CN110014482A - 一种高强度的指接结构净醛生态板及其制造方法 - Google Patents
一种高强度的指接结构净醛生态板及其制造方法 Download PDFInfo
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Abstract
本发明涉及生态板制造技术领域,具体为一种高强度的指接结构净醛生态板及其制造方法,包括芯板、面板和装饰胶膜纸,芯板由多个板条利用指接结构拼接组成,芯板的上下表面均设置有筋条,指接结构包括板条上分别设置的凸棱和与凸棱相适配的凹槽,芯板由一个所述板条的凸棱插接在另一个所述板条上的凹槽内拼接组成,芯板的表面上沿板条的长度走向等间隔开设有多条滑槽,筋条滑动插接在滑槽内。该种高强度的指接结构净醛生态板及其制造方法,通过利用指接结构连接拼成芯板,提高了芯板的连接强度和抗剪切强度,并且筋条与板条纵横交错,大大提高生态板的综合机械特性,木楔条的作用提高了生态板的强度抗弯曲特性,并提高生态板的加工性能。
Description
技术领域
本发明涉及生态板制造技术领域,具体为一种高强度的指接结构净醛生态板及其制造方法。
背景技术
生态板是由芯板和芯板两面的面板粘接固定,并在面板的表面压贴有装饰胶膜纸,而净醛生态板是将装饰胶膜纸浸渍在氨基树脂胶液和甲醛分解胶液中,从而对甲醛进行净化后的生产出的生态板,有利于环境和人体健康。现有的生态板的芯板由木板条或岁模块直接拼合组成然后利用胶黏剂粘接即可,这样方式,虽然生产速度快,但是由于芯板的组成部分之间连接强度较弱,受到冲击应力、挠性形变以及拉伸应力时很容易折断,不利于制造成品件,鉴于此,我们提出一种高强度的指接结构净醛生态板及其制造方法。
发明内容
本发明的目的在于提供一种高强度的指接结构净醛生态板及其制造方法,以解决上述背景技术中提出的问题。为实现上述目的,本发明提供如下技术方案:一种高强度的指接结构净醛生态板及其制造方法,包括芯板、固定粘接在芯板上下表面的面板和浸渍有氨基树脂胶液和甲醛分解胶液装饰胶膜纸,且装饰胶膜纸压贴在面板的表面,芯板由多个板条利用指接结构成平面状拼接组成,且相邻的板条相互平行,芯板的上下表面均设置有筋条,且筋条的走向与板条的长度走向垂直,指接结构包括板条的长度方向的两侧面分别设置的凸棱和与凸棱相适配的凹槽,芯板由一个所述板条的凸棱插接在另一个所述板条上的凹槽内拼接组成,芯板的表面上沿板条的长度走向等间隔开设有多条滑槽,且筋条滑动插接在滑槽内。
优选的,板条的凸棱上开设有多个凹孔一,且多个所述凹孔一沿凸棱的长度走向等间隔排列,板条的凹槽的槽底处开设有与凹孔一对应的凹孔二,且凹孔一和凹孔二中心轴线重合并且结构相同,相邻的两个所述板条之间对合的凹孔一和凹孔二内部插接有插接柱。
优选的,面板通过胶黏剂粘接固定在芯板的表面,并且通过钻头在面板上开设通孔,并在芯板的表面同样利用钻头开设与通孔对应的楔槽,通孔和对应的楔槽内插接固定木楔条。
优选的,芯板表面的滑槽横截面为燕尾型或T型,筋条的横截面与所述滑槽的横截面相同,且芯板上下表面的所述滑槽相互交错排列。
优选的,板条和面板均浸渍有阻燃剂,且阻燃剂由以重量计,7-10份粒径为8-12µm的超细氢氧化铝和2-2.8份无机含磷阻燃剂组成。
一种高强度的指接结构净醛生态板的制造方法,其特征在于:包括以下步骤:
步骤一:板条沿长度走向的两侧面利用刨刀或钻头进行凸棱和凹槽的加工;
步骤二:将步骤一中加工完成的所述板条的凸棱上沿长度方向等间隔钻削凹孔一,然后在凹槽的长度走向上等间隔钻削与凹孔一对应的凹孔二;
