Bathroom product based on EPP polymer composite material and preparation method thereof

Abstract

The invention provides a bathroom product based on an EPP polymer composite material and a preparation method of the bathroom product, and relates to the field of bathroom products. The invention relates to a bathroom product based on an EPP polymer composite material. The bathroom product comprises the following components in percentage by mass: 60-80% of EPP particles; 10%-30% of reinforced fibers; 5%-10% of a flame retardant; 1%-3% of an antioxidant; the bathroom product is of an integrally-formed structure, honeycomb-shaped reinforcing ribs are arranged in the bathroom product, and a smooth hydrophobic coating is arranged on the surface of the bathroom product. The preparation method comprises the following steps: a, mixing and foaming; b, compression molding; and c, surface treatment. The environment-friendly flame-retardant plastic has the advantages of good flame retardance, high strength, light weight, good impact resistance, environment friendliness, recyclability, good safety, good touch feeling, simple preparation process and the like.

Description

Technical Field

[0001] The present invention relates to the field of sanitary ware, and in particular to a sanitary ware based on an EPP polymer composite material and a preparation method thereof. Background Art

[0002] Traditional bathroom products, such as toilets, urinals, above-the-counter basins and bathtubs, are basically made of ceramics, which have the following defects:

[0003] 1. Heavy weight: Ceramic products have high density and heavy weight, resulting in high transportation and installation costs;

[0004] 2. Fragile: Ceramics have poor impact resistance and are easily broken;

[0005] 3. Insufficient environmental protection: Ceramics cannot be recycled and pollute the environment after being discarded;

[0006] 4. Poor safety: Ceramic has high hardness. If the elderly or children with limited mobility slip or bump into it, it may cause life-threatening accidents.

[0007] 5. Poor touch: The ceramic surface is cold, and the experience is poor when used in winter. Summary of the Invention

[0008] In view of the above problems, the present invention proposes a bathroom product based on EPP polymer composite material and a preparation method thereof.

[0009] The technical solution of the present invention is achieved as follows:

[0010] A bathroom product based on EPP polymer composite material, comprising the following components in percentage by mass:

[0011] EPP particles 60%-80%;

[0012] Reinforcement fiber 10%-30%;

[0013] Flame retardant 5%-10%;

[0014] Antioxidants 1%-3%;

[0015] The bathroom product is an integrally formed structure, with honeycomb-shaped reinforcement ribs provided inside and a smooth hydrophobic coating provided on the surface.

[0016] Furthermore, the reinforcing fiber is carbon fiber or glass fiber.

[0017] Furthermore, the flame retardant is at least one of an inorganic hydroxide flame retardant, a halogen flame retardant, a phosphorus flame retardant, a nitrogen flame retardant, a silicon flame retardant, a bromine-antimony synergistic system flame retardant and a halogen-free flame retardant.

[0018] Furthermore, the hydrophobic coating is one of a water-based fluorocarbon coating, a silicone-modified acrylic coating, a hydrophobic nano-silica coating or a nano-scale titanium dioxide coating.

[0019] Furthermore, the sanitary ware is subjected to surface pretreatment before spraying the hydrophobic coating to improve the adhesion of the hydrophobic coating on the surface of the sanitary ware.

[0020] Furthermore, surface pretreatment includes corona treatment, flame treatment and spraying of chemical primer.

[0021] Furthermore, the corona treatment includes oxidizing the EPP surface through discharge treatment to increase polar groups; the flame treatment includes short flame exposure to activate the surface, and the chemical primer is a chlorinated polypropylene primer.

[0022] Furthermore, the bathroom product is one of a toilet, a urinal, an above-counter basin and a bathtub.

[0023] A method for preparing bathroom products based on EPP polymer composite materials comprises the following steps:

[0024] a. Mixing and foaming: Mix EPP particles with reinforcing fibers, flame retardants, and antioxidants, and add foaming agent for foaming;

[0025] b. Compression molding: inject the mixed foaming material into the mold and perform compression molding at a temperature of 120-150°C and a pressure of 8-12 MPa;

[0026] c. Surface treatment: Spray hydrophobic coating or antibacterial coating on the surface of the molded product.

