Polymer calcium crystal decorative plate and preparation method thereof

Abstract

The invention discloses a high-molecular calcium crystal decorative plate and a preparation method thereof, and the preparation method comprises the following steps: taking superfine calcite as a base material; polypropylene resin and auxiliaries are added; wherein the mass ratio of the calcite to the polypropylene resin to the auxiliary agent is (67%-84%): (15%-30%): (1%-3%); the materials are subjected to high-temperature banburying and modification treatment to be prepared into master batches; extruding the master batch into three layers of calcium-based plates with different densities and different thicknesses through three-layer co-extrusion equipment; the upper and lower layers of plates are both double-sided high-strength wiredrawing calcium plastic plates, and the middle plate is a honeycomb calcium plate; and calendering and slip-forming to prepare the high-molecular calcium crystal decorative plate. The invention further provides the macromolecular calcium crystal decorative plate which is prepared by adopting the preparation method. Through an innovative formula and process, the macromolecular calcium crystal decorative plate based on superfine calcite is designed, and the characteristics of light weight, high strength, environmental protection and the like are realized by combining a three-layer co-extrusion structure and honeycomb design.

Description

Technical Field

[0001] This application belongs to the field of decorative panel technology, specifically relating to a polymer calcium crystal decorative panel and its preparation method. Background Technology

[0002] Currently, the decorative panel market, constrained by traditional materials and technological approaches, has long been plagued by several core pain points. Firstly, in terms of weight, widely used natural stone, solid wood panels, and even some cement fiberboards generally suffer from excessive weight. This not only significantly increases the structural load on buildings but also brings considerable difficulties and cost increases to transportation, handling, and high-rise construction. Especially in the field of modern rapid installation, it has become one of the key bottlenecks restricting efficiency.

[0003] Secondly, in terms of performance, many boards are prone to warping and deformation due to uneven internal stress or limitations in production processes, making it difficult to meet the stringent flatness requirements of high-end decoration. This defect not only affects the aesthetics of the final finish but also leads to material waste and uneven joints during subsequent processing and installation, lowering the overall construction quality and efficiency.

[0004] Finally, and most importantly for the market today, is the environmental issue. Some engineered wood products use formaldehyde-containing adhesives during production, leading to the continuous release of harmful substances such as formaldehyde and VOCs, posing a long-term threat to indoor air quality. With increasingly stringent global environmental regulations and growing consumer awareness of health, the market demand for non-toxic, harmless, low-carbon, and environmentally friendly "green boards" is becoming increasingly urgent, highlighting the environmental shortcomings of traditional materials. These pain points collectively constitute the urgent need for industry upgrading and provide a clear direction for innovation in new materials. Summary of the Invention

[0005] In view of the shortcomings or deficiencies of the prior art, the technical problem to be solved by this application is a polymer calcium crystal decorative board and its preparation method. This application designs a polymer calcium crystal decorative board based on ultrafine calcite through innovative formula and process, and combines a three-layer co-extrusion structure and honeycomb design to achieve lightweight, high strength and environmental protection characteristics.

[0006] To solve the above-mentioned technical problems, this application provides the following technical solution: This application proposes a method for preparing a polymer calcium crystal decorative panel, including: The base material is ultrafine calcite with a mesh size of 2600 to 3000. Add polypropylene resin and additives; The mass ratio of the calcite, the polypropylene resin, and the additives is (67%-84%):(15%-30%):(1%-3%). The above materials are subjected to high-temperature intensive mixing, modification treatment and made into masterbatch; The masterbatch is extruded into three layers of calcium-based boards with different densities and thicknesses through a three-layer co-extrusion extrusion equipment; the top and bottom layers are double-sided high-strength drawn calcium-plastic boards, and the middle layer is a honeycomb calcium board; Calendering and slip molding are used to prepare high-molecular calcium crystal decorative panels.

[0007] Further optionally, the additives include heat stabilizers, plasticizers, lubricants, coupling agents and colorants, and the mass ratios of their addition are (0.2%-0.5%): (0.3%-0.8%): (0.2%-0.5%): (0.2%-0.5%): (0.1%-0.7%).

[0008] Further optionally, the heat stabilizer includes: an environmentally friendly calcium-zinc stabilizer or an organotin stabilizer, with an applicable temperature range of 180-220°C.

[0009] Further optionally, the plasticizer includes: non-toxic dioctyl phthalate (DOP) or epoxidized soybean oil-based environmentally friendly plasticizers.

[0010] Alternatively, the lubricant may be stearic acid or polyethylene wax.

[0011] Further optionally, the coupling agent is a silane coupling agent (such as KH-550) or a titanate coupling agent.

