Composite film material, urea-formaldehyde product and method for producing the same, toilet bowl

Abstract

The application relates to a composite film material, a urea-formaldehyde product and a preparation method thereof, and a toilet bowl. The composite film material comprises a modified film material, the modified film material comprises a reinforcing cloth and a PVB matrix coated on the surface of the reinforcing cloth and filled in the reinforcing cloth, the total thickness of the modified film material is 0.1mm-2mm, the modified film material is provided with a plurality of through holes arranged in the thickness direction, and the diameter of each through hole is 1mm-5mm; the grammage of the reinforcing cloth is 10g / m 2 ~120g / m 2 ; the material for preparing the PVB matrix comprises PVB 85-92 parts and a plasticizer 8-15 parts in mass fraction, the total mass fraction of the PVB and the plasticizer is 100 parts, and the viscosity of a 10% PVB ethanol solution at 20 DEG C is 30s-120s. The composite film material has high hardness and high impact resistance, is applied in the urea-formaldehyde product, and is favorable for improving the impact resistance of the urea-formaldehyde product.

Description

Technical Field

[0001] This application relates to the field of materials, particularly to composite membrane materials, urea-formaldehyde products and their preparation methods, and toilets. Background Technology

[0002] Currently, the main materials used for toilet seat covers include polypropylene (PP), acrylonitrile-butadiene-styrene copolymer (ABS), and urea-formaldehyde resin. PP and ABS are low-cost, but their surfaces are easily scratched and lack a ceramic-like texture. Urea-formaldehyde resin has a certain ceramic-like texture and is scratch-resistant with high surface hardness; however, it is brittle and not impact-resistant, and in actual use, it is at risk of cracking or breaking under significant external impact. Summary of the Invention

[0003] Based on this, this application provides a composite membrane material and its preparation method, which has high hardness and high impact resistance. When applied to urea-formaldehyde products, it is beneficial to improve the impact resistance of urea-formaldehyde products.

[0004] In addition, other aspects of this application also provide a urea-formaldehyde product and a method for preparing the same, as well as a toilet.

[0005] A composite membrane material includes: a modified membrane material, the modified membrane material comprising a reinforcing fabric and a PVB matrix covering the surface of the reinforcing fabric and filling the interior therein, the total thickness of the modified membrane material being 0.1mm to 2mm, and the modified membrane material having a plurality of through holes arranged along the thickness direction, each through hole having a diameter of 1mm to 5mm;

[0006] The reinforcing fabric has a basis weight of 10 g / m². 2 ~120g / m 2 The materials used to prepare the PVB matrix, by mass percentage, include 85 to 92 parts of PVB and 8 to 15 parts of plasticizer, with a total mass percentage of 100 parts of PVB and plasticizer. The viscosity of the ethanol solution of the PVB with a mass percentage concentration of 10% is 30 s to 120 s at 20°C.

[0007] Optionally, at 20°C, the viscosity of the 10% (w / w) ethanol solution of the PVB is 50 s to 100 s; and / or,

[0008] The plasticizer includes one or more of carboxylic acid ester plasticizers and phosphate ester plasticizers, wherein the carboxylic acid ester plasticizer includes one or more of polyol carboxylic acid ester plasticizers, aliphatic dicarboxylic acid ester plasticizers, phthalate plasticizers and citrate plasticizers.

[0009] Optionally, the polyol carboxylic acid ester plasticizer includes one or more of triethylene glycol diisooctanoate, triethylene glycol diheptanoate, tetraethylene glycol diisooctanoate, and di(butyl diethylene glycol) adipate; the aliphatic dicarboxylic acid ester plasticizer includes one or more of dibutyl sebacate, dioctyl sebacate, and dioctyl adipate; the phthalate plasticizer includes one or more of dioctyl phthalate, diisooctyl phthalate, and dibutyl phthalate; the citrate plasticizer includes triethyl citrate; and the phosphate plasticizer includes tricresyl phosphate.

[0010] Optionally, the plasticizer includes a polyol carboxylic acid ester plasticizer, and the polyol carboxylic acid ester plasticizer accounts for more than 80% by mass in the plasticizer.

[0011] Optionally, one or more of the following conditions must be met:

[0012] (1) The materials used to prepare the PVB matrix, by weight, further include: 0.8 to 1.5 parts of antioxidant, optionally, the antioxidant includes one or more of hindered phenolic antioxidants and phosphite antioxidants;

[0013] (2) The materials used to prepare the PVB matrix, by mass, further include: 0.3 to 0.8 parts of coupling agent; optionally, the coupling agent includes one or more of silane coupling agents and titanate coupling agents; optionally, the coupling agent includes one or more of aminosilane coupling agents and amino titanate coupling agents; optionally, the coupling agent includes one or more of γ-aminopropyltriethoxysilane, γ-aminopropyltriethoxysilane, N-β-(aminoethyl)-γ-aminopropyltrimethoxysilane, N-β-(aminoethyl)-γ-aminopropylmethyldimethoxysilane, γ-(poly(ethyleneamino)propyltrimethoxysilane), N-phenyl-γ-aminopropyltrimethoxysilane, and di(dimethoxyethoxy)titanate di(dilauryl)phosphite oxyethyl ester.

[0014] (3) By mass, the material used to prepare the PVB matrix further includes 2 to 5 parts of filler. Optionally, the filler includes one or more of talc, natural mica, synthetic mica, glass flakes, boron nitride, kaolin, graphite, molybdenum disulfide, titanium dioxide, barium sulfate, and calcium carbonate.

[0015] (4) The material used to prepare the PVB matrix further includes 5 to 10 parts of impact modifier by mass. Optionally, the impact modifier includes one or more of the following: methyl methacrylate-butadiene-styrene core-shell copolymer, styrene-butadiene / ethylene-butene-styrene block copolymer, chlorinated polyethylene, acrylate rubber, acrylate core-shell impact modifier, acrylonitrile-styrene-acrylate copolymer, thermoplastic polyurethane, and thermoplastic polyolefin. Optionally, the impact modifier includes one or two of the following: methyl methacrylate-butadiene-styrene core-shell copolymer and acrylate core-shell impact modifier.

[0016] Optionally, the reinforcing fabric satisfies one or more of the following conditions:

[0017] (1) The material used to prepare the reinforcing fabric includes one or more of inorganic non-metallic fibers, metal fibers and organic fibers; wherein the inorganic non-metallic fibers include glass fibers, basalt fibers, carbon fibers and ceramic fibers; and / or, the metal fibers include one or more of stainless steel fibers, iron fibers, silver fibers, aluminum fibers, tungsten fibers and molybdenum fibers; and / or, the organic fibers include one or more of poly(p-phenylenebenzodioxazole) fibers, polyamide fibers, polyethylene terephthalate fibers, polyacrylonitrile fibers, polyvinyl alcohol fibers, polypropylene fibers, polyethylene fibers, vinylon fibers, aramid fibers, pulp fibers, bamboo fibers and cotton fibers;

[0018] (2) The basis weight of the reinforcing fabric is 30 g / m². 2 ~100g / m 2 ;

[0019] (3) The reinforcing fabric is one of non-woven fabric, woven fabric or mesh fabric;

[0020] (4) The total thickness of the modified membrane material is 0.2mm~1.2mm.

