CN110593483B - 一种轻质环保复合墙板制造方法 - Google Patents

一种轻质环保复合墙板制造方法 Download PDF

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CN110593483B
CN110593483B CN201910886552.XA CN201910886552A CN110593483B CN 110593483 B CN110593483 B CN 110593483B CN 201910886552 A CN201910886552 A CN 201910886552A CN 110593483 B CN110593483 B CN 110593483B
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composite wallboard
fiberboard
isocyanate
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CN110593483A (zh
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王丽
陈秀兰
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Dare Wood Based Panel Group Co ltd
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Abstract

本发明属于建筑装饰材料技术领域，涉及复合墙板，尤其涉及一种轻质环保复合墙板制造方法，包括：将板面喷涂有异氰酸酯的薄型无醛纤维板置于模具底部，喷涂面向上，均匀倒入聚氨酯发泡材料；再将另一块板面喷涂有异氰酸酯的薄型无醛纤维板置于模具内，其喷涂板面与聚氨酯发泡材料接触；然后将模具置于热压机中，温度60～80℃、压力20～40kg/cm2下反应5～15min，自然冷却至室温，打开模具，去除边角余料后即得。本发明所用材料中不含甲醛，制备方法工艺简便，无污染，所制得的是绿色健康环保板材；且木质纤维板材料与聚氨酯发泡材料适当组合，所制备的复合墙板具有较好的物理力学性能、轻质、无醛、保温隔热、隔音等优点，可广泛应用于室内墙体装修领域。

Description

一种轻质环保复合墙板制造方法
技术领域
本发明属于建筑装饰材料技术领域，涉及复合墙板，尤其涉及一种轻质环保复合墙板制造方法。
背景技术
随着社会的发展和人们生活水平的提高，消费者对室内装修提出了更高的要求，特别是对墙体的装饰。砖墙由砖和砂浆两种材料组成，砂浆将砖胶结在一起筑成墙体或砌块。砖墙属于砌筑墙体，具有保温、隔热、隔音等优点。但传统砖砌墙体也存在着施工速度慢、自重大、劳动强度大、搬运拆除较困难等缺点，已部分被新型材料所取代。
本发明主要针对传统墙体存在的不足，公开一种轻质环保复合墙板的制备方法，所制得墙板具有轻质、无甲醛释放、保温隔热、隔音等优点，可广泛应用于室内墙体装修领域。
发明内容
针对上述现有技术中存在的不足，本发明的目的是公开一种轻质环保复合墙板制备方法。
一种轻质环保复合墙板制备方法，包括以下步骤：
（1）将板面喷涂有异氰酸酯的薄型无醛纤维板置于模具底部，喷涂面向上，均匀倒入聚氨酯发泡材料；
（2）再将另一块板面喷涂有异氰酸酯的薄型无醛纤维板置于模具内，其喷涂板面与聚氨酯发泡材料接触；
