CN114103280A - 一种适于工业化生产的osb基保温复合板及其制备方法 - Google Patents
一种适于工业化生产的osb基保温复合板及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种适于工业化生产的OSB基保温复合板及其制备方法,包括位于上下表面的上木制面板、下木制面板和位于上、下木制面板之间的酚醛芯板,还包括分别位于上木制面板和酚醛芯板之间、以及位于下木制面板和酚醛芯板之间的柔性薄材,柔性薄材上下表面分别涂布胶黏剂并与对应的上木制面板、下木制面板和酚醛芯板贴合。本发明制备的OSB基轻质保温复合板具有表面装饰性强、保温性好、节能环保、轻质高强、隔声降噪、安装迅速等特点,可广泛应用于建筑和木结构房屋的墙体、屋面等保温领域,并且通过柔性薄材作为胶黏剂的涂覆载体,可利用双面滚涂机等设备自动完成,并配合冷压机、堆叠机构等实现自动化或半自动化生产,从而适于机械化生产。
Description
技术领域:
本发明涉及建筑板材领域,具体讲是一种适于工业化生产的OSB基保温复合板及其制备方法。
背景技术:
现有技术中,保温复合板如OSB基轻质保温复合板,由于面板是木质面板,中间是酚醛泡沫芯材,在制备时以人工方式直接在面板上涂水性胶,特别是在制备大尺寸复合板时,由于人工操作慢,在黏合之前,水性胶中含有的的水分会渗透进入木质面板,这样,先涂胶部分和后涂胶部分因为渗透的水含量不同,会导致黏合后两边应力不一,尺寸稳定性差。
具体的,如中国专利申请2015100860996所公开的一种酚醛泡沫夹芯复合板的制备方法,其采用人工辊涂的方式,将添加固化剂的酚醛树脂胶黏剂涂布于木质板材上,按照木质板材、酚醛泡沫板、木质板材的顺序叠放冷压制备而成。该专利申请中采用木质面板的表面进行涂胶,主要是基于酚醛泡沫板本身容易脱粉掉渣,高粘度的胶黏剂辊涂时容易将酚醛泡沫表面材料剥离而造成涂胶辊堵塞考虑的。然而木质面板表面是木纤维或者木纤维经过胶黏剂压制而成的,因此其表面具有强烈的亲水性,如果采用木质板材涂胶,尤其是采用水性的酚醛树脂胶黏剂,人工涂胶过程中,在木质面板与酚醛泡沫板粘合之前,大量的水分渗透进入木质面板,尤其像定向刨花板这种表面大片刨花相互叠加的板材会造成很多局部粗糙度较大,木质面板上施胶时会显著增加施胶量,提高了生产成本,同时也带来了更多的甲醛残留危害。并且由于木质面板本身容易吸水而发生厚度膨胀,导致力学强度降低和尺寸稳定性较差。此外,后续冷压固化后,水分难以逸出,也会造成胶合界面强度低、容易剥离等缺陷。
中国专利申请2015100862313所公布的一种酚醛泡沫夹芯复合板的制备方法。其与专利申请201510086099 6的实质性区别在于采用人工辊涂在木质板材表面涂布脲醛树脂胶黏剂,然后将酚醛树脂预发泡料加入框架模具,并在模具上下放置两张涂布了胶黏剂的木质板材,经过70℃热压20min获得夹芯复合板。而专利申请201510086763.7所公布的一种酚醛泡沫夹芯板的制备方法,其与专利申请2015100862313的实质性区别在于将酚醛泡沫板直接置于涂布了脲醛树脂胶黏剂的木质板材之间,冷压48小时获得的板夹芯复合板。其显著的不足之处在于脲醛树脂胶黏剂水分含量高,容易造成水分提前渗透进入木质板材而导致木质板材力学强度下降和尺寸稳定性较差等问题;此外该专利指出所用木质板材为纤维板、木胶合板、刨花板、竹木复合板或细木工板的一种。其中定向刨花板采用大片刨花、按照一定方向排列后压制而成的高强度板材,板材表面刨花与刨花相互叠加,表面不平整度极高,木质面板涂胶同样会显著增加胶黏剂使用量,增加甲醛风险。
