A carbon-based filling novel plate capable of decomposing formaldehyde and purifying air and a preparation method thereof

Abstract

The present application belongs to the technical field of polyvinyl chloride composite material, and particularly relates to a carbon-based filling novel plate capable of decomposing formaldehyde and purifying air, which comprises the following raw materials: PVC, fly ash, crushed material, high-strength long carbon fiber, organic foaming agent, inorganic foaming agent, stabilizer, reinforcing modifier, lubricant, negative ion powder and toughening agent; a production process thereof comprises the following steps: mixing PVC, a heat stabilizer, a foaming agent, a toughening agent, a lubricant, activated fly ash inorganic filler mixture and activated high-strength long carbon fiber with a set weight ratio, simultaneously mixing them by a double-screw mixing mill, extruding them by a single-screw extruder, and finally performing shaping treatment to obtain the carbon-based filling novel plate capable of decomposing formaldehyde and purifying air; the present application has the characteristics of environmental protection, non-toxicity, formaldehyde decomposition and air purification, and the formaldehyde decomposition capacity is 5-10 times that of common other types of plates; the production process is simple, energy consumption is low, the product can be recycled, is green and environmentally friendly, and economic cost is saved.

Description

Technical Field

[0001] This invention belongs to the field of polyvinyl chloride composite material technology, specifically a novel carbon-based filled board material that can decompose formaldehyde and purify air, and its preparation method. Background Technology

[0002] Polyvinyl chloride (PVC) is the second most widely used general-purpose plastic after polypropylene (PP), with 70% of total PVC consumption in the building materials sector. Due to its low price and excellent performance, PVC products are widely used, especially PVC composite panels. PVC composite panels, with their advantages of lightweight, functionality, and structural integrity, are ubiquitous in industrial and household applications, showing broad application prospects. However, with the development of technology in the building materials industry, more stringent requirements have been placed on whether composite panels can remove formaldehyde. Currently, the comprehensive utilization of fly ash is a significant research topic. Many scientists and engineers both domestically and internationally have made meaningful explorations in this area. However, due to factors such as performance and usage habits, it has not yet been widely promoted. This project will fully utilize fly ash waste and leverage the vast market of building formwork to effectively utilize fly ash.

[0003] To improve the performance of PVC boards, many studies have focused on enhancing the mechanical properties during the composite process, but none have provided detailed explanations regarding the effect of PVC composite boards on formaldehyde. Patent CN10864130A invented a PVC-wood composite material, patent CN101885884A invented a bamboo shoot fiber / PVC composite material and its preparation method, and patent CN101348594A invented a carbon fiber reinforced polyvinyl chloride material and its preparation method. These patents all focus on the mechanical properties of PVC boards, not on targeted improvements for formaldehyde removal, and do not provide specific quantitative calculations for formaldehyde removal. Patent CN1061147078A invented a bio-enzyme modified wood flour PVC composite material, using wood flour mixed with PVC to make boards, and studied its mechanical and flame-retardant properties. Patent CN106751194A invented a method for preparing crack-resistant PVC floor tiles by adding coal gangue powder, improving the dimensional stability and crack resistance of the product by adding coal gangue to PVC. However, none of the above existing technologies possess the ability to decompose formaldehyde or purify the air. Summary of the Invention

[0004] The purpose of this invention is to provide a novel carbon-based filled board material that can decompose formaldehyde and purify air, and its preparation method. This material is environmentally friendly and non-toxic, and can decompose formaldehyde and purify air. Its formaldehyde decomposition ability is 5 to 10 times that of other ordinary boards. Moreover, its production process is simple, energy consumption is low, and cost is low. It can also be recycled, making it green and environmentally friendly, and saving economic costs.

[0005] To achieve the above-mentioned objectives, the technical solution of this invention is: a novel carbon-based filled board that can decompose formaldehyde and purify air, comprising the following raw materials in parts by weight: 25-37.5 parts PVC, 40-60 parts fly ash, 100-125 parts crushed material, 0.1-0.2 parts high-strength long carbon fiber, 0.5-0.8 parts organic foaming agent, 0.8-1.2 parts inorganic foaming agent, 2-3 parts stabilizer, 1.5-2 parts reinforcing modifier, 1.5-2 parts lubricant, 0.2-0.5 parts negative ion powder, and 9-10 parts toughening agent.