（3）将模具置于热压机中，温度60～80℃、压力20～40kg/cm2下反应5～15min，自然冷却至室温，打开模具，去除边角余料后即得。
本发明较优公开例中，步骤（1）或（2）中所述异氰酸酯的喷涂量80～120g/㎡，优选100 g/㎡。
本发明较优公开例中，步骤（1）或（2）中所述薄型无醛纤维板厚度为1～3mm，优选2mm。
本发明较优公开例中，步骤（3）中所述将模具置于热压机中，温度70℃、压力30kg/cm2下反应10min。
本发明较优公开例中，步骤（1）或（2）中所述聚氨酯发泡材料是将A料和B料高速搅拌混合均匀而成，其中所述A料质量份数100～160份，B料质量份数100份。
进一步的，所述A料为异氰酸酯；
所述B料按质量份数包括：聚酯多元醇20～100份，聚醚多元醇50～100份，改性二甲基环已胺0～5份、三乙醇胺0～5份、二丁基锡二月桂酸酯0.1～5份、甘油0～5份、磺化蓖麻油2～10份、聚醚改性聚硅氧烷2～10份、木粉5～20份。
所述B料制备方法为：依配比称取各组分，先将聚酯多元醇、聚醚多元醇、改性二甲基环已胺、三乙醇胺、二丁基锡二月桂酸酯、甘油、磺化蓖麻油、聚醚改性聚硅氧烷投入反应釜中，500～700r/min转速搅拌混合均匀，再将木粉投入反应釜中，500～700r/min转速搅拌混合均匀，得到B料。
本发明所述薄型无醛纤维板的生产步骤包括：木材剥皮→削片→筛选→水洗→蒸煮→热磨→纤维干燥→调施胶→铺装成型→预压→热压→冷却→砂光→养生→检验分等→包装入库。
所述铺装成型步骤中，调整铺装纤维密度，制得无醛薄型纤维板密度900～960kg/m³；
所述调施胶步骤中，胶黏剂为异氰酸酯，施胶量55～65kg/m³；
所述养生步骤中，通过调整养生环境温湿度，使得薄型无醛纤维板含水率在5.0～6.5%。
根据本发明所公开方法制得的轻质环保复合墙板，包含上、中、下三层，其中上、下两层是薄型无醛纤维板，中间层是聚氨酯发泡材料，所述聚氨酯发泡材料厚度10～100mm。
业内常规无醛纤维板密度在780～880kg/m³之间，异氰酸酯施加量25～40kg/m³，本发明所制得的轻质环保复合墙板上下表层纤维板密度900～960kg/m³，异氰酸酯施加量55～65kg/m³，使用高施胶量、高密度的无醛纤维板作为上下表层，可降低芯层聚氨酯发泡材料密度，提高复合墙板的吸音效果，同时能保证复合墙板的性能，还能降低生产成本。聚氨酯发泡材料中添加甘油和磺化蓖麻油，能适当破坏发泡材料内部分子结构的规整性，形成的交联键会限制分子链间的滑移，提高发泡材料的抗变形能力，从而提高复合墙板性能；添加聚醚改性聚硅氧烷，可以使得发泡过程更加稳定，避免大泡过多产生空隙、分层，从而使得复合墙板性能更加稳定。生产线砂光粉一般作为燃料使用，本发明将砂光粉作为填充料，既可以降低聚氨酯发泡材料的成本，还能够增加发泡材料的开孔性，提高力学性能，同时避免砂光粉作为燃料造成的能源浪费，起到节约资源的作用。
本发明所述聚酯多元醇、聚醚多元醇、改性二甲基环已胺、三乙醇胺、二丁基锡二月桂酸酯、甘油、磺化蓖麻油、聚醚改性聚硅氧烷都为工业品；所述木粉为纤维板生产中的砂光粉，粉碎至200～300目。
有益效果
本发明所公开的轻质环保复合墙板，包含上、中、下三层结构，其中上、下两层是高密度薄型无醛纤维板，中间层是聚氨酯发泡材料。本发明所用材料中都不含甲醛，制备方法工艺简便，无污染，所制得的是绿色健康环保板材；且木质纤维板材料与聚氨酯发泡材料适当组合，所制备的复合墙板具有较好的物理力学性能、轻质、无醛、保温隔热、隔音等优点，可广泛应用于室内墙体装修领域。