另外,中国专利申请2010105999521公布了这一种木质纤维增强阻燃泡沫复合板材及其制备方法。其显著特征在于制备了一种木质纤维增强的阻燃酚醛泡沫材料,然后将木质平板预先涂布胶黏剂,酚醛泡沫板上下两面涂布胶黏剂,所用胶黏剂选自酚醛胶、脲醛胶、三聚氰胺改性脲醛胶、万能胶、白乳胶的一种;然后将涂胶后的泡沫放置于涂胶后的木质平板之间,120℃热压复合5-10min;或者将酚醛树脂预发泡料加入双层木质平板模具中,置于70℃恒温箱中发泡30-60min获得。其同样存在在黏合时易侧滑、尺寸稳定性较差,用胶量多导致成本上升等问题。
发明内容:
本发明所要解决的技术问题是,提供一种适于工业化生产的OSB基保温复合板,该保温复合板通过设置柔性的胶黏剂载体,便于工业化生产,同时增强胶合强度以提高复合板整体的强度,还可以防止在黏合时板材之间发生侧滑,以及合理控制用胶量,避免甲醛含量增加的风险。
本发明的技术解决方案是,提供一种适于工业化生产的OSB基保温复合板,包括位于上下表面的上木制面板、下木制面板和位于上、下木制面板之间的酚醛芯板,还包括分别位于上木制面板和酚醛芯板之间、以及位于下木制面板和酚醛芯板之间的柔性薄材,柔性薄材上下表面分别涂布胶黏剂并与对应的上木制面板、下木制面板和酚醛芯板贴合。
制备的轻质保温复合板具有表面装饰性强、保温性好、节能环保、轻质高强、隔声降噪、安装迅速等特点,可广泛应用于建筑和木结构房屋的墙体、屋面等保温领域。并且通过柔性薄材作为胶黏剂的涂覆载体,可利用双面滚涂机由设备自动完成,并配合冷压机、堆叠机构等实现自动化或半自动化生产。从而克服现有技术将胶黏剂直接涂覆在木制板材或酚醛树脂上的缺陷。解决现有酚醛板芯与定向刨花板粘结强度不高以及定向刨花板表面人工涂胶、陈放等工序使水性胶黏剂过多渗透在木质面板内部,造成木质面板吸水厚度膨胀率升高,降低木质面板弯曲强度和与芯板的结合强度,涂胶生产效率低等问题。定向刨花板与酚醛板都属于硬质材料,胶合界面接触不充分,生产的成品在进行后续的锯切、成型、搬运时,面板与芯板容易剥离、脱落,造成产品破坏,残次品率显著增加,而且在层叠压合过程总容易发生侧滑。而采用柔性薄材进行胶黏剂涂覆,可完美规避上述问题。
作为优选,所述柔性薄材至少需要2个,柔性薄材为无纺布、热风棉毡或玻璃纤维毡中的任一种或其组合。作为柔性薄材,其厚度优选≤3mm。
作为优选,所述柔性薄材的面密度在12g/m2-20g/m2之间。
作为优选,所述上木制面板、下木制面板为定向刨花板。所述定向刨花板面板的厚度为6mm、9mm或11mm。对应的,所述酚醛板芯的密度为0.05g/cm3,厚度为50mm、80mm或120mm。
优选的,保温复合板为OSB基轻质保温板,产品有三个系列6个标准厚度:
(1)62mm(OSB厚度6mm,酚醛板50mm)
(2)92mm(OSB厚度6mm,酚醛板80mm)
(3)132mm(OSB厚度6mm,酚醛板120mm)
(4)68mm(OSB厚度9mm,酚醛板50mm)
(5)98mm(OSB厚度9mm,酚醛板80mm)
(6)138mm(OSB厚度9mm,酚醛板120mm)
其它非标准厚度,产品的宽度、长度、厚度可根据实际所需尺寸进行定制。
