate layer is tightly wrapped on both sides by the surface layer. The surface layer is prepared from 950-1000 parts of general-purpose polystyrene resin and 25-50 parts of light-diffusing masterbatch, and the intermediate layer is prepared from 890-980 parts of general-purpose polystyrene resin, 1-60 parts of foaming masterbatch and 5-100 parts of light-diffusing masterbatch.

[0008] Preferably, the method for preparing the light diffusion masterbatch includes the following steps:

[0009] Q1: Add titanium dioxide to a container, along with a mixed solution of silane coupling agent and deionized water. After stirring and reacting, centrifuge, wash, and dry to obtain modified titanium dioxide microspheres.

[0010] Q2: Add modified titanium dioxide microspheres and polyvinylpyrrolidone to a container, add a mixed solution of anhydrous ethanol and deionized water, stir, heat, add a mixed solution of styrene and azobisisobutyronitrile dropwise, heat the reaction under nitrogen protection, after the reaction is completed, cool, centrifuge, wash, and vacuum dry to obtain composite microspheres;

[0011] Q3: Polydimethylsiloxane and tert-butanol peroxide are mixed evenly to obtain a polydimethylsiloxane mixed solution. At the same time, the composite microspheres are mixed with tetrahydrofuran solution and ultrasonically dispersed to obtain a composite microsphere solution. The composite microsphere solution is added to the polydimethylsiloxane mixed solution, stirred evenly, vacuum bubbled at room temperature, placed in a mold, and cured to obtain light diffusion masterbatch.

[0012] Preferably, in Q1, the molar ratio of titanium dioxide to silane coupling agent is (1-2):(1.1-2.2), the stirring speed is 300-400 rpm, the reaction time is 2-3 h, the centrifugation speed is 5000-6000 rpm, the time is 30-45 min, the product is washed with deionized water 3-5 times, and the drying temperature is 60-70℃ for 10-12 h.

[0013] Preferably, in Q2, the ratio of modified titanium dioxide microspheres, polyvinylpyrrolidone, anhydrous ethanol, deionized water, styrene, and azobisisobutyronitrile is (4-6) g : (10-15) mL : (80-90) mL : (20-40) mL : (5-10) mL : (0.3-0.6) g, the stirring speed is 300-400 rpm, the time is 30-45 min, the temperature is raised to 60-65℃, the heating reaction temperature is 70-75℃, the time is 20-24 h, the stirring speed is 200-300 rpm, the centrifugation speed is 8000-9000 rpm, the time is 30-45 min, the product is washed 3-5 times with anhydrous ethanol, and the vacuum drying temperature is 60-70℃, the time is 10-12 h.

[0014] Preferably, in Q3, the ratio of polydimethylsiloxane, tert-butanol peroxide, composite microspheres and tetrahydrofuran is (9-12) mL: (1-1.4) mL: (1-3) g: (10-20) mL, the ultrasonic dispersion time is 6-8 h, the vacuum degassing time is 30-45 min, the curing temperature is 70-80 °C, and the curing time is 3-4 h.

[0015] Preferably, the method for preparing the foaming masterbatch includes the following steps:

[0016] S1: Add the dried cellulose to a container and add formic acid solution. Heat and stir continuously, then add deionized water to terminate the reaction. Centrifuge, wash, and dialyze to obtain cellulose formic acid.

[0017] S2: Add cellulose formate to deionized water, stir evenly, add polyurethane prepolymer, stir, and solidify to obtain foaming masterbatch.

[0018] In the above process, cellulose formate is first prepared by formic acid hydrolysis, and then added as a filler to polyurethane prepolymer to obtain foaming masterbatch.

[0019] Preferably, in step S1, the ratio of cellulose to formic acid solution is (1-2) g: (30-60) mL, the mass fraction of formic acid solution is 88 wt%, the heating and stirring temperature is 90-110℃, the time is 10-12 h, the stirring speed is 500-700 rpm, and the solution is dialyzed with deionized water to pH=7-7.2; in step S2, the ratio of cellulose formic acid, deionized water and polyurethane prepolymer is (2-4) g: (10-12) mL: (6-8) g, the stirring time is 10-12 s, the curing temperature is 45-50℃, and the time is 20-24 h.