具体实施方式
下面结合实施例对本发明进行详细说明，以使本领域技术人员更好地理解本发明，但本发明并不局限于以下实施例。
实施例1
一种轻质环保复合墙板制备方法，首先制备薄型无醛纤维板，厚度为2mm，具体生产步骤包括：木材剥皮→削片→筛选→水洗→蒸煮→热磨→纤维干燥→调施胶→铺装成型→预压→热压→冷却→砂光→养生→检验分等→包装入库。
所述铺装成型步骤中，通过调整铺装密度，控制薄型无醛纤维板密度900kg/m³；
所述调施胶步骤中，胶黏剂为异氰酸酯，施胶量60kg/m³；
所述养生步骤中，通过调整养生环境温度和湿度，使得薄型无醛纤维板含水率在5.0～6.5%；
然后准备好聚氨酯发泡材料A料和B料，在倒入磨具前将A料和B料在1200～1700r/min转速下快速混合均匀制得发泡材料，其中A料130份，B料100份。
所述A料为异氰酸酯；
所述B料质量份数包括：聚酯多元醇20份，聚醚多元醇80份，改性二甲基环已胺2份、三乙醇胺1份、二丁基锡二月桂酸酯1份、甘油2份、磺化蓖麻油2份、聚醚改性聚硅氧烷10份、木粉10份。
所述聚酯多元醇、聚醚多元醇、改性二甲基环已胺、三乙醇胺、二丁基锡二月桂酸酯、甘油、磺化蓖麻油、聚醚改性聚硅氧烷都为工业品；所述木粉为纤维板生产中砂光粉，粉碎至200～300目；
所述B料制备方法为：将聚酯多元醇、聚醚多元醇、改性二甲基环已胺、三乙醇胺、二丁基锡二月桂酸酯、甘油、磺化蓖麻油、聚醚改性聚硅氧烷投入反应釜中，在500～700r/min下混合均匀，将木粉投入反应釜中，在500～700r/min混合均匀，得到B料；
最后通过以下步骤制备复合墙板，包括：
（1）将薄型无醛纤维板置于磨具底部，并在纤维板上喷涂异氰酸酯，喷涂量120g/㎡；
（2）将发泡材料均匀倒入磨具内；
（3）在另一块纤维板上喷涂异氰酸酯，喷涂量120g/㎡，并将喷涂异氰酸酯的纤维板置于磨具内，异氰酸酯面与发泡材料层接触；
（4）将磨具置于热压机中，通过厚度规控制复合墙板厚度，并控制压机上下板面温度60℃，压力30kg/cm2，反应10min，得到成品复合墙板一。
实施例2
一种轻质环保复合墙板制备方法，首先制备薄型无醛纤维板，厚度为1.5mm，具体生产步骤包括：木材剥皮→削片→筛选→水洗→蒸煮→热磨→纤维干燥→调施胶→铺装成型→预压→热压→冷却→砂光→养生→检验分等→包装入库。
所述铺装成型步骤中，通过调整铺装密度，控制无醛薄型纤维板密度920kg/m³；
所述调施胶步骤中，胶黏剂为异氰酸酯，施胶量65kg/m³；
所述养生步骤中，通过调整养生环境温度和湿度，使得薄型无醛纤维板含水率在5.0～6.5%；
然后准备好聚氨酯发泡材料A料和B料，在倒入磨具前将A料和B料在1200～1700r/min转速下快速混合均匀制得发泡材料，其中A料150份，B料100份。
所述A料为异氰酸酯；
所述B料质量份数包括：聚酯多元醇30份，聚醚多元醇70份，改性二甲基环已胺3份、二丁基锡二月桂酸酯1份、甘油2份、磺化蓖麻油3份、聚醚改性聚硅氧烷8份、木粉15份。
所述聚酯多元醇、聚醚多元醇、改性二甲基环已胺、二丁基锡二月桂酸酯、甘油、磺化蓖麻油、聚醚改性聚硅氧烷都为工业品；所述木粉为纤维板生产中砂光粉，粉碎至200～300目；
所述B料制备方法为：将聚酯多元醇、聚醚多元醇、改性二甲基环已胺、二丁基锡二月桂酸酯、甘油、磺化蓖麻油、聚醚改性聚硅氧烷投入反应釜中，在500～700r/min下混合均匀，将木粉投入反应釜中，在500～700r/min混合均匀，得到B料；
最后通过以下步骤制备复合墙板，包括：