[0027] Furthermore, before spraying the hydrophobic coating, the formed product is subjected to surface pretreatment, which can be one of the following:

[0028] Corona treatment: oxidize the EPP surface through discharge treatment to increase polar groups;

[0029] Flame treatment, a brief flame exposure to activate the surface;

[0030] Spray chemical primer, spray chlorinated polypropylene primer.

[0031] Beneficial effects of the present invention:

[0032] 1. Material: The chemical structure of EPP material itself has certain flame retardant properties. Its molecular structure contains a large number of hydrocarbons. These molecules require higher energy to decompose when burning. In addition, EPP material produces less smoke when burning and the combustion process is relatively slow, which helps to reduce the harm of fire to personnel and is conducive to fire fighting and personnel evacuation. After adding flame retardants, the flame retardant properties are further increased, so the bathroom products made from it have good fire resistance and safety performance.

[0033] 2. Structure: Using one-piece molding technology, honeycomb reinforcement ribs are set inside to improve compressive strength.

[0034] 3. Lightweight: density ≤ 0.8g / cm 3 , 60% lighter than ceramic products, easy to transport and install, and low cost.

[0035] 4. Impact resistance: Drop ball impact test (1kg steel ball 1m height) has no cracks, is not easy to break, and will not be damaged by ordinary collision.

[0036] 5. Environmental protection: The material is 100% recyclable and the production energy consumption is reduced by 40%.

[0037] 6. Safety: It has a certain degree of elasticity and cushioning, so even if the elderly and children bump into it, it generally does not cause safety hazards.

[0038] 7. Good touch: When used in winter, it will not be too cold and the experience is good.

[0039] 8. Preparation process: The preparation process is simple, including mixing foaming, compression molding and surface treatment, with high production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0041] Figure 1 The present invention is a flow chart of the preparation method of bathroom products based on EPP polymer composite materials. DETAILED DESCRIPTION

[0042] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0043] A bathroom product based on EPP polymer composite material, comprising the following components in percentage by mass:

[0044] EPP particles 60%-80%;

[0045] Reinforcement fiber 10%-30%;

[0046] Flame retardant 5%-10%;

[0047] Antioxidants 1%-3%;

[0048] The bathroom product is an integrally formed structure, with honeycomb-shaped reinforcement ribs provided inside and a smooth hydrophobic coating provided on the surface.

[0049] Furthermore, the reinforcing fiber is carbon fiber or glass fiber.

[0050] Furthermore, the flame retardant is at least one of an inorganic hydroxide flame retardant, a halogen flame retardant, a phosphorus flame retardant, a nitrogen flame retardant, a silicon flame retardant, a bromine-antimony synergistic system flame retardant and a halogen-free flame retardant.

[0051] Furthermore, the hydrophobic coating is one of a water-based fluorocarbon coating, a silicone-modified acrylic coating, a hydrophobic nano-silica coating or a nano-scale titanium dioxide coating.

[0052] Furthermore, the sanitary ware is subjected to surface pretreatment before spraying the hydrophobic coating to improve the adhesion of the hydrophobic coating on the surface of the sanitary ware.

[0053] Furthermore, surface pretreatment includes corona treatment, flame treatment and spraying of chemical primer.

[0054] Furthermore, the corona treatment includes oxidizing the EPP surface through discharge treatment to increase polar groups; the flame treatment includes short flame exposure to activate the surface, and the chemical primer is a chlorinated polypropylene primer.

[0055] Furthermore, the bathroom product is one of a toilet, a urinal, an above-counter basin and a bathtub.

[0056] like Figure 1 A method for preparing bathroom products based on EPP polymer composite materials comprises the following steps:

[0057] a. Mixing and foaming: Mix EPP particles with reinforcing fibers, flame retardants, and antioxidants, and add foaming agent for foaming;

[0058] b. Compression molding: inject the mixed foaming material into the mold and perform compression molding at a temperature of 120-150°C and a pressure of 8-12 MPa;

[0059] c. Surface treatment: Spray a hydrophobic coating on the surface of the molded product.

[0060] Furthermore, before spraying the hydrophobic coating, the formed product is subjected to surface pretreatment, which can be one of the following:

[0061] Corona treatment: oxidize the EPP surface through discharge treatment to increase polar groups;

[0062] Flame treatment, a brief flame exposure to activate the surface;

[0063] Spray chemical primer, spray chlorinated polypropylene primer.