步骤三:将步骤二中所述板条的凸棱和凹槽表面均匀涂抹胶黏剂,然后将插接条上涂抹胶黏剂,并将插接条的一端插接在凸棱上的凹孔一内,再将插接有插接条的凸棱插接在另一板条的凹槽内,在插接时使得插接条外露在凹孔一外侧的端部对应插接在凹槽上的凹孔二内,依次进行板条的拼接组成芯板;
步骤四:将步骤三中所述的芯板的上下表面刨平,并在芯板的表面垂直于所述板条的方向等间隙铣削所述滑槽,然后在所述滑槽内涂抹胶黏剂,并将对应的筋条插接连接在所述滑槽内;
步骤五:将步骤四中所述的芯板利用热压机加热加压,并烘干,冷却至室温,然后将芯板的上下表面再次刨平并砂光处理;
步骤六:将步骤五种所述的芯板上下表面涂抹胶黏剂并将面板对应粘接在芯板的表面,然后利用热压机加热加压,并烘干,冷却至室温;
步骤七:在步骤六中所述的面板表面钻削通孔,并穿过通孔在芯板表面钻削楔槽,然后将木楔条涂抹胶黏剂并插接在通孔和对应的楔槽内,然后利用热压机加热加压,并烘干,冷却至室温,最后对面板表面再次刨平并砂光处理;
步骤八:将浸渍有氨基树脂胶液和甲醛分解胶液装饰胶膜纸压贴在步骤七中所述面板的表面;
步骤九:对步骤八中的板材进行裁边处理,并分等打包,打包入库。
优选的,步骤一中所述的板条含水率为7%-14%,板条的厚度为总板厚度的75%,且板条的宽度与厚度之比为1.2-1.8,且凸棱的厚度为板条的厚度的60%,凸棱的宽度与厚度之比为1.5,凹槽的规格与凸棱相适配,且误差不大于0.5mm。
优选的,步骤三、步骤四、步骤六和步骤七中的胶黏剂均为为改性大豆蛋白胶黏剂,且所述板条通过胶黏剂拼接后、筋条通过胶黏剂插接在滑槽内以及由板条拼接组成的芯板和面板通过胶黏剂胶合后,先通过微波处理18-20min,再经过超声处理30min。
优选的,步骤五中所述的热压机对芯板施加的单位压力为0.6—1.2 MPa,热压温度100—120摄氏度,步骤六中所述的热压机对面板施加的单位压力为1.0—1.2 MPa,热压温度在125—145摄氏度,步骤七中所述的热压机对面板施加的压力为0.8—1.0 MPa,热压温度在80—100摄氏度,其中步骤五和步骤六中的热压时长取决于板材厚度,每增加1mm,热压时间增加1min,步骤七中热压时长为3min-5min。
优选的,步骤八中的压贴工艺为压力0.7—0.9MPa,热压温度在100—120摄氏度,热压时长15-20min。
与现有技术相比,本发明的有益效果:
本发明中,通过多个板条之间利用指接结构连接拼成芯板,并配合胶黏剂的使用以及插接柱的定位连接作用,从而提高了芯板在接缝处的连接强度和抗剪切强度;
本发明中,在芯板的表面设置筋条,并且筋条与板条形成纵横交错的连接方式,从而大大提高生态板的综合机械特性;
本发明中,面板和芯板之间利用木楔条连接,从而进一步提高了面板与芯板之间的连接强度和坑剪切强度,在对生态板的使用时,木楔条避免生态板遇到扭曲应力时面板相对芯板发生翘曲形变,从而提高了生态板的强度抗弯曲特性,并提高生态板的加工性能。
附图说明
图1为本发明的总装截面结构示意图;
图2为本发明的芯板结构俯视图;
图3为本图2中的A-A截面结构示意图;
图4为本发明中板条的横截面结构示意图;
图5为图1中的B处放大结构示意图。
图中:1-芯板;2-面板;3-装饰胶膜纸;4-板条;5-凸棱;6-凹槽;7-插接柱;8-木楔条;9-凹孔一;10-凹孔二;11-楔槽;12-筋条;13-通孔。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术工作人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