[0012] Alternatively, the colorant may be titanium dioxide or an iron oxide-based pigment.

[0013] Further optionally, the polypropylene resin is added at a ratio of 15%-20% for the intermediate layer and at a ratio of 25%-30% for the upper and lower layers.

[0014] Alternatively, a "Boeing" film may be attached to the front of the polymer calcium crystal decorative panel by hot pressing or adhesive bonding.

[0015] Alternatively, during the application of the "Boeing" film, the temperature is 100-150°C and the pressure is 0.5-1 MPa; then air-cooled or water-cooled tunnel curing is used, and finally it is automatically cut to standard size.

[0016] Further optionally, the above-mentioned calendering and slipforming process includes: the calendered sheet immediately enters a three-roll calender, wherein the roll temperature is 80-120°C and the pressure is 5-10 MPa; the variable thickness of 10-30 mm is achieved by adjusting the roll gap; and then the cooling roll and traction machine are used simultaneously to keep the sheet dimensionally stable and the surface smoother during the curing process.

[0017] Further optionally, the above-mentioned three-layer co-extrusion includes: a temperature of 160-200°C, a pressure of 10-20 MPa, and a speed of 1-5 m / min.

[0018] This application also proposes a polymer calcium crystal decorative panel, which is prepared using the aforementioned preparation method.

[0019] Compared with the prior art, this application has the following technical effects: This application designs a polymer calcium crystal decorative board based on ultrafine calcite through innovative formula and process, combining a three-layer co-extrusion structure and honeycomb design to achieve lightweight, high strength and environmentally friendly properties.

[0020] This application features an innovative formulation: it combines ultrafine calcite (2600-3000 mesh) with polypropylene resin and modifies it with additives to form a high-performance masterbatch, which significantly improves the mechanical properties and processability of the board.

[0021] This application features a structural innovation: a composite structure consisting of a central honeycomb calcium board and double-sided high-strength brushed calcium plastic board is manufactured through a three-layer co-extrusion process, optimizing the weight-to-strength ratio.

[0022] This application features innovative processes: integrating high-temperature mixing, modification, three-layer co-extrusion, calendering, and slipforming processes to ensure high flatness and variable thickness of the sheet material, and applying "Boeing" PVC film decoration to the front to enhance aesthetics and durability. Detailed Implementation

[0023] The technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0024] In one embodiment of this application, a method for preparing a polymeric calcium crystal decorative panel includes: The base material is ultrafine calcite with a mesh size of 2600 to 3000. In this embodiment, ultrafine calcite is used as the main filler. It has a high specific surface area, which can enhance the interfacial bonding with the resin, improve the rigidity and strength of the composite material, avoid agglomeration, and ensure that the surface of the board is smooth and flat. Using ultrafine calcite as a filler can reduce the amount of resin used while maintaining environmental friendliness. Polypropylene resin and additives are added to modify the calcite. Specifically, ultrafine calcite is subjected to dry surface treatment with a coupling agent (such as a silane coupling agent) in a high-speed mixer at a temperature of 80-100°C for 10-15 minutes to form an activated filler and improve its compatibility with the polypropylene resin. The polypropylene resin is treated by removing moisture in a dryer to avoid the generation of air bubbles during processing. The mass ratio of the calcite, the polypropylene resin, and the additives is (67%-84%):(15%-30%):(1%-3%). The above materials are subjected to high-temperature intensive mixing, modification treatment and made into masterbatch; The masterbatch is extruded into three layers of calcium-based boards with different densities and thicknesses through a three-layer co-extrusion extrusion equipment; the top and bottom layers are double-sided high-strength drawn calcium-plastic boards, and the middle layer is a honeycomb calcium board; Calendering and slip molding are used to prepare high-molecular calcium crystal decorative panels.

[0025] This embodiment uses a polymer calcium crystal decorative board based on ultrafine calcite, combined with a three-layer co-extrusion structure and honeycomb design, to achieve lightweight, high strength and environmental protection characteristics.

[0026] More preferably, this embodiment can adjust the toughness and hardness of the board. Specifically, the polypropylene resin is added at a ratio of 15%-20% for the intermediate layer, which is used for the intermediate honeycomb layer, emphasizing lightweight and compressive strength; the polypropylene resin is added at a ratio of 25%-30% for the upper and lower layers, which is used for the surface layer, emphasizing wear resistance and hardness.

[0027] More preferably, the polypropylene resin is a homopolymer of polypropylene (such as PP-H) with a high melting point (approximately 160-170°C), chemical resistance, and good processing fluidity. The polypropylene resin provides the sheet with toughness, impact resistance, and weather resistance.

