Reinforced polystyrene lamp tube and its manufacturing method

Abstract

The application provides a reinforced polystyrene lamp tube and a manufacturing method thereof. The lamp tube comprises a polystyrene base material, an acrylonitrile-styrene copolymer base material, a flame retardant, a flame retardant auxiliary agent, a surface modifier and a dispersing agent. The mass percentage of the polystyrene base material is 50.5%-70.5%. The mass percentage of the acrylonitrile-styrene copolymer base material is 10%-30%. The mass percentage of the flame retardant is 4%-10%. The mass percentage of the flame retardant auxiliary agent is 2%-8%. The mass percentage of the surface modifier is 0.5%-2%. The mass percentage of the dispersing agent is 0.4%-2%.

Description

Technical Field

[0001] This application relates to a lamp tube, and more particularly to a reinforced polystyrene lamp tube. This application also relates to a method for manufacturing this reinforced polystyrene lamp tube. Background Technology

[0002] Currently, lamp tubes made primarily of polystyrene (PS) can be manufactured. However, existing manufacturing methods still face several technical bottlenecks that urgently need to be overcome in terms of practical application and mass production, preventing large-scale practical applications from yet to be realized.

[0003] For example, existing lamp tubes have poor mechanical properties and are highly brittle. As a result, they are prone to breakage during subsequent cutting and trimming processes, which not only reduces product yield but also severely restricts automated continuous production processes.

[0004] In addition, polystyrene itself has inherent deficiencies in flame retardancy, which directly makes it difficult to improve the flame retardancy rating of lamps. Therefore, its safety cannot yet meet the requirements for use, which greatly limits its application range.

[0005] Furthermore, the flame retardants added to improve flame retardant properties have introduced new optical performance problems. Flame retardants significantly affect the optical properties of materials, causing a substantial decrease in the light transmittance of the lamp tube and thus affecting its optical performance. Summary of the Invention

[0006] According to one embodiment of this application, a reinforced polystyrene lamp tube is provided, comprising a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant facilitator, a surface modifier, and a dispersant. The polystyrene substrate comprises 50.5% to 70.5% by mass. The acrylonitrile-styrene copolymer substrate comprises 10% to 30% by mass. The flame retardant comprises 4% to 10% by mass. The flame retardant facilitator comprises 2% to 8% by mass. The surface modifier comprises 0.5% to 2% by mass. The dispersant comprises 0.4% to 2% by mass.

[0007] In one embodiment, the flame retardant is decabromodiphenyl ether. The flame retardant facilitator is antimony trioxide. The surface modifier is silica. The dispersant is polyethylene wax.

[0008] In one embodiment, the reinforced polystyrene lamp tube is characterized in that it further comprises a graft compatibilizer. The polystyrene substrate comprises 55% to 65% by mass. The acrylonitrile-styrene copolymer substrate comprises 15% to 25% by mass. The flame retardant comprises 4% to 7% by mass. The flame retardant auxiliaries comprise 2% to 5% by mass. The surface modifier comprises 0.7% to 1.5% by mass. The dispersant comprises 0.4% to 1.5% by mass. The graft compatibilizer comprises 4% to 10% by mass.

[0009] In one embodiment, the lamp tube further includes a toughening agent. The polystyrene substrate comprises 56% to 64% by weight. The acrylonitrile-styrene copolymer substrate comprises 16% to 24% by weight. The flame retardant comprises 4% to 6% by weight. The flame retardant auxiliary agent comprises 2% to 4% by weight. The surface modifier comprises 0.7% to 1.3% by weight. The dispersant comprises 0.4% to 1% by weight. The graft compatibilizer comprises 4% to 8% by weight. The toughening agent comprises 4% to 8% by weight.

[0010] In one embodiment, the graft compatibilizer is maleic anhydride. The toughening agent is MBS toughening agent or SBS toughening agent.

[0011] According to another embodiment of this application, a method for manufacturing a reinforced polystyrene lamp tube is proposed, comprising the following steps: placing multiple raw materials into a mixer to perform a mixing process to mix the multiple raw materials to produce a mixed material, wherein the multiple raw materials include a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant assisted agent, a surface modifier, and a dispersant, wherein the mass percentage of the polystyrene substrate is 50.5%~70.5%, the mass percentage of the acrylonitrile-styrene copolymer substrate is 10%~30%, the mass percentage of the flame retardant is 4%~10%, the mass percentage of the flame retardant assisted agent is 2%~8%, the mass percentage of the surface modifier is 0.5%~2%, and the mass percentage of the dispersant is 0.4%~2%; placing the mixed material into a screw extruder to perform an extrusion granulation and cutting process to extrude the mixed material into linear material and cut the linear material to produce granular material; and placing the granular material into an extruder to perform an extrusion molding process to produce a lamp tube.