（1）将薄型无醛纤维板置于磨具底部，并在纤维板上喷涂异氰酸酯，喷涂量110g/㎡；
（2）将发泡材料均匀倒入磨具内；
（3）在另一块纤维板上喷涂异氰酸酯，喷涂量110g/㎡，并将喷涂异氰酸酯的纤维板置于磨具内，异氰酸酯面与发泡材料层接触；
（4）将磨具置于热压机中，通过厚度规控制复合墙板厚度，并控制压机上下板面温度65℃，压力35kg/cm2，反应10min，得到成品复合墙板二。
表1 复合墙板检测数据
检测项目 成品复合墙板一 成品复合墙板二
密度（kg/m³） 265 260
厚度（mm） 30 40
静曲强度（MPa） 13.8 11.6
内结合强度（MPa） 0.69 0.61
抗冲击性能（次） 8 9
空气隔声量（dB） 36 45
传热系数（W/㎡·K） 1.23 1.06
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (8)

1.一种轻质环保复合墙板制备方法，其特征在于，包括以下步骤：
(1)将板面喷涂有异氰酸酯的薄型无醛纤维板置于模具底部，喷涂面向上，均匀倒入聚氨酯发泡材料；
所述聚氨酯发泡材料是将A料和B料高速搅拌混合均匀而成，所述A料质量份数100～160份，B料质量份数100份；其中，所述A料为异氰酸酯；
所述B料按质量份数包括：聚酯多元醇20～100份，聚醚多元醇50～100份，改性二甲基环已胺0～5份、三乙醇胺0～5份、二丁基锡二月桂酸酯0.1～5份、甘油0～5份、磺化蓖麻油2～10份、聚醚改性聚硅氧烷2～10份、木粉5～20份，其中所述木粉为纤维板生产中砂光粉，粉碎至200～300目；
所述薄型无醛纤维板，其生产步骤包括：木材剥皮→削片→筛选→水洗→蒸煮→热磨→纤维干燥→调施胶→铺装成型→预压→热压→冷却→砂光→养生→检验分等→包装入库，
其中，
所述铺装成型步骤中，调整铺装纤维密度，制得无醛薄型纤维板密度900～960kg/m3；
所述调施胶步骤中，胶黏剂为异氰酸酯，施胶量55～65kg/m3；
所述养生步骤中，通过调整养生环境温湿度，使得薄型无醛纤维板含水率在5.0～6.5％；
(2)再将另一块板面喷涂有异氰酸酯的薄型无醛纤维板置于模具内，其喷涂板面与聚氨酯发泡材料接触；
(3)将模具置于热压机中，温度60～80℃、压力20～40kg/cm2下反应5～15min，自然冷却至室温，打开模具，去除边角余料后即得。
2.根据权利要求1所述轻质环保复合墙板制备方法，其特征在于：步骤(1)或(2)中所述异氰酸酯的喷涂量80～120g/㎡。
3.根据权利要求1所述轻质环保复合墙板制备方法，其特征在于：步骤(1)或(2)中所述异氰酸酯的喷涂量100g/㎡。
4.根据权利要求1所述轻质环保复合墙板制备方法，其特征在于：步骤(1)或(2)中所述薄型无醛纤维板厚度为1～3mm。
5.根据权利要求1所述轻质环保复合墙板制备方法，其特征在于：步骤(1)或(2)中所述薄型无醛纤维板厚度为2mm。
6.根据权利要求1所述轻质环保复合墙板制备方法，其特征在于：步骤(3)中所述将模具置于热压机中，温度70℃、压力30kg/cm2下反应10min。
7.根据权利要求1-6任一所述方法制备得到的轻质环保复合墙板。
8.根据权利要求7所述轻质环保复合墙板，其特征在于：所述轻质环保复合墙板，包含上、中、下三层，其中上、下两层是薄型无醛纤维板，中间层是聚氨酯发泡材料，所述聚氨酯发泡材料厚度10～100mm。
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