作为优选,所述胶黏剂为聚氨酯胶黏剂或改性脲醛树脂胶黏剂。优选为聚氨酯胶黏剂。
作为优选,所述定向刨花板面板的物理力学性能符合以下要求,
厚度h:6mm≤h≤12mm
密度ρ:0.40g/cm3≤ρ≤0.65g/cm3
静曲强度MOR:MOR≥14MPa
弹性模量MOE:MOE≥1400MPa
24小时吸水厚度膨胀率24TS:24TS≤15%
甲醛释放量:≤1.5mg/L。
作为优选,酚醛板芯的物理力学性能复合以下要求,
厚度h:50mm≤h≤200mm
密度ρ:0.04g/cm3≤ρ≤0.06g/cm3
抗压强度:≥0.15MPa
甲醛释放量:≤1.5mg/L。
本发明还提供一种适于工业化生产的OSB基保温复合板的制备方法,包括以下步骤,
选材:提供定向刨花板面板与酚醛芯板;
施胶:柔性薄材通过液体胶料池进行表面胶黏剂的预施加,通过机械涂胶辊压缩柔性薄材以控制胶黏剂施加量,胶黏剂的施胶量控制在双面200-320g/m2;
组坯:按照上定向刨花板面板、施胶的柔性薄材、酚醛芯板、施胶的柔性薄材、下定向刨花板面板依序进行层叠;
冷压:将层叠结构经过冷压机压合,冷压压力0.10Mpa-0.15MPa,保压时间0.5-2.0小时。
优选的,包括以下步骤,
选材:提供定向刨花板面板与酚醛芯板;
施胶:热风棉毡在室温条件下利用双面滚涂机进行双面涂胶,胶黏剂的施胶量控制在双面200-320g/m2;
组坯:上定向刨花板面板、施胶的柔性薄材、酚醛芯板、施胶的柔性薄材、下定向刨花板面板依序进行层叠;
冷压:将五层结构的板材经过冷压机,冷压压力0.10Mpa-0.15MPa,保压时间0.5-2.0小时。
采用以上方案后与现有技术相比,本发明具有以下优点:制备的轻质保温复合板具有表面装饰性强、保温性好、节能环保、轻质高强、隔声降噪、安装迅速等特点,可广泛应用于建筑和木结构房屋的墙体、屋面等保温领域。并且通过柔性薄材作为胶黏剂的涂覆载体,可利用双面滚涂机由设备自动完成,并配合冷压机、堆叠机构等实现自动化或半自动化生产,从而适于机械化生产。并且可以克服现有技术将胶黏剂直接涂覆在木制板材或酚醛树脂上的缺陷。解决了现有酚醛板芯与定向刨花板粘结强度不高以及定向刨花板表面人工涂胶、陈放等工序使水性胶黏剂过多渗透在木质面板内部,造成木质面板吸水厚度膨胀率升高,降低木质面板弯曲强度和与芯板的结合强度,涂胶生产效率低等问题。另外,由于采用的是柔性薄材进行涂胶以连接木制面板和酚醛芯板,在层叠压合时不易出现侧滑,增加胶合强度,进而增强复合板整体的强度。
附图说明:
图1为本发明的实施例的保温复合板的结构示意图。
具体实施方式:
下面就具体实施方式对本发明作进一步说明:
实施例1
如图1所示,一种适于工业化生产的OSB基保温复合板,包括位于上下表面的上木制面板1、下木制面板2和位于上、下木制面板之间的酚醛芯板3,以及分别位于上木制面板1和酚醛芯板3之间、以及位于下木制面板2和酚醛芯板3之间的柔性薄材4,柔性薄材4上下表面分别涂布胶黏剂并与对应的上木制面板、下木制面板和酚醛芯板贴合。具体的,上木制面板1和下木制面板2使用9mm厚度的定向刨花板(密度0.60g/cm3,静曲强度15.2MPa,弹性模量1600MPa,24小时吸水厚度膨胀率10%,甲醛释放量1.0mg/L)、80mm厚度的酚醛芯板3(密度0.05g/cm3、抗压强度0.15MPa,甲醛释放量0.5mg/L);胶黏剂为聚氨酯胶黏剂(市售产品,粘度400mPa·s),两个柔性薄材4均为0.3mm厚的热风棉毡,热风棉毡面密度18g/m2,自动涂胶辊控制胶黏剂在热风棉毡的负载量为双面200g/m2,按照定向刨花板面板、施胶的热风棉毡、酚醛芯板、施胶的热风棉毡、定向刨花板面板顺序进行层叠,并在0.15MPa压力下保压0.5小时。
