CN111331990A - 一种轻质墙饰板及其制备方法 - Google Patents

一种轻质墙饰板及其制备方法 Download PDF

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CN111331990A
CN111331990A CN202010297774.0A CN202010297774A CN111331990A CN 111331990 A CN111331990 A CN 111331990A CN 202010297774 A CN202010297774 A CN 202010297774A CN 111331990 A CN111331990 A CN 111331990A
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layer
natural
fiber reinforced
reinforced polypropylene
natural fiber
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王志民
肖峰
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Shanghai Shengfeng Building Material Technology Co ltd
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Shanghai Shengfeng Building Material Technology Co ltd
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Abstract

本发明公开了一种轻质墙饰面板，包括装饰面层和天然纤维增强聚丙烯板层；所述装饰面层和所述天然纤维增强聚丙烯板层通过湿固化反应型聚氨酯热熔胶粘合；所述天然纤维增强聚丙烯板层由过渡层、中间层和平衡层组成，所述天然纤维增强聚丙烯板层由40～60％天然纤维和60～40％的丙纶短纤维三维交织成纤维毡、两面分别贴上过渡层和平衡层后热压粘合而成，其中，所述过渡层和所述平衡层为材质相同的涤纶无纺布，所述天然纤维增强聚丙烯板层通过所述过渡层和所述装饰面层粘合。本发明的轻质墙饰面板中使用的天然纤维下脚料可以开松后100％回收利用，生产过程不会有挥发性污染物产生，不仅环保，还可以满足不同审美要求。