[0020] Preferably, the processing method of the ABA in-mold composite sheet includes the following steps:

[0021] Step (1): The raw materials are fed into the feeding system and then added to the extruder through the proportioning, weighing and mixing system;

[0022] Step (2): Set the extruder temperature, and extrude the material into a three-layer composite mold through the cooperation of two non-exhaust single-screw extruders to obtain a composite board;

[0023] Step (3): The composite board is rolled and pressed by a three-roll calender to obtain the board material;

[0024] Step (4): The sheet material is cooled, cut, and stacked on a roller platform to obtain ABA in-mold composite sheet material.

[0025] Preferably, in step (2), the extruder temperature is 190-235°C, and the thickness ratio of the extruded surface layer to the intermediate layer is (1:5)-(1:15).

[0026] Preferably, in step (3), the rolling temperature of the three-roll calender is 80-120℃; in step (4), the length of the roller platform is 15-40m.

[0027] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0028] This invention first uses titanium dioxide, silane coupling agent, styrene and polydimethylsiloxane as raw materials to prepare a light diffusion masterbatch, and then uses cellulose, formic acid and polyurethane prepolymer as raw materials to prepare a foaming masterbatch. Using the light diffusion masterbatch, foaming masterbatch and general-purpose polystyrene resin as raw materials, the prepared ABA in-mold composite board has excellent light diffusion performance, durability, strength and heat insulation and sound absorption properties. The composite microspheres in the light-diffusing masterbatch can transform point or line light sources into uniform surface light sources through the scattering effect of their surface and internal structure when light enters the ABA composite board, thereby improving light diffusion performance. The introduction of polydimethylsiloxane material can enhance the bonding force between the light-diffusing masterbatch and the ABA composite board, improve the weather resistance, chemical corrosion resistance, and mechanical strength of the board, and help extend the service life of the board and reduce the frequency of maintenance and replacement. Polyurethane prepolymer, as one of the main components of the foaming masterbatch, has good toughness and strength, which can increase the compressive and bending resistance of the composite board. Moreover, the microbubbles in the foaming masterbatch can effectively block the heat conduction path, reduce the thermal conductivity of the material, and the porous structure can also absorb and dissipate sound wave energy, reducing noise propagation. The impact strength of the ABA in-mold composite board is 3.4-3.9 KJ·m. -2 Its thermal conductivity is 0.68-0.83 W / m·K, and its sound absorption coefficient is >40 dB. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the processing equipment for the ABA in-mold composite sheet of the present invention;

[0031] Figure 2 This is a schematic diagram of the cross-sectional structure of the ABA in-mold composite plate obtained in Embodiment 2 of the present invention;

[0032] Figure 3 This is a schematic diagram of the cross-sectional structure of the ABA in-mold composite plate obtained in Embodiment 3 of the present invention.

[0033] Figure descriptions: 1. First feed hopper, 2. Second feed hopper, 3. Surface material mixing zone, 4. Intermediate layer material mixing zone, 5. Surface material mixing and compression zone, 6. Intermediate layer material mixing and compression zone, 7. Particle-to-fluid conversion zone, 8. Surface texture transfer roller, 9. Conveyor belt zone, 10. Extrusion molding outflow zone, 1-1. First surface layer, 1-2. First intermediate layer, 2-1. Second surface layer, 2-2. Second intermediate layer. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0035] See Figure 1 As shown, the processing equipment structure for the ABA in-mold composite board of the present invention includes a particle-to-fluid zone 7. The top of one side of the particle-to-fluid zone 7 is connected to one end of the surface material mixing and compression zone 5. The other end of the surface material mixing and compression zone 5 is connected to the surface material mixing zone 3. The top of the surface material mixing zone 3 is provided with a first feed hopper 1. The bottom of one side of the particle-to-fluid zone 7 is connected to one side of the intermediate layer material mixing and compression zone 6. The other side of the intermediate layer material mixing and compression zone 6 is connected to the intermediate layer material mixing zone 4. The top of the intermediate layer material mixing zone 4 is provided with a second feed hopper 2. The bottom of the particle-to-fluid zone 7 is connected to an extrusion molding outflow zone 10. The extrusion molding outflow zone 10 interlaced through the gaps between multiple surface texture transfer rollers 8. The bottom of the extrusion molding outflow zone 10 is provided with a conveyor belt zone 9. Example 2

[0036] This embodiment discloses a method for preparing a light diffusion masterbatch, including the following steps:

[0037] Q1: Add 1.5g of titanium dioxide with a particle size of 50nm to a container, and add a mixed solution of 5.12g of silane coupling agent KH570 and 10mL of deionized water. Stir at 400rpm for 3h, centrifuge at 6000rpm for 30min, wash with deionized water 3 times, and dry at 60℃ for 12h to obtain modified titanium dioxide microspheres.