[0012] In one embodiment, the flame retardant is decabromodiphenyl ether. The flame retardant facilitator is antimony trioxide. The surface modifier is silica. The dispersant is polyethylene wax.

[0013] In one embodiment, the aforementioned raw materials further include a graft compatibilizer. The polystyrene substrate comprises 55% to 65% by mass. The acrylonitrile-styrene copolymer substrate comprises 15% to 25% by mass. The flame retardant comprises 4% to 7% by mass. The flame retardant auxiliaries comprise 2% to 5% by mass. The surface modifier comprises 0.7% to 1.5% by mass. The dispersant comprises 0.4% to 1.5% by mass. The graft compatibilizer comprises 4% to 10% by mass.

[0014] In one embodiment, the aforementioned raw materials further include a toughening agent. The polystyrene substrate comprises 56% to 64% by mass. The acrylonitrile-styrene copolymer substrate comprises 16% to 24% by mass. The flame retardant comprises 4% to 6% by mass. The flame retardant auxiliaries comprise 2% to 4% by mass. The surface modifier comprises 0.7% to 1.3% by mass. The dispersant comprises 0.4% to 1% by mass. The graft compatibilizer comprises 4% to 8% by mass. The toughening agent comprises 4% to 8% by mass.

[0015] In one embodiment, the graft compatibilizer is maleic anhydride, and the toughening agent is MBS toughening agent or SBS toughening agent.

[0016] As described above, the reinforced polystyrene lamp tube and its manufacturing method according to the embodiments of this application may have one or more of the following advantages:

[0017] (1) In one embodiment of this application, the lamp tube includes a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant facilitator, a surface modifier, and a dispersant. The mass percentage of the polystyrene substrate is 50.5% to 70.5%. The mass percentage of the acrylonitrile-styrene copolymer substrate is 10% to 30%. The mass percentage of the flame retardant is 4% to 10%. The mass percentage of the flame retardant facilitator is 2% to 8%. The mass percentage of the surface modifier is 0.5% to 2%. The mass percentage of the dispersant is 0.4% to 2%. Through the above-mentioned special formulation, the appropriate proportion of acrylonitrile-styrene copolymer substrate can change the properties of the polystyrene substrate, thereby significantly improving the mechanical strength of the lamp tube (especially impact resistance and heat resistance). Therefore, the product yield of the lamp tube can be significantly improved, and an automated continuous production process can be adopted.

[0018] (2) In one embodiment of this application, the above-mentioned special formulation allows for the improvement of the tensile strength of the polystyrene substrate and the reduction of the lamp's haze by using an appropriate proportion of surface modifier. An appropriate proportion of dispersant can improve the light transmittance of the lamp and also serve as an interface lubricant during processing. Therefore, the optical performance of the lamp can be significantly improved, and it is easier to manufacture and process.

[0019] (3) In one embodiment of this application, the lamp tube further includes a graft compatibilizer. The mass percentage of the polystyrene substrate is 55%~65%. The mass percentage of the acrylonitrile-styrene copolymer substrate is 15%~25%. The mass percentage of the flame retardant is 4%~7%. The mass percentage of the flame retardant auxiliary agent is 2%~5%. The mass percentage of the surface modifier is 0.7%~1.5%. The mass percentage of the dispersant is 0.4%~1.5%. The mass percentage of the graft compatibilizer is 4%~10%. Through the above-mentioned special formulation, the appropriate proportion of graft compatibilizer can effectively improve the tensile strength, impact strength and melt flow index of the mixed material. Therefore, the manufacturing method of the lamp tube can use complex and thin-walled molds to produce more lamp tubes with different structures. Therefore, the lamp tube products can be more diversified to meet market demands.

[0020] (4) In one embodiment of this application, the lamp tube further includes a toughening agent. The mass percentage of the polystyrene substrate is 56%~64%. The mass percentage of the acrylonitrile-styrene copolymer substrate is 16%~24%. The mass percentage of the flame retardant is 4%~6%. The mass percentage of the flame retardant auxiliary agent is 2%~4%. The mass percentage of the surface modifier is 0.7%~1.3%. The mass percentage of the dispersant is 0.4%~1%. The mass percentage of the graft compatibilizer is 4%~8%. The mass percentage of the toughening agent is 4%~8%. Through the above-mentioned special formulation, the appropriate proportion of toughening agent can reduce the brittleness of the lamp tube, further improve the mechanical strength of the lamp tube, and not affect the optical performance of the lamp tube. Therefore, the product yield of the lamp tube can be further improved, and an automated continuous production process can be adopted. Attached Figure Description

[0021] Figure 1 This is a first cross-sectional view of the reinforced polystyrene lamp tube according to the first embodiment of this application.

