Carbon-based silicon-aluminum plate and preparation method thereof

Abstract

This invention belongs to the field of building materials technology, and particularly relates to a carbon-based silicon-aluminum sheet and its preparation method, comprising the following raw materials: PVC resin, coal gangue powder, stabilizer, lubricant, processing aid, plasticizer, and toughening agent; the preparation method includes the following steps: drying and surface modifying the coal gangue powder to obtain modified coal gangue powder; mixing the raw materials in proportion to obtain a premix; feeding the premix into a screw extruder for melt plasticization and mixing; extruding the molten material through a slit-type flat die to form a slab, and performing calendering, thickness setting, and preliminary cooling; cutting the cooled and solidified slab to a set length to obtain the composite sheet; this invention significantly reduces raw material costs by using a large amount of coal gangue powder (industrial solid waste) as a filler, and realizes the resource utilization of solid waste, which is in line with the concept of green manufacturing.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically a carbon-based silicon-aluminum sheet and its preparation method. Background Technology

[0002] Currently, the inorganic fillers used in PVC sheet production are mostly at least one of coal gangue powder, marble powder, or granite powder. Using coal gangue powder as an inorganic filler in PVC sheet production can effectively reduce production costs. Coal gangue, as a solid waste generated during coal mining, poses a threat to human production and daily life, but also possesses immeasurable value. While coal gangue powder can be used as a filler, its complex composition, low surface polarity, and poor compatibility with PVC mean that direct, large-scale filling can severely degrade product performance. Research on how to replace marble powder and granite powder with coal gangue while ensuring excellent sheet performance is currently insufficient. Summary of the Invention

[0003] The purpose of this invention is to provide a carbon-based silicon-aluminum plate and its preparation method. By using a large amount of coal gangue powder (industrial solid waste) as filler, the raw material cost is significantly reduced, and the resource utilization of solid waste is realized, which is in line with the concept of green manufacturing.

[0004] To achieve the above-mentioned objective, a carbon-based silicon-aluminum sheet comprises the following raw materials in parts by weight: 167-250 parts of PVC resin, 500-750 parts of coal gangue powder, 2.7-6.0 parts of stabilizer, 2-3.3 parts of lubricant, 1-1.7 parts of processing aid, 4-8.3 parts of plasticizer, and 10-13.3 parts of toughening agent.

[0005] Furthermore, the coal gangue powder is modified coal gangue powder that has undergone surface modification treatment, and the modification method is to use a modifier for surface coating treatment.

[0006] Furthermore, the modifier is one of silane coupling agent, aluminate coupling agent, and titanate coupling agent, and the amount of modifier used is 0.5%-2.0% of the weight of coal gangue powder.

[0007] Furthermore, the coal gangue powder has a particle size of 400-450 mesh, which results in low shrinkage, excellent toughness, and relatively low warpage of the slab.

[0008] Furthermore, the stabilizer is a calcium-zinc stabilizer, which has excellent light stability and weather resistance, effectively inhibiting the discoloration and degradation of PVC under light, resulting in a long service life for the product outdoors; the processing aid is an ACR processing aid; the toughening agent is a PVC / ABS blend toughening modification, and PVC and ABS have good compatibility; the plasticizer is chlorinated paraffin, which is an auxiliary plasticizer for PVC, and when used in combination with antimony trioxide, it has a synergistic flame retardant effect.