[0006] A new type of carbon-based filled board that can decompose formaldehyde and purify air comprises the following raw materials in parts by weight: 30 parts PVC, 50 parts fly ash, 100 parts crushed material, 0.1 parts high-strength long carbon fiber, 0.6 parts organic foaming agent, 1.0 part inorganic foaming agent, 3 parts stabilizer, 1.8 parts reinforcing modifier, 1.6 parts lubricant, 0.3 parts negative ion powder, and 7 parts toughening agent.

[0007] Furthermore, the fly ash has a particle size of 80-100 mesh and its surface is activated by an aminosilane coupling agent; the high-strength long carbon fiber is alkali-free high-strength long carbon fiber with a fiber diameter of 0.01-0.02 mm and a stranded yarn of more than 1000 monofilaments, and its surface is activated by an aminosilane coupling agent.

[0008] Further, the PVC is one or a mixture of two of PVC (SG-5) and PVC (SG-7), with a degree of polymerization of 600~800; the organic foaming agent is azodicarbonamide; and the inorganic foaming agent is NaHCO3.

[0009] Furthermore, the stabilizer is a PVC foam stabilizer.

[0010] Furthermore, the stabilizer is a calcium-zinc composite stabilizer.

[0011] Furthermore, the lubricant is one or a mixture of two or more of polyethylene wax, chlorinated polyvinyl chloride wax, and paraffin wax; the toughening agent is one or a mixture of two or more of chlorinated polyethylene (CPE), acrylate copolymer (ACR), and acrylonitrile-butadiene-styrene copolymer (ABS).

[0012] A method for preparing a novel carbon-based filled board material capable of decomposing formaldehyde and purifying air includes the following steps: a. Activation treatment of a specified weight proportion of fly ash and high-strength long carbon fibers using an aminosilane coupling agent; b. Mix the specified weight proportions of PVC, heat stabilizer, foaming agent, toughening agent, lubricant, and activated fly ash inorganic filler, then heat to 100~115℃ and cool to below 40℃; c. The mixture from step b and the activated high-strength long carbon fibers from step a are simultaneously mixed in a twin-screw internal mixer and then extruded through a single-screw extruder. The screw speed is 15-25 rpm, the barrel temperature is 130-180℃, the screw oil temperature is 130-170℃, the confluence core temperature is 130-160℃, and the die temperature is 150-180℃. Finally, the mixture is molded to obtain a new type of carbon-based filled board that decomposes formaldehyde and purifies the air.

[0013] Further, in step a, fly ash and high-strength long carbon fibers are soaked in a silane coupling agent with a concentration of 0.5% and a pH of 6 at a temperature of 20-30℃ for 0.8-1.5 hours, and then dried at a temperature of 110℃-130℃.

[0014] Further, in step b, the materials are mixed and then added to a high-speed mixer and mixed until the temperature reaches 100~115℃, and then transferred to a cold mixer until the cold mixing temperature is below 40℃ before stopping.

[0015] The beneficial effects of this invention are: Formaldehyde removal and odor elimination: This invention uses a high-molecular silicon-aluminum glue-free polymerization process, which fundamentally eliminates the polymerization process of traditional furniture boards using formaldehyde resin glue, and completely eliminates the hidden danger of formaldehyde in the material. The oxygen-increasing factors in the board combine with water molecules in the air to release negative oxygen ions, thereby purifying formaldehyde and eliminating odors. Innovation in raw materials: The National Development and Reform Commission's newly revised "Product Catalogue" lists calcium carbonate as a restricted product. This invention, however, uses fly ash from coal hundreds of meters deep within the Earth, produced at temperatures exceeding 1000 degrees Celsius, as the primary material, separating silicon-aluminum compounds. This responds to the national call and abandons the traditional process that uses calcium carbonate as the main material. Water resistance: Carbon-based furniture boards utilize a high-polymer resin waterproof technology system, making the chance of deformation when exposed to moisture extremely low. Durability: The free amorphous silica in carbon-based furniture boards, due to its free nature, becomes more evenly distributed over time, making the physical properties of the board more stable, enhancing product performance, and extending the warranty period and service life. Detailed Implementation

[0016] 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.

