Resin-based composite material, preparation method thereof and application of resin-based composite material in reducing VOC (volatile organic compounds) of automobile

Abstract

The invention provides a resin-based composite material. The resin-based composite material comprises a first surface layer, a foaming layer and a second surface layer, the foaming layer is positioned between the first surface layer and the second surface layer; the first surface layer, the foaming layer and the second surface layer respectively and independently comprise resin and active manganese; and the content of active manganese in the foaming layer is smaller than the content of active manganese in the first surface layer and the second surface layer. Compared with the prior art, the active manganese exists on the surface of the resin-based composite material, the resin-based composite material is used as an automotive trim injection molding part, and the active manganese can make contact with air in an automobile and continuously catalyze and decompose harmful gas such as aldehydes, so that the air quality in the automobile is improved, and human health is guaranteed; meanwhile, the foaming layer is filled with air holes, so that the resin-based composite material has the characteristics of good impact resistance, sound insulation, heat insulation, elasticity, light weight and the like, and the comfort of a user is improved.

Description

Technical Field

[0001] This invention belongs to the field of materials technology, and particularly relates to a resin-based composite material, its preparation method, and its application in reducing VOCs in automobiles. Background Technology

[0002] VOCs, or volatile organic compounds, released from the interior of automobiles are a significant component of the vehicle's internal environment. They primarily originate from adhesives used in car carpets, dashboard plastic parts, headliners, seats, and other trim materials. Volatile components such as organic solvents, additives, and auxiliaries contained in plastic and rubber parts, fabrics, paints, insulation materials, and adhesives used in automobiles are released into the vehicle's interior, causing air pollution. Due to the confined space and limited air volume inside a car, coupled with its well-sealed design, excessive levels of harmful gases in a car can be more harmful to human health than excessive levels of harmful gases indoors. When VOC concentrations in a car exceed safe limits, people may experience symptoms such as headaches, nausea, vomiting, and weakness in the limbs within a short period. In severe cases, it can even lead to convulsions, coma, and memory loss. Long-term exposure to high concentrations of VOCs can also damage the liver, kidneys, brain, and nervous system, and may even increase the risk of cancer. Summary of the Invention

[0003] In view of this, the technical problem to be solved by the present invention is to provide a resin-based composite material that can sustainably and efficiently decompose harmful gases such as aldehydes, its preparation method, and its application in reducing VOCs in automobiles.

[0004] The present invention provides a resin-based composite material, comprising a first surface layer, a foamed layer, and a second surface layer; the foamed layer is located between the first surface layer and the second surface layer; the first surface layer, the foamed layer, and the second surface layer each independently comprise resin and active manganese; and the content of active manganese in the foamed layer is less than the content of active manganese in the first surface layer and the second surface layer.

[0005] Preferably, the thickness of the first surface layer and the second surface layer are each independently 1 / 15 to 1 / 5 of the thickness of the resin-based composite material.

[0006] Preferably, the content of active manganese in the first surface layer is 3-15 wt%.

[0007] And / or, the content of active manganese in the second surface layer is 3 to 15 wt%;

[0008] And / or, the porosity of the foamed layer is 10% to 60%.

[0009] Preferably, the resin is selected from one or more of polypropylene, nylon, acrylonitrile-styrene-butadiene copolymer, polycarbonate, acetal resin and epoxy resin.

[0010] This invention also provides a method for preparing a resin-based composite material, comprising the following steps:

[0011] S1) Mix injection molding particles, active manganese and foaming agent to obtain a mixture; the injection molding particles include resin;

[0012] S2) The mixture is heated and melted, injected into a mold, foamed and molded, and cooled to obtain a resin-based composite material.

[0013] Preferably, the mass ratio of the resin, active manganese, and foaming agent is (20-15):(0.5-2):(0.5-2);

[0014] And / or, the foaming agent is selected from inorganic foaming agents;

[0015] The inorganic foaming agent is selected from one or more of sodium bicarbonate foaming agents, ammonium bicarbonate foaming agents, ammonium chloride foaming agents, and ammonium carbonate foaming agents.

[0016] Preferably, the heating and melting temperature is 150°C to 250°C;

[0017] And / or, the injection rate is 70–150 mm / s;

[0018] And / or, the mold temperature is 20℃~70℃;

[0019] And / or, the holding time for the injection foaming process is 2 to 30 seconds.

[0020] Preferably, the cooling rate is 5–25 °C / s;

[0021] And / or, the cooling time is 10 to 60 seconds.