[0009] ACR processing aids have the following functions: 1. They have good compatibility and dispersibility with PVC, intertwining with PVC molecular chains to promote PVC melt plasticization, effectively reducing PVC melt processing temperature, and improving the weather resistance of products while achieving slight energy savings; 2. They can change the melt rheological behavior of PVC materials, improving the fluidity of PVC materials, thus making them easier to mold and extrude, and ensuring the stability of long-term processing and molding; 3. They can improve the melt strength of PVC materials, prevent melt fracture, solve surface problems such as sharkskin, and improve the internal quality and surface gloss of products; 4. They can effectively prevent pressure fluctuations and flow marks caused by extrusion molding during extrusion and injection molding, effectively avoiding surface problems such as ripples and zebra stripes; 5. They can improve the surface gloss of products, and due to uniform plasticization, they can also help improve the tensile strength, impact strength, elongation at break, and other mechanical properties of products; 6. They can significantly reduce the deposition of various additives such as stabilizers, pigments, and calcium powder on the surface of PVC products. 7. Foaming regulators can effectively adjust the density and size of cells, significantly improve the melt strength of PVC materials, effectively encapsulate foaming gas, form a uniform honeycomb structure, prevent gas from escaping, and reduce the density of the product; 8. Good metal peelability, because it is a polymer material, it will not cause problems such as precipitation like lubricants.

[0010] Furthermore, the lubricant is stearic acid 1801, which has excellent internal and external lubrication balance and good softness and plasticity, and its dispersion and migration behavior in the melt is more balanced when used as a lubricant.

[0011] A method for preparing a carbon-based silicon-aluminum plate includes the following steps: S1 Raw Material Pretreatment: Dry the coal gangue powder to a moisture content of less than 1%, then mix it with a coupling agent at high speed to complete surface modification and obtain modified coal gangue powder; S2 High-speed mixing: Add PVC resin, stabilizer, plasticizer, lubricant and modified coal gangue powder obtained in step S1 into a high-speed mixer and mix at 110-135℃ for 5-10 minutes to allow the material to initially gel. S3 Cooling and Mixing: Transfer the mixture from step S2 to a cold mixer and cool it to 40-50°C. Then add processing aids, toughening agents, and lubricants, and mix thoroughly to obtain a premix. S4 Plasticizing and Molding: The premixed material obtained in step S3 is fed into a screw extruder for melt plasticizing, mixing, vacuum degassing, and filtration through a filter screen; S5 Shaping and Cooling: The molten material in step S4 is extruded into a slab through a slit-type flat die, and then introduced into a three-roll calender for calendering, thickness setting and preliminary cooling, and then enters a cooling rack for full cooling and solidification; S6 Post-processing: The cooled and cured board is pulled at a constant speed by a traction machine and cut to a set length to obtain the composite board.

[0012] Furthermore, in step S4, the screw extruder is a parallel co-rotating twin-screw extruder, the vacuum degree of the barrel vacuum exhaust port is not lower than -0.08MPa, and the barrel temperature zone and the die head temperature zone of the screw extruder are 170~200℃.

[0013] Furthermore, in step S5, the roller temperature of the three-roll calender is controlled as follows: upper roller 80-100℃, middle roller 60-80℃, and lower roller 40-60℃.

[0014] The beneficial effects of this invention are: 1. This invention significantly reduces raw material costs by using a large amount of coal gangue powder (industrial solid waste) as filler, and realizes the resource utilization of solid waste, which is in line with the concept of green manufacturing.

[0015] 2. This invention cleverly solves the two core contradictions of "poor processing fluidity" and "poor product toughness" in high-filler systems through the synergistic effect of processing aids (ACR), toughening agents, and modified coal gangue powder. ACR promotes uniform plasticization, and toughening agents provide impact resistance, enabling the sheet to maintain high rigidity (thanks to high filler) while having excellent toughness and low-temperature impact resistance.

[0016] 3. This invention, through the combination of a specific lubrication system and processing aids, ensures the smooth plasticization, flow and demolding of high-viscosity, high-filler materials during processing, thereby improving production efficiency, reducing equipment energy consumption, and ensuring the smoothness and flatness of the sheet surface.

[0017] 4. The components of this invention have clearly defined functions and work synergistically. The stabilizer ensures the stability of PVC under high-temperature processing; the modified coal gangue powder has enhanced bonding strength with the matrix, avoiding interface defects; the plasticizer has a flexible dosage range, allowing for the preparation of different specifications of boards from rigid to semi-rigid.