[0021] Optionally, the material used to prepare the composite membrane further includes urea-formaldehyde powder, which is embedded in two surfaces of the modified membrane that are disposed opposite to each other along the thickness direction.

[0022] Optionally, the amount of urea-formaldehyde powder used in the composite membrane material is 20 g / m². 2 ~50g / m 2 .

[0023] Optionally, the total thickness of the composite membrane is 0.2mm to 2.1mm, or alternatively, the total thickness of the composite membrane is 0.25mm to 1.25mm.

[0024] Optionally, the distance between two adjacent through holes is 1 to 3 times the diameter of the through hole.

[0025] A method for preparing a composite membrane material includes the following steps:

[0026] PVB and plasticizer are mixed and stirred at a temperature of less than or equal to 65°C to obtain a modified PVB material composition.

[0027] The modified PVB material composition is melt-extruded to coat and impregnate the reinforcing fabric, and then cooled to obtain the modified membrane material.

[0028] The modified membrane material is subjected to porous punching to obtain multiple through holes arranged along the thickness direction, the diameter of which is 1mm~5mm;

[0029] The composite membrane material includes the modified membrane material, the total thickness of which is 0.1 mm to 2 mm. At 20°C, the viscosity of a 10% PVB ethanol solution is 30 s to 120 s. The mass fraction of PVB is 85 to 92 parts, the mass fraction of the plasticizer is 8 to 15 parts, the total mass fraction of PVB and the plasticizer is 100 parts, and the basis weight of the reinforcing fabric is 10 g / m². 2 ~120g / m 2 .

[0030] Optionally, the mixing temperature is 50℃~65℃; and / or,

[0031] The maximum mixing speed is 800 rpm to 1000 rpm, and the time is 10 min to 15 min.

[0032] Optionally, before the step of porous punching the modified membrane material, the method further includes: when the modified membrane material is cooled to 60°C to 80°C, adhering urea-formaldehyde powder to two surfaces of the modified membrane material that are opposite each other along the thickness direction, and rolling to embed the urea-formaldehyde powder into the surface of the modified membrane material. Optionally, the particle size of the urea-formaldehyde powder is between 20 mesh and 60 mesh.

[0033] A urea-formaldehyde product includes a first urea-formaldehyde layer, an intermediate film layer, and a second urea-formaldehyde layer stacked together. The materials for preparing the first urea-formaldehyde layer and the second urea-formaldehyde layer include urea-formaldehyde molding compound. The materials for preparing the intermediate film layer include a composite film material, wherein the composite film material is the composite film material described above or a composite film material prepared by the preparation method described above.

[0034] Optionally, the urea-formaldehyde product includes a toilet seat.

[0035] A method for preparing a urea-formaldehyde product includes the following steps:

[0036] Urea-formaldehyde molding compound is laid on two surfaces of a composite membrane that are opposite each other along the thickness direction, and then molded to prepare urea-formaldehyde products.

[0037] The composite membrane material is either the composite membrane material described above or a composite membrane material prepared by the preparation method described above.

[0038] Optionally, before the step of laying urea-formaldehyde molding compound on two surfaces of the composite membrane that are opposite each other along the thickness direction, the method further includes: performing a vacuum treatment on the composite membrane for a time greater than 5 minutes; and / or,

[0039] The step of laying urea-formaldehyde molding compound on two surfaces of the composite membrane that are opposite each other along the thickness direction includes:

[0040] The composite membrane material is cut, and the size of the cut composite membrane material is 10mm to 30mm smaller than the size of the urea-formaldehyde product.

[0041] Urea-formaldehyde molding compound, the cut composite film, and urea-formaldehyde molding compound are sequentially laid in the molding machine.

[0042] A toilet seat comprising the urea-formaldehyde product described above or the urea-formaldehyde product prepared by the above preparation method.

[0043] The composite membrane material of this application includes a modified membrane material with a certain thickness and pore diameter. The modified membrane material includes a reinforcing fabric and a PVB (polyvinyl butyral) matrix covering and filling the reinforcing fabric. The reinforcing fabric has a certain basis weight. The materials for preparing the PVB matrix include a certain ratio of PVB and plasticizer. By using a specific ratio and a specific viscosity of PVB, it is beneficial to obtain a PVB matrix with high hardness and good impact resistance. Combining the PVB matrix with good toughness and the reinforcing fabric with high strength, when applied to urea-formaldehyde products, helps to improve their impact resistance and reduce the risk of cracking due to large external impacts. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 This is a schematic diagram of a process flow for preparing composite membrane materials according to some embodiments of this application. Detailed Implementation

[0046] To facilitate understanding of this application, a more comprehensive description of the application will be provided below in conjunction with specific embodiments. Preferred embodiments of the application are given in the specific embodiments. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0047] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0048] Unless otherwise stated or in case of conflict, the terms or phrases used in this application shall have the following meanings:

[0049] In this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" and "second" may explicitly or implicitly include at least one of those features.

[0050] In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise expressly and specifically limited.

[0051] In this application, "one or more" refers to any one, two, or more of the listed items. "Multiple" refers to any two or more of the listed items.

[0052] Unless otherwise specified, all percentage concentrations mentioned in this application refer to the final concentration. The final concentration refers to the proportion of the added component in the system after the addition of that component.

[0053] In this application, terms such as "further," "even more," "particularly," "for example," "like," "example," and "exemplary" are used for descriptive purposes to indicate a connection in the coverage of different technical solutions presented earlier and later, but should not be construed as limiting the preceding technical solution or restricting the scope of protection herein. Unless otherwise specified herein, A (e.g., B) indicates that B is a non-limiting example of A, and it can be understood that A is not limited to B.

[0054] In this application, "optionally," "optionally," and "optional" mean that something is optional, that is, it is selected from either "present" or "absent." If multiple "options" appear in a technical solution, unless otherwise specified and there are no contradictions or mutual constraints, each "option" is independent. In this application, descriptions such as "optionally contains" and "optionally includes" indicate "contains or does not contain." "Optional component X" indicates whether component X exists or does not exist, or whether component X is contained or not.

[0055] When a numerical range is disclosed in this application, the range is considered continuous and includes the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Furthermore, when the range refers to an integer, it includes every integer between the minimum and maximum values ​​of the range. Additionally, when multiple ranges are provided to describe a feature or characteristic, the ranges may be merged. In other words, unless otherwise specified, all ranges disclosed in this application should be understood to include any and all subranges to which they are included.

[0056] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0057] The terms "comprising" and "having," and any variations thereof, used in the embodiments of this application, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to such processes, methods, products, or devices.

[0058] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0059] In the flowchart of this application, although the steps are shown sequentially according to the arrows, these steps are not necessarily performed in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps. They can be executed in other orders. Moreover, at least some of the steps in the diagram may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily completed at the same time, but can be executed at different times. Their execution order is not necessarily sequential, but can be performed alternately or in turn with at least some of other steps or other sub-steps or stages.