[0038] Q2: Add 5g of modified titanium dioxide microspheres and 12.5mL of polyvinylpyrrolidone to a container, add a mixed solution of 85mL of anhydrous ethanol and 30mL of deionized water, stir at 400rpm for 35min, heat to 65℃, add a mixed solution of 7.5mL of styrene and 0.45g of azobisisobutyronitrile, and heat at 75℃ and 300rpm for 24h under nitrogen protection. After the reaction is completed, cool, centrifuge at 8000rpm for 45min, wash 5 times with anhydrous ethanol, and vacuum dry at 60℃ for 12h to obtain composite microspheres;

[0039] Q3: Mix 10.5 mL of polydimethylsiloxane and 1.2 mL of tert-butanol peroxide evenly to obtain a polydimethylsiloxane mixed solution. At the same time, mix 2 g of composite microspheres with 15 mL of tetrahydrofuran solution and ultrasonically disperse for 8 h to obtain a composite microsphere solution. Add the composite microsphere solution to the polydimethylsiloxane mixed solution, stir evenly, vacuum bubble at room temperature for 30 min, place in a mold, and cure at 75℃ for 3 h to obtain light diffusion masterbatch.

[0040] This embodiment discloses a method for preparing foaming masterbatch, including the following steps:

[0041] S1: Add 1.5g of dried cellulose to a container and add 45mL of 88wt% formic acid solution. Heat and stir continuously at 100℃ for 12h at 700rpm. Then add 30mL of deionized water to terminate the reaction. Centrifuge, wash, and dialyze with deionized water to pH=7 to obtain cellulose formic acid.

[0042] S2: Add 3g of cellulose formate to 11mL of deionized water, stir evenly, then add 7g of polyurethane prepolymer, stir for 12s, and cure at 50℃ for 24h to obtain foaming masterbatch.

[0043] This embodiment discloses an ABA in-mold composite board, comprising a surface layer and an intermediate layer. The intermediate layer is tightly wrapped on both sides by the surface layer. The surface layer is prepared from 980 parts of general-purpose polystyrene resin and 25 parts of light-diffusing masterbatch, and the intermediate layer is prepared from 935 parts of general-purpose polystyrene resin, 30 parts of foaming masterbatch and 52 parts of light-diffusing masterbatch.

[0044] This embodiment discloses a method for processing ABA in-mold composite sheets, including the following steps:

[0045] Step (1): The raw materials are fed into the feeding system and then added to the extruder through the proportioning, weighing and mixing system;

[0046] Step (2): Set the extruder temperature to 215℃. Through the cooperation of two non-exhaust single-screw extruders, the material is extruded into a three-layer composite mold. The thickness ratio of the extruded surface layer to the middle layer is 1:10, and a composite board is obtained.

[0047] Step (3): The composite board is rolled and pressed by a three-roll calender at 120°C to obtain the board material;

[0048] Step (4): The sheet material is cooled, cut, and stacked on a 30m roller platform to obtain the ABA in-mold composite sheet. The cross-sectional diagram of the ABA in-mold composite sheet is shown below. Figure 2 As shown, it includes a first intermediate layer 1-2 and a first surface layer 1-1 on both sides.

[0049] Example 3

[0050] This embodiment discloses a method for preparing a light diffusion masterbatch, including the following steps:

[0051] Q1: Add 2g of titanium dioxide with a particle size of 50nm to a container, and simultaneously add a mixed solution of 3.14g of silane coupling agent KH570 and 10mL of deionized water. Stir at 400rpm for 3h, centrifuge at 6000rpm for 30min, wash three times with deionized water, and dry at 60℃ for 12h to obtain modified titanium dioxide microspheres.