[0022] Figure 2 This is a second cross-sectional view of the reinforced polystyrene lamp tube according to the first embodiment of this application.

[0023] Figure 3 This is a flowchart illustrating a method for manufacturing a reinforced polystyrene lamp tube according to a second embodiment of this application.

[0024] Explanation of reference numerals in the attached figures:

[0025] 1-Lamp tube; 11-Light emitting part; 12-First structural reinforcement part; 121-First vertical part; 122-First horizontal part; 123-First inclined part; 13-Second structural reinforcement part; 131-Second vertical part; 132-Second horizontal part; 133-Second inclined part; 14-Light source board mounting part; 141-Substrate; 142-First fixing part; 143-Second fixing part; 15-First horizontal wing; 16-Second horizontal wing; 17-First vertical wing; 18-Second vertical wing; BS-Light source board mounting slot; LS-Light source board; S31~S33-Step flow.

[0026] The following detailed description of the features and advantages of the present invention is sufficient to enable anyone skilled in the art to understand the technical content of the present invention and implement it accordingly. Based on the content and drawings disclosed in this specification, anyone skilled in the art can easily understand the purpose and advantages of this invention. Detailed Implementation

[0027] The following description, with reference to the accompanying drawings, illustrates embodiments of the reinforced polystyrene lamp tube and its manufacturing method according to this application. For clarity and convenience, the dimensions and proportions of the components in the drawings may be exaggerated or reduced. In the following description, when a component is referred to as "connected" or "coupled" to another component, it may be directly connected or coupled to that other component or there may be an intervening component; when a component is referred to as "directly connected" or "directly coupled" to another component, there is no intervening component. Other terms used to describe the relationship between components or layers should be interpreted in the same manner. For ease of understanding, the same components in the following embodiments are indicated by the same symbols.

[0028] Please see Figure 1 and Figure 2 . Figure 1 This is a first cross-sectional view of the reinforced polystyrene lamp tube according to the first embodiment of this application. Figure 2 This is a second cross-sectional view of the reinforced polystyrene lamp tube according to the first embodiment of this application. As shown in the figure, the lamp tube 1 includes a light-emitting part 11, a first structural reinforcement part 12, a second structural reinforcement part 13, a light source plate mounting part 14, a first horizontal wing part 15, a second horizontal wing part 16, a first vertical wing part 17, and a second vertical wing part 18.

[0029] The light-emitting section 11 has an arc-shaped cross-section (major or minor arc). In one embodiment, the cross-section of the light-emitting section 11 may also be V-shaped or U-shaped, and its shape can be adjusted according to actual needs.

[0030] The first structural reinforcement portion 12 is disposed on one side of the light-emitting portion 11. The cross-section of the first structural reinforcement portion 12 is triangular. In this embodiment, the cross-section of the first structural reinforcement portion 12 is a right-angled triangle and includes a first vertical portion 121, a first horizontal portion 122, and a first inclined portion 123 that are connected to each other. In another embodiment, the cross-section of the first structural reinforcement portion 12 may also be other different triangles, such as an isosceles triangle.

[0031] The second structural reinforcement portion 13 is disposed on the other side of the light-emitting portion 11, and the cross-section of the second structural reinforcement portion 13 is triangular. In this embodiment, the cross-section of the second structural reinforcement portion 13 is also a right-angled triangle, and includes a second vertical portion 131, a second horizontal portion 132, and a second inclined portion 133 that are connected to each other. In another embodiment, the cross-section of the second structural reinforcement portion 13 may also be other different triangles, such as an isosceles triangle.

[0032] The light source board mounting portion 14 includes a substrate 141, a first fixing portion 142, and a second fixing portion 143. One end of the substrate 141 is connected to a first structural reinforcement portion 12 (the first vertical portion 121 of the first structural reinforcement portion 12), and the other end of the substrate 141 is connected to a second structural reinforcement portion 13 (the second vertical portion 131 of the second structural reinforcement portion 13). The cross-sections of the first fixing portion 142 and the second fixing portion 143 are L-shaped. The first fixing portion 142 and the second fixing portion 143 are disposed on the surface of the substrate 141. Thus, a light source board mounting groove BS can be formed between the first fixing portion 142, the second fixing portion 143, and the substrate 141 to accommodate the light source board LS.