[0060] The first aspect of this application provides a composite membrane material, comprising: a modified membrane material, the modified membrane material including a reinforcing fabric and a PVB matrix covering the surface of the reinforcing fabric and filling therein, the total thickness of the modified membrane material being 0.1mm to 2mm, and the modified membrane material having a plurality of through holes arranged along the thickness direction, each through hole having a diameter of 1mm to 5mm;

[0061] The weight of the reinforcing fabric is 10 g / m². 2 ~120g / m 2 The materials used to prepare the PVB matrix, by mass percentage, include 85 to 92 parts of PVB and 8 to 15 parts of plasticizer, with a total mass percentage of 100 parts of PVB and plasticizer. The viscosity of a 10% PVB ethanol solution at 20°C is 30 to 120 s.

[0062] This application research found that traditional PVB film materials typically contain 20-25 parts plasticizer; however, such films have low hardness and poor impact resistance. Therefore, this application obtains a film with higher hardness and better impact resistance by reducing the plasticizer content and combining it with a PVB resin of a certain viscosity. This film is then combined with a reinforcing fabric of a certain weight, allowing the PVB matrix with good toughness and the reinforcing fabric to work synergistically. When applied to urea-formaldehyde products, this improves their impact resistance and reduces the risk of cracking due to significant external impact.

[0063] In some embodiments, the reinforcing fabric and the PVB matrix form an integrated composite structure in the modified membrane material.

[0064] In some embodiments, at 20°C, the viscosity of a 10% PVB ethanol solution is 30 s to 120 s. For example, at 20°C, the viscosity of a 10% PVB ethanol solution can be, but is not limited to, 30 s, 40 s, 50 s, 60 s, 70 s, 80 s, 90 s, 100 s, 110 s, 120 s, or any combination of these values. Optionally, at 20°C, the viscosity of a 10% PVB ethanol solution is 50 s to 100 s.

[0065] In some embodiments, the total mass fraction of PVB and plasticizer is 100 parts. The mass fraction of PVB can be, but is not limited to, 85, 86, 87, 88, 89, 90, 91, 92 parts, or any combination of these values. The mass fraction of plasticizer can be, but is not limited to, 8, 9, 10, 11, 12, 13, 14, 15 parts, or any combination of these values. If the mass fraction of PVB is too large and the mass fraction of plasticizer is too small, it will be difficult to extrude and mold in subsequent preparation processes, making it unsuitable for use in the preparation of urea-formaldehyde products. If the mass fraction of PVB is too small and the mass fraction of plasticizer is too large, the urea-formaldehyde products will have insufficient strength and impact resistance, and small air bubbles are likely to appear on their surface.

[0066] In some embodiments, the plasticizer includes one or more of carboxylic acid ester plasticizers and phosphate ester plasticizers, wherein the carboxylic acid ester plasticizers include one or more of polyol carboxylic acid ester plasticizers, aliphatic dicarboxylic acid ester plasticizers, phthalate plasticizers and citrate plasticizers.

[0067] Specifically, polyol carboxylic acid ester plasticizers refer to a class of plasticizers obtained by esterification of polyols (such as ethylene glycol, glycerol, pentaerythritol, etc.) with monocarboxylic acids (mainly fatty acids). Specifically, polyol carboxylic acid ester plasticizers include one or more of triethylene glycol diisooctanoate (3G8), triethylene glycol diheptanoate (3G7), tetraethylene glycol diisooctanoate, and di(butyl diethylene glycol) adipate.

[0068] Aliphatic dicarboxylic acid ester plasticizers are a class of plasticizers obtained by esterification of aliphatic dicarboxylic acids with monohydric alcohols. Specifically, aliphatic dicarboxylic acid esters include one or more of dibutyl sebacate (DBS), dioctyl sebacate (DOS), and dioctyl adipate (DOA).

[0069] Phthalate plasticizers are a class of plasticizers obtained by esterification of phthalic acid with a monohydric alcohol. Specifically, phthalate plasticizers include one or more of dioctyl phthalate (DOP), diisooctyl phthalate (DEHP), and dibutyl phthalate (DBP).

[0070] Citrate ester plasticizers are a class of plasticizers obtained by esterification of citric acid with a monohydric alcohol. Specifically, citrate ester plasticizers include triethyl citrate.

[0071] Phosphate ester plasticizers include tricresyl phosphate.

[0072] In some embodiments, the plasticizer includes a polyol carboxylic acid ester plasticizer, and the polyol carboxylic acid ester plasticizer accounts for more than 80% by mass in the plasticizer.

[0073] Specifically, the plasticizer is a polyol carboxylic acid ester plasticizer, or a mixture of polyol carboxylic acid ester plasticizer and other types of plasticizers, wherein the mass percentage of the polyol carboxylic acid ester plasticizer is greater than 80%, that is, the polyol carboxylic acid ester plasticizer is the main plasticizer, and the other types of plasticizers are auxiliary plasticizers. This configuration helps to further improve the impact resistance of urea-formaldehyde products in low-temperature environments.

[0074] In some embodiments, the materials used to prepare the PVB matrix further include, by weight, 0.8 to 1.5 parts of an antioxidant. Specifically, the antioxidant includes one or more of hindered phenolic antioxidants and phosphite antioxidants. In one example, the antioxidant is antioxidant 168.

[0075] In some embodiments, the materials used to prepare the PVB matrix further include, by weight, 0.3 to 0.8 parts of coupling agent. Specifically, the coupling agent includes one or more of silane coupling agents and titanate coupling agents. Further, the coupling agent includes one or more of aminosilane coupling agents and amino titanate coupling agents. The presence of amino groups in the coupling agent is beneficial for further improving the bonding strength between the film material and the reinforcing fabric, while also improving the bonding strength between the film material and the urea-formaldehyde resin, thereby improving the overall mechanical properties.

[0076] In some embodiments, the coupling agent includes one or more of γ-aminopropyltriethoxysilane (KH-550, also known as APTS), γ-aminopropyltriethoxysilane (also known as APTMS), N-β-(aminoethyl)-γ-aminopropyltrimethoxysilane (KH-792, also known as APTMS), N-β-(aminoethyl)-γ-aminopropylmethyldimethoxysilane, γ-(polyethylamino)propyltrimethoxysilane, N-phenyl-γ-aminopropyltrimethoxysilane, and bis(dimethoxyethoxy)titanate di(dilauryl)phosphite oxyethyl ester (KR-44).

[0077] In some embodiments, the material used to prepare the PVB matrix further includes 2 to 5 parts by weight of filler. Specifically, the filler includes one or more of talc, natural mica, synthetic mica, glass flakes, boron nitride, kaolin, graphite, molybdenum disulfide, titanium dioxide, barium sulfate, and calcium carbonate. In some embodiments, the filler includes one or more of talc, natural mica, synthetic mica, glass flakes, boron nitride, and kaolin. Talc, natural mica, synthetic mica, glass flakes, boron nitride, and kaolin are flake-shaped fillers. The flake-shaped fillers are spread along the extrusion direction, and the portion parallel to the surface of the urea-formaldehyde product is much larger than the portion perpendicular to it, thus further improving the impact resistance.

