CN117601205A - 一种浸渍胶膜纸饰面胶合板和细木工板及其制备方法 - Google Patents
一种浸渍胶膜纸饰面胶合板和细木工板及其制备方法 Download PDFInfo
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- B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
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Abstract
本发明涉及一种浸渍胶膜纸饰面胶合板和细木工板及其制备方法,属于人造饰面板技术领域。一种浸渍胶膜纸饰面胶合板和细木工板,从上至下依次包括第一饰面单板、第一胶膜层、基材板、第二胶膜层和第二饰面单板;所述的第一胶膜层和第二胶膜层均为改性PU热熔胶膜,所述的第一饰面单板和第二饰面单板均包括单板层和浸渍胶膜纸层。本发明使用热熔型聚氨酯胶膜替代传统脲醛树脂胶进行热压胶合,减少了传统工艺中的布胶工序,并且本发明制得的板材具有浸渍剥离性能好,甲醛释放量低的优点。
Description
技术领域
本发明涉及一种浸渍胶膜纸饰面胶合板和细木工板及其制备方法,属于饰面人造板技术领域。
背景技术
浸渍胶膜纸饰面胶合板和细木工板通常是指以浸渍氨基树脂的胶膜纸铺装在胶合板或细木工板基材上,经热压而成的装饰板材,市场俗称生态板。随着GB/T 39600标准的发布,ENF级板材逐渐步入大众视野。目前绝大部分生产厂家的生态板使用脲醛树脂胶进行布胶,致使生态板的甲醛释放量偏高。一些行业先驱者在生产原材料的选择上逐渐从E0往ENF靠拢,有效降低板材甲醛释放量。
浸渍胶膜纸饰面胶合板和细木工板属于劳动密集型工业产成品,整个生产流程工艺复杂,需要经过布胶、冷压、热压等多道工序。
现代社会飞速发展,消费者对产品质量的要求逐年提升。近年来纯色生态板广受消费者的欢迎,但是在传统的生产制造过程中,仍然存在着色差、压贴效果差等问题。
发明内容
本发明要解决上述技术问题,从而提供一种浸渍胶膜纸饰面胶合板和细木工板。本发明提供的板材,具有外观无色差、胶合强度高、甲醛含量低等优点。
本发明解决上述问题的技术方案如下:
一种浸渍胶膜纸饰面胶合板和细木工板,从上至下依次包括第一饰面单板、第一胶膜层、基材板、第二胶膜层和第二饰面单板;所述的第一胶膜层和第二胶膜层均为改性PU热熔胶膜,所述的第一饰面单板和第二饰面单板均包括单板层和浸渍胶膜纸层。
本发明上述技术方案中,通过改性PU胶膜层来替代现有技术中的脲醛树脂胶,既降低了甲醛释放量,也提高了胶合强度;同时,在工艺实施上,铺设胶膜比涂覆胶黏剂具有明显的优点:1、采用无醛PU胶膜替代脲醛树脂胶,降低甲醛释放量;2、不需要涂胶机,缩减产品生产所需工序;3、产品成品外观美观,不存在色差等问题。
作为上述技术方案的优选,所述的单板层为科技木单板。
作为上述技术方案的优选,所述的科技木单板的制备方法如下:
a)、将原木制成厚0.50~2.00mm的薄木;
b)、采用漂白液对步骤a制备的薄木进行漂白和软化,漂白时间3~8h,漂白温度25~85℃;所述漂白液包含20~30%的双氧水、2~3%的硅酸钙/硅酸钠、2~3%的氢氧化钠/氢氧化钾,余量为水;
c)、将薄木漂白后烘干至含水率10~16%;
d)、使用三聚氰胺改性脲醛树脂胶对烘干的薄木进行涂胶,组坯,冷压固化,制成科技木方;
e)、将步骤d制得的科技木方,以垂直于叠层的方向,刨切为厚度0.3~0.5mm的科技木单板。