Description

一种轻质墙饰板及其制备方法
技术领域
本发明属于护墙板领域，尤其涉及一种轻质墙饰板及其制备方法。
背景技术
护墙饰面板目前主要集中在实木复合板、木塑板、石塑板等中高密度板材，它们是在制作过程中使用胶黏剂、树脂、填充剂、阻燃剂、防水剂等含有挥发性污染物的物质按比例经高温高压而制成的合成板材。在制备过程中溶剂挥发产生有毒有害气体，对人体和环境产生一定危害。另外，其在回收利用过程中容易产生颗粒粉尘，且分解缓慢，对地球生态环境产生不良影响。另一方面，传统的护墙饰面板密度大、硬度脆性大、韧性低、较为沉重，不适合轻量化、模块化安装。因此，制备出具有高质量、绿色生态环保的功能性墙板材料是十分必要的。另外，对于护墙饰面板还要求美观，因此，能满足不同审美要求的护墙板更加受关注。
发明内容
本发明的目的是提供绿色生态环保且可以满足不同审美要求的轻质护墙板。
本发明的构思是：天然纤维为可再生资源，低污染，低能耗，使用后可自然降解，使用天然纤维和丙纶纤维交织成毡，并利用丙纶纤维的热塑性加热将两者固定，克服传统制作墙饰板使用有机溶剂、挥发有毒气体的危害。同时，为了满足各种不同审美的需求，可以在制作墙饰板的外表面贴不同需求所用的各种花样的饰面层。
本发明的技术方案如下：
一种轻质墙饰面板，包括装饰面层和天然纤维增强聚丙烯板层；所述装饰面层和所述天然纤维增强聚丙烯板层通过湿固化反应型聚氨酯热熔胶粘合；所述天然纤维增强聚丙烯板层由过渡层、中间层和平衡层组成，所述天然纤维增强聚丙烯板层由40～60％天然纤维和60～40％的丙纶短纤维三维交织成纤维毡、两面分别贴上过渡层和平衡层后热压粘合而成，其中，所述过渡层和所述平衡层为材质相同的涤纶无纺布，所述天然纤维增强聚丙烯板层通过所述过渡层和所述装饰面层粘合。
在本发明的上述技术方案中，饰面层和天然纤维增强聚丙烯板层通过湿固化反应型聚氨酯热熔胶粘合，该过程是热熔物理方法粘合，不使用有毒有害物质；并且粘合是在较低温度下进行，一般在110～130℃下即可，不会对饰面层表面造成变色等损害，因此可以进行各种不同材质饰面层的自由拼接而制成不同材质形成的具有立体感的纹理，满足人们不同审美的需求。而如果不用本发明的方法，直接通过聚丙烯板热熔时将饰面层热熔粘贴的方法，则会因为聚丙烯熔点为165℃、热压成型的温度在180℃～240℃，而在这样的较高的温度下，饰面层表面会产生变色等损害；另外一些不耐高温的饰面层也将不能使用，限制了人们对各种花样饰面层的需求。
在本发明中，40～60％天然纤维和60～40％的丙纶短纤维三维交织成纤维毡，交织的纤维之间存在空气，在纤维毡两面分别贴上过渡层和平衡层后，再进行饰面层的热压粘合。这样，在热压过程中，交织在天然纤维中的丙纶短纤维遇热熔化，压力下成型，将部分纤维中的空气封闭在纤维之间，从而形成了具有一定静止空气的低密度的天然纤维增强聚丙烯板层，均匀分布的聚丙烯使得天然纤维增强聚丙烯板层强度高、韧性大，适合轻量化集成安装。过渡层和平衡层在热压前贴在纤维毡的两面，由于两者材质相同，可以保证在热压过程中纤维毡正反两面受力均衡，平直不翘曲。在热压过程中，熔化的丙纶纤维将过渡层和平衡层粘合牢固，从而形成了天然纤维增强聚丙烯板层。
天然纤维增强聚丙烯板层在热压过程中熔化的丙纶纤维不仅将过渡层和平衡层粘在一起，同时还在靠近过渡层和平衡层的内面将纤维中的空隙端部大部分封闭，在用湿固化反应型聚氨酯热熔胶粘合饰面层时，过渡层可以阻挡热熔的胶液进入天然纤维增强聚丙烯板层内部，这样不仅减少了胶液浪费、增强了粘合牢度，改善了丙纶纤维和饰面板层的粘结强度，同时还避免了胶液浸入并堵塞天然纤维增强聚丙烯板层的内部的气孔。因此在本发明中湿固化反应型聚氨酯热熔胶用量很少就能将饰面层粘结牢固，并不需要再专门设置热熔胶膜进行粘结，节约材料。由于本发明中的轻质墙饰板的装饰面层和天然纤维增强聚丙烯板层是通过湿固化反应型聚氨酯热熔胶粘合的，粘合所需温度较低，不会因为粘结时需要过高的温度而导致装饰面层或是装饰面层上的花纹变色，所以可以使用的装饰面层材料较为广泛，广泛的装饰面层的选择可以满足人们不同的审美要求。平衡层保证板材不翘曲，使正反两面受力均衡，保证产品平直。
本发明的技术方案中可使用的天然纤维有剑麻纤维、蕉麻纤维、苎麻纤维、亚麻纤维、***纤维等，优选所述天然纤维为天然黄麻纤维或天然竹原纤维。天然麻纤维具有天然抑菌抗菌组分麻甾醇，天然麻纤维中的半纤维素组分具有吸收紫外线功能；天然竹原纤维具有天然抑菌抗菌组分竹琨，天然竹原纤维中的半纤维素组分具有吸收紫外线功能，因此，以天然黄麻纤维或天然竹原纤维制备的本发明的墙饰板具有天然抗菌、抑菌、吸收紫外线功能。
优选地，所述装饰面层为装饰墙布、PVC装饰膜或皮革。当然，也可以是以上多种装饰材料搭配使用，制成各种立体或是平面的拼接装饰面层。
优选地，所述轻质墙饰面板中含有75％～80％的静止空气。静止空气密封在轻质墙饰面板中，所以本发明的轻质墙饰板质量轻，并且还具有明显的隔热保温、吸音降噪效果，适合模块化安装。
本发明还提供了上述轻质墙饰面板的制备方法，包括如下步骤：
步骤一：制作天然纤维增强聚丙烯板层
A、将天然纤维和丙纶短纤维按比例混合后经粗开松、精开松后，梳理成纤维网，经预针刺和主针刺制成纤维毡；
B、在上述制得的纤维毡两面贴上材质相同的涤纶无纺布，用连续接触式平板压机先180～200℃热压，再10～15℃冷压成型；
步骤二：用湿固化反应型聚氨酯热熔胶在上述天然纤维增强聚丙烯板层的表面粘合上装饰面层。