[0078] In some embodiments, the materials used to prepare the PVB matrix, by mass parts, include: 85 to 92 parts of PVB, 8 to 15 parts of plasticizer, 0.8 to 1.5 parts of antioxidant, 0.3 to 0.8 parts of coupling agent, and 2 to 5 parts of filler. The total mass parts of PVB and plasticizer are 100 parts. At 20°C, the viscosity of a 10% PVB ethanol solution is 30 s to 120 s.

[0079] In some embodiments, the material used to prepare the PVB matrix further includes 5 to 10 parts by weight of an impact modifier. Optionally, the impact modifier includes one or more of MBS (methyl methacrylate-butadiene-styrene core-shell copolymer), SEBS (styrene-butadiene / ethylene-butene-styrene block copolymer), CPE (chlorinated polyethylene), ACM (acrylate rubber), ACR (acrylate core-shell impact modifier), ASA (acrylonitrile-styrene-acrylate copolymer), TPU (thermoplastic polyurethane), and TPO (thermoplastic polyolefin). Optionally, the impact modifier includes one or both of MBS and ACR. Adding impact modifiers not only further improves its impact resistance but also increases its processability, mitigating the problem of decreased processability caused by reducing plasticizer content.

[0080] In some embodiments, the materials used to prepare the PVB matrix, by weight, include: 85-92 parts of PVB, 8-15 parts of plasticizer, 0.8-1.5 parts of antioxidant, 0.3-0.8 parts of coupling agent, 2-5 parts of filler, and 5-10 parts of impact modifier. The total weight of PVB and plasticizer is 100 parts. At 20°C, the viscosity of a 10% PVB ethanol solution is 30s-120s.

[0081] The aforementioned composite membrane combines a PVB matrix with good toughness with a reinforcing fabric with high strength, resulting in high hardness and high impact resistance. When applied to urea-formaldehyde products, it helps to improve their impact resistance and reduce the risk of cracking due to large external impacts.

[0082] In some embodiments, the materials used to prepare the reinforcing fabric include one or more of inorganic non-metallic fibers, metallic fibers, and organic fibers.

[0083] The inorganic non-metallic fibers include one or more of glass fibers, basalt fibers, carbon fibers, and ceramic fibers. Ceramic fibers include aluminosilicate fibers, alumina fibers, silicon carbide fibers, boron fibers, and quartz fibers. Optionally, the inorganic non-metallic fibers include one or more of glass fibers, basalt fibers, and quartz fibers.

[0084] Metal fibers include one or more of stainless steel fibers, iron fibers, silver fibers, aluminum fibers, tungsten fibers, and molybdenum fibers. Optionally, metal fibers include one or two of stainless steel fibers and iron fibers.

[0085] Organic fibers include one or more of the following: PBO fiber (poly(p-phenylenebenzodioxazole) fiber), PA fiber (polyamide fiber), PET fiber (polyethylene terephthalate fiber), PAN fiber (polyacrylonitrile fiber), PVA fiber (polyvinyl alcohol fiber), polypropylene fiber, polyethylene fiber, PVF fiber (vinylon fiber), aramid fiber, pulp fiber, bamboo fiber, and cotton fiber. Specifically, PA fiber includes, but is not limited to, nylon 6 fiber and nylon 66 fiber. PVA fiber includes, but is not limited to, high-strength, high-modulus PVA fiber; for example, high-strength, high-modulus PVA fiber has a breaking strength ≥10 CN / dtex and a modulus ≥250 CN / dtex. Ordinary PVA fiber has a breaking strength ≤5 CN / dtex and a modulus ≥150 CN / dtex.

[0086] Alternatively, the organic fibers include one or more of high-strength, high-modulus PVA fibers, PVF fibers, and PA fibers.

[0087] It is understood that the material used to prepare the reinforcing fabric can be one, two, or a mixture of three of the above-mentioned fiber types. In some embodiments, the material used to prepare the reinforcing fabric includes a mixture of glass fiber and high-strength, high-modulus PVA fiber, or a mixture of glass fiber and vinylon fiber.

[0088] In some embodiments, the reinforcing fabric may be one of nonwoven fabric, woven fabric, or mesh fabric.

[0089] In some embodiments, the basis weight of the reinforcing fabric is 10 g / m². 2 ~120g / m 2 For example, the basis weight of the reinforcing fabric can be, but is not limited to, 10 g / m². 2 20g / m 2 40g / m 2 60g / m 2 80g / m 2 100g / m 2 120g / m 2 Or a range consisting of any two of these values. A reinforcing fabric basis weight within the above range is beneficial for improving the strength and impact resistance of the prepared urea-formaldehyde products. If the reinforcing fabric basis weight is too high, the prepared urea-formaldehyde products will exhibit delamination and brittleness. Optionally, the reinforcing fabric basis weight is 30 g / m². 2 ~100g / m 2 .

[0090] In some embodiments, the thickness of the modified membrane material is 0.1 mm to 2 mm. For example, the thickness of the modified membrane material can be, but is not limited to, 0.1 mm, 0.2 mm, 0.5 mm, 0.8 mm, 1 mm, 1.2 mm, 1.5 mm, 1.8 mm, 2 mm, or any combination of these values. Using the above thickness is beneficial for process implementation and improves the appearance of the prepared urea-formaldehyde products. If the thickness of the modified reinforcing fabric membrane material is too small, the current process is difficult to implement; if the thickness of the modified reinforcing fabric membrane material is too large, although the prepared urea-formaldehyde products have high strength and impact resistance, the appearance flatness is poor, making it difficult to meet appearance requirements. Optionally, the thickness of the modified membrane material is 0.2 mm to 1.2 mm.

[0091] In some embodiments, the modified membrane material has multiple through holes arranged along the thickness direction, each with a diameter of 1mm to 5mm. By providing multiple through holes with a diameter of 1mm to 5mm, macroscopic (millimeter-level) interconnection of the upper and lower urea-formaldehyde materials is achieved during the preparation of urea-formaldehyde products, further ensuring strength and toughness while improving the consistency of the entire product. Without through holes, when the composite membrane material is applied to urea-formaldehyde products, gas cannot be completely discharged, resulting in air bubbles on the surface of the urea-formaldehyde products. These air bubbles can cause cracks or breakage under impact. Furthermore, without through holes, when the composite membrane material is applied to urea-formaldehyde products, the upper and lower urea-formaldehyde materials are separated by an intermediate layer, resulting in reduced integrity and mechanical properties. With through holes, the overall consistency of the product is higher, and the mechanical properties are also improved.

[0092] For example, the diameter of the through hole can be, but is not limited to, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, or any combination of these values. A through hole diameter within this range is beneficial for matching current processes and further improves the appearance of urea-formaldehyde products. If the through hole diameter is too small, current processes are difficult to implement; if the through hole diameter is too large, while the resulting urea-formaldehyde products will have high strength and impact resistance, they will be prone to dents.