作为上述技术方案的优选,用作所述第一饰面单板和第二饰面单板的浸渍胶膜纸饰面单板的制备方法如下:将科技木单板与三聚氰胺浸渍胶膜纸热压贴合,热压单位压力1.2~1.8MPa,时间5~30s,温度150~200℃,热压后喷水雾保存。
作为上述技术方案的优选,用作所述第一胶膜层和第二胶膜层的改性PU热熔胶膜的制备方法包括以下步骤:
1)原料准备:将改性PU原料进行熔融;
2)挤出:将熔融后的改性PU原料通过挤出机挤出成薄膜状;
3)冷却:将挤出的热熔胶膜进行冷却;
4)拉伸:将冷却后的胶膜通过拉伸装置进行拉伸至0.1~0.2mm厚度。
作为上述技术方案的优选,所述改性PU原料使用Diels-Alder反应进行改性合成,合成方法包括以下步骤:
S1、在1-4-丁二醇缩水甘油醚中添加1-呋喃-2-乙胺制备合成含呋喃基团的小分子扩链剂A;摩尔比1-4-丁二醇缩水甘油醚∶1-呋喃-2-乙胺=2∶1;
S2、将丙二醇与二异氰酸酯混合,控制釜温在58~62℃;摩尔比丙二醇∶二异氰酸酯=6∶1;
S3、将马来酰亚胺和小分子链剂A先后加入步骤S2的反应釜,并维持釜温;摩尔比马来酰亚胺∶小分子链剂A=2∶1;反应后制成改性PU原料。
本发明的另一个目的是提供上述浸渍胶膜纸饰面胶合板和细木工板的制备方法。
一种浸渍胶膜纸饰面胶合板和细木工板的制备方法,按照第一饰面单板、第一胶膜层、基材板、第二胶膜层和第二饰面单板的顺序进行组坯;然后送入压机进行热压,热压参数控制为:温度50~100℃,压强0.1~0.5MPa,时间100~1000s。
综上所述,本发明具有以下有益效果:
1、本发明所用科技木单板相比于传统科技木单板,因使用过氧化氢溶液软化,质地较软,并有效改善在肤感钢板和麻面钢板压贴过程中科技木在长度方向上的纹理问题,提升外观质量;所述肤感钢板、麻面钢板是指压机设备直接作用于工件的热压板的类型;用肤感钢板、麻面钢板热压,能够赋予胶合板的表面具有肤感板或麻面板的质感;肤感板和麻面板是当前市场较为主流的板材类型;
2、本发明的所述的科技木使用过氧化氢溶液进行漂白处理,在压贴素色三聚氰胺浸渍胶膜纸时,不会造成压贴色差;
3、本发明使用聚氨酯胶膜替代传统脲醛树脂胶进行热压胶合,减少传统工艺中的布胶工序;
4、通过对PU改性制备出具有自修复功能的改性PU热熔胶膜;改性PU热熔胶膜因分子间的交联属于可逆键合,从而在使用过程中具备自修复功能,可以有效提升改性PU热熔胶膜力学性能,提升板材浸渍剥离理化性能。
附图说明
图1是本发明的结构示意图;
图中,1-第一饰面单板,2-第一胶膜层,3-基材板,4-第二胶膜层,5-第二饰面单板;101-单板层,102-浸渍胶膜纸层。
具体实施方式
以下结合附图对本发明进行进一步的解释说明。
本具体实施方式仅仅是对本发明的解释,并不是对本发明的限制,本领域技术人员在阅读了本发明的说明书之后,所做的任何改变,只要在权利要求书的范围内,都将受到专利法的保护。
实施例1
如图1所示,一种浸渍胶膜纸饰面细木工板,从上至下依次包括第一饰面单板1、第一胶膜层2、基材板3、第二胶膜层4和第二饰面单板5;所述的第一胶膜层2和第二胶膜层4均为改性PU热熔胶膜层,所述的第一饰面单板1和第二饰面单板5均包括单板层101和浸渍胶膜纸层102。
上述浸渍胶膜纸饰面细木工板的制备方法如下:
一、科技木生产:
速生原木旋切:将速生原木以旋切方式制成长2500mm,厚0.50的薄木作为原料;去除黑节、虫孔等缺陷;
单板漂白:使用无机氧化漂白提高单板白度和柔软度,采用双氧水作为漂白主剂,硅酸钠作为稳定剂,氢氧化钠保持漂白环境为碱性。双氧水、硅酸钠、氢氧化钠、水进行复配成漂白溶液,质量比例25∶2.5∶2.5∶70,漂白时间5h,漂白温度50℃;
漂白后进行单板烘干,保持单板含水率10~16%;