[0033] The first horizontal wing portion 15 is parallel to the first horizontal portion 122 of the first structural reinforcement portion 12. The first horizontal wing portion 15 is disposed on the first vertical portion 121 of the first structural reinforcement portion 12 and extends in a direction away from the first vertical portion 121.

[0034] The first vertical wing 17 is parallel to the first vertical portion 121 of the first structural reinforcement portion 12. The first vertical wing 17 is disposed on the first horizontal portion 122 of the first structural reinforcement portion 12 and extends in a direction away from the first horizontal portion 122.

[0035] The second horizontal wing 16 is parallel to the second horizontal wing 132 of the second structural reinforcement 13. The second horizontal wing 16 is disposed on the second vertical wing 131 of the second structural reinforcement 13 and extends in a direction away from the second vertical wing 131.

[0036] The second vertical wing 18 is parallel to the second vertical portion 131 of the second structural reinforcement portion 13. The second vertical wing 18 is disposed on the second horizontal portion 132 of the second structural reinforcement portion 13 and extends in a direction away from the second horizontal portion 132.

[0037] Through the structural design of the first structural reinforcement part 12 and the second structural reinforcement part 13 described above, the structural strength on both sides of the light source plate mounting part 14 can be greatly improved to withstand the stress generated during cutting, thereby making the light source plate mounting part 14 less prone to deformation during the cutting of the lamp tube 1. Therefore, the production yield of the lamp tube 1 can be greatly improved.

[0038] Furthermore, through the aforementioned right-angled triangular structural design, the lamp tube 1 can more easily offset the impact of external forces to achieve force balance, enabling the light source board mounting portion 14 to maintain extremely high dimensional stability and shape accuracy even when subjected to external forces. Therefore, the structural strength of the lamp tube 1 can be further improved to enhance its structural stability.

[0039] Therefore, lamp tube 1 can be made of a material with lower structural strength but higher optical performance. Thus, the manufacturer of lamp tube 1 can prioritize materials with superior optical properties, thereby improving the overall optical performance of lamp tube 1. Consequently, lamp tube 1 better meets the needs of practical applications.

[0040] Of course, this embodiment is only an example, and the structure of lamp tube 1 can be modified according to actual needs, and is not limited to the above structural design.

[0041] The lamp tube 1 can be made from a variety of raw materials, including polystyrene substrate, acrylonitrile-styrene copolymer substrate, flame retardant, flame retardant assisted agent, surface modifier and dispersant.

[0042] The polystyrene (PS) substrate comprises 50.5% to 70.5% by weight. The polystyrene substrate can be transparent. For example, the polystyrene substrate may comprise 50.5%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, or 70.5% by weight.

[0043] The acrylonitrile-styrene copolymer (AS copolymer) substrate comprises 10% to 30% by weight. The acrylonitrile-styrene copolymer substrate can be transparent. For example, the mass percentage of the acrylonitrile-styrene copolymer substrate can be 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, or 30%.

[0044] The flame retardant has a mass percentage of 4% to 10%. For example, the flame retardant may be decabromodiphenyl ether (or decabromodiphenyl oxide). For example, the mass percentage of the flame retardant may be 4%, 5%, 6%, 7%, 8%, 9%, or 10%.

[0045] The flame retardant auxiliaries are present in a mass percentage of 2% to 8%. For example, the flame retardant auxiliaries may be antimony trioxide (Sb₂O₃). For example, the mass percentage of the flame retardant auxiliaries may be 2%, 3%, 4%, 5%, 6%, 7%, or 8%.

[0046] The surface modifier has a mass percentage of 0.5% to 2%. For example, the surface modifier may be (nano)silica (SiO2). For example, the mass percentage of the surface modifier may be 0.5%, 0.7%, 1%, 1.3%, 1.5%, 1.8%, or 2%.

[0047] The dispersant has a mass percentage of 0.4% to 2%. For example, the dispersant may be polyethylene wax. For example, the mass percentage of the dispersant may be 0.4%, 0.5%, 0.8%, 1%, 1.3%, 1.5%, 1.7%, or 2%.

[0048] In this embodiment, through the aforementioned special formulation, an appropriate proportion of acrylonitrile-styrene copolymer substrate can alter the properties of the polystyrene substrate, significantly improving the mechanical strength of the lamp tube 1 (especially its impact resistance and heat resistance). Therefore, the product yield of the lamp tube 1 can be greatly improved, and an automated continuous production process can be employed.