[0093] In some embodiments, the distance between two adjacent through holes is 1 to 3 times the diameter of the through hole. The distance between two adjacent through holes refers to the distance between their edges. For example, if the diameter of the through hole is 1 mm, the distance between two adjacent through holes can be 3 times the diameter of the through hole, i.e., 3 mm; or, if the diameter of the hole is 5 mm, the distance between two adjacent through holes can be 1 time the diameter of the through hole, i.e., 5 mm.

[0094] It is understood that in some embodiments, the composite membrane material may only include the modified membrane material, while in other embodiments, the composite membrane material may also include other materials. Specifically, in some embodiments, the material used to prepare the composite membrane material further includes urea-formaldehyde powder, which is embedded in two surfaces of the modified membrane material that are disposed opposite to each other along the thickness direction. Urea-formaldehyde powder refers to urea-formaldehyde resin molding powder, generally obtained by reacting urea and formaldehyde with pulp fiber-reinforced and modified urea. By embedding urea-formaldehyde powder on the surface of the modified membrane material, it is beneficial to form a sub-millimeter level through-and-through and semi-through-and-through structure during the preparation of urea-formaldehyde products, further improving its impact resistance.

[0095] In some embodiments, the amount of urea-formaldehyde powder used in the composite membrane is 20 g / m². 2 ~50g / m 2 .

[0096] In some embodiments, the thickness of the composite membrane material is 0.2 mm to 2.1 mm. For example, the thickness of the composite membrane material may be, but is not limited to, 0.2 mm, 0.5 mm, 0.8 mm, 1 mm, 1.2 mm, 1.5 mm, 1.8 mm, 2 mm, 2.1 mm, or any range of two of these values. Optionally, the thickness of the composite membrane material is 0.25 mm to 1.25 mm.

[0097] The fourth aspect of this application provides a method for preparing a composite membrane material; please refer to [link to relevant documentation]. Figure 1 It includes the following steps:

[0098] Step S110: Mix and stir PVB and plasticizer at a temperature of less than or equal to 65°C to obtain a modified PVB material composition;

[0099] Step S120: The modified PVB material composition is melt-extruded to coat and impregnate the reinforcing fabric, and then cooled to obtain the modified membrane material;

[0100] Step S130: Perform porous punching on the modified membrane material to obtain multiple through holes arranged along the thickness direction, with the diameter of the through holes being 1mm~5mm;

[0101] The composite membrane material includes a modified membrane material with a total thickness of 0.1 mm to 2 mm. At 20°C, the viscosity of a 10% (w / w) PVB ethanol solution is 30 s to 120 s. The mass fraction of PVB is 85 to 92 parts, the mass fraction of the plasticizer is 8 to 15 parts, the total mass fraction of PVB and the plasticizer is 100 parts, and the basis weight of the reinforcing fabric is 10 g / m². 2 ~120g / m 2 .

[0102] In some embodiments, the mixing temperature is less than or equal to 65°C. For example, the mixing temperature may be, but is not limited to, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, or a range of any two of these values. If the mixing temperature is too high, the materials will agglomerate during mixing, making them difficult to use in the preparation of urea-formaldehyde products. Optionally, the mixing temperature is 50°C to 65°C.

[0103] In some embodiments, the maximum mixing speed is 800 rpm to 1000 rpm, and the mixing time is 10 min to 15 min.

[0104] In some embodiments, the mixing step is performed in a vacuum high-speed mixer.

[0105] Specifically, the modified PVB material composition is melted, plasticized, and degassed under heating and shearing in a twin-screw extruder to form a uniform melt. As the melt passes through the extruder die, the reinforcing fabric is simultaneously pulled through the extruder die. Inside the extruder die, the melt impregnates and coats the reinforcing fabric. After cooling, the modified film material is obtained.

[0106] In some embodiments, prior to the step of porous punching the modified membrane material, the method for preparing the composite membrane material further includes: when the modified membrane material is cooled to 60°C to 80°C, adhering urea-formaldehyde powder to two surfaces of the modified membrane material that are opposite to each other along the thickness direction, and rolling to embed the urea-formaldehyde powder into the surface of the modified membrane material.

[0107] By adhering urea-formaldehyde powder to the surface of the modified membrane, the powder can be largely embedded in the surface of the modified membrane during rolling, forming a structure with vertical and semi-vertical interconnection at the submicron level, which greatly improves its impact resistance.

[0108] In one example, the modified membrane material is passed through a urea-formaldehyde powder roller press. Under conditions of 60℃~80℃, the modified membrane material has a certain degree of adhesion. Then, through the action of upper and lower scrapers, the urea-formaldehyde powder is adhered to the surface of the modified membrane material.

[0109] In some embodiments, the particle size of urea-formaldehyde powder is between 20 mesh and 60 mesh. It is understood that urea-formaldehyde powder is a powder with a certain particle size distribution range. In some embodiments of this application, the particle size of urea-formaldehyde powder between 20 mesh and 60 mesh means that the particle size of the urea-formaldehyde powder is entirely within the above range.

[0110] In some embodiments, the rolling temperature is 60°C to 80°C. For example, the rolling temperature may be, but is not limited to, 60°C, 62°C, 65°C, 68°C, 70°C, 72°C, 75°C, 78°C, 80°C, or any combination of these values. A rolling temperature within the above range is beneficial for improving the strength and impact resistance of urea-formaldehyde products.

[0111] In some embodiments, the composite membrane material is wound up, vacuumed, and stored for later use.

[0112] A third aspect of this application provides a urea-formaldehyde product, comprising a first urea-formaldehyde layer, an intermediate film layer, and a second urea-formaldehyde layer stacked together. The materials for preparing the first and second urea-formaldehyde layers include urea-formaldehyde molding compound, and the materials for preparing the intermediate film layer include a composite film material. The composite film material is the composite film material described in the first aspect or a composite film material prepared by the preparation method described in the second aspect.

[0113] In some embodiments, the urea-formaldehyde molding compound is prepared by using urea-formaldehyde resin obtained from the reaction of urea and formaldehyde as a base material and reinforcing it with pulp fibers or the like. In this application, the urea-formaldehyde molding compound has the same composition as urea-formaldehyde powder.

[0114] In some embodiments, urea-formaldehyde products include, but are not limited to, toilet seat covers.

[0115] The fourth aspect of this application provides a method for preparing a urea-formaldehyde product, comprising the following steps:

[0116] Urea-formaldehyde molding compound is laid on two surfaces of a composite membrane that are opposite each other along the thickness direction, and then molded to prepare urea-formaldehyde products.

[0117] The composite membrane material is either the composite membrane material described in the first aspect or the composite membrane material prepared by the preparation method described in the second aspect.

[0118] In some embodiments, the preparation method of urea-formaldehyde products further includes: vacuuming the composite membrane material.

[0119] Specifically, the vacuuming process should last for more than 5 minutes. For example, the vacuuming time can be, but is not limited to, 5.5 minutes, 6 minutes, 7 minutes, 8 minutes, 9 minutes, 10 minutes, 12 minutes, 15 minutes, or any combination of these values. Using this setting helps improve the appearance of urea-formaldehyde products. If the vacuuming time is too short, although the prepared urea-formaldehyde products will have high strength and impact resistance, small air bubbles are prone to appear on the surface. Vacuuming can remove small molecule materials from the composite film, thus reducing the likelihood of air bubbles forming during molding.