使用E0级三聚氰胺改性脲醛树脂胶进行单板布胶组坯,冷压固化;
刨切为厚度0.4mm,长2500mm,宽1240mm的科技木单板。
二、复贴科技木单板:
将科技木单板与三聚氰胺浸渍胶膜纸组合热压,热压单位压力11MPa,时间8s,温度180℃,热压后进行喷水雾保存。
三、聚氨酯柔性胶膜生产:
(1)原料准备:将改性PU原料进行熔融;
(2)挤出:将熔融后的改性PU原料通过挤出机挤出成薄膜状;
(3)冷却:将挤出的热熔胶膜通过冷却装置进行快速冷却,使其达到所需的机械性能;
(4)拉伸:将冷却后的胶膜通过拉伸装置进行拉伸至0.1~0.2mm厚度,改变其物理性能;
(5)收卷:将制备好的热熔胶膜通过收卷装置进行卷取,获得改性PU胶膜。
四、浸渍胶膜纸饰面细木工板生产:
按照第一饰面单板1、第一胶膜层2、基材板3、第二胶膜层4和第二饰面单板5的顺序进行组坯;然后送入压机进行热压,热压工艺为:时间600s,温度85℃,单位压力0.4MPa,制备成浸渍胶膜纸饰面细木工板成品。
本例中,所述改性PU使用Diels-Alder反应进行改性制备合成;合成步骤如下:
S1、在1-4-丁二醇缩水甘油醚中添加1-呋喃-2-乙胺制备合成含呋喃基团的小分子扩链剂A;摩尔比1-4-丁二醇缩水甘油醚∶1-呋喃-2-乙胺=2∶1;
S2、将丙二醇与二苯甲烷二异氰酸酯混合,控制釜温在58~62℃;摩尔比丙二醇∶二异氰酸酯=6∶1;
S3、将马来酰亚胺和小分子链剂A先后加入步骤S2的反应釜,并维持釜温;摩尔比马来酰亚胺∶小分子链剂A=2∶1;反应后制成改性PU。
实施例2
如图1所示,一种浸渍胶膜纸饰面细木工板,从上至下依次包括第一饰面单板1、第一胶膜层2、基材板3、第二胶膜层4和第二饰面单板5;所述的第一胶膜层2和第二胶膜层4均为改性PU热熔胶膜层,所述的第一饰面单板1和第二饰面单板5均包括单板层101和浸渍胶膜纸层102。
上述浸渍胶膜纸饰面细木工板的制备方法如下:
一、科技木生产:
速生原木旋切:将速生原木以旋切方式制成长2500mm,厚0.50的薄木作为原料;去除黑节、虫孔等缺陷;
单板漂白:使用无机氧化漂白提高单板白度和柔软度,采用双氧水作为漂白主剂,硅酸钠作为稳定剂,氢氧化钠保持漂白环境为碱性。双氧水、硅酸钠、氢氧化钠、水进行复配成漂白溶液,质量比例25∶3∶3∶70,漂白时间6h,漂白温度55℃;
使用E0级三聚氰胺改性脲醛树脂胶,冷压固化;
刨切为厚度0.5mm,长2500mm,宽1240mm的科技木单板。
二、复贴科技木单板:
将科技木与三聚氰胺浸渍胶膜纸组合热压,热压单位压力9MPa,时间10s,温度190℃,热压后进行喷水雾保存。
三、聚氨酯柔性胶膜生产:
(1)原料准备:将改性PU原料进行熔融;
(2)挤出:将熔融后的改性PU原料通过挤出机挤出成薄膜状;
(3)冷却:将挤出的热熔胶膜通过冷却装置进行快速冷却,使其达到所需的机械性能;
(4)拉伸:将冷却后的胶膜通过拉伸装置进行拉伸至0.1~0.2mm厚度,改变其物理性能;
(5)收卷:将制备好的热熔胶膜通过收卷装置进行卷取,获得改性PU胶膜。
四、浸渍胶膜纸饰面细木工板生产:
按照第一饰面单板1、第一胶膜层2、基材板3、第二胶膜层4和第二饰面单板5的顺序进行组坯;然后送入压机进行热压,热压工艺为:时间540s,温度80℃,单位压力0.3MPa,制备成浸渍胶膜纸饰面细木工板成品。
实施例3
如图1所示,一种浸渍胶膜纸饰面细木工板,从上至下依次包括第一饰面单板1、第一胶膜层2、基材板3、第二胶膜层4和第二饰面单板5;所述的第一胶膜层2和第二胶膜层4均为改性PU热熔胶膜层,所述的第一饰面单板1和第二饰面单板5均包括单板层101和浸渍胶膜纸层102。