请参阅图1-5,本发明提供一种技术方案:一种高强度的指接结构净醛生态板及其制造方法,包括芯板1、固定粘接在芯板1上下表面的面板2和浸渍有氨基树脂胶液和甲醛分解胶液装饰胶膜纸3,这样能够使得生态板表面具有分解甲醛的能力,起到净化空气的作用,且装饰胶膜纸3压贴在面板2的表面,芯板1由多个板条4利用指接结构成平面状拼接组成,且相邻的板条4相互平行,芯板1的上下表面均设置有筋条12,且筋条12的走向与板条4的长度走向垂直,指接结构包括板条4的长度方向的两侧面分别设置的凸棱5和与凸棱5相适配的凹槽6,芯板1由一个所述板条4的凸棱5插接在另一个所述板条4上的凹槽6内拼接组成,芯板1的表面上沿板条4的长度走向等间隔开设有多条滑槽,且筋条12滑动插接在滑槽内。
本实施例中,板条4的凸棱5上开设有多个凹孔一9,且多个所述凹孔一9沿凸棱5的长度走向等间隔排列,板条4的凹槽6的槽底处开设有与凹孔一9对应的凹孔二10,且凹孔一9和凹孔二10中心轴线重合并且结构相同,相邻的两个所述板条4之间对合的凹孔一9和凹孔二10内部插接有插接柱7。
本实施例中,面板2通过胶黏剂粘接固定在芯板1的表面,并且通过钻头在面板2上开设通孔13,并在芯板1的表面同样利用钻头开设与通孔13对应的楔槽11,通孔13和对应的楔槽11内插接固定木楔条8。
本实施例中,芯板1表面的滑槽横截面为燕尾型或T型,筋条12的横截面与所述滑槽的横截面相同,且芯板1上下表面的所述滑槽相互交错排列。
本实施例中,板条4和面板2均浸渍有阻燃剂,且阻燃剂由以重量计,7-10份粒径为8-12µm的超细氢氧化铝和2-2.8份无机含磷阻燃剂组成,阻燃剂的作用提高生态板的阻燃能力,提高阻燃效果。
一种高强度的指接结构净醛生态板的制造方法,其特征在于:包括以下步骤:
步骤一:板条4沿长度走向的两侧面利用刨刀或钻头进行凸棱5和凹槽6的加工,加工时刨刀或钻头的进刀量不大于3mm,这样避免因板条4厚度较小时,因进刀量过大导致板条4受力过大受到损伤,而且过大的进刀量会增加刀具的磨损,并在切削量的冲击下容易出现凹坑,降低了凸棱5或凹槽6的表面质量,不利于保持有效的加工误差;
步骤二:将步骤一中加工完成的所述板条4的凸棱5上沿长度方向等间隔钻削凹孔一9,然后在凹槽6的长度走向上等间隔钻削与凹孔一9对应的凹孔二10,钻孔时,应确保凹孔的深度不大于板条4宽度的三分之一,且凹孔与插接条7的连接时的间隙不大于0.5mm,这样既能够对拼接板条4时起到定位作用还能够起到加强指接结构的抗剪切能力,从而提高生态板的强度;
步骤三:将步骤二中所述板条4的凸棱5和凹槽6表面均匀涂抹胶黏剂,然后将插接条7上涂抹胶黏剂,并将插接条7的一端插接在凸棱5上的凹孔一9内,再将插接有插接条7的凸棱5插接在另一板条4的凹槽6内,在插接时使得插接条7外露在凹孔一9外侧的端部对应插接在凹槽6上的凹孔二10内,依次进行板条4的拼接组成芯板1,涂抹胶黏剂的作用一方面时起到拼接时的润滑作用,另一方面时胶黏剂起到粘接牢固的作用,使得凸棱5和凹槽6具有更加牢固的连接能力,从而提高了芯板1在接缝处的机械特性;