[0120] Specifically, in the vacuuming process, the vacuum level is <500Pa and the temperature is <35℃.

[0121] In some embodiments, the step of laying urea-formaldehyde molding compound on two surfaces of the composite membrane that are disposed opposite each other along the thickness direction includes:

[0122] The composite membrane material is cut to a size that is 10mm to 30mm smaller than that of the urea-formaldehyde product.

[0123] Inside the molding machine, urea-formaldehyde molding material, cut composite film, and urea-formaldehyde molding material are laid out in sequence.

[0124] It is understandable that during the preparation of urea-formaldehyde products, the proportion of urea-formaldehyde molding material added can be adjusted according to the required thickness of the urea-formaldehyde product to be prepared, and no special limitation is made here.

[0125] Specifically, the composite membrane is cut into the shape of the actual urea-formaldehyde product, and the outer dimensions of the cut composite membrane are 10mm to 30mm smaller than the actual urea-formaldehyde product, that is, offset inward by 10mm to 30mm based on the outer dimensions of the urea-formaldehyde product.

[0126] In some embodiments, the urea-formaldehyde product is a toilet seat. In the step of cutting the composite film material, a hole 3mm to 5mm larger than the outer dimensions of the foot pad is punched in the corresponding foot pad mounting area of ​​the toilet seat.

[0127] In some embodiments, the compression molding step can be one commonly used in the art, and is not particularly limited herein. For example, the compression molding temperature can be, but is not limited to, 132°C to 145°C.

[0128] The fifth aspect of this application provides a toilet that includes the urea-formaldehyde product of the third aspect above or includes the urea-formaldehyde product prepared by the preparation method of the fourth aspect above.

[0129] It is understandable that toilets also include other commonly used components, which are not specifically limited here.

[0130] To make the objectives and advantages of this application clearer, the urea-formaldehyde products and their effects are further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are only for explaining this application and should not be used to limit this application. Unless otherwise specified, the following embodiments do not include components other than unavoidable impurities. Unless otherwise specified, the drugs and instruments used in the embodiments are conventional choices in the art. Experimental methods in the embodiments that do not specify specific conditions are implemented according to conventional conditions, such as those described in literature, books, or methods recommended by the manufacturer.

[0131] Example 1

[0132] This embodiment provides a urea-formaldehyde product, the preparation method of which includes the following steps:

[0133] (1) By mass fraction, 89 parts of PVB (10% ethanol solution viscosity is 120s), 11 parts of plasticizer (triethylene glycol diisooctanoate), 1.2 parts of antioxidant 168, 0.5 parts of coupling agent (γ-aminopropyltriethoxysilane (KH-550, also known as APTS)), 3 parts of filler (talc) and 8 parts of impact modifier MBS were added to a vacuum high-speed mixer and mixed at 65°C and a maximum speed of 900 rpm for 12 min to obtain a powdered modified PVB material composition.

[0134] (2) The modified PVB material composition is passed through a twin-screw extruder and melted, plasticized and degassed under heating and shearing to form a uniform melt, which is then transported to an impregnation mold.

[0135] (3) The weight is 30g / m 2High-strength, high-modulus PVA nonwoven fabric (tensile strength ≥10CN / dtex, modulus ≥250CN / dtex) is passed through an impregnation mold by a traction device. Inside the impregnation mold, the melt uniformly covers and impregnates the PVA nonwoven fabric under pressure. After cooling, a modified film material with a thickness of 0.5mm is obtained.

[0136] (4) When the modified membrane material is cooled to 70°C, urea-formaldehyde powder (particle size between 20 mesh and 60 mesh) is adhered to the upper and lower surfaces of the modified membrane material by upper and lower scrapers. Then, the urea-formaldehyde powder is embedded into the upper and lower surfaces of the modified membrane material by roller pressing at a roller pressing temperature of 70°C to obtain a composite membrane material with a thickness of 0.6 mm.

[0137] (5) Under the action of the punch, the composite membrane material obtained in step (4) is punched with multiple holes to obtain multiple through holes set along the thickness direction. The diameter of the through holes is 1 mm and the distance between two adjacent through holes is 3 mm.

[0138] (6) Based on the external dimensions of the urea-formaldehyde product, the composite membrane material obtained in step (5) is cut into the shape of the urea-formaldehyde product, so that the external dimensions of the cut porous composite membrane material are 20 mm smaller than the dimensions of the urea-formaldehyde product.

[0139] (7) The cut composite membrane material is vacuumed at a vacuum level of 300 Pa and a temperature of 30 °C for 6 min.

[0140] (8) Spread a portion of the urea-formaldehyde molding material evenly on the mold of the molding machine, then spread the composite film material after vacuuming in step (7) in the center of the mold, and then spread the remaining urea-formaldehyde molding material evenly on the composite film material, and obtain the urea-formaldehyde product of this embodiment by molding.

[0141] Example 2

[0142] This embodiment provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the mass fractions of PVB and plasticizer in step (1) are different. In this embodiment, the mass fractions of PVB and plasticizer are 85 parts and 15 parts, respectively.

[0143] Example 3

[0144] This embodiment provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the viscosity, mass fraction of PVB, and mass fraction of plasticizer in step (1) are different. In this embodiment, the viscosity of the 10% PVB ethanol solution is 30s, and the mass fractions of PVB and plasticizer are 92 parts and 8 parts, respectively.

[0145] Example 4

[0146] This embodiment provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the plasticizer used in step (1) is different. In this embodiment, the plasticizer is dibutyl sebacate.

[0147] Example 5

[0148] This embodiment provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the filler used in step (1) is different. In this embodiment, the filler is titanium dioxide.

[0149] Example 6

[0150] This embodiment provides a urea-formaldehyde product, which is similar to the urea-formaldehyde product of Example 1, except that no impact modifier is added in step (1).

[0151] Example 7

[0152] This embodiment provides a urea-formaldehyde product, which is similar to the urea-formaldehyde product in Example 1, except that the composite membrane does not contain urea-formaldehyde powder, that is, the preparation method does not include step (4).

[0153] Comparative Example 1

[0154] Comparative Example 1 provides a modified PVB material composition, similar to the modified PVB material composition of Example 3, except that the mass fractions of PVB and plasticizer are different. In Comparative Example 1, the mass fractions of PVB and plasticizer are 95 parts and 5 parts, respectively.

[0155] Because the amount of PVB used is too large and the amount of plasticizer used is too small, it cannot be extruded and therefore cannot be used to prepare urea-formaldehyde products.

[0156] Comparative Example 2

[0157] Comparative Example 2 provides a urea-formaldehyde product similar to the urea-formaldehyde product of Example 3, except that the mass fractions of PVB and plasticizer are different. In Comparative Example 2, the mass fractions of PVB and plasticizer are 82 parts and 18 parts, respectively.

[0158] Comparative Example 3

[0159] Comparative Example 3 provides a modified PVB material composition, similar to the modified PVB material composition of Example 1, except that the mixing temperature is different. In Comparative Example 3, the mixing temperature is 75°C.