上述浸渍胶膜纸饰面细木工板的制备方法如下:
一、科技木生产:
速生原木旋切:将速生原木以旋切方式制成长2500mm,厚0.5的薄木作为原料;去除黑节、虫孔等缺陷;
单板漂白:使用无机氧化漂白提高单板白度和柔软度,采用双氧水作为漂白主剂,硅酸钠作为稳定剂,氢氧化钠保持漂白环境为碱性。双氧水、硅酸钠、氢氧化钠、水进行复配成漂白溶液,质量比例28∶2.3∶2.6∶72,漂白时间7h,漂白温度65℃;
使用E0级三聚氰胺改性脲醛树脂胶,冷压固化;
刨切为厚度0.4mm,长2500mm,宽1240mm的科技木单板。
二、复贴科技木单板:
将科技木与三聚氰胺浸渍胶膜纸组合热压,热压单位压力11MPa,时间9s,温度185℃,热压后进行喷水雾保存。
三、聚氨酯柔性胶膜生产:
(1)原料准备:将改性PU原料进行熔融;
(2)挤出:将熔融后的改性PU原料通过挤出机挤出成薄膜状;
(3)冷却:将挤出的热熔胶膜通过冷却装置进行快速冷却,使其达到所需的机械性能;
(4)拉伸:将冷却后的胶膜通过拉伸装置进行拉伸至0.1~0.2mm厚度,改变其物理性能;
(5)收卷:将制备好的热熔胶膜通过收卷装置进行卷取,获得改性PU胶膜。
四、浸渍胶膜纸饰面细木工板生产:
按照第一饰面单板1、第一胶膜层2、基材板3、第二胶膜层4和第二饰面单板5的顺序进行组坯;然后送入压机进行热压,热压工艺为:时间580s,温度90℃,单位压力0.35MPa,制备成浸渍胶膜纸饰面细木工板成品。
对比例1
浸渍胶膜纸饰面细木工板包括第一饰面单板、第一胶粘剂层、基板层、第二胶粘剂层、第二饰面单板。具体的结构层次跟实施例相比,区别仅在于:胶膜层替换为脲醛树脂胶。
具体制备方法如下:
步骤一、将科技木单板与浸渍胶膜纸进行压贴,热压单位压力11MPa,时间9s,温度185℃,热压后进行喷水雾保存,制备用作第一饰面单板和第二饰面单板的饰面单板;
步骤二、取基板,使用脲醛树脂胶进行双面布胶,并与第一、第二饰面单板进行组坯;
步骤三、对坯板进行冷压,单位压力0.6MPa,时间30min;
步骤四、进行热压,时间540s,温度85℃,单位压力0.35MPa,制得浸渍胶膜纸饰面细木工板成品。
对比例2
在浸渍胶膜纸饰面细木工板生产过程中和对比例1一样使用脲醛树脂胶,科技木单板使用实施例1所制备的科技木单板。
对比例3
与实施例1、2、3不同的是,PU胶膜为常规胶膜,即在PU胶膜生产过程中不添加1-呋喃-2-乙胺和马来酰亚胺;小分子扩链剂使用1,4-丁二醇。所得聚氨酯柔性胶膜成膜力学性能较低。
对实施例、对比例按照GB/T 34722、GB/T 17657进行理化性能、外观检测,检测结果如下:
上述实施例和对比例中,所用基材(基材板、基板层)均为细木工板。合格率测试时,试件数量每项均为6块。浸渍剥离按照三类试验,即:将试件放置在35±3℃的温水中浸渍2h,取出后置于63±3℃的干燥箱中干燥3h。
Claims (10)
1.一种浸渍胶膜纸饰面胶合板和细木工板,从上至下依次包括第一饰面单板(1)、第一胶膜层(2)、基材板(3)、第二胶膜层(4)和第二饰面单板(5);其特征在于:所述的第一胶膜层(2)和第二胶膜层(4)均为改性PU热熔胶膜,所述的第一饰面单板(1)和第二饰面单板(5)均包括单板层(101)和浸渍胶膜纸层(102)。
2.根据权利要求1所述的一种浸渍胶膜纸饰面胶合板和细木工板,其特征在于:所述的单板层(101)为科技木单板。
3.根据权利要求2所述的一种浸渍胶膜纸饰面胶合板和细木工板,其特征在于:所述的科技木单板的制备方法如下:
a)、将原木制成厚0.50~2.00mm的薄木;
