Disclosure of Invention
The invention aims at overcoming the defects in the prior art and provides an intrinsic flame-retardant polypropylene foaming material and a preparation method thereof.
The preparation method of the intrinsic flame-retardant polypropylene foaming material comprises the following steps:
(1) The polypropylene powder, the peroxide initiator and the polymerization monomer A containing double bonds and isocyanate groups are placed in a ball mill to be uniformly mixed, and the graft 1 polymer is obtained by a solid phase grafting method. The ball mill is controlled at 80-140 ℃ and the ball milling time is 0.5-2 h.
The polypropylene powder is preferably homo-polymerization polypropylene, and the particle size of the powder is controlled to be 1-100 microns. The mass ratio of the polypropylene powder to the peroxide initiator is 100:0.2-3, and the mole fraction of double bonds in the polymerized monomer A used by the polypropylene powder per 100 g is 0.1-5%.
The peroxide initiator is selected from lauroyl peroxide, benzoyl peroxide, diisopropyl peroxydicarbonate, dicyclohexyl peroxydicarbonate, bis (4-tert-butylcyclohexyl) peroxydicarbonate, tert-butylperoxybenzoate, tert-butylpivalate, di-tert-butylperoxide, cumene hydroperoxide, diisopropylbenzene hydroperoxide, p- meng alkane hydroperoxide, and bis (2-phenoxyethyl) peroxydicarbonate.
The polymerization monomer A is selected from vinyl isocyanate, 3-propylene isocyanate, methacrylic acid isocyanate, 2-butene isocyanate, styryl isocyanate, isoprene isocyanate, cyclopentene isocyanate, norbornene isocyanate and methyl styrene isocyanate.
The principle of the reaction of polypropylene, peroxide and polymerized monomer A (vinyl isocyanate) to obtain the graft 1 polymer is as follows:
;
The polypropylene molecular monomer is grafted with isocyanate groups.
(2) Mixing the grafted 1 polymer and ungrafted polypropylene powder according to a certain proportion, extruding by a double-screw extruder, adding phosphoramidate flame retardant at the middle section of the extruder by a side feeding system, and performing secondary grafting reaction by heating and shearing the screw, namely, reacting the amino group of the phosphoramidate flame retardant with the isocyanate group in the grafted 1 polymer to obtain a grafted 2 polymer. The reaction principle is as follows:
;
the mass ratio of the polypropylene powder used in the step (1) to the ungrafted polypropylene powder used in the step (2) is 100:0-50.
The phosphoramidate flame retardant is selected from diphenyl phosphoramidate, tri (2-aminoethyl) phosphate, tri (2-hydroxyethyl) aminomethyl phosphate and diethyl amine phosphate. The amount of the phosphoramidate flame retardant is that the molar ratio of amino groups in the flame retardant to isocyanate groups in the polymer grafted 1 is (55-90) to 100, so that 10% -45% excess of the isocyanate groups is ensured, and isocyanate groups are provided for subsequent stiffening reaction.
(3) And (3) carrying out stiffening reaction on the grafted 2 polymer and excessive isocyanate groups through high-temperature steam to obtain polyurea groups, and improving the melt strength of the material. The stiffening reaction generates CO 2 gas, and the reaction principle is as follows:
;
(4) And (3) performing supercritical foaming on the material obtained in the step (3) to obtain the intrinsic flame-retardant polypropylene foaming material. The supercritical foaming condition is that the temperature of a mould pressing foaming cavity is controlled at 140-160 ℃, the pressure of injected supercritical fluid CO 2 or/and nitrogen is 8-20 MPa, the constant temperature and the constant pressure are 1-4 h, then the pressure is quickly released, the pressure release speed is 1-10 MPa/s, and after the pressure is released to normal pressure, the mould is opened to obtain the foaming material.
The intrinsic flame-retardant polypropylene foaming material is prepared by adopting the preparation method.
The invention has the advantages that:
1. The grafting temperature is controlled below Tm of polypropylene by solid phase grafting of ball milling, and the polypropylene is prevented from being degraded at the temperature of Wen Jiezhi.
2. The amino group of the phosphoramidate flame retardant reacts with the isocyanate group in the polymer of the graft 1 quickly, the grafting efficiency is high in a screw rod, and the side reaction is less.