[0160] Because the mixing temperature was too high, the materials agglomerated during mixing, making subsequent extrusion impossible. Therefore, the subsequent steps were not performed.

[0161] Comparative Example 4

[0162] Comparative Example 4 provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the basis weight of the nonwoven fabric in step (3) is different. In Comparative Example 4, the basis weight of the high-strength, high-modulus PVA nonwoven fabric is 125 g / m². 2 .

[0163] Comparative Example 5

[0164] Comparative Example 5 provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the rolling temperature in step (4) is different. In Comparative Example 5, the rolling temperature is 90°C.

[0165] Comparative Example 6

[0166] Comparative Example 6 provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the rolling temperature in step (4) is different. In Comparative Example 6, the rolling temperature is 50°C.

[0167] Comparative Example 7

[0168] Comparative Example 7 provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the thickness of the modified membrane material in step (3) is different, and correspondingly, the thickness of the composite membrane material in step (4) is also different. In Comparative Example 7, the thickness of the modified membrane material is 2.5 mm, and the thickness of the composite membrane material is 2.6 mm.

[0169] Comparative Example 8

[0170] Comparative Example 8 provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the diameter and spacing of the through holes are different in step (5). In Comparative Example 8, the diameter of the through holes is 8 mm, and the spacing between two adjacent through holes is 8 mm.

[0171] Comparative Example 9

[0172] Comparative Example 9 provides a urea-formaldehyde product, similar to the urea-formaldehyde product of Example 1, except that the vacuuming time in step (7) is different. In Comparative Example 9, the vacuuming time is 3 minutes.

[0173] Comparative Example 10

[0174] Comparative Example 10 provides a urea-formaldehyde product, which is similar to the urea-formaldehyde product of Example 1, except that the composite membrane is not porous, i.e. the preparation method does not include step (5).

[0175] The urea-formaldehyde products of the above embodiments and comparative examples were subjected to drop ball impact and static load tests, and the appearance of the urea-formaldehyde was recorded, resulting in the data shown in Table 1 below. The drop ball impact test refers to an impact test with an 800g steel ball at a height of 900mm, or an impact test with a 900g steel ball at a height of 900mm, or an impact test with a 1000g steel ball at a height of 900mm. The static load test refers to a test with a pressure of 2000N for 3 minutes.

[0176] The main process parameters and test data of the above embodiments and comparative examples are shown in Table 1 and Table 2, respectively.

[0177] Table 1

[0178]

[0179] Table 2

[0180]

[0181] It should be noted that in Tables 1 and 2 above, OK indicates that the test has been passed and the performance meets the requirements, while NG indicates "not good," meaning the test was not passed and the performance does not meet the requirements, and NA indicates that the test was not performed. Specifically, in the drop ball impact test, an 800-gram steel ball is used to impact the ball from a height of 900 mm; meeting the requirements is sufficient to satisfy the actual usage requirements.

[0182] As can be seen from Tables 1 and 2 above, the urea-formaldehyde products prepared in each embodiment have better impact resistance, higher strength, and better appearance compared to the comparative example. Furthermore, by optimizing the types of plasticizers and fillers in the composite membrane material, and by adding impact modifiers, urea-formaldehyde powder, and creating through-holes of a certain diameter, its impact resistance can be further improved.

[0183] In Comparative Example 1, the modified PVB material composition had an excessive amount of PVB and an insufficient amount of plasticizer, making extrusion molding impossible and rendering it unsuitable for preparing urea-formaldehyde products. In Comparative Example 2, the modified PVB material composition had an insufficient amount of PVB and an excessive amount of plasticizer, resulting in urea-formaldehyde products with insufficient strength, poor impact resistance, and surface bubbles. In Comparative Example 3, the mixing temperature was too high during preparation, causing material agglomeration and preventing subsequent extrusion, rendering it unsuitable for preparing urea-formaldehyde products. In Comparative Example 4, the nonwoven fabric used had an excessively high basis weight, resulting in poor strength and impact resistance, and delamination and brittleness. In Comparative Examples 5 and 6, the rolling temperature was either too high or too low, leading to poor strength and impact resistance. In Comparative Examples 7 through 9, the thickness, pore diameter, vacuuming time, and other process parameters of the composite film used did not meet requirements, resulting in poor appearance of the prepared urea-formaldehyde products. In Comparative Example 10, the composite membrane material lacked through-holes, preventing complete gas escape and resulting in air bubbles on the appearance of the urea-formaldehyde product. These air bubbles can cause cracks or splits upon impact with a falling ball.

[0184] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0185] The embodiments described above are merely illustrative of several implementation methods of this application, intended to facilitate a detailed understanding of the technical solutions of this application, but should not be construed as limiting the scope of protection of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application. It should be understood that technical solutions obtained by those skilled in the art based on the technical solutions provided in this application through logical analysis, reasoning, or limited experimentation are all within the scope of protection of the appended claims. Therefore, the scope of protection of this patent application should be determined by the content of the appended claims, and the specification and drawings can be used to interpret the content of the claims.

Claims

1. A composite membrane material, characterized in that, include: A modified membrane material, comprising a reinforcing fabric and a PVB matrix covering the surface of the reinforcing fabric and filling the interior thereof, wherein the total thickness of the modified membrane material is 0.1mm to 2mm, and the modified membrane material is provided with a plurality of through holes arranged along the thickness direction, each through hole having a diameter of 1mm to 5mm; The reinforcing fabric has a basis weight of 10 g / m². 2 ~120g / m 2 ; The materials used to prepare the PVB matrix, by mass percentage, include 85 to 92 parts of PVB and 8 to 15 parts of plasticizer, with a total mass percentage of 100 parts of PVB and plasticizer. At 20°C, the viscosity of a 10% PVB ethanol solution is 30 to 120 s.

2. The composite membrane material according to claim 1, characterized in that, At 20°C, the viscosity of a 10% (w / w) PVB ethanol solution is 50 s to 100 s; and / or, The plasticizer includes one or more of carboxylic acid ester plasticizers and phosphate ester plasticizers, and the carboxylic acid ester plasticizer includes one or more of polyol carboxylic acid ester plasticizers, aliphatic dicarboxylic acid ester plasticizers, phthalate plasticizers and citrate plasticizers; Optionally, the polyol carboxylic acid ester plasticizer includes one or more of triethylene glycol diisooctanoate, triethylene glycol diheptanoate, tetraethylene glycol diisooctanoate, and di(butyl diethylene glycol) adipate; the aliphatic dicarboxylic acid ester plasticizer includes one or more of dibutyl sebacate, dioctyl sebacate, and dioctyl adipate; the phthalate plasticizer includes one or more of dioctyl phthalate, diisooctyl phthalate, and dibutyl phthalate; the citrate plasticizer includes triethyl citrate; and the phosphate plasticizer includes tricresyl phosphate. Optionally, the plasticizer includes a polyol carboxylic acid ester plasticizer, wherein the polyol carboxylic acid ester plasticizer accounts for more than 80% by mass in the plasticizer.