本实施例产品的物理、力学性能测试结果:抗弯强度3.2MPa,表面粘结强度0.14MPa,抗剪强度0.1MPa,导热系数0.041W/(m·k),24小时吸水厚度膨胀率4.5%。
上述保温复合板的制备方法包括以下步骤,
选材:提供定向刨花板面板与酚醛芯板;
施胶:热风棉毡在室温条件下利用双面滚涂机进行双面涂胶,胶黏剂的施胶量控制在双面200g/m2;
组坯:上定向刨花板面板、施胶的柔性薄材、酚醛芯板、施胶的柔性薄材、下定向刨花板面板依序进行层叠;
冷压:将五层结构的板材经过冷压机,冷压压力0.15MPa,保压时间0.5小时。
实施例2
一种适于工业化生产的OSB基保温复合板,包括位于上下表面的上木制面板1、下木制面板2和位于上、下木制面板之间的酚醛芯板3,以及分别位于上木制面板1和酚醛芯板3之间、以及位于下木制面板2和酚醛芯板3之间的柔性薄材4,柔性薄材4上下表面分别涂布胶黏剂并与对应的上木制面板、下木制面板和酚醛芯板贴合。具体的,上木制面板1和下木制面板2使用9mm厚度的定向刨花板(密度0.60g/cm3,静曲强度15.2MPa,弹性模量1600MPa,24小时吸水厚度膨胀率10%,甲醛释放量1.0mg/L)、80mm厚度的酚醛芯板3(密度0.05g/cm3、抗压强度0.15MPa,甲醛释放量0.5mg/L);胶黏剂为改性脲醛树脂胶黏剂(市售产品,粘度380mPa·s),两个柔性薄材4均为0.3mm厚的玻纤纤维毡,玻璃纤维毡面密度16g/m2,自动涂胶辊控制胶黏剂在热风棉毡的负载量为双面220g/m2,按照定向刨花板面板、施胶的热风棉毡、酚醛芯板、施胶的热风棉毡、定向刨花板面板顺序进行层叠,并在0.15MPa压力下保压0.5小时。
本实施例产品的物理、力学性能测试结果:抗弯强度3.4MPa,表面粘结强度0.13MPa,抗剪强度0.15MPa,导热系数0.043W/(m·k),24小时吸水厚度膨胀率4.3%。
对照例
使用9mm厚度的定向刨花板(密度0.60g/cm3,静曲强度15.2MPa,弹性模量1600MPa,24小时吸水厚度膨胀率10%,甲醛释放量1.0mg/L)、80mm厚度的酚醛芯板(密度0.05g/cm3、抗压强度0.15MPa,甲醛释放量0.5mg/L),胶黏剂为聚氨酯胶黏剂(市售产品,粘度2000mPa·s),直接将胶黏剂涂布在定向刨花板表面,单面200g/m2,按照定向刨花板面板、酚醛芯板、定向刨花板面板顺序进行组合,0.15MPa压力下保压0.5小时。
本对照例产品的物理、力学性能测试结果:抗弯强度2.2MPa,表面粘结强度0.09MPa,抗剪强度0.07MPa,导热系数0.045W/(m·k),24小时吸水厚度膨胀率7.5%。
可见,未使用柔性薄材来涂布胶黏剂,胶层的粘结强度低,产品在弯曲载荷时定向刨花板与酚醛芯板表面较早出现滑移,造成抗弯强度低,抗剪强度值低,导热系数变差,24小时吸水厚度膨胀率变差,主要是由于未使用柔性薄材涂布胶黏剂,在定向刨花板面涂布胶黏剂,使得胶黏剂与芯板结合不牢固,水分容易渗透进定向刨花板和胶层而破坏板材强度。柔性薄材涂布胶黏剂使得定向刨花板与酚醛板芯之间形成良好结合,克服了硬质材料直接接触缺陷,增加了接触比表面积,降低了施胶量,提高了产品的力学和物理性能。