本发明的轻质墙饰面板的制备方法中将纤维经混合、开松、梳理、针刺等过程，使得纤维之间充分交织并保持适度的空隙，有助于在热压过程中形成有规则的静止空气，降低轻质墙饰板的密度。
本发明的轻质墙饰板的制备方法的步骤一的B中，先在纤维毡两面贴上相同材质的涤纶无纺布，然后再进行热压。在热压过程中，交织在天然纤维之间的丙纶短纤维先熔融后固化，形成具有一定强度的聚丙烯支撑，使得轻质墙饰面板的强度增加；另外，在进行热压过程中熔融的聚丙烯与过渡层和平衡层粘在一起，在靠近过渡层和平衡层的内面将纤维中的空隙大部分封闭，避免了在步骤二中湿固化反应型聚氨酯热熔胶粘合时胶液向纤维空隙的渗透，一方面可以节约湿固化反应型聚氨酯热熔胶，另一方面粘结更加牢固。
优选地，步骤一所述接触式冷热平板机为连续式。连续的热烘可以提高热效率，并能生产较长的板材。
本发明的有益效果为：
本发明的轻质墙饰面板中使用的天然纤维下脚料可以开松后100％回收利用，绿色生态环保。本发明的轻质墙饰面板在制备过程中过渡层和平衡层靠热熔的聚丙烯粘结；装饰面层使用湿固化反应型聚氨酯热熔胶粘合，这些粘合过程都是热熔物理方法粘合，不会有挥发性污染物的产生，制备过程环保。在制备过程中过渡层和平衡层先贴在丙纶短纤维和天然纤维所成的纤维毡的两面，然后再进行热熔粘合，在轻质墙饰面板内部形成了密闭的静止空气，降低了密度同时又起到隔音和保温作用，同时还可以减少湿固化反应型聚氨酯热熔胶的用量，增强粘结力。使用湿固化反应型聚氨酯热熔胶进行装饰面层的粘贴，不易变色，可以实现多种材料粘贴。因此，本发明的轻质墙饰面板绿色环保，密度小、强度大，可以满足不同审美的要求。
附图说明
图1为本发明的轻质墙饰面板的结构示意图。
图中：1、装饰面层；2、过渡层；3、中间层；4、平衡层。
具体实施方式
下面结合实施例对本发明做详细说明。
如图1为本发明的一种轻质墙饰板，包括装饰面层1和天然纤维增强聚丙烯板层；所述装饰面层1和所述天然纤维增强聚丙烯板层通过湿固化反应型聚氨酯热熔胶粘合；所述天然纤维增强聚丙烯板层由过渡层2、中间层3和平衡层4组成，所述天然纤维增强聚丙烯板层由40～60％天然纤维和60～40％的丙纶短纤维三维交织成纤维毡、两面分别贴上过渡层2和平衡层4后热压粘合而成，所述由40～60％天然纤维和60～40％的丙纶短纤维三维交织成的纤维毡热压后冷却成为中间层；其中，所述过渡层2和所述平衡层4为材质相同的涤纶无纺布，所述天然纤维增强聚丙烯板层通过所述过渡层2和所述装饰面1层粘合。
实施例1
制备一种天然竹原纤维轻质墙饰板，具体制备过程如下：
步骤一：制作天然竹原纤维增强聚丙烯板层
A、将天然竹原纤维和丙纶短纤维喂入开包机，分别按40％和60％的质量比例配比后进行混合初开松、精开松，然后经过梳理机梳理成上下两层纤维网。将纤维网喂入铺网机层叠成所需厚度的纤维网，送入针刺机进行预针刺成形，然后再进行上下主针刺成纤维毡。
B、在上述制得的纤维毡两面贴上材质相同的涤纶无纺布，用连续接触式平板压机先180～200℃热压，再10～15℃冷压成型；
在热压过程中，交织在天然竹原纤维中的丙纶短纤维高温下热熔塑化并与天然竹原纤维粘合，压力下成型，将部分纤维中的空气封闭在纤维之间，从而形成了具有一定静止空气的低密度的增强聚丙烯板层。同时，在热压过程中熔化的丙纶纤维与过渡层和平衡层的无纺布粘合在一起，制成竹原纤维增强聚丙烯板层。
将竹原纤维增强聚丙烯板层裁切成所需的尺寸。
步骤二：用湿固化反应型聚氨酯热熔胶在上述天然竹原纤维增强聚丙烯板层的表面粘合上装饰墙布，即为天然竹原纤维轻质墙饰板。
将上述实施例1中制作天然竹原纤维轻质墙饰板的制作过程中，将天然竹原纤维替换为天然黄麻纤维即可制作成天然黄麻纤维轻质墙饰板，制作过程相同。当然，可以使用的天然纤维还有剑麻纤维、蕉麻纤维、苎麻纤维、亚麻纤维、***纤维等。天然麻纤维具有天然抑菌抗菌组分麻甾醇，天然麻纤维中的半纤维素组分具有吸收紫外线功能；天然竹原纤维具有天然抑菌抗菌组分竹琨，天然竹原纤维中的半纤维素组分具有吸收紫外线功能，因此，以天然黄麻纤维或天然竹原纤维制备的本发明的墙饰板具有天然抗菌、抑菌、吸收紫外线功能。
本发明制备的天然竹原纤维轻质饰板进行检测，结果见表1。
本发明制备天然黄麻纤维轻质饰板，其中天然黄麻纤维和丙纶短纤维按60％和40％的质量比例配比，其余过程同上述制作天然竹原纤维轻质饰板。制得的天然黄麻纤维轻质饰板进行检测，结果见表1。
其中，静止空气百分含量(％)计算公式为：(1-材料体积÷板材体积)×100％；其中所述材料体积为材料的真实体积；板材体积为板材的表观体积。
表1
Figure BDA0002452858910000051
由以上结果可以看出，本发明制备的轻质墙饰板不含甲醛等挥性污染物，并且防霉效果好，吸声效果好，保温效果好，粘结牢固，不易剥离。
在此需要说明的是，对于这些实施方式的说明用于帮助理解本发明，但并不构成对本发明的限定。此外，以上所描述的本发明各个实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互结合。另外以上仅为本发明的部分实施例，而不是全部实施例，基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动的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。