[0017] 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.

[0018] The stabilizer is a composite calcium-zinc stabilizer, synthesized using a special compounding process with calcium salts, zinc salts, lubricants, and antioxidants as the main components. It not only replaces toxic stabilizers such as lead-cadmium salts and organotin compounds, but also possesses excellent thermal stability, light stability, transparency, and coloring power. Practical experience has shown that in PVC resin products, it exhibits good processing performance and thermal stabilization equivalent to lead-based stabilizers, making it a good, non-toxic stabilizer.

[0019] I. Stabilizers: Ensure stability "from processing to use" Core function: To prevent materials from degrading or deteriorating in performance due to factors such as heat, light, and oxygen during production and use, and to ensure the durability of the board.

[0020] Heat stabilizer Timing of application: Primarily during the production and processing stages (such as mixing, extrusion, calendering, and hot pressing), especially for heat-sensitive plastic sheets such as polyvinyl chloride (PVC).

[0021] Mechanism of action: It absorbs or neutralizes the hydrogen chloride generated by processing heat and shear force, preventing the chain reaction of molecular chain breakage and discoloration (yellowing, blackening) that is triggered by this.

[0022] Ultimate impact: Ensures that the board retains its original color, gloss, and mechanical properties after high-temperature processing, with a smooth surface free of bubbles and decomposition lines.

[0023] Light stabilizers (UV stabilizers) Timing of application: Primarily during the product usage stage, especially for outdoor-use panels (such as exterior wall panels, advertising light box panels, and polycarbonate panels).

[0024] Mechanism of action: UV absorbers: Like sunscreen, they selectively absorb high-energy ultraviolet light and convert it into harmless heat.

[0025] Hindered amine light stabilizers: capture free radicals generated by ultraviolet light, interrupting the oxidation reaction chain that leads to material aging, embrittlement, and discoloration.

[0026] Ultimate impact: Significantly extends the service life of outdoor panels, preventing fading, chalking, surface cracking, and decreased mechanical strength.

[0027] antioxidants Timing of action: Throughout the entire processing and use process, it combats thermo-oxidative aging.

[0028] Mechanism of action: It inhibits oxygen-induced free radical chain oxidation reactions during high-temperature processing and long-term use.

[0029] Ultimate impact: Prevents the board from yellowing and becoming brittle during processing and maintains stable performance during long-term use. Example

[0030] A new type of carbon-based filled board that can decompose formaldehyde and purify air comprises the following raw materials in parts by weight: 25 parts PVC, 40 parts fly ash, 100 parts crushed material, 0.1 parts high-strength long carbon fiber, 0.5 parts organic foaming agent, 0.8 parts inorganic foaming agent, 2 parts stabilizer, 1.5 parts reinforcing modifier, 1.5 parts lubricant, 0.2 parts negative ion powder, and 9 parts toughening agent.

[0031] The fly ash has a particle size of 80-100 mesh and its surface is activated by an aminosilane coupling agent; the high-strength long carbon fiber is alkali-free high-strength long carbon fiber with a fiber diameter of 0.01-0.02 mm and a stranded yarn of more than 1000 monofilaments, and its surface is activated by an aminosilane coupling agent.

[0032] The PVC is one or a mixture of two of PVC (SG-5) and PVC (SG-7), with a degree of polymerization of 600~800; the organic foaming agent is azodicarbonamide; and the inorganic foaming agent is NaHCO3.

[0033] The stabilizer is a PVC foam stabilizer.

[0034] The stabilizer is a calcium-zinc composite stabilizer.

[0035] The lubricant is one or a mixture of two or more of polyethylene wax, chlorinated polyvinyl chloride wax, and paraffin wax; the toughening agent is one or a mixture of two or more of chlorinated polyethylene (CPE), acrylate copolymer (ACR), and acrylonitrile-butadiene-styrene copolymer (ABS).