[0049] Furthermore, through the aforementioned special formulation, an appropriate proportion of surface modifier can improve the tensile strength of the polystyrene substrate and reduce the haze of lamp tube 1. An appropriate proportion of dispersant can improve the light transmittance of lamp tube 1 and can also serve as an interface lubricant during processing. Therefore, the optical performance of lamp tube 1 can be significantly improved, and it is easier to manufacture and process.

[0050] In another embodiment, the lamp tube 1 may further include a graft compatibilizer. The polystyrene substrate comprises 55% to 65% by mass. The acrylonitrile-styrene copolymer substrate comprises 15% to 25% by mass. The flame retardant comprises 4% to 7% by mass. The flame retardant auxiliaries comprise 2% to 5% by mass. The surface modifier comprises 0.7% to 1.5% by mass. The dispersant comprises 0.4% to 1.5% by mass. The graft compatibilizer comprises 4% to 10% by mass. For example, the graft compatibilizer may be maleic anhydride (MA). For example, the mass percentage of the graft compatibilizer may be 4%, 5%, 6, 7%, 8%, 9%, or 10%.

[0051] Through the aforementioned special formulation, an appropriate proportion of grafted compatibilizer can effectively improve the tensile strength, impact strength, and melt flow index of the mixed material. Therefore, the manufacturing method of lamp tube 1 can employ complex and thin-walled molds to produce lamp tubes with more diverse structures. Consequently, the product range of lamp tube 1 can be more diversified to meet market demands.

[0052] In another embodiment, the lamp tube 1 may further include a toughening agent. The polystyrene substrate comprises 56% to 64% by mass. The acrylonitrile-styrene copolymer substrate comprises 16% to 24% by mass. The flame retardant comprises 4% to 6% by mass. The flame retardant auxiliaries comprise 2% to 4% by mass. The surface modifier comprises 0.7% to 1.3% by mass. The dispersant comprises 0.4% to 1% by mass. The graft compatibilizer comprises 4% to 8% by mass. The toughening agent comprises 4% to 8% by mass. For example, the toughening agent may be an MBS toughening agent or an SBS toughening agent. For example, the toughening agent may comprise 4%, 5%, 6%, 7%, or 8% by mass.

[0053] Through the aforementioned special formula, an appropriate proportion of toughening agent can reduce the brittleness of lamp tube 1, further enhancing its mechanical strength without affecting its optical performance. Therefore, the product yield of the lamp tube can be further improved, and an automated continuous production process can be adopted.

[0054] For example, the polystyrene substrate accounts for 60.5% by mass. The acrylonitrile-styrene copolymer substrate accounts for 20% by mass. The flame retardant accounts for 5% by mass. The flame retardant auxiliaries account for 3% by mass. The surface modifier accounts for 1% by mass. The dispersant accounts for 0.5% by mass. The graft compatibilizer accounts for 5% by mass. The toughening agent accounts for 5% by mass. The performance comparison of lamp tube 1 with the above formulation and existing lamp tubes is shown in Table 1 below:

[0055] Table 1. Performance Comparison of Lamp 1 with Existing Lamps

[0056] ;

[0057] Of course, this embodiment is only for illustrative purposes and is not intended to limit the scope of this application. Equivalent modifications or changes made to the reinforced polystyrene lamp tube 1 according to this embodiment should still be included within the patent scope of this application.

[0058] It is worth mentioning that existing lamp tubes have poor mechanical properties. Their material is highly brittle, making them prone to breakage during subsequent cutting and trimming processes. This not only reduces product yield but also severely restricts automated continuous production processes. Furthermore, polystyrene itself has inherently insufficient flame retardant properties, directly hindering the improvement of the lamp tube's flame retardant rating. Consequently, its safety cannot meet usage requirements, greatly limiting its application range. Moreover, the flame retardants added to improve flame retardant performance introduce new optical performance problems. Flame retardants significantly affect the optical properties of the material, causing a substantial decrease in the lamp tube's light transmittance and impacting its optical performance. In contrast, according to the embodiments of this application, the lamp tube includes a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant facilitator, a surface modifier, and a dispersant. The polystyrene substrate comprises 50.5% to 70.5% by mass. The acrylonitrile-styrene copolymer substrate comprises 10% to 30% by mass. The flame retardant comprises 4% to 10% by mass. The flame retardant accelerator accounts for 2% to 8% of the mass. The surface modifier accounts for 0.5% to 2% of the mass. The dispersant accounts for 0.4% to 2% of the mass. Through the above special formulation, an appropriate proportion of acrylonitrile-styrene copolymer substrate can change the properties of polystyrene substrate, significantly improving the mechanical strength of the lamp tube (especially impact resistance and heat resistance). Therefore, the product yield of the lamp tube can be greatly improved, and an automated continuous production process can be adopted.