b)、采用漂白液对步骤a制备的薄木进行漂白和软化,漂白时间3~8h,漂白温度25~85℃;所述漂白液包含20~30%的双氧水、2~3%的硅酸钙/硅酸钠、2~3%的氢氧化钠/氢氧化钾,余量为水;
c)、将薄木漂白后烘干至含水率10~16%;
d)、使用三聚氰胺改性脲醛树脂胶对烘干的薄木进行涂胶,组坯,冷压固化,制成科技木方;
e)、将步骤d制得的科技木方,以垂直于叠层的方向,刨切为厚度0.3~0.5mm的科技木单板。
4.根据权利要求2所述的一种浸渍胶膜纸饰面胶合板和细木工板,其特征在于:用作所述第一饰面单板(1)和第二饰面单板(5)的浸渍胶膜纸饰面单板的制备方法如下:将科技木单板与三聚氰胺浸渍胶膜纸热压贴合,热压压力8~15MPpa,时间5~30s,温度150~200℃。
5.根据权利要求1所述的一种浸渍胶膜纸饰面胶合板和细木工板,其特征在于:用作所述第一胶膜层(2)和第二胶膜层(4)的改性PU热熔胶膜的制备方法包括以下步骤:
1)原料准备:将改性PU原料进行熔融;
2)挤出:将熔融后的改性PU原料通过挤出机挤出成薄膜状;
3)冷却:将挤出的热熔胶膜进行冷却;
4)拉伸:将冷却后的胶膜通过拉伸装置进行拉伸至0.1~0.2mm厚度。
6.根据权利要求5所述的一种浸渍胶膜纸饰面胶合板和细木工板,其特征在于:
所述的改性PU原料使用Diels-Alder反应进行改性合成,合成方法包括以下步骤:
S1、在1-4-丁二醇缩水甘油醚中添加1-呋喃-2-乙胺制备合成含呋喃基团的小分子扩链剂A;摩尔比1-4-丁二醇缩水甘油醚∶1-呋喃-2-乙胺=2∶1;
S2、将丙二醇与二异氰酸酯混合,控制釜温在58~62℃;摩尔比丙二醇∶二异氰酸酯=6∶1;
S3、将马来酰亚胺和小分子链剂A先后加入步骤S2的反应釜,并维持釜温;摩尔比马来酰亚胺∶小分子链剂A=2∶1;反应后制成改性PU原料。
7.根据权利要求1所述的一种浸渍胶膜纸饰面胶合板和细木工板的制备方法,其特征在于:按照第一饰面单板(1)、第一胶膜层(2)、基材板(3)、第二胶膜层(4)和第二饰面单板(5)的顺序进行组坯;然后送入压机进行热压,热压参数控制为:温度50~100℃,压强0.1~0.5MPa,时间100~1000s。
8.根据权利要求7所述的一种浸渍胶膜纸饰面胶合板和细木工板的制备方法,其特征在于:用作所述第一胶膜层(2)和第二胶膜层(4)的改性PU热熔胶膜的制备方法包括以下步骤:
1)原料准备:将改性PU原料进行熔融;
2)挤出:将熔融后的改性PU原料通过挤出机挤出成薄膜状;
3)冷却:将挤出的热熔胶膜进行冷却;
4)拉伸:将冷却后的胶膜通过拉伸装置进行拉伸至0.1~0.2mm厚度。
9.根据权利要求8所述的一种浸渍胶膜纸饰面胶合板和细木工板的制备方法,其特征在于,所述的改性PU原料的制备方法包括以下步骤:
S1、在1-4-丁二醇缩水甘油醚中添加1-呋喃-2-乙胺制备合成含呋喃基团的小分子扩链剂A;摩尔比1-4-丁二醇缩水甘油醚∶1-呋喃-2-乙胺=2∶1;
S2、将丙二醇与二异氰酸酯混合,控制釜温在58~62℃;摩尔比丙二醇∶二异氰酸酯=6∶1;
S3、将马来酰亚胺和小分子链剂A先后加入步骤S2的反应釜,并维持釜温;摩尔比马来酰亚胺∶小分子链剂A=2∶1;反应后制成改性PU原料。
10.根据权利要求7所述的浸渍胶膜纸饰面胶合板和细木工板的制备方法,其特征在于:用作所述第一饰面单板(1)和第二饰面单板(5)的浸渍胶膜纸饰面单板的制备方法如下:将科技木单板与三聚氰胺浸渍胶膜纸热压贴合,热压压力8~15MPpa,时间5~30s,温度150~200℃。
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