[0036] A method for preparing a novel carbon-based filled board material capable of decomposing formaldehyde and purifying air includes the following steps: a. Activation treatment of fly ash and high-strength long carbon fibers in a specified weight ratio using an aminosilane coupling agent; b. Mix the PVC, heat stabilizer, foaming agent, toughening agent, lubricant, and activated fly ash inorganic filler in the specified weight proportions, heat to 110°C, then cool in a cold roller to below 40°C (e.g., 35°C) and place in a storage silo. c. The mixture from step b and the activated high-strength long carbon fibers from step a are simultaneously mixed in a twin-screw internal mixer and then extruded through a single-screw extruder. The screw speed is 18 rpm, the barrel temperature is 140℃, the screw oil temperature is 150℃, the confluence core temperature is 155℃, and the die temperature is 165℃. Finally, the material is shaped, cooled and shaped on a sizing table, and then cut after the tension is eliminated to obtain a new type of carbon-based filled board that decomposes formaldehyde and purifies the air.

[0037] In step a, fly ash and high-strength long carbon fibers are soaked in a silane coupling agent with a concentration of 0.5% and a pH of 6 at a temperature of 20-30℃ for 0.8-1.5 hours, and then dried at a temperature of 110℃-130℃.

[0038] The preparation methods of Examples 2-4 are the same as those of Example 1, except that the amount of each raw material in the artificial stone slab is adjusted based on Example 1. Example

[0039] A new type of carbon-based filled board that can decompose formaldehyde and purify air comprises the following raw materials in parts by weight: 37.5 parts PVC, 40 parts fly ash, 100 parts crushed material, 0.1 parts high-strength long carbon fiber, 0.5 parts organic foaming agent, 0.8 parts inorganic foaming agent, 2 parts stabilizer, 1.5 parts reinforcing modifier, 1.5 parts lubricant, 0.2 parts negative ion powder, and 9 parts toughening agent.

[0040] The increased use of PVC will improve the impact resistance and toughness of the sheet, increase the ultimate tensile strength and flexural strength, and increase the elongation at break. Example

[0041] A new type of carbon-based filled board that can decompose formaldehyde and purify air comprises the following raw materials in parts by weight: 25 parts PVC, 60 parts fly ash, 100 parts crushed material, 0.1 parts high-strength long carbon fiber, 0.5 parts organic foaming agent, 0.8 parts inorganic foaming agent, 2 parts stabilizer, 1.5 parts reinforcing modifier, 1.5 parts lubricant, 0.2 parts negative ion powder, and 9 parts toughening agent.

[0042] Increasing the amount of fly ash will reduce the impact strength of the board, make the board more brittle, and worsen the surface finish. Example

[0043] A new type of carbon-based filled board that can decompose formaldehyde and purify air comprises the following raw materials in parts by weight: 25 parts PVC, 40 parts fly ash, 100 parts crushed material, 0.1 parts high-strength long carbon fiber, 0.5 parts organic foaming agent, 0.8 parts inorganic foaming agent, 2 parts stabilizer, 1.5 parts reinforcing modifier, 1.5 parts lubricant, 0.5 parts negative ion powder, and 9 parts toughening agent.

[0044] The increased use of negative ion powder enhances the air purification capacity of the board and improves its antibacterial and anti-mildew properties.

[0045] In the above embodiments, the chemical name of the AC foaming agent is azodicarbonamide, with the molecular formula C2H4O2N4; PVC is polyvinyl chloride, also known as resin powder; PVC(SG-7) and PVC(SG-5) refer to type VII and type V polyvinyl chloride, respectively. Depending on the polymerization process, reaction conditions, composition of reactants, additives, and other factors, the resin powder produced will be of different types, and the resin properties will also be different.

[0046] 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.

[0047] The exemplary embodiments of the present invention have been described in detail above with reference to preferred embodiments. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the concept of the present invention, and various combinations can be made to the various technical features and structures proposed in the present invention without exceeding the protection scope of the present invention.