[0059] Furthermore, according to embodiments of this application, the aforementioned special formulation, with an appropriate proportion of surface modifier, can improve the tensile strength of the polystyrene substrate and reduce the haze of the lamp tube. An appropriate proportion of dispersant can improve the light transmittance of the lamp tube and also serve as an interface lubricant during processing. Therefore, the optical performance of the lamp tube can be significantly improved, and it is easier to manufacture and process.

[0060] Furthermore, according to embodiments of this application, the lamp tube also includes a graft compatibilizer. The polystyrene substrate comprises 55% to 65% by mass. The acrylonitrile-styrene copolymer substrate comprises 15% to 25% by mass. The flame retardant comprises 4% to 7% by mass. The flame retardant auxiliaries comprise 2% to 5% by mass. The surface modifier comprises 0.7% to 1.5% by mass. The dispersant comprises 0.4% to 1.5% by mass. The graft compatibilizer comprises 4% to 10% by mass. Through the above-mentioned special formulation, an appropriate proportion of graft compatibilizer can effectively improve the tensile strength, impact strength, and melt flow index of the mixed material. Therefore, the manufacturing method of the lamp tube can employ complex and thin-walled molds to produce lamp tubes with more different structures. Thus, the lamp tube products can be more diversified to meet market demands.

[0061] Furthermore, according to embodiments of this application, the lamp tube also includes a toughening agent. The mass percentage of the polystyrene substrate is 56%~64%. The mass percentage of the acrylonitrile-styrene copolymer substrate is 16%~24%. The mass percentage of the flame retardant is 4%~6%. The mass percentage of the flame retardant auxiliary agent is 2%~4%. The mass percentage of the surface modifier is 0.7%~1.3%. The mass percentage of the dispersant is 0.4%~1%. The mass percentage of the graft compatibilizer is 4%~8%. The mass percentage of the toughening agent is 4%~8%. Through the above-mentioned special formulation, the appropriate proportion of toughening agent can reduce the brittleness of the lamp tube, further improve the mechanical strength of the lamp tube, and not affect the optical performance of the lamp tube. Therefore, the product yield of the lamp tube can be further improved, and an automated continuous production process can be adopted. As can be seen from the above, the reinforced polystyrene lamp tube according to the embodiments of this application can indeed achieve excellent technical effects.

[0062] Please see Figure 3 The figure shows a flowchart of a method for manufacturing a reinforced polystyrene lamp tube according to a second embodiment of this application. As shown, the manufacturing method of this embodiment may include the following steps:

[0063] Step S31: Multiple raw materials are fed into a mixer to execute a mixing process, mixing the raw materials to produce a composite material. These raw materials include a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant facilitator, a surface modifier, and a dispersant. The mass percentage of the polystyrene substrate is 50.5%–70.5%, the mass percentage of the acrylonitrile-styrene copolymer substrate is 10%–30%, the mass percentage of the flame retardant is 4%–10%, the mass percentage of the flame retardant facilitator is 2%–8%, the mass percentage of the surface modifier is 0.5%–2%, and the mass percentage of the dispersant is 0.4%–2%. The screw extruder's processing temperature can adopt a stepped heating mode, such as 160°C→180°C→200°C→210°C→205°C. Furthermore, the processing temperature should not be too high to prevent the decomposition of the flame retardant.

[0064] Step S32: The mixed material is fed into a screw extruder to perform an extrusion granulation and cutting process to extrude the mixed material into linear material and cut the linear material to produce granular material.

[0065] Step S33: Feed the granular material into the extruder to perform the extrusion molding process to produce lamp tube 1.

[0066] In another embodiment, the aforementioned raw materials further include a graft compatibilizer. The polystyrene substrate comprises 55%–65% by mass. The acrylonitrile-styrene copolymer substrate comprises 15%–25% by mass. The flame retardant comprises 4%–7% by mass. The flame retardant auxiliaries comprise 2%–5% by mass. The surface modifier comprises 0.7%–1.5% by mass. The dispersant comprises 0.4%–1.5% by mass. The graft compatibilizer comprises 4%–10% by mass.