[0018] 6. This invention employs hot and cold mixing, with a maximum mixing temperature of 135°C. Within this temperature range, the moisture in the raw materials can be evaporated while ensuring that the raw materials remain in powder form, which is beneficial for raw material mixing and subsequent processing. Detailed Implementation

[0019] To more clearly illustrate the present invention, the following description, in conjunction with preferred embodiments, further clarifies the invention. Those skilled in the art should understand that the specific descriptions below are illustrative rather than restrictive, and should not be construed as limiting the scope of protection of the present invention.

[0020] The raw materials used in the embodiments of the present invention are as follows, but are not limited to the following raw materials. The present invention only uses the following raw materials as specific examples to further illustrate the effect of the artificial stone slabs described in the present invention.

[0021] The following examples are used to illustrate the present invention, but are not intended to limit the scope of the invention. Unless otherwise specified, the examples are conducted under conventional experimental conditions. Furthermore, for those skilled in the art, various modifications or improvements to the material composition and dosage in these embodiments without departing from the spirit and scope of the present invention are all within the scope of protection claimed by the present invention.

[0022] Examples 1-3 and Comparative Examples 1-2 of this invention are shown in the table below (unit: parts by weight). PVC resin 250 250 250 250 250 Modified coal gangue powder (400 mesh) 500 600 750 600 600 (Unmodified) stabilizer 2.7 4.5 6.0 4.5 4.5 lubricant 2 2.7 3.3 2.7 2.7 Processing aids 1 1.3 1.7 0 1.3 toughening agent 10 12.5 13.3 0 12.5 plasticizer 4 6 8.3 6 6 The preparation method of the carbon-based silicon-aluminum plate in Examples 1-3 of this invention includes the following steps: S1 Raw Material Pretreatment: Dry the coal gangue powder to a moisture content of less than 1%, then mix it with a coupling agent at high speed to complete surface modification and obtain modified coal gangue powder; S2 High-speed mixing: Add PVC resin, stabilizer, plasticizer, lubricant and modified coal gangue powder obtained in step S1 into a high-speed mixer and mix at 110-135℃ for 5-10 minutes to allow the material to initially gel. S3 Cooling and Mixing: Transfer the mixture from step S2 to a cold mixer and cool it to 40-50°C. Then add processing aids, toughening agents, and lubricants, and mix thoroughly to obtain a premix. S4 Plasticizing and Molding: The premixed material obtained in step S3 is fed into a screw extruder for melt plasticizing, mixing, vacuum degassing, and filtration through a filter screen; S5 Shaping and Cooling: The molten material in step S4 is extruded into a slab through a slit-type flat die, and then introduced into a three-roll calender for calendering, thickness setting and preliminary cooling, and then enters a cooling rack for full cooling and solidification; S6 Post-processing: The cooled and cured board is pulled at a constant speed by a traction machine and cut to a set length to obtain the composite board.

[0023] In step S4, the screw extruder is a parallel co-rotating twin-screw extruder, and the vacuum degree of the barrel vacuum exhaust port is not lower than -0.08MPa.

[0024] In step S5, the roller temperature of the three-roll calender is controlled as follows: upper roller 80-100℃, middle roller 60-80℃, and lower roller 40-60℃.