3. The high melt grafting of polypropylene is to make isocyanate react with water to generate polyurea stiffening on an extrusion line after extruding a screw rod, the stiffening efficiency is high, the formed material is not sheared by the screw rod, the degradation problem of branched materials is avoided, CO 2 is generated in the stiffening process, a gas passage is provided for the subsequent supercritical foaming, and the saturation efficiency in the supercritical foaming is improved.
4. The foaming precursor is foamed by supercritical fluid CO 2 or/and nitrogen, and the whole preparation process has the advantages of cleanness and environmental protection.
5. The invention provides a novel flame-retardant polypropylene foaming material which contains nitrogen element and phosphorus element, has high halogen-free flame-retardant efficiency through testing, and has excellent physical and mechanical properties. The preparation method is novel, and solves the problems of low melt strength and low flame retardant efficiency of polypropylene.
Detailed Description
The embodiment is implemented on the premise of the technical scheme of the invention, and detailed implementation modes and processes are given, but the protection scope of the invention is not limited to the following embodiment. Unless otherwise indicated, the materials used are all commercially available conventional articles.
In an embodiment, the polypropylene used may be T30S、C1608、CP80M、CP80S、EP1X37F、F401、S1004、CF-501、EPS30R、F3002、F400-H、F800E、F800E(DF)、FC801、FC801M、FC801MX、JF300、T36F、X37F、X47F、YPF-3003 or YPF-3008. They are all homo-polypropylene, the particle size of the powder is 1-100 microns.
The peroxide initiator is selected from lauroyl peroxide, benzoyl peroxide, diisopropyl peroxydicarbonate, dicyclohexyl peroxydicarbonate, bis (4-tert-butylcyclohexyl) peroxydicarbonate, tert-butylperoxybenzoate, tert-butylpivalate, di-tert-butylperoxide, cumene hydroperoxide, diisopropylbenzene hydroperoxide, p- meng alkane hydroperoxide, bis (2-phenoxyethyl) peroxydicarbonate. Their use is the same as that of the examples which list only part of the peroxides.
The polymeric monomer A is selected from vinyl isocyanate, 3-propylene isocyanate, methacrylic acid isocyanate, 2-butylene isocyanate, styrene isocyanate, isoprene isocyanate, cyclopentene isocyanate, norbornene isocyanate and methyl styrene isocyanate. They contain both double bonds and isocyanate groups and the same effect is achieved, examples only listing part of the polymerized monomers A.
The phosphoramidate flame retardant is selected from diphenyl phosphoramidate, tris (2-aminoethyl) phosphate, tris (2-hydroxyethyl) aminomethyl phosphate, and diethyl amine phosphate.
Example 1
100 G polypropylene powder, 0.5 g benzoyl peroxide and 20.7 g vinyl isocyanate are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 100 ℃, the ball milling time is 0.5 h, and the graft 1 polymer is obtained through a solid phase grafting method.
Mixing the obtained graft 1 polymer with 20 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 54.82 g diphenyl phosphoramidate at the middle section of the extruder by a side feeding system, and performing secondary grafting reaction by heating and shearing of a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 145 ℃, injecting supercritical fluid CO 2 to obtain a pressure of 10 MPa, keeping the temperature and the pressure constant at 2h, rapidly releasing the pressure at 1-10 MPa/s, releasing the pressure to normal pressure, and opening the mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 2
100 G polypropylene powder, 1.5 g lauroyl peroxide and 166.2 g of 3-isocyanatopropylene are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 120 ℃, the ball milling time is 1h, and the graft 1 polymer is obtained through a solid phase grafting method.
And mixing the obtained graft 1 polymer with 30 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 91.84 g tri (2-aminoethyl) phosphate at the middle section of the extruder by a side feeding system, and performing secondary grafting reaction by heating and shearing by a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 150 ℃, injecting supercritical fluid nitrogen at 15 MPa, keeping constant temperature and pressure at 3: 3 h, rapidly releasing pressure at 1-10 MPa/s, releasing pressure to normal pressure, and opening the mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 3
100G polypropylene powder, 3 g diisopropyl peroxydicarbonate and 635 g methacrylic acid isocyanate are placed into a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 140 ℃, the ball milling time is 0.8 h, and the graft 1 polymer is obtained through a solid phase grafting method.
