Polypropylene Board Composition to Prevent Extrusion Delamination
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Solution Overview
Problem
Existing polyvinyl chloride (PVC) floors release toxic gases and plasticizers, while polypropylene (PP) boards face delamination issues during extrusion molding, hindering large-scale production and application.
Innovation Solution
A method for preparing polypropylene boards using a modified polypropylene resin with a melt flow rate of 2-9 g/10 min, combined with fillers and lubricants, without plasticizers, antioxidants, or colorants, through extrusion molding, followed by lamination and quenching to form a stable, layered structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If calcium carbonate is used as filler in polypropylene plates, then cost is reduced and stiffness is improved, but surface quality deteriorates and formability worsens
Solution Approach 1:
A surface treatment layer comprising polypropylene resin and a master batch is applied to the calcium carbonate-filled polypropylene plate. This intermediary layer masks the rough surface caused by calcium carbonate particles while maintaining the underlying stiffness, thereby resolving the contradiction between improved stiffness and deteriorated surface quality
Solution Approach 2:
The plate structure is designed as a composite with an inner layer (calcium carbonate-filled polypropylene) and an outer surface treatment layer (polypropylene resin + master batch). This composite structure allows the inner layer to provide stiffness while the outer layer provides smooth surface quality, resolving the contradiction between these two properties
2Strength
If calcium carbonate is used as filler in polypropylene plates, then cost is reduced and stiffness is improved, but formability worsens
Solution Approach 1:
The plate is designed with different local properties: the inner layer contains calcium carbonate for stiffness, while the outer surface treatment layer has optimized composition (polypropylene resin + master batch) to provide good formability. This local differentiation allows the plate to achieve both high stiffness and good formability simultaneously
3Strength
If plate thickness is increased to prevent bending, then bending resistance is improved, but processing difficulty increases and material consumption increases
Solution Approach 1:
The plate uses a composite structure with calcium carbonate filler (30-70 wt%) in the polypropylene matrix to achieve high bending resistance. The optimized filler content and surface treatment layer provide sufficient stiffness without requiring increased plate thickness, thereby avoiding the processing difficulties and material consumption associated with thicker plates
Data Source
AI summary
The disclosure relates to the manufacturing of floors, and more particularly to a polypropylene board and a method for preparing the same. The polypropylene board is prepared from 25-40 parts by weight of a modified polypropylene resin, 30-70 parts by weight of a filler, 3-10 parts by weight of a stabilizer and 1-8 parts by weight of a lubricant. A melt flow rate of the modified polypropylene resin is 2-9 g/10 min. In the method, the raw material formula is optimized by using the modified polypropylene resin with a melt flow rate of 2-9 g/10 min, the filler, the stabilizer and the lubricant as raw materials, such that the polypropylene board can be molded by extrusion in the absence of a plasticizer, and will not experience delamination.