3. The composite membrane material according to claim 1 or 2, characterized in that, One or more of the following conditions must be met: (1) The materials used to prepare the PVB matrix, by weight, further include: 0.8 to 1.5 parts of antioxidant, optionally, the antioxidant includes one or more of hindered phenolic antioxidants and phosphite antioxidants; (2) The materials used to prepare the PVB matrix, by mass, further include: 0.3 to 0.8 parts of coupling agent; optionally, the coupling agent includes one or more of silane coupling agents and titanate coupling agents; optionally, the coupling agent includes one or more of aminosilane coupling agents and amino titanate coupling agents; optionally, the coupling agent includes one or more of γ-aminopropyltriethoxysilane, γ-aminopropyltriethoxysilane, N-β-(aminoethyl)-γ-aminopropyltrimethoxysilane, N-β-(aminoethyl)-γ-aminopropylmethyldimethoxysilane, γ-(poly(ethyleneamino)propyltrimethoxysilane), N-phenyl-γ-aminopropyltrimethoxysilane, and di(dimethoxyethoxy)titanate di(dilauryl)phosphite oxyethyl ester. (3) By mass, the material used to prepare the PVB matrix further includes 2 to 5 parts of filler. Optionally, the filler includes one or more of talc, natural mica, synthetic mica, glass flakes, boron nitride, kaolin, graphite, molybdenum disulfide, titanium dioxide, barium sulfate, and calcium carbonate. (4) The material used to prepare the PVB matrix further includes 5 to 10 parts by weight of impact modifier. Optionally, the impact modifier includes one or more of the following: methyl methacrylate-butadiene-styrene core-shell copolymer, styrene-butadiene / ethylene-butene-styrene block copolymer, chlorinated polyethylene, acrylate rubber, acrylate core-shell impact modifier, acrylonitrile-styrene-acrylate copolymer, thermoplastic polyurethane, and thermoplastic polyolefin. Optionally, the impact modifier includes one or two of the following: methyl methacrylate-butadiene-styrene core-shell copolymer and acrylate core-shell impact modifier.

4. The composite membrane material according to claim 1, characterized in that, The reinforcing fabric satisfies one or more of the following conditions: (1) The material used to prepare the reinforcing fabric includes one or more of inorganic non-metallic fibers, metal fibers and organic fibers; wherein the inorganic non-metallic fibers include glass fibers, basalt fibers, carbon fibers and ceramic fibers; and / or, the metal fibers include one or more of stainless steel fibers, iron fibers, silver fibers, aluminum fibers, tungsten fibers and molybdenum fibers; and / or, the organic fibers include one or more of poly(p-phenylenebenzodioxazole) fibers, polyamide fibers, polyethylene terephthalate fibers, polyacrylonitrile fibers, polyvinyl alcohol fibers, polypropylene fibers, polyethylene fibers, vinylon fibers, aramid fibers, pulp fibers, bamboo fibers and cotton fibers; (2) The basis weight of the reinforcing fabric is 30 g / m². 2 ~100g / m 2 ; (3) The reinforcing fabric is one of non-woven fabric, woven fabric or mesh fabric; (4) The total thickness of the modified membrane material is 0.2mm~1.2mm.

5. The composite membrane material according to claim 1, 2, or 4, characterized in that, The spacing between two adjacent through holes is 1 to 3 times the diameter of the through hole; and / or, The materials used to prepare the composite membrane also include: urea-formaldehyde powder, wherein the urea-formaldehyde powder is embedded in two surfaces of the modified membrane that are disposed opposite to each other along the thickness direction; Optionally, the amount of urea-formaldehyde powder used in the composite membrane material is 20 g / m². 2 ~50g / m 2 ; Optionally, the total thickness of the composite membrane is 0.2mm to 2.1mm, or alternatively, the total thickness of the composite membrane is 0.25mm to 1.25mm.

6. A method for preparing a composite membrane material, characterized in that, Includes the following steps: PVB and plasticizer are mixed and stirred at a temperature of less than or equal to 65°C to obtain a modified PVB material composition. The modified PVB material composition is melt-extruded to coat and impregnate the reinforcing fabric, and then cooled to obtain the modified membrane material. The modified membrane material is subjected to porous punching to obtain multiple through holes arranged along the thickness direction, the diameter of which is 1mm~5mm; The composite membrane material includes the modified membrane material, the total thickness of which is 0.1 mm to 2 mm. At 20°C, the viscosity of a 10% PVB ethanol solution is 30 s to 120 s. The mass fraction of PVB is 85 to 92 parts, the mass fraction of the plasticizer is 8 to 15 parts, the total mass fraction of PVB and the plasticizer is 100 parts, and the basis weight of the reinforcing fabric is 10 g / m². 2 ~120g / m 2 .

7. The method for preparing the composite membrane material according to claim 6, characterized in that, The mixing temperature is 50℃~65℃; and / or, The maximum mixing speed is 800 rpm to 1000 rpm, and the time is 10 min to 15 min.

8. The method for preparing the composite membrane material according to claim 6 or 7, characterized in that, Before the step of punching the modified membrane material with a porous structure, the method further includes: when the modified membrane material is cooled to 60°C~80°C, adhering urea-formaldehyde powder to two surfaces of the modified membrane material that are opposite each other along the thickness direction, and rolling to embed the urea-formaldehyde powder into the surface of the modified membrane material. Optionally, the particle size of the urea-formaldehyde powder is between 20 mesh and 60 mesh.

9. A urea-formaldehyde product, characterized in that, The invention comprises a first urea-formaldehyde layer, an intermediate film layer, and a second urea-formaldehyde layer stacked together. The materials used to prepare the first urea-formaldehyde layer and the second urea-formaldehyde layer include urea-formaldehyde molding compound. The materials used to prepare the intermediate film layer include a composite film material. The composite film material is the composite film material according to any one of claims 1 to 5 or a composite film material prepared by the preparation method according to any one of claims 6 to 8. Optionally, the urea-formaldehyde product includes a toilet seat.

10. A method for preparing a urea-formaldehyde product, characterized in that, Includes the following steps: Urea-formaldehyde molding compound is laid on two surfaces of a composite membrane that are opposite each other along the thickness direction, and then molded to prepare urea-formaldehyde products. The composite membrane material is the composite membrane material according to any one of claims 1 to 5 or the composite membrane material prepared by the preparation method according to any one of claims 6 to 8.

11. The method for preparing urea-formaldehyde products according to claim 10, characterized in that, Before the step of laying urea-formaldehyde molding compound on two surfaces of the composite membrane that are opposite each other along the thickness direction, the method further includes: performing a vacuum treatment on the composite membrane for a time greater than 5 minutes; and / or, The step of laying urea-formaldehyde molding compound on two surfaces of the composite membrane that are opposite each other along the thickness direction includes: The composite membrane material is cut, and the size of the cut composite membrane material is 10mm to 30mm smaller than the size of the urea-formaldehyde product. Urea-formaldehyde molding compound, the cut composite film, and urea-formaldehyde molding compound are sequentially laid in the molding machine.

12. A toilet seat, characterized in that, Includes the urea-formaldehyde product as described in claim 9 or the urea-formaldehyde product prepared by the preparation method described in any one of claims 10-11.

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