Mixing the obtained graft 1 polymer with 50 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 894 g tri (2-hydroxyethyl) aminomethyl phosphate at the middle section of the extruder by a side feeding system, and performing a secondary grafting reaction by heating and shearing by a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 160 ℃, injecting supercritical fluid nitrogen at 8 MPa, keeping constant temperature and constant pressure at 4: 4 h, rapidly releasing pressure at 1-10 MPa/s, releasing pressure to normal pressure, and opening the mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 4
100 G polypropylene powder, 0.2 g dicyclohexyl peroxydicarbonate and 13.3 g styryl isocyanate are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 80 ℃, the ball milling time is 2h, and the graft 1 polymer is obtained by a solid phase grafting method.
And mixing the obtained graft 1 polymer with 40 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 10.2 g diethyl phosphate amine at the middle section of the extruder by a side feeding system, and carrying out secondary grafting reaction by heating and shearing of a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 140 ℃, injecting a mixture of supercritical fluid CO 2 and supercritical fluid nitrogen to 20 MPa, performing constant temperature and constant pressure 1h, performing rapid decompression, performing decompression at the decompression speed of 1-10 MPa/s, and opening the mould after decompression to normal pressure to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 5
100 G polypropylene powder, 2g tert-butyl peroxybenzoate and 146 g methyl styrene isocyanate are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 110 ℃, the ball milling time is 1.5h, and the graft 1 polymer is obtained through a solid phase grafting method.
Extruding the obtained graft 1 polymer through a double-screw extruder, adding 198 g diphenyl phosphoramidate at the middle section of the extruder through a side feeding system, and carrying out a secondary grafting reaction through heating and shearing of a screw to obtain a graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 155 ℃, injecting supercritical fluid CO 2 at a pressure of 13: 13 MPa, keeping constant temperature and constant pressure of 2.5: 2.5 h, rapidly releasing pressure at a pressure release speed of 1-10: 10 MPa/s, releasing pressure to normal pressure, and opening a mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 6
100 G polypropylene powder, 1 g tert-butyl pivalate peroxide and 440 g cyclopentene isocyanate are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 90 ℃, the ball milling time is 1.8 h, and the graft 1 polymer is obtained through a solid phase grafting method.
And mixing the obtained graft 1 polymer with 10 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 186 g tri (2-aminoethyl) phosphate at the middle section of the extruder by a side feeding system, and performing secondary grafting reaction by heating and shearing by a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 145 ℃, injecting supercritical fluid CO 2 at 17: 17 MPa, maintaining constant temperature and pressure at 1.5: 1.5 h, rapidly releasing pressure at 1-10 MPa/s, releasing pressure to normal pressure, and opening the mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 7
100 G polypropylene powder, 2.5 g cumene hydroperoxide and 242.5 g 2-butene isocyanate are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 130 ℃, the ball milling time is 1.2 h, and the graft 1 polymer is obtained through a solid phase grafting method.
And mixing the obtained graft 1 polymer with 25 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 342.7 g diphenyl phosphoramidate at the middle section of the extruder by a side feeding system, and performing secondary grafting reaction by heating and shearing of a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 150 ℃, injecting supercritical fluid nitrogen at 11 MPa, keeping constant temperature and constant pressure at 3.5: 3.5 h, rapidly releasing pressure at the pressure release speed of 1-10 MPa/s, releasing pressure to normal pressure, and opening the mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Example 8
100 G polypropylene powder, 1.2 g hydrogen peroxide pair meng alkane and 249 g 3-isocyanatopropylene are placed into a ball mill to be uniformly mixed, the temperature of the ball mill is controlled to be 120 ℃, the ball milling time is 1 h, and the graft 1 polymer is obtained through a solid phase grafting method.
Mixing the obtained graft 1 polymer with 15 g ungrafted polypropylene powder, extruding by a double-screw extruder, adding 672.8 g diphenyl phosphoramidate at the middle section of the extruder by a side feeding system, and performing secondary grafting reaction by heating and shearing of a screw to obtain the graft 2 polymer.