[0022] The present invention also provides an injection-molded automotive interior part, wherein the injection-molded automotive interior part is the above-mentioned resin-based composite material.

[0023] The present invention also provides an automobile, including the above-described automotive interior injection molded parts.

[0024] This invention provides a resin-based composite material comprising a first surface layer, a foamed layer, and a second surface layer; the foamed layer is located between the first and second surface layers; each of the first, foamed, and second surface layers independently comprises resin and active manganese; and the content of active manganese in the foamed layer is less than the content of active manganese in the first and second surface layers. Compared with the prior art, the resin-based composite material provided by this invention allows active manganese to exist on the surface of the resin-based composite material. When used as an injection-molded part for automotive interiors, the active manganese can come into contact with the air inside the vehicle and continuously catalyze the decomposition of harmful gases such as aldehydes, improving the air quality inside the vehicle and ensuring human health; at the same time, the foamed layer is filled with pores, giving the resin-based composite material excellent impact resistance, sound insulation, heat insulation, elasticity, and lightweight properties, improving user comfort. Attached Figure Description

[0025] Figure 1 This is a schematic diagram illustrating the principle of formaldehyde removal by active manganese in the resin-based composite material provided by the present invention.

[0026] Figure 2 This is a schematic diagram of the preparation process of the resin-based composite material provided by the present invention;

[0027] Figure 3 This is a cross-sectional view of the automotive interior injection molded part obtained in Example 1. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0029] The present invention provides a resin-based composite material, comprising a first surface layer, a foamed layer, and a second surface layer; the foamed layer is located between the first surface layer and the second surface layer; the first surface layer, the foamed layer, and the second surface layer each independently comprise resin and active manganese; and the content of active manganese in the foamed layer is less than the content of active manganese in the first surface layer and the second surface layer.

[0030] In a specific embodiment of the present invention, the thickness of the first surface layer is preferably 1 / 12 to 1 / 5 of the thickness of the resin-based composite material, more preferably 1 / 10 to 1 / 5, and even more preferably 1 / 8 to 1 / 6.

[0031] In one specific embodiment of the present invention, the content of active manganese in the first surface layer is preferably 3 to 15 wt%.

[0032] In one specific embodiment of the present invention, the thickness of the second surface layer is preferably 1 / 12 to 1 / 5 of the thickness of the resin-based composite material, more preferably 1 / 10 to 1 / 5, and even more preferably 1 / 8 to 1 / 6.

[0033] In one specific embodiment of the present invention, the content of active manganese in the second surface layer is preferably 3 to 15 wt%.

[0034] A foamed layer is provided between the first surface layer and the second surface layer; in a specific embodiment of the present invention, the porosity of the foamed layer is preferably 20% to 60%; the pore size of the foamed layer is preferably 50 to 200 μm.

[0035] In one specific embodiment of the present invention, the pore size distribution of the foamed layer is not uniform. Specifically, in the thickness direction, the pore size of the foamed layer located at the center of the thickness of the resin-based composite material is larger than the pore size near the first and second surface layers. That is, the pore size of the foamed layer gradually decreases from the center of the thickness to the two surface layers.

[0036] In one specific embodiment of the present invention, the resin is preferably one or more selected from polypropylene, nylon, acrylonitrile-styrene-butadiene copolymer, polycarbonate, acetal resin and epoxy resin.

[0037] This invention incorporates active manganese on the surface of a resin-based composite material, making it suitable for use as an injection-molded part in automotive interiors. The active manganese comes into contact with the air inside the vehicle and continuously catalyzes the decomposition of harmful gases such as aldehydes, improving air quality and protecting human health. See also... Figure 1 , Figure 1 This is a diagram illustrating the principle of formaldehyde removal using activated manganese.

[0038] The present invention also provides a method for preparing a resin-based composite material, comprising the following steps: S1) mixing injection molding particles, active manganese and a foaming agent to obtain a mixture; wherein the injection molding particles include resin; S2) heating and melting the mixture, injecting it into a mold for injection molding and foaming, and cooling to obtain a resin-based composite material.

[0039] See Figure 2 , Figure 2 This is a schematic diagram of the preparation process of resin-based composite materials.

[0040] In this invention, there are no special restrictions on the source of any raw materials; they can be commercially available.

[0041] According to the present invention, the injection molding particles include resin; the resin is preferably one or more of polypropylene, nylon, acrylonitrile-styrene-butadiene copolymer, polycarbonate, acetal resin and epoxy resin; in the present invention, PPEPDM T20 is specifically used as an example, and Runjia 4050CT10 or Kingfa AIP-2016 are further specifically used as examples.