步骤四:将步骤三中所述的芯板1的上下表面刨平,芯板1的表面刨平采用双面刨的加工方式,一方面提高加工效率,另一方面可以使得凹槽6两侧壁的厚度均匀,并且刨削采用二级加工的方式,最终使得芯板1表面平整度误差不超过0.25mm,并在芯板1的表面垂直于所述板条4的方向等间隙铣削所述滑槽,然后在所述滑槽内涂抹胶黏剂,并将对应的筋条12插接连接在所述滑槽内,筋条12的作用起到对指接结构提升抗拉能力,使得芯板1在进行产品加工时,具有更好的抗拉和抗弯应力,而且筋条12和滑槽的横截面结构使得筋条12与滑槽之间不易脱落,并与板条4形成纵横连接方式,从而大大提高生态板的综合机械特性;
步骤五:将步骤四中所述的芯板1利用热压机加热加压,并烘干,冷却至室温,然后将芯板1的上下表面再次刨平并砂光处理,该步骤中的刨平方式先采用平刨的方式使得筋条12与板条4之间的高度差小于0.1后,在使用双面刨的方式对芯板1的表面进行包鞋,使得芯板1表面平整度误差不超过0.1mm,这样能够提高面板2与芯板1的胶合效果,而且能够使得面板2与芯板1之间的胶黏剂层厚度均匀;
步骤六:将步骤五种所述的芯板1上下表面涂抹胶黏剂并将面板2对应粘接在芯板1的表面,然后利用热压机加热加压,并烘干,冷却至室温;
步骤七:在步骤六中所述的面板2表面钻削通孔13,并穿过通孔13在芯板1表面钻削楔槽11,然后将木楔条8涂抹胶黏剂并插接在通孔13和对应的楔槽11内,木楔条8的作用进一步提高了面板2与芯板1之间的连接强度和坑剪切强度,在对生态板的使用时,木楔条8避免生态板遇到扭曲应力时面板2相对芯板1发生翘曲形变,从而提高了生态板的强度抗弯曲特性,并提高生态板的加工性能,然后利用热压机加热加压,并烘干,冷却至室温,最后对面板2表面再次刨平并砂光处理,先采用平刨的方式将木楔条8外露在通孔13外侧的端部刨削除去,并利用砂光机对面板2表面进行抛光处理,使得其表面光洁,误差不大于0.1mm,这样能够确保在粘贴装饰胶膜纸3时,保持表面平整;
需要说明的是,在步骤一到步骤七中,进行了三次加热加压,并烘干冷却处理工艺,这样就尽可能的除去生态板在加工过程中出现的内部应力,使生态板的内部应力越来越小,板材的平整度逐渐变高,板材变形也越小,从而大大提高生态板的生产质量;
步骤八:将浸渍有氨基树脂胶液和甲醛分解胶液装饰胶膜纸3压贴在步骤七中所述面板2的表面;
步骤九:对步骤八中的板材进行裁边处理,并分等打包,打包入库,对于裁切掉的边角料可进行收集碎化处理,并可加工成密度板等,进行废物回收再利用,提高经济价值。
作为本实施例的一种优选实施方式,步骤一中所述的板条4含水率为7%-14%,板条4最好采用木材结构均匀,干缩率小,材质较软,变形小,并且木材弦向与径向干缩率差异较少的树种,同一张细木工板上的芯条应该采用同一树种,或者物理力学性能相近的树种,这样能够确保生产处的板材保持更好的稳定性,板条4的厚度为总板厚度的75%,且板条4的宽度与厚度之比为1.2-1.8,且凸棱5的厚度为板条4的厚度的60%,凸棱5的宽度与厚度之比为1.5,凹槽6的规格与凸棱5相适配,且误差不大于0.5mm。
作为本实施例的一种优选实施方式,步骤三、步骤四、步骤六和步骤七中的胶黏剂均为为改性大豆蛋白胶黏剂,无甲醛释放,有利于保护环境和人体健康,且所述板条4通过胶黏剂拼接后、筋条12通过胶黏剂插接在滑槽内以及由板条4拼接组成的芯板1和面板通过胶黏剂胶合后,先通过微波处理18-20min,再经过超声处理30min,这样能够更好的使胶黏剂均匀的填充在接缝里,从而提高芯板1的连接强度,而且一部分胶黏剂会在微波和超声的作用下渗透进板条4内部,使得板条4之间类似焊接连为一个整体,提高了芯板1的整体强度。