The grafting 2 polymer is subjected to stiffening reaction and CO 2 gas circuit establishment through high-temperature vapor and excessive isocyanate groups, the speed is 3m per minute, the length of an oven is 12 m, polyurea groups are obtained, and the melt strength of the material is improved. The grafted high-melt intrinsic polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 150 ℃, injecting supercritical fluid CO 2 to obtain a pressure of 14: 14 MPa, keeping constant temperature and constant pressure of 3: 3 h, rapidly releasing pressure at a pressure release speed of 1-10: 10 MPa/s, releasing pressure to normal pressure, and opening the mould to obtain the intrinsic flame-retardant polypropylene foaming material.
Comparative example 1
100 G polypropylene powder, 0.5 g benzoyl peroxide and 20.7 g vinyl isocyanate are placed in a ball mill for uniform mixing, the temperature of the ball mill is controlled to be 100 ℃, the ball milling time is 0.5 h, and the graft 1 polymer is obtained through a solid phase grafting method.
Mixing the obtained graft 1 polymer with 20 g ungrafted polypropylene powder, extruding by a double screw extruder, then carrying out stiffening reaction by high-temperature steam and establishing a CO 2 gas circuit, and controlling the speed of the dryer to be 3 m per minute and the length of the oven to be 12 m. The grafted high-melt polypropylene material is respectively injection-molded into solid sheets with the thickness of 4 mm.
And (3) performing supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 145 ℃, injecting supercritical fluid CO 2 to 10 MPa, keeping constant temperature and constant pressure at 2h, rapidly releasing pressure at 1-10 MPa/s, releasing pressure to normal pressure, and opening the mould to obtain the polypropylene foaming material.
The difference from example 1 is that no flame retardant grafting was performed.
Comparative example 2
100 G polypropylene powder was extruded through a twin screw extruder, passed through a high temperature steam, vehicle speed 3 m per minute, oven length 12 m, and then the polypropylene material was injection molded into 4 mm thick solid sheets, respectively. Finally, carrying out supercritical foaming on the solid sheet, controlling the temperature of a mould pressing foaming cavity at 145 ℃, injecting supercritical fluid CO 2 to obtain a pressure of 10 MPa, keeping the constant temperature and constant pressure at 2h, then rapidly releasing the pressure at the pressure release speed of 1-10 MPa/s, releasing the pressure to normal pressure, and opening the mould to obtain the polypropylene foaming material.
The difference from example 1 is that no isocyanate group grafting, flame retardant grafting and stiffening reaction was carried out.
Performance testing
The foaming materials prepared in example 1 and comparative example 2 were tested, horizontal flame retardant and vertical flame retardant test method UL94, tensile strength ASTM-D3574-08, bending test method GB-T8812.2-2007, surface rubberizing strength test GB/T33332, and the results are shown in table 1.
Table 1 results of testing the foaming materials of example 1 and comparative example 1, comparative example 2
From the test results, the halogen-free flame retardant containing nitrogen and phosphorus elements is grafted on the molecular chain through complete two grafting reactions and one stiffening reaction in the embodiment 1, the solid sheet can be vertically combusted through V-0, and meanwhile, the flame retardant grade of the foamed material can reach V-1, and compared with the comparative example 2, the flame retardant has the advantages of improved tensile property, improved melt strength and improved flame retardant property. In comparative example 1, since the raw material still contains nitrogen element in the first grafting, the solid sheet still has a certain flame retardant grade, and after the solid sheet is subjected to stiffening reaction, the stiffening effect is good because the isocyanate group content in the molecular chain is high, the tensile strength and the melt strength are higher than those of example 1, and the density of the obtained material is higher under the same foaming condition. Both example 1 and comparative example 1 underwent foaming reaction, and the surface had more bubbles, so that the surface-coating peeling force showed an upward trend after foaming. The comparative example 2 has poor physical and mechanical properties without grafting and stiffening reaction, and cannot meet the melt strength required by supercritical foaming, and the pure material has no flame retardant effect.
The foregoing is merely a preferred embodiment of the present invention, and it should be noted that modifications and additions may be made to those skilled in the art without departing from the method of the present invention, which modifications and additions are also to be considered as within the scope of the present invention.