Claims

1. A novel carbon-based filled board material capable of decomposing formaldehyde and purifying air, characterized in that, The raw materials include the following parts by weight: PVC 25~37.5 parts, fly ash 40~60 parts, crushed material 100~125 parts, high-strength long carbon fiber 0.1~0.2 parts, organic foaming agent 0.5~0.8 parts, inorganic foaming agent 0.8~1.2 parts, stabilizer 2~3 parts, reinforcing modifier 1.5~2 parts, lubricant 1.5~2 parts, negative ion powder 0.2~0.5 parts, and toughening agent 9~10 parts.

2. The novel carbon-based filled board material that can decompose formaldehyde and purify air according to claim 1, characterized in that, The raw materials include the following parts by weight: 30 parts PVC, 50 parts fly ash, 100 parts crushed material, 0.1 parts high-strength long carbon fiber, 0.6 parts organic foaming agent, 1.0 part inorganic foaming agent, 3 parts stabilizer, 1.8 parts reinforcing modifier, 1.6 parts lubricant, 0.3 parts negative ion powder, and 7 parts toughening agent.

3. A novel carbon-based filled board material capable of decomposing formaldehyde and purifying air, as described in claim 1 or 2, characterized in that... The fly ash has a particle size of 80-100 mesh and its surface is activated by an aminosilane coupling agent; the high-strength long carbon fiber is an alkali-free high-strength long carbon fiber with a fiber diameter of 0.01-0.02 mm and a strand of more than 1000 monofilaments of untwisted direct yarn, and its surface is activated by an aminosilane coupling agent.

4. A novel carbon-based filled board material capable of decomposing formaldehyde and purifying air, as described in claim 1 or 2, characterized in that... The PVC is one or a mixture of two of PVC (SG-5) and PVC (SG-7), with a degree of polymerization of 600~800; the organic foaming agent is azodicarbonamide; and the inorganic foaming agent is NaHCO3.

5. A novel carbon-based filled board material capable of decomposing formaldehyde and purifying air, as described in claim 1 or 2, characterized in that... The stabilizer is a PVC foam stabilizer.

6. A novel carbon-based filled board material capable of decomposing formaldehyde and purifying air according to claim 5, characterized in that, The stabilizer is a calcium-zinc composite stabilizer.

7. A novel carbon-based filled board material capable of decomposing formaldehyde and purifying air according to claim 1 or 2, characterized in that: The lubricant is one or a mixture of two or more of polyethylene wax, chlorinated polyvinyl chloride wax, and paraffin wax; the toughening agent is one or a mixture of two or more of chlorinated polyethylene (CPE), acrylate copolymer (ACR), and acrylonitrile-butadiene-styrene copolymer (ABS).

8. A method for preparing a novel carbon-based filled board material capable of decomposing formaldehyde and purifying air, characterized in that, Includes the following steps: a. Activation treatment of a specified weight proportion of fly ash and high-strength long carbon fibers using an aminosilane coupling agent; b. Mix the specified weight proportions of PVC, heat stabilizer, foaming agent, toughening agent, lubricant, and activated fly ash inorganic filler, then heat to 100~115℃ and cool to below 40℃; c. The mixture from step b and the activated high-strength long carbon fibers from step a are simultaneously mixed in a twin-screw internal mixer and then extruded through a single-screw extruder. The screw speed is 15-25 rpm, the barrel temperature is 130-180℃, the screw oil temperature is 130-170℃, the confluence core temperature is 130-160℃, and the die temperature is 150-180℃. Finally, the mixture is molded to obtain a new type of carbon-based filled board that decomposes formaldehyde and purifies the air.

9. The method for preparing a novel carbon-based filled board material capable of decomposing formaldehyde and purifying air according to claim 8, characterized in that, In step a, fly ash and high-strength long carbon fibers are soaked in a silane coupling agent with a concentration of 0.5% and a pH of 6 at a temperature of 20-30℃ for 0.8-1.5 hours, and then dried at a temperature of 110℃-130℃.

10. The method for preparing a novel carbon-based filled board material capable of decomposing formaldehyde and purifying air according to claim 8, characterized in that: In step b, the materials are mixed and then added to a high-speed mixer and mixed until the temperature reaches 100~115℃. Then, they are transferred to a cold mixer and the mixing is stopped when the temperature drops below 40℃.