[0042] According to the present invention, the injection-molded particles preferably further include one or more of additives, fillers, and catalysts; the additives are any additives known to those skilled in the art that can improve the performance of the injection-molded particles, and there are no special limitations. In the present invention, one or more of stabilizers, lubricants, colorants, and flame retardants are preferred; the mass of the additives is preferably 0.1% to 1% of the mass of the injection-molded particles; the fillers can be used to enhance the strength, hardness, or reduce the cost of the material, and can be glass fiber, talc, etc.; the mass of the fillers is preferably 0.1% to 1% of the mass of the injection-molded particles; the catalyst can be used to promote polymerization reactions or other chemical reactions; the mass of the catalyst is preferably 0.1% to 1% of the mass of the injection-molded particles.

[0043] According to the present invention, the particle size of the injection molding particles is preferably 0.5-5 mm, more preferably 1-4 mm, and even more preferably 2-3 mm.

[0044] According to the present invention, the particle size of the active manganese, i.e., manganese dioxide, is preferably in the micrometer range, more preferably 50 to 100 micrometers, even more preferably 50 to 80 micrometers, and most preferably 60 to 70 micrometers.

[0045] According to the present invention, the foaming agent is preferably an organic foaming agent and / or an inorganic foaming agent; the organic foaming agent is preferably one or more of azo compounds, sulfonyl hydrazides, and nitroso compounds; the azo compound is preferably one or more of azobisisobutyronitrile, diisopropyl azodicarbonate, diethyl azodicarbonate, and azoaminobenzene; the sulfonyl hydrazide is preferably N,N-dimethyl-N,N-dinitrosoterephthalamide; the nitroso compound is preferably one or more of benzenesulfonyl hydrazide, p-toluenesulfonyl hydrazide, and 4,4-bisbenzenesulfonyl hydrazide oxide; the inorganic foaming agent is preferably one or more of sodium bicarbonate foaming agents, ammonium bicarbonate foaming agents, ammonium chloride foaming agents, and ammonium carbonate foaming agents.

[0046] In one specific embodiment of the present invention, the foaming agent is an inorganic foaming agent.

[0047] In one specific embodiment of the present invention, the foaming agent is a sodium bicarbonate foaming agent; in the embodiments provided by the present invention, Yonghe Chemical Industry Co., Ltd. EE25C is specifically used as an example for illustration.

[0048] In a specific embodiment of the present invention, the mass ratio of the resin, active manganese and foaming agent is preferably (20-15):(0.5-2):(0.5-2), more preferably (20-16):(0.8-1.5):(0.8-1.5), and even more preferably 18:1:1.

[0049] The injection molding particles, active manganese and foaming agent are mixed to obtain a mixture; the mixing method can be any method known to those skilled in the art and there are no special restrictions. In this invention, mechanical stirring is preferred; the speed of mechanical stirring is preferably 100 to 500 rpm; the mixing time is preferably 5 to 30 minutes.

[0050] The mixture is heated and melted, injected into a mold, and foamed through injection molding. After cooling, a resin-based composite material is obtained. The heating and melting temperature is preferably 150℃~250℃, more preferably 150℃~220℃. The injection rate is preferably 70~150mm / s. And / or, the mold temperature is preferably 20℃~70℃. The injection molding pressure, i.e., the injection pressure, is related to the final size of the composite material. In the embodiments provided by this invention, 20~60MPa is used as an example. The holding time for injection molding is 2~30s. The cooling rate is preferably 5~25℃ / s. The cooling time is preferably 10~60s, more preferably 10~50s, and even more preferably 20~30s.

[0051] This invention utilizes a combination of activated manganese material and chemical foaming to bring the activated manganese closer to the surface of the parts, thereby improving the efficiency of the activated manganese's activation function and achieving the effect of continuously reducing the concentration of volatile aldehydes in the vehicle and improving the air quality inside the vehicle. At the same time, the foam layer is filled with pores, giving the resin-based composite material excellent impact resistance, sound insulation, heat insulation, elasticity, and lightweight properties, thus improving user comfort.

[0052] The present invention also provides an injection-molded automotive interior part, wherein the injection-molded automotive interior part is the above-mentioned resin-based composite material.

[0053] The present invention also provides an automobile, including the above-described automotive interior injection molded parts.

[0054] To further illustrate the present invention, the following describes in detail, with reference to embodiments, a resin-based composite material provided by the present invention, its preparation method, and its application in reducing automotive VOCs.