[0064] EPP (expanded polypropylene) material mainly achieves flame retardancy by adding flame retardants. The following is an explanation of the selection of flame retardant systems:

[0065] Inorganic hydroxides

[0066] Magnesium hydroxide / aluminum hydroxide: It absorbs heat by decomposing and lowers the surface temperature of the material, generating a magnesium oxide / aluminum oxide protective layer to isolate oxygen.

[0067] Phosphorus and nitrogen synergistic system

[0068] Phosphorus-based flame retardants (red phosphorus masterbatch) and nitrogen-based flame retardants (MCA / MA) work synergistically to generate an expanded carbon layer during combustion to isolate heat and oxygen, and have both gas-phase and condensed-phase flame retardant mechanisms.

[0069] Silicone flame retardants

[0070] Forms a ceramic protective layer with excellent weather resistance and thermal stability.

[0071] New environmental protection system

[0072] Halogen-free flame retardants (such as silicone modified systems) are gradually replacing traditional halogen systems.

[0073] The following is a description of antioxidants for EPP (expanded polypropylene):

[0074] 1. Primary antioxidant (free radical capture type)

[0075] Hindered phenols

[0076] LENOX 1010: Pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], suitable for high temperature processing environment (≤220℃).

[0077] LENOX 1076: β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate, which can be used synergistically with phosphites to enhance the antioxidant effect.

[0078] Aromatic amines

[0079] LENOX 1098: N,N'-bis-(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionyl)hexanediamine, suitable for EPP products with high weather resistance requirements.

[0080] 2. Auxiliary antioxidant (hydroperoxide decomposition type)

[0081] Phosphates

[0082] LENOX 168: tris(2,4-di-tert-butylphenyl) phosphite, which inhibits PP molecular chain breakage during processing;

[0083] LENOX 626: Bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, suitable for EPP foaming process (160-200℃).

[0084] Thioesters

[0085] DLTDP (Dilauryl Thiodipropionate): When combined with phenolic antioxidants, it can extend the outdoor service life of EPP.

[0086] 3. Compound antioxidants

[0087] Antioxidant B215

[0088] It is compounded by LENOX 1076 (phenol) and LENOX 168 (phosphite) in a ratio of 1:2.

[0089] Masterbatch type EP-V701

[0090] Contains nitrogen and phosphorus composite structure, and has both anti-UV and anti-aging functions.

[0091] The present invention has the following advantages:

[0092] Materials: The chemical structure of EPP material itself has certain flame retardant properties. Its molecular structure contains a large amount of hydrocarbons. These molecules require higher energy to decompose when burning. In addition, EPP material produces less smoke when burning and the combustion process is relatively slow, which helps to reduce the harm of fire to people and is conducive to fire fighting and personnel evacuation. After adding flame retardants, the flame retardant properties are further increased, so the bathroom products made from it have good fire resistance and safety performance.

[0093] In terms of structure: it adopts one-piece molding technology and sets honeycomb reinforcement ribs inside to improve the compressive strength.

[0094] Lightweight: density ≤ 0.8g / cm 3 , 60% lighter than ceramic products, easy to transport and install, and low cost.

[0095] Impact resistance: Drop ball impact test (1kg steel ball 1m height) has no cracks, is not easy to break, and will not be damaged by ordinary collision.

[0096] Environmental protection: materials are 100% recyclable and production energy consumption is reduced by 40%.

[0097] Safety: It has a certain degree of elasticity and cushioning, and even if the elderly and children bump into it, it generally does not cause safety hazards.

[0098] Good touch: When used in winter, it is not too cold and the experience is good.

[0099] Preparation process: Preparation process: The preparation process is simple, including mixing foaming, compression molding and surface treatment, and has high production efficiency.

[0100] Example 1

[0101] A bathroom product based on an EPP polymer composite material comprises the following components in percentage by mass: 70% EPP particles; 20% carbon fiber; 8% halogen flame retardant; and 2% antioxidant. The bathroom product is an integrally molded structure with honeycomb-shaped reinforcing ribs inside and a silicone-modified acrylic coating on the surface.

[0102] The sanitary ware is subjected to corona treatment before the organic silicon modified acrylic coating is sprayed, thereby improving the adhesion of the organic silicon modified acrylic coating on the surface of the sanitary ware.