[0067] In another embodiment, the aforementioned raw materials further include a toughening agent. The polystyrene substrate comprises 56% to 64% by mass. The acrylonitrile-styrene copolymer substrate comprises 16% to 24% by mass. The flame retardant comprises 4% to 6% by mass. The flame retardant auxiliaries comprise 2% to 4% by mass. The surface modifier comprises 0.7% to 1.3% by mass. The dispersant comprises 0.4% to 1% by mass. The graft compatibilizer comprises 4% to 8% by mass. The toughening agent comprises 4% to 8% by mass.

[0068] Of course, this embodiment is only for illustrative purposes and is not intended to limit the scope of this application. Equivalent modifications or changes made to the manufacturing method of the reinforced polystyrene lamp tube according to this embodiment should still be included within the patent scope of this application.

[0069] Although the steps of the methods described in this application are shown and described in a specific order, the order of operation of each method may be changed, some steps may be performed in reverse order, or some steps may be performed simultaneously with other steps. In another embodiment, different steps may be implemented in an intermittent and / or alternating manner.

[0070] In summary, according to the embodiments of this application, the lamp tube comprises a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant facilitator, a surface modifier, and a dispersant. The mass percentage of the polystyrene substrate is 50.5% to 70.5%. The mass percentage of the acrylonitrile-styrene copolymer substrate is 10% to 30%. The mass percentage of the flame retardant is 4% to 10%. The mass percentage of the flame retardant facilitator is 2% to 8%. The mass percentage of the surface modifier is 0.5% to 2%. The mass percentage of the dispersant is 0.4% to 2%. Through the above-mentioned special formulation, an appropriate proportion of acrylonitrile-styrene copolymer substrate can change the properties of the polystyrene substrate, significantly improving the mechanical strength of the lamp tube (especially impact resistance and heat resistance). Therefore, the product yield of the lamp tube can be significantly improved, and an automated continuous production process can be adopted.

[0071] Furthermore, according to embodiments of this application, the aforementioned special formulation, with an appropriate proportion of surface modifier, can improve the tensile strength of the polystyrene substrate and reduce the haze of the lamp tube. An appropriate proportion of dispersant can improve the light transmittance of the lamp tube and also serve as an interface lubricant during processing. Therefore, the optical performance of the lamp tube can be significantly improved, and it is easier to manufacture and process.

[0072] Furthermore, according to embodiments of this application, the lamp tube also includes a graft compatibilizer. The polystyrene substrate comprises 55% to 65% by mass. The acrylonitrile-styrene copolymer substrate comprises 15% to 25% by mass. The flame retardant comprises 4% to 7% by mass. The flame retardant auxiliaries comprise 2% to 5% by mass. The surface modifier comprises 0.7% to 1.5% by mass. The dispersant comprises 0.4% to 1.5% by mass. The graft compatibilizer comprises 4% to 10% by mass. Through the above-mentioned special formulation, an appropriate proportion of graft compatibilizer can effectively improve the tensile strength, impact strength, and melt flow index of the mixed material. Therefore, the manufacturing method of the lamp tube can employ complex and thin-walled molds to produce lamp tubes with more different structures. Thus, the lamp tube products can be more diversified to meet market demands.

[0073] Furthermore, according to embodiments of this application, the lamp tube also includes a toughening agent. The polystyrene substrate comprises 56% to 64% by mass. The acrylonitrile-styrene copolymer substrate comprises 16% to 24% by mass. The flame retardant comprises 4% to 6% by mass. The flame retardant auxiliary agent comprises 2% to 4% by mass. The surface modifier comprises 0.7% to 1.3% by mass. The dispersant comprises 0.4% to 1% by mass. The graft compatibilizer comprises 4% to 8% by mass. The toughening agent comprises 4% to 8% by mass. Through the above-mentioned special formulation, the appropriate proportion of toughening agent can reduce the brittleness of the lamp tube, further improving its mechanical strength without affecting its optical performance. Therefore, the product yield of the lamp tube can be further improved, and an automated continuous production process can be adopted.

[0074] It should be noted that although the above embodiments have been described herein, this does not limit the scope of patent protection for this invention. Therefore, any changes and modifications made to the embodiments described herein based on the innovative concept of this invention, or equivalent structural or procedural transformations made using the description and drawings of this invention, directly or indirectly applying the above technical solutions to other related technical fields, are all included within the scope of protection of this invention.