Claims (6)

1.一种轻质墙饰板，其特征在于，所述轻质墙饰板包括装饰面层和天然纤维增强聚丙烯板层；所述装饰面层和所述天然纤维增强聚丙烯板层通过湿固化反应型聚氨酯热熔胶粘合；
所述天然纤维增强聚丙烯板层由过渡层、中间层和平衡层组成，所述天然纤维增强聚丙烯板层由40～60％天然纤维和60～40％的丙纶短纤维三维交织成纤维毡、两面分别贴上过渡层和平衡层后热压粘合而成，其中，所述过渡层和所述平衡层为材质相同的涤纶无纺布，所述天然纤维增强聚丙烯板层通过所述过渡层和所述装饰面层粘合。
2.如权利要求1所述的轻质墙饰板，其特征在于，所述天然纤维为天然黄麻纤维或天然竹原纤维。
3.如权利要求1所述的轻质墙饰板，其特征在于，所述装饰面层为装饰墙布、PVC装饰膜或皮革。
4.如权利要求1至3之一所述的轻质墙饰板，其特征在于，所述轻质墙饰面板中含有75％～80％的静止空气。
5.如权利要求1至4之一所述的轻质墙饰板的制备方法，其特征在于，包括如下步骤：
步骤一：制作天然纤维增强聚丙烯板层
A、将天然纤维和丙纶短纤维按比例混合后经粗开松、精开松后，梳理成纤维网，经预针刺和主针刺制成纤维毡；
B、在上述制得的纤维毡两面贴上材质相同的涤纶无纺布，用连续接触式平板压机先180～200℃热压，再10～15℃冷压成型；
步骤二：用湿固化反应型聚氨酯热熔胶在上述天然纤维增强聚丙烯板层的表面粘合上装饰面层。
6.如权利要求5所述的轻质墙饰板的制备方法，其特征在于，所述步骤一中所述接触式冷、热平板机为连续式。
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