[0103] The bathroom product is one of a toilet, a urinal, an above-the-counter basin and a bathtub. Of course, it can also be other bathroom products.

[0104] A method for preparing bathroom products based on EPP polymer composite materials comprises the following steps:

[0105] a. Mix EPP particles with carbon fiber, halogen flame retardant, and antioxidant, and add foaming agent for foaming;

[0106] b. Inject the mixed foaming material into a mold and perform compression molding at a temperature of 130°C and a pressure of 10 MPa;

[0107] c. The molded product is subjected to corona treatment to oxidize the EPP surface through discharge treatment to increase polar groups, and then sprayed with a hydrophobic nano-silica coating.

[0108] Example 2

[0109] A sanitary ware based on an EPP polymer composite material comprises the following components in percentage by mass: 75% EPP particles; 15% glass fiber; 8% phosphorus flame retardant; and 2% antioxidant. The sanitary ware is an integrally formed structure with honeycomb-shaped reinforcing ribs provided inside. The surface of the sanitary ware is first sprayed with chlorinated polypropylene and then with a water-based fluorocarbon coating to improve the adhesion of the water-based fluorocarbon coating.

[0110] The bathroom product is one of a toilet, a urinal, an above-the-counter basin and a bathtub. Of course, it can also be other bathroom products.

[0111] A method for preparing bathroom products based on EPP polymer composite materials comprises the following steps:

[0112] a. Mix EPP particles with glass fiber, phosphorus flame retardant, antioxidant, and add foaming agent for foaming;

[0113] b. Inject the mixed foaming material into a mold and perform compression molding at a temperature of 135°C and a pressure of 9 MPa;

[0114] c. First spray chlorinated polypropylene on the surface of the molded product, and then spray water-based fluorocarbon coating.

[0115] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A bathroom product based on EPP polymer composite material, characterized by: The following components are included in mass percentage: EPP particles 60%-80%; Reinforcement fiber 10%-30%; Flame retardant 5%-10%; Antioxidants 1%-3%; The bathroom product is an integrally formed structure, with honeycomb-shaped reinforcement ribs provided inside and a smooth hydrophobic coating provided on the surface.

2. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: The reinforcing fibers are carbon fibers or glass fibers.

3. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: The flame retardant is at least one of an inorganic hydroxide flame retardant, a halogen flame retardant, a phosphorus flame retardant, a nitrogen flame retardant, a silicon flame retardant, a bromine-antimony synergistic system flame retardant and a halogen-free flame retardant.

4. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: The hydrophobic coating is one of a water-based fluorocarbon coating, an organosilicon-modified acrylic coating, a hydrophobic nano-silicon dioxide coating or a nano-scale titanium dioxide coating.

5. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: Before spraying the hydrophobic coating on the sanitary ware, the surface is pretreated to improve the adhesion of the hydrophobic coating on the surface of the sanitary ware.

6. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: Surface preparation includes corona treatment, flame treatment and spraying chemical primer.

7. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: The corona treatment includes oxidizing the EPP surface through discharge treatment to increase polar groups; the flame treatment includes short flame exposure to activate the surface, and the chemical primer is a chlorinated polypropylene primer.

8. The bathroom product based on EPP polymer composite material according to claim 1, characterized in that: The bathroom product is one of a toilet, a urinal, an above-the-counter basin and a bathtub.

9. The method for preparing a bathroom product based on an EPP polymer composite material according to any one of claims 1 to 8, comprising the following steps: a. Mixing and foaming: Mix EPP particles with reinforcing fibers, flame retardants, and antioxidants, and add foaming agent for foaming; b. Compression molding: inject the mixed foaming material into the mold and perform compression molding at a temperature of 120-150°C and a pressure of 8-12 MPa; c. Surface treatment: Spray hydrophobic coating or antibacterial coating on the surface of the molded product.

10. The method for preparing bathroom products based on EPP polymer composite materials according to claim 9, characterized in that: Before spraying the hydrophobic coating, the molded product is first subjected to surface pretreatment, which can be one of the following: Corona treatment: oxidize the EPP surface through discharge treatment to increase polar groups; Flame treatment, a brief flame exposure to activate the surface; Spray chemical primer, spray chlorinated polypropylene primer.

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