[0028] In this application, the additives are used to improve processability and final performance, and the components are formulated in the required proportions: Heat stabilizer (0.2%-0.5%): Prevents polypropylene degradation during high-temperature processing. Environmentally friendly calcium-zinc stabilizers or organotin stabilizers are preferred. Applicable temperature range: 180-220°C.

[0029] Plasticizer (0.3%-0.8%): Increases the flexibility of the board and reduces brittleness. It is preferred to use non-toxic dioctyl phthalate (DOP) or epoxidized soybean oil-based environmentally friendly plasticizers.

[0030] Lubricant (0.2%-0.5%): Improves processing fluidity and reduces equipment wear; stearic acid or polyethylene wax is preferred.

[0031] Coupling agent (0.2%-0.5%): A key modifier used to enhance the interfacial bond between calcite and polypropylene. Preferably, a silane coupling agent (such as KH-550) or a titanate coupling agent is used, and surface treatment improves filler dispersibility and composite strength.

[0032] Colorant (0.1%-0.7%): Provides color options such as titanium dioxide (white) or iron oxide pigments to ensure uniform color.

[0033] In one embodiment, the formulation is optimized using response surface methodology or design of experiments (DOE) to ensure optimal performance: for example, the flexural strength and abrasion resistance of the sheet reach peak values ​​when the calcite content is 75%, the polypropylene content is 20%, and the additives content is 3%. The calcite and polypropylene used in this application are both recyclable materials, and the additives are non-toxic and comply with RoHS and REACH standards.

[0034] The "Boeing" film is attached to the front of the polymer calcium crystal decorative panel by hot pressing or adhesive bonding.

[0035] The above-mentioned high-temperature mixing and masterbatch preparation process further includes: high-temperature mixing using a mixer or a twin-screw extruder. Specifically, the preferred process parameters are: Temperature: 180-220°C, segmented control (feeding zone 180°C, mixing zone 200°C, discharge zone 220°C).

[0036] Time: 5-10 minutes, to ensure complete melting and uniform dispersion.

[0037] Rotation speed: 30-50 rpm, avoid over-shearing.

[0038] Output: The intensively mixed material is cut into masterbatches (2-4 mm in diameter) by a granulator for subsequent extrusion. The masterbatches prepared by the above process have uniform composition and flowability.

[0039] In the aforementioned three-layer co-extrusion process, a dedicated three-layer co-extrusion extruder is preferably used, equipped with three independent extrusion units and a composite die.

[0040] Specifically, a layered design is preferred: The upper and lower layers (each approximately 1-3 mm thick) consist of high-strength brushed calcium carbonate board. High-density masterbatch (70% calcite, 25% polypropylene, 5% additives) is extruded through extruders A and C, and the surface is brushed (e.g., using textured rollers) to form a dense, wear-resistant, and scratch-resistant layer.

[0041] Intermediate layer (thickness 8-24mm): Honeycomb calcium board. Extruded using low-density masterbatch (80% calcite, 15% polypropylene, 5% additives) via extruder B. A foaming agent (e.g., azodicarbonamide, 0.1-0.3%) is introduced into the mold or a honeycomb structure (e.g., hexagonal pores, 2-5mm diameter, 0.5-1mm wall thickness) is formed through a special flow channel design to achieve lightweight and compressive strength.

[0042] The extrusion parameters involved are preferably as follows: Temperature: 160-200°C, adjusted by layer (higher for surface layer, lower for intermediate layer).

[0043] Pressure: 10-20 MPa, to ensure interlayer bonding.

[0044] Speed: 1-5 m / min, adjusted according to thickness.

[0045] The above-mentioned calendering and slipforming process includes: the extruded sheet material immediately enters a three-roll calender, wherein the roll temperature is 80-120°C and the pressure is 5-10 MPa; the variable thickness of 10-30 mm is achieved by adjusting the roll gap; and then the cooling roll and traction machine are used simultaneously to keep the sheet material dimensionally stable and the surface smoother during the curing process.

[0046] Furthermore, during the application of the "Boeing" film, this embodiment can provide patterns such as wood grain and stone grain, and enhance stain resistance and weather resistance. Preferably, the temperature is 100-150°C and the pressure is 0.5-1 MPa; then air-cooled or water-cooled tunnel curing is used, and finally it is automatically cut to standard size (e.g., 1220mm*2440mm).

[0047] This application also proposes a polymeric calcium crystal decorative panel, prepared using the method described above. The specific preparation method is described above and will not be repeated here.