[0025] Preparation and testing: Following the aforementioned preparation method, the materials in the above formula were mixed, extruded, and calendered into a sheet with a thickness of 3 mm. Its performance was tested according to national standards, and the results are as follows: Notched impact strength (kJ / m², 23℃) 8.5 7.2 5.8 2.1 (Easily broken) 4.0 Tensile strength (MPa) 38.2 40.5 42.8 35.0 36.5 Bending strength (MPa) 52.1 58.6 63.4 55.0 56.8 Heating dimensional change rate (%) 1.5 1.2 1.0 2.8 2.0 Surface smoothness smooth smooth good Rough, with flow lines Generally, there are pockmarks. Processing evaluation Smooth Smooth acceptable High torque, prone to sticking to the mold Large torque Conclusion: As can be seen from Examples 1-3, the plates prepared by this invention maintain good comprehensive mechanical properties and surface quality over a wide filling range. Comparative Example 1 lacks key processing aids and toughening agents, leading to processing difficulties, extremely brittle finished products, and severely insufficient impact strength. Comparative Example 2 uses unmodified coal gangue; due to poor interfacial bonding between the filler and matrix, both impact strength and surface smoothness are significantly reduced. This demonstrates the necessity and superiority of component synergy and filler pretreatment in this invention.

[0026] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0027] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A carbon-based silicon-aluminum panel, characterized in that, The raw materials include the following parts by weight: 167-250 parts PVC resin, 500-750 parts coal gangue powder, 2.7-6.0 parts stabilizer, 2-3.3 parts lubricant, 1-1.7 parts processing aid, 4-8.3 parts plasticizer, and 10-13.3 parts toughening agent.

2. The carbon-based silica-alumina platelet of claim 1, wherein, The coal gangue powder is a modified coal gangue powder that has undergone surface modification treatment. The modification method is to use a modifier to perform surface coating treatment.

3. The carbon-based silica-alumina platelet of claim 2, wherein, The modifier is one of silane coupling agent, aluminate coupling agent, and titanate coupling agent, and the amount of modifier used is 0.5%-2.0% of the weight of coal gangue powder.

4. The carbon-based silica-alumina platelet of claim 1, wherein, The particle size of the coal gangue powder is 400-450 mesh.

5. The carbon-based silica-alumina platelet of claim 1, wherein, The stabilizer is a calcium-zinc composite stabilizer; the processing aid is an ACR processing aid; the toughening agent is a PVC / ABS blend toughening modification; and the plasticizer is chlorinated paraffin.

6. The carbon-based silicon-aluminum sheet according to claim 1, characterized in that, The lubricant is stearic acid 1801, which has both internal and external lubricating effects.

7. A method for preparing a carbon-based silicon-aluminum plate, characterized in that, Includes the following steps: S1 Raw Material Pretreatment: Dry the coal gangue powder to a moisture content of less than 1%, then mix it with a coupling agent at high speed to complete surface modification and obtain modified coal gangue powder; S2 High-speed mixing: Add PVC resin, stabilizer, plasticizer, lubricant and modified coal gangue powder obtained in step S1 into a high-speed mixer and mix at 110-135℃ for 5-10 minutes to allow the material to initially gel. S3 Cooling and Mixing: Transfer the mixture from step S2 to a cold mixer and cool it to 40-50°C. Then add processing aids, toughening agents, and lubricants, and mix thoroughly to obtain a premix. S4 Plasticizing and Molding: The premixed material obtained in step S3 is fed into a screw extruder for melt plasticizing, mixing, vacuum degassing, and filtration through a filter screen; S5 Shaping and Cooling: The molten material in step S4 is extruded into a slab through a slit-type flat die, and then introduced into a three-roll calender for calendering, thickness setting and preliminary cooling, and then enters a cooling rack for full cooling and solidification; S6 Post-processing: The cooled and cured board is pulled at a constant speed by a traction machine and cut to a set length to obtain the composite board.

8. The method for preparing carbon-based silicon-aluminum sheet according to claim 7, characterized in that, In step S4, the screw extruder is a parallel co-rotating twin-screw extruder, the vacuum degree of the barrel vacuum exhaust port is not lower than -0.08MPa, and the barrel temperature zone and the die head temperature zone of the screw extruder are 170~200℃.

9. The method for preparing carbon-based silicon-aluminum sheet according to claim 7, characterized in that, In step S5, the roller temperature of the three-roll calender is controlled as follows: upper roller 80-100℃, middle roller 60-80℃, and lower roller 40-60℃.