作为本实施例的一种优选实施方式,步骤五中所述的热压机对芯板1施加的单位压力为0.6—1.2 MPa,热压温度100—120摄氏度,步骤六中所述的热压机对面板2施加的单位压力为1.0—1.2 MPa,热压温度在125—145摄氏度,步骤七中所述的热压机对面板2施加的压力为0.8—1.0 MPa,热压温度在80—100摄氏度,其中步骤五和步骤六中的热压时长取决于板材厚度,每增加1mm,热压时间增加1min,步骤七中热压时长为3min-5min,在对板材进行热压烘干处理时,一方面是通过加热加压提高胶黏剂在接缝力的流动性,使得胶黏剂能够均匀的填充在接缝处,提高接缝处的连接强度,并且高温使得胶黏剂加快干燥,从而提高板材的生产效率,并能够消除板材内部的应力。
作为本实施例的一种优选实施方式,步骤八中的压贴工艺为压力0.7—0.9MPa,热压温度在100—120摄氏度,热压时长15-20min。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术工作人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的仅为本发明的优选例,并不用来限制本发明,在不脱离本发明精神和范围的前提下,本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (10)
1.一种高强度的指接结构净醛生态板,包括芯板(1)、固定粘接在芯板(1)上下表面的面板(2)和浸渍有氨基树脂胶液和甲醛分解胶液装饰胶膜纸(3),且装饰胶膜纸(3)压贴在面板(2)的表面,其特征在于:所述芯板(1)由多个板条(4)利用指接结构成平面状拼接组成,且相邻的板条(4)相互平行,所述芯板(1)的上下表面均设置有筋条(12),且筋条(12)的走向与板条(4)的长度走向垂直;
所述指接结构包括板条(4)的长度方向的两侧面分别设置的凸棱(5)和与凸棱(5)相适配的凹槽(6),所述芯板(1)由一个所述板条(4)的凸棱(5)插接在另一个所述板条(4)上的凹槽(6)内拼接组成;
所述芯板(1)的表面上沿板条(4)的长度走向等间隔开设有多条滑槽,且筋条(12)滑动插接在滑槽内。
2.根据权利要求1所述的一种高强度的指接结构净醛生态板,其特征在于:所述板条(4)的凸棱(5)上开设有多个凹孔一(9),且多个所述凹孔一(9)沿凸棱(5)的长度走向等间隔排列,所述板条(4)的凹槽(6)的槽底处开设有与凹孔一(9)对应的凹孔二(10),且凹孔一(9)和凹孔二(10)中心轴线重合并且结构相同,相邻的两个所述板条(4)之间对合的凹孔一(9)和凹孔二(10)内部插接有插接柱(7)。
3.根据权利要求2所述的一种高强度的指接结构净醛生态板,其特征在于:所述面板(2)通过胶黏剂粘接固定在芯板(1)的表面,并且通过钻头在面板(2)上开设通孔(13),并在芯板(1)的表面同样利用钻头开设与通孔(13)对应的楔槽(11),所述通孔(13)和对应的楔槽(11)内插接固定木楔条(8)。
4.根据权利要求3所述的一种高强度的指接结构净醛生态板,其特征在于:所述芯板(1)表面的滑槽横截面为燕尾型或T型,所述筋条(12)的横截面与所述滑槽的横截面相同,且芯板(1)上下表面的所述滑槽相互交错排列。
5.根据权利要求4所述的一种高强度的指接结构净醛生态板,其特征在于:所述板条(4)和面板(2)均浸渍有阻燃剂,且阻燃剂由以重量计,7-10份粒径为8-12µm的超细氢氧化铝和2-2.8份无机含磷阻燃剂组成。
6.根据权利要求1-5任意一项所述的一种高强度的指接结构净醛生态板的制造方法,其特征在于:包括以下步骤:
步骤一:板条(4)沿长度走向的两侧面利用刨刀或钻头进行凸棱(5)和凹槽(6)的加工;
步骤二:将步骤一中加工完成的所述板条(4)的凸棱(5)上沿长度方向等间隔钻削凹孔一(9),然后在凹槽(6)的长度走向上等间隔钻削与凹孔一(9)对应的凹孔二(10);
步骤三:将步骤二中所述板条(4)的凸棱(5)和凹槽(6)表面均匀涂抹胶黏剂,然后将插接条(7)上涂抹胶黏剂,并将插接条(7)的一端插接在凸棱(5)上的凹孔一(9)内,再将插接有插接条(7)的凸棱(5)插接在另一板条(4)的凹槽(6)内,在插接时使得插接条(7)外露在凹孔一(9)外侧的端部对应插接在凹槽(6)上的凹孔二(10)内,依次进行板条(4)的拼接组成芯板(1);
步骤四:将步骤三中所述的芯板(1)的上下表面刨平,并在芯板(1)的表面垂直于所述板条(4)的方向等间隙铣削所述滑槽,然后在所述滑槽内涂抹胶黏剂,并将对应的筋条(12)插接连接在所述滑槽内;
步骤五:将步骤四中所述的芯板(1)利用热压机加热加压,并烘干,冷却至室温,然后将芯板(1)的上下表面再次刨平并砂光处理;
步骤六:将步骤五种所述的芯板(1)上下表面涂抹胶黏剂并将面板(2)对应粘接在芯板(1)的表面,然后利用热压机加热加压,并烘干,冷却至室温;
步骤七:在步骤六中所述的面板(2)表面钻削通孔(13),并穿过通孔(13)在芯板(1)表面钻削楔槽(11),然后将木楔条(8)涂抹胶黏剂并插接在通孔(13)和对应的楔槽(11)内,然后利用热压机加热加压,并烘干,冷却至室温,最后对面板(2)表面再次刨平并砂光处理;
步骤八:将浸渍有氨基树脂胶液和甲醛分解胶液装饰胶膜纸(3)压贴在步骤七中所述面板(2)的表面;
步骤九:对步骤八中的板材进行裁边处理,并分等打包,打包入库。
7.根据权利要求6所述的一种高强度的指接结构净醛生态板的制造方法,其特征在于:所述步骤一中所述的板条(4)含水率为7%-14%,所述板条(4)的厚度为总板厚度的75%,且板条(4)的宽度与厚度之比为1.2-1.8,且凸棱(5)的厚度为板条(4)的厚度的60%,所述凸棱(5)的宽度与厚度之比为1.5,所述凹槽(6)的规格与凸棱(5)相适配,且误差不大于0.5mm。
8.根据权利要求7所述的一种高强度的指接结构净醛生态板的制造方法,其特征在于:所述步骤三、步骤四、步骤六和步骤七中的胶黏剂均为为改性大豆蛋白胶黏剂,且所述板条(4)通过胶黏剂拼接后、筋条(12)通过胶黏剂插接在滑槽内以及由板条(4)拼接组成的芯板(1)和面板通过胶黏剂胶合后,先通过微波处理18-20min,再经过超声处理30min。
9.根据权利要求8所述的一种高强度的指接结构净醛生态板的制造方法,其特征在于:所述步骤五中所述的热压机对芯板(1)施加的单位压力为0.6—1.2 MPa,热压温度100—120摄氏度,所述步骤六中所述的热压机对面板(2)施加的单位压力为1.0—1.2 MPa,热压温度在125—145摄氏度,所述步骤七中所述的热压机对面板(2)施加的压力为0.8—1.0MPa,热压温度在80—100摄氏度,其中步骤五和步骤六中的热压时长取决于板材厚度,每增加1mm,热压时间增加1min,所述步骤七中热压时长为3min-5min。
10.根据权利要求9所述的一种高强度的指接结构净醛生态板的制造方法,其特征在于:所述步骤八中的压贴工艺为压力0.7—0.9MPa,热压温度在100—120摄氏度,热压时长15-20min。
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