更为主要的是,通过上述结构,可以方便进行机械化生产,从而在提高产品质量的基础上还可以提高生产效率。
以上仅就本发明较佳的实施例作了说明,但不能理解为是对权利要求的限制。凡是利用本发明说明书所做的等效结构或等效流程变换,均包括在本发明的专利保护范围之内。
Claims (9)
1.一种适于工业化生产的OSB基保温复合板,包括位于上下表面的上木制面板、下木制面板和位于上、下木制面板之间的酚醛芯板,其特征在于:还包括分别位于上木制面板和酚醛芯板之间、以及位于下木制面板和酚醛芯板之间的柔性薄材,柔性薄材上下表面分别涂布胶黏剂并与对应的上木制面板、下木制面板和酚醛芯板贴合。
2.根据权利要求1所述的适于工业化生产的OSB基保温复合板,其特征在于:所述柔性薄材至少有两个,所述柔性薄材为无纺布、热风棉毡或玻璃纤维毡中的任一种或其组合。
3.根据权利要求2所述的适于工业化生产的OSB基保温复合板,其特征在于:所述柔性薄材的面密度在12g/m2-20g/m2之间。
4.根据权利要求1所述的适于工业化生产的OSB基保温复合板,其特征在于:所述上木制面板、下木制面板为定向刨花板。
5.根据权利要求1所述的适于工业化生产的OSB基保温复合板,其特征在于:所述胶黏剂为聚氨酯胶黏剂或改性脲醛树脂胶黏剂。
6.根据权利要求4所述的适于工业化生产的OSB基保温复合板,其特征在于:所述定向刨花板面板的物理力学性能符合以下要求,
厚度h:6mm≤h≤12mm
密度ρ:0.40g/cm3≤ρ≤0.65g/cm3
静曲强度MOR:MOR≥14MPa
弹性模量MOE:MOE≥1400MPa
24小时吸水厚度膨胀率24TS:24TS≤15%
甲醛释放量:≤1.5mg/L。
7.根据权利要求1所述的适于工业化生产的OSB基保温复合板,其特征在于:酚醛板芯的物理力学性能复合以下要求,
厚度h:50mm≤h≤200mm
密度ρ:0.04g/cm3≤ρ≤0.06g/cm3
抗压强度:≥0.15MPa
甲醛释放量:≤1.5mg/L。
8.一种适于工业化生产的OSB基保温复合板的制备方法,其特征在于:包括以下步骤,
选材:提供定向刨花板面板与酚醛芯板;
施胶:柔性薄材通过液体胶料池进行表面胶黏剂的预施加,通过机械涂胶辊压缩柔性薄材以控制胶黏剂施加量,胶黏剂的施胶量控制在双面200-320g/m2;
组坯:按照上定向刨花板面板、施胶的柔性薄材、酚醛芯板、施胶的柔性薄材、下定向刨花板面板依序进行层叠;
冷压:将层叠结构经过冷压机压合,冷压压力0.10Mpa-0.15MPa,保压时间0.5-2.0小时。
9.根据权利要求8所述的适于工业化生产的OSB基保温复合板的制备方法,其特征在于:包括以下步骤,
选材:提供定向刨花板面板与酚醛芯板;
施胶:热风棉毡在室温条件下利用双面滚涂机进行双面涂胶,胶黏剂的施胶量控制在双面200-320g/m2;
组坯:上定向刨花板面板、施胶的柔性薄材、酚醛芯板、施胶的柔性薄材、下定向刨花板面板依序进行层叠;
冷压:将五层结构的板材经过冷压机,冷压压力0.10Mpa-0.15MPa,保压时间0.5-2.0小时。
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