[0048] The polymeric calcium crystal decorative panel prepared in this application has the following characteristics: 1) Light: Density 0.8-1.2 g / cm³ 3 It is more than 50% lighter than traditional stone slabs, thanks to its honeycomb structure; 2) Hard: The surface hardness can reach Shore D70-80, which comes from the high-density calcium plastic layer; 3) Environmentally friendly: formaldehyde-free, recyclable, and rich in calcite resources; 4) High flatness: The calendering and slip die processes ensure a flatness error of <0.1mm / m; 5) Wear resistance: Wear resistance ≥ 1000 revolutions (Taber test); 6) Compressive strength: ≥15 MPa, with honeycomb structure dispersing stress; 7) Corrosion resistance: Resistant to acids and alkalis (pH 3-11); 8) Variable thickness: 10-30mm, suitable for different applications (such as furniture, architectural decoration); 9) Stable dimensions: 1220mm x 2440mm, conforming to standard board specifications.

[0049] The above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. The preferred embodiments have been described in detail. Those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this application without departing from the spirit and scope of the technical solutions of this application, and all such modifications and substitutions should be covered within the scope of the claims of this application.

Claims

1. A method for preparing a polymer calcium crystal decorative panel, characterized in that, include: The base material is ultrafine calcite with a mesh size of 2600 to 3000. Add polypropylene resin and additives; The mass ratio of the calcite, the polypropylene resin, and the additives is (67%-84%):(15%-30%):(1%-3%). The above materials are subjected to high-temperature intensive mixing, modification treatment and made into masterbatch; The masterbatch is extruded into three layers of calcium-based boards with different densities and thicknesses through a three-layer co-extrusion extrusion equipment; the top and bottom layers are double-sided high-strength drawn calcium-plastic boards, and the middle layer is a honeycomb calcium board; Calendering and slip molding are used to prepare high-molecular calcium crystal decorative panels.

2. The method for preparing the polymer calcium crystal decorative panel according to claim 1, characterized in that, The additives include heat stabilizers, plasticizers, lubricants, coupling agents, and colorants, and their mass ratios are (0.2%-0.5%): (0.3%-0.8%): (0.2%-0.5%): (0.2%-0.5%): (0.1%-0.7%).

3. The method for preparing the polymer calcium crystal decorative panel according to claim 2, characterized in that, The heat stabilizer includes: environmentally friendly calcium-zinc stabilizer or organotin stabilizer, with an applicable temperature range of 180-220°C.

4. The method for preparing the polymer calcium crystal decorative panel according to claim 2, characterized in that, The plasticizers include: non-toxic dioctyl phthalate (DOP) or environmentally friendly plasticizers based on epoxidized soybean oil.

5. The method for preparing the polymer calcium crystal decorative panel according to claim 2, characterized in that, The lubricant used is stearic acid or polyethylene wax.

6. The method for preparing the polymer calcium crystal decorative panel according to claim 2, characterized in that, The coupling agent used is a silane coupling agent (such as KH-550) or a titanate coupling agent.

7. The method for preparing the polymer calcium crystal decorative panel according to claim 2, characterized in that, The colorant used is titanium dioxide or iron oxide pigment.

8. A method for preparing a polymeric calcium crystal decorative panel according to any one of claims 1 to 7, characterized in that, The polypropylene resin is added at a rate of 15%-20% for the intermediate layer and at a rate of 25%-30% for the upper and lower layers.

9. The method for preparing a polymeric calcium crystal decorative panel according to any one of claims 1 to 7, characterized in that, The "Boeing" film is attached to the front of the polymer calcium crystal decorative panel by hot pressing or adhesive bonding.

10. The method for preparing the polymer calcium crystal decorative panel according to claim 8, characterized in that, During the application of the "Boeing" film, the temperature is 100-150°C and the pressure is 0.5-1 MPa; then air-cooled or water-cooled tunnel curing is used, and finally it is automatically cut to standard size.

11. The method for preparing a polymeric calcium crystal decorative panel according to any one of claims 1 to 7, characterized in that, The above-mentioned calendering and slipforming process includes: the extruded sheet material immediately enters a three-roll calender, wherein the roll temperature is 80-120°C and the pressure is 5-10 MPa; the variable thickness of 10-30 mm is achieved by adjusting the roll gap; and then the cooling roll and traction machine are used simultaneously to keep the sheet material dimensionally stable during the curing process.

12. The method for preparing a polymeric calcium crystal decorative panel according to any one of claims 1 to 7, characterized in that, The three-layer co-extrusion process described above includes a temperature of 160-200°C, a pressure of 10-20 MPa, and a speed of 1-5 m / min.

13. A polymer calcium crystal decorative board, characterized in that, It is prepared by the preparation method according to any one of claims 1 to 12.