Claims

1. A reinforced polystyrene lamp tube, characterized in that, The product comprises a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant facilitator, a surface modifier, and a dispersant. The polystyrene substrate comprises 50.5% to 70.5% by mass, the acrylonitrile-styrene copolymer substrate comprises 10% to 30% by mass, the flame retardant comprises 4% to 10% by mass, the flame retardant facilitator comprises 2% to 8% by mass, the surface modifier comprises 0.5% to 2% by mass, and the dispersant comprises 0.4% to 2% by mass. The flame retardant is decabromodiphenyl ether, the flame retardant facilitator is antimony trioxide, the surface modifier is silicon dioxide, and the dispersant is polyethylene wax.

2. The reinforced polystyrene lamp tube as described in claim 1, characterized in that, It also includes a graft compatibilizer, wherein the polystyrene substrate has a mass percentage of 55% to 65%, the acrylonitrile-styrene copolymer substrate has a mass percentage of 15% to 25%, the flame retardant has a mass percentage of 4% to 7%, the flame retardant auxiliary agent has a mass percentage of 2% to 5%, the surface modifier has a mass percentage of 0.7% to 1.5%, the dispersant has a mass percentage of 0.4% to 1.5%, and the graft compatibilizer has a mass percentage of 4% to 10%.

3. The reinforced polystyrene lamp tube as described in claim 2, characterized in that, It also includes a toughening agent, wherein the polystyrene substrate has a mass percentage of 56% to 64%, the acrylonitrile-styrene copolymer substrate has a mass percentage of 16% to 24%, the flame retardant has a mass percentage of 4% to 6%, the flame retardant auxiliary agent has a mass percentage of 2% to 4%, the surface modifier has a mass percentage of 0.7% to 1.3%, the dispersant has a mass percentage of 0.4% to 1%, the graft compatibilizer has a mass percentage of 4% to 8%, and the toughening agent has a mass percentage of 4% to 8%.

4. The reinforced polystyrene lamp tube as described in claim 3, characterized in that, The graft compatibilizer is maleic anhydride, and the toughening agent is MBS toughening agent or SBS toughening agent.

5. A method for manufacturing a reinforced polystyrene lamp tube, characterized in that, include: Multiple raw materials are placed into a mixer to perform a mixing process to mix the multiple raw materials to produce a mixed material. The multiple raw materials include a polystyrene substrate, an acrylonitrile-styrene copolymer substrate, a flame retardant, a flame retardant assisted agent, a surface modifier, and a dispersant. The mass percentage of the polystyrene substrate is 50.5%~70.5%, the mass percentage of the acrylonitrile-styrene copolymer substrate is 10%~30%, the mass percentage of the flame retardant is 4%~10%, the mass percentage of the flame retardant assisted agent is 2%~8%, the mass percentage of the surface modifier is 0.5%~2%, and the mass percentage of the dispersant is 0.4%~2%. The flame retardant is decabromodiphenyl ether, the flame retardant assisted agent is antimony trioxide, the surface modifier is silicon dioxide, and the dispersant is polyethylene wax. The mixture is fed into a screw extruder to perform an extrusion granulation and cutting process to extrude the mixture into linear material and cut the linear material to produce granular material; as well as The granular material is fed into an extruder to perform an extrusion molding process to produce a lamp tube.

6. The method for manufacturing a reinforced polystyrene lamp tube as described in claim 5, characterized in that, The various raw materials also include a graft compatibilizer, wherein the polystyrene substrate has a mass percentage of 55% to 65%, the acrylonitrile-styrene copolymer substrate has a mass percentage of 15% to 25%, the flame retardant has a mass percentage of 4% to 7%, the flame retardant auxiliary agent has a mass percentage of 2% to 5%, the surface modifier has a mass percentage of 0.7% to 1.5%, the dispersant has a mass percentage of 0.4% to 1.5%, and the graft compatibilizer has a mass percentage of 4% to 10%.

7. The method for manufacturing a reinforced polystyrene lamp tube as described in claim 6, characterized in that, The various raw materials also include a toughening agent, wherein the polystyrene substrate has a mass percentage of 56% to 64%, the acrylonitrile-styrene copolymer substrate has a mass percentage of 16% to 24%, the flame retardant has a mass percentage of 4% to 6%, the flame retardant auxiliary agent has a mass percentage of 2% to 4%, the surface modifier has a mass percentage of 0.7% to 1.3%, the dispersant has a mass percentage of 0.4% to 1%, the graft compatibilizer has a mass percentage of 4% to 8%, and the toughening agent has a mass percentage of 4% to 8%.

8. The method for manufacturing a reinforced polystyrene lamp tube as described in claim 7, characterized in that, The graft compatibilizer is maleic anhydride, and the toughening agent is MBS toughening agent or SBS toughening agent.

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