[0052] Q2: Add 6g of modified titanium dioxide microspheres and 10mL of polyvinylpyrrolidone to a container, add a mixed solution of 80mL of anhydrous ethanol and 20mL of deionized water, stir at 400rpm for 35min, heat to 65℃, add 5mL of a mixed solution of styrene and 0.6g of azobisisobutyronitrile, and heat at 75℃ and 300rpm for 24h under nitrogen protection. After the reaction is completed, cool, centrifuge at 8000rpm for 45min, wash 5 times with anhydrous ethanol, and vacuum dry at 60℃ for 12h to obtain composite microspheres;

[0053] Q3: Mix 9 mL of polydimethylsiloxane and 1 mL of tert-butanol peroxide evenly to obtain a polydimethylsiloxane mixed solution. At the same time, mix 1 g of composite microspheres with 10 mL of tetrahydrofuran solution and ultrasonically disperse for 8 h to obtain a composite microsphere solution. Add the composite microsphere solution to the polydimethylsiloxane mixed solution, stir evenly, vacuum bubble at room temperature for 30 min, place in a mold, and cure at 75℃ for 3 h to obtain light diffusion masterbatch.

[0054] This embodiment discloses a method for preparing foaming masterbatch, including the following steps:

[0055] S1: Add 1g of dried cellulose to a container and add 30mL of formic acid solution with a mass fraction of 88wt%. Heat and stir continuously at 700rpm and 100℃ for 12h. Then add 30mL of deionized water to terminate the reaction. Centrifuge, wash, and dialyze with deionized water to pH=7 to obtain cellulose formic acid.

[0056] S2: Add 2g of cellulose formate to 10mL of deionized water, stir evenly, then add 6g of polyurethane prepolymer, stir for 12s, and cure at 50℃ for 24h to obtain foaming masterbatch.

[0057] This embodiment discloses an ABA in-mold composite board, comprising a surface layer and an intermediate layer. The intermediate layer is tightly wrapped on both sides by the surface layer. The surface layer is prepared from 980 parts of general-purpose polystyrene resin, 25 parts of light-diffusing masterbatch and 10 parts of foaming masterbatch. The intermediate layer is prepared from 935 parts of general-purpose polystyrene resin, 30 parts of foaming masterbatch and 52 parts of light-diffusing masterbatch.

[0058] This embodiment discloses a method for processing ABA in-mold composite sheets, including the following steps:

[0059] Step (1): The raw materials are fed into the feeding system and then added to the extruder through the proportioning, weighing and mixing system;

[0060] Step (2): Set the extruder temperature to 215℃. Through the cooperation of two non-exhaust single-screw extruders, the material is extruded into a three-layer composite mold. The thickness ratio of the extruded surface layer to the middle layer is 1:10, and a composite board is obtained.

[0061] Step (3): The composite board is rolled and pressed by a three-roll calender at 120°C to obtain the board material;

[0062] Step (4): The sheet material is cooled, cut, and stacked on a 30m roller platform to obtain the ABA in-mold composite sheet. The cross-sectional diagram of the ABA in-mold composite sheet is shown below. Figure 3 As shown, it includes a second intermediate layer 2-2 and a second surface layer 2-1 on both sides.

[0063] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

[0064] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to specific implementations. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An ABA in-mold composite sheet, characterized in that, It includes a surface layer and an intermediate layer, with the intermediate layer tightly wrapped on both sides by the surface layer. The surface layer is prepared from 950-1000 parts of general-purpose polystyrene resin and 25-50 parts of light-diffusing masterbatch, and the intermediate layer is prepared from 890-980 parts of general-purpose polystyrene resin, 1-60 parts of foaming masterbatch and 5-100 parts of light-diffusing masterbatch. The method for preparing the light diffusion masterbatch includes the following steps: Q1: Add titanium dioxide to a container, along with a mixed solution of silane coupling agent and deionized water. After stirring and reacting, centrifuge, wash, and dry to obtain modified titanium dioxide microspheres. Q2: Add modified titanium dioxide microspheres and polyvinylpyrrolidone to a container, add a mixed solution of anhydrous ethanol and deionized water, stir, heat, add a mixed solution of styrene and azobisisobutyronitrile dropwise, heat the reaction under nitrogen protection, after the reaction is completed, cool, centrifuge, wash, and vacuum dry to obtain composite microspheres; Q3: Polydimethylsiloxane and tert-butanol peroxide are mixed evenly to obtain a polydimethylsiloxane mixed solution. At the same time, the composite microspheres are mixed with tetrahydrofuran solution and ultrasonically dispersed to obtain a composite microsphere solution. The composite microsphere solution is added to the polydimethylsiloxane mixed solution, stirred evenly, vacuum bubbled at room temperature, placed in a mold, and cured to obtain light diffusion masterbatch.