[0055] All reagents used in the following examples are commercially available; the foaming agent used in the examples is EE25C from Yonghe Chemical Industry Co., Ltd.

[0056] Examples and Comparative Examples

[0057] According to the formula in Table 1, the injection molding particles, active manganese powder and foaming agent are mixed at 300 rpm for 10 minutes to obtain the mixture.

[0058] The mixture is heated to 180°C to melt, the molds are combined, and then the molten material is injected at a rate of 100 mm / s. The mold temperature is 60°C, the holding pressure is 40 MPa, and the foaming process is carried out for 40 seconds. After cooling for 20 seconds, the mold is opened to obtain the injection molded automotive interior parts.

[0059] Table 1 Formulation and preparation conditions for injection-molded automotive interior parts

[0060]

[0061] Figure 3 This is a cross-sectional view of the automotive interior injection molded part obtained in Example 1.

[0062] The performance of the automotive interior injection molded parts obtained in the examples and comparative examples was tested, and the results are shown in Table 2.

[0063] Table 2 Performance test results of automotive interior injection molded parts

[0064] Example 1 Comparative Example 1 <![CDATA[Density (g / cm 3 )]]> 0.78 0.76 <![CDATA[Formaldehyde (μg / m 3 )]]> 8.23 19.85 <![CDATA[Acetaldehyde (μg / m 3 )]]> 82.89 177.36 acrolein ND ND

[0065] The table lists the experimental equipment as follows: 60L release chamber, UV spectrophotometer, ATD-GC / MS; experimental conditions: temperature 25℃, 60℃; relative humidity 40%~60%.

[0066] Experimental method: The injection-molded automotive parts were placed in a 60L release chamber and sealed for 24 hours under test conditions. The gas inside the chamber was then collected to test the concentration of pollutants inside the chamber.

[0067] As shown in Table 1, the injection molded parts with added active manganese powder in Example 1 can significantly reduce the release of volatile organic compounds from the injection molded parts.

[0068] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A resin-based composite material, characterized in that, It includes a first surface layer, a foamed layer, and a second surface layer; the foamed layer is located between the first surface layer and the second surface layer; the first surface layer, the foamed layer, and the second surface layer each independently include resin and active manganese; and the content of active manganese in the foamed layer is less than the content of active manganese in the first surface layer and the second surface layer.

2. The resin-based composite material according to claim 1, characterized in that, The thickness of the first surface layer and the second surface layer are each independently 1 / 15 to 1 / 5 of the thickness of the resin-based composite material.

3. The resin-based composite material according to claim 1, characterized in that, The content of active manganese in the first surface layer is 3-15 wt%; And / or, the content of active manganese in the second surface layer is 3 to 15 wt%; And / or, the porosity of the foamed layer is 10% to 60%.

4. The resin-based composite material according to claim 1, characterized in that, The resin is selected from one or more of polypropylene, nylon, acrylonitrile-styrene-butadiene copolymer, polycarbonate, acetal resin and epoxy resin.

5. A method for preparing a resin-based composite material, characterized in that, Includes the following steps: S1) Mix injection molding particles, active manganese and foaming agent to obtain a mixture; the injection molding particles include resin; S2) The mixture is heated and melted, injected into a mold, foamed and molded, and cooled to obtain a resin-based composite material.

6. The preparation method according to claim 5, characterized in that, The mass ratio of the resin, active manganese, and foaming agent is (20-15):(0.5-2):(0.5-2); And / or, the foaming agent is selected from inorganic foaming agents; The inorganic foaming agent is selected from one or more of sodium bicarbonate foaming agents, ammonium bicarbonate foaming agents, ammonium chloride foaming agents, and ammonium carbonate foaming agents.

7. The preparation method according to claim 5, characterized in that, The heating and melting temperature is 150℃~250℃; And / or, the injection rate is 70–150 mm / s; And / or, the mold temperature is 20℃~70℃; And / or, the holding time for the injection foaming process is 2 to 30 seconds.

8. The preparation method according to claim 5, characterized in that, The cooling rate is 5–25 °C / s; And / or, the cooling time is 10 to 60 seconds.

9. A type of injection-molded automotive interior part, characterized in that, The automotive interior injection molded parts are resin-based composite materials as described in any one of claims 1 to 4 or resin-based composite materials prepared by any one of the preparation methods of claims 5 to 8.

10. A car, characterized in that, Including the automotive interior injection molded parts as described in claim 9.

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