2. The ABA in-mold composite sheet according to claim 1, characterized in that, In Q1, the molar ratio of titanium dioxide to silane coupling agent is (1-2):(1.1-2.2), the stirring speed is 300-400 rpm, the reaction time is 2-3 h, the centrifugation speed is 5000-6000 rpm, the time is 30-45 min, the product is washed with deionized water 3-5 times, and the drying temperature is 60-70℃ for 10-12 h.

3. The ABA in-mold composite sheet according to claim 1, characterized in that, In Q2, the ratio of modified titanium dioxide microspheres, polyvinylpyrrolidone, anhydrous ethanol, deionized water, styrene, and azobisisobutyronitrile is (4-6) g : (10-15) mL : (80-90) mL : (20-40) mL : (5-10) mL : (0.3-0.6) g. The stirring speed is 300-400 rpm, the time is 30-45 min, the temperature is raised to 60-65℃, the heating reaction temperature is 70-75℃, the time is 20-24 h, the stirring speed is 200-300 rpm, the centrifugation speed is 8000-9000 rpm, the time is 30-45 min, the product is washed 3-5 times with anhydrous ethanol, and the vacuum drying temperature is 60-70℃, the time is 10-12 h.

4. The ABA in-mold composite sheet according to claim 1, characterized in that, In Q3, the ratio of polydimethylsiloxane, tert-butanol peroxide, composite microspheres and tetrahydrofuran is (9-12) mL: (1-1.4) mL: (1-3) g: (10-20) mL, the ultrasonic dispersion time is 6-8 h, the vacuum degassing time is 30-45 min, the curing temperature is 70-80 ℃, and the time is 3-4 h.

5. The ABA in-mold composite sheet according to claim 1, characterized in that, The method for preparing the foaming masterbatch includes the following steps: S1: Add the dried cellulose to a container and add formic acid solution. Heat and stir continuously, then add deionized water to terminate the reaction. Centrifuge, wash, and dialyze to obtain cellulose formic acid. S2: Add cellulose formate to deionized water, stir evenly, add polyurethane prepolymer, stir, and solidify to obtain foaming masterbatch.

6. The ABA in-mold composite sheet according to claim 5, characterized in that, In step S1, the ratio of cellulose to formic acid solution is (1-2) g: (30-60) mL, the mass fraction of formic acid solution is 88 wt%, the heating and stirring temperature is 90-110℃, the time is 10-12 h, the stirring speed is 500-700 rpm, and the solution is dialyzed with deionized water to pH=7-7.

2. In step S2, the ratio of cellulose formic acid, deionized water and polyurethane prepolymer is (2-4) g: (10-12) mL: (6-8) g, the stirring time is 10-12 s, the curing temperature is 45-50℃, and the time is 20-24 h.

7. A method for processing ABA in-mold composite sheet material as described in any one of claims 1-6, characterized in that, Includes the following steps: Step (1): The raw materials are fed into the feeding system and then added to the extruder through the proportioning, weighing and mixing system; Step (2): Set the extruder temperature, and extrude the material into a three-layer composite mold through the cooperation of two non-exhaust single-screw extruders to obtain a composite board; Step (3): The composite board is rolled and pressed by a three-roll calender to obtain the board material; Step (4): The sheet material is cooled, cut, and stacked on a roller platform to obtain ABA in-mold composite sheet material.

8. The processing method of the ABA in-mold composite sheet according to claim 7, characterized in that, In step (2), the extruder temperature is 190-235℃, and the thickness ratio of the extruded surface layer to the intermediate layer is (1:5)-(1:15).

9. The processing method of the ABA in-mold composite sheet according to claim 7, characterized in that, In step (3), the rolling temperature of the three-roll calender is 80-120℃; in step (4), the length of the roller platform is 15-40m.

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