CN101277817A - 含有内茎片的木板 - Google Patents

含有内茎片的木板 Download PDF

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CN101277817A
CN101277817A CNA2006800364393A CN200680036439A CN101277817A CN 101277817 A CN101277817 A CN 101277817A CN A2006800364393 A CNA2006800364393 A CN A2006800364393A CN 200680036439 A CN200680036439 A CN 200680036439A CN 101277817 A CN101277817 A CN 101277817A
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bamboo
plank
weight
culm
bar
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O·尼安-华
M·赫安-昆
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Huber Engineered Woods LLC
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Abstract

本发明公开了一种含有从竹茎内部切割的竹条的木板。

Description

含有内茎片的木板
发明背景
竹由于它的高强度、耐久性和极佳的尺寸稳定性，以及随时供应和快速补充-竹子生长非常快，2-6年内即可完全成熟，而甚至是最快生长的木材树种也要花费长达15-30年才能生长到完全成熟，因此是一种在全亚洲广泛用作建筑材料的木质纤维素材料。
然而，除了这些优点外，竹也有许多缺点。由于竹是中空的，它不能被加工成实心木材板(lumber board)或厚板(plank)。
不仅它不可能制成实心木材板形式，竹还不能通过用于制造木材复合材料的常规技术进行加工。例如，由于竹茎太薄而无法切割成制备胶合板的单板，因此难以由竹制成胶合板。竹也不能通过用于制造条(strand)复合木材(是由树脂涂覆的条经优选取向和以该取向放置在下面经过的传送带上而制成的复合材料)的技术成功加工。
尽管有这些缺点，但由于竹具有随时供给和极佳的性能特性，制造商已开发了由竹制造木材复合材料的技术。例如，可以通过将竹茎的外部或表面手工切割成竹条，然后将所述条编织(通常又是手工)成垫来制造复合竹结构板。然后将这些手工切割、手工编织的竹垫与几个其它类似的垫子一起堆叠，然后在高温下将这些垫子压制到一起。
这种制造竹板的方法的问题是费时；切割竹条和然后将竹条编织成垫子形式的步骤需要花费相当多的时间。这些加工不仅仅耗时，而且它们可能会对最终板产品造成严重的缺陷。例如，将几个垫子成层地放到另一垫子上面产生的内部间隙可以导致在板中产生洞眼或其它缺陷，而会导致断裂。此外，使2个编织竹垫粘合到一起包括使两个配合表面粘合到一起，这是缺陷的另外来源。然而，上述方法的另一个缺点是因为它们由大量的竹层组成，所以它们每层都需要非常高剂量的树脂，在高石油价格时期，这大大增加了产品的价格。
在上述背景技术的情况下，本领域存在对部分或完全由竹组成的、缺陷较少、无需冗长制造过程和消耗石油基产品较少的结构竹板的需求。
发明概述
本发明涉及含有从竹茎内部切割的竹条的木板。
发明详述
除非另外规定，本文采用的所有份、百分比和比率均以重量表示。本文引用的所有文件均以其全文纳入本文作参考。
本文采用的“木质纤维素材料”是指一种细胞结构，具有通过木质素聚合物结合到一起的纤维素和半纤维素纤维组成的细胞壁。木材是一种木质纤维素材料。
“木材复合材料”或“木材复合部件”指一种含有木质纤维素材料和一种或多种其它添加剂，如粘合剂或蜡的复合材料。木材复合材料的非限制性例子包括定向纤维板(oriented strand board，“OSB”)，如，华夫刨花板、刨花板、碎木胶合板、中密度纤维板、胶合板和为条和层片单板复合物的板。认为本文采用的“片“、“条”和“华夫刨花”彼此等同和可以互换使用。木材复合材料的非排它性描述可以参见的《可可欧诗玛化学技术百科全书(Kirk-Othmer Encyclopedia of ChmicalTechnology)》的增补卷，第765-810，第6版，以其全文纳入本文作参考。
以下描述了本发明的优选实施方式，提供了一种含有从竹茎内部切割的竹条的OSB木板。由从竹茎内部切割的条形成OSB产品结果形成具有极佳强度和耐久特性的OSB木板。
以前，利用取自竹茎的薄片的尝试均告失败，这是因为在竹茎外层薄片上有蜡质和高度角质化的表面覆盖物，使常规的木材复合树脂(像苯酚甲醛)不能渗透到该薄片中，因此相邻薄片间不能形成强的粘合。
通过除去阻止常规复合木材树脂渗透的竹茎外部，本发明解决了该问题。将该外部剥去后，可以将竹茎内部加工成木条，采用常规配置复合木材树脂进行利用。结果是用竹制成的木材复合板，但因为竹外部是竹茎中存在的最强的材料，因此它的强度和耐久性不如包括茎外部的木材复合板那么好。
现在将对所述竹材作更详细的描述，接着详细讨论将竹条结合进复合材料中的方法。
像其它木材一样，竹的基本组成部分是通过木质素聚合物结合到一起的纤维素纤维，但竹的组成细胞的构造和形态与其它木材不同。通常，竹的大部分强度特性(拉伸强度、挠曲强度和刚性)在竹和竹纤维纵向最大。这是由于纤维素纤维在纵向的微纤丝角度相对较小。竹茎本身的硬度取决于竹纤维束的密度和它们的分离方式。在竹茎纵向或竹茎横截面中的纤维百分比不一致。在纵向，纤维密度从茎底到茎顶增加，而竹茎横截面中的纤维密度在接近外表面处最高，随着深入该材料的芯而减小。
因此，高度有益地是采用取自竹茎内部的条制造木板。竹茎外部是竹茎外径2mm内的茎部。本文中将竹茎内径和竹茎外部之间的竹茎部分定义为“竹茎内部”；因此，本发明中竹茎内部的条是取自离竹茎外径2mm或更远的茎部的那些条。本发明已发现即使除去了来自竹茎外部的条，竹中的纤维素纤维仍然比大部分木类的更坚硬和更强，因此，含有竹的板具有比其它类型木纤维制成的板高得多的强度与重量之比。
本发明的制备中第一步是通过剥皮、磨削或砂光竹茎外部来除去竹茎外部。可以例如，通过将茎送到喷砂隧道或通过砂轮完成所述砂光。为了改进与常规木条的相容性和粘合性，优选将竹条切割成厚度小于约0.2英寸，如小于0.15英寸，如约0.01-0.15英寸；和切割成宽度优选大于约0.1英寸，如大于约0.15英寸，如大于约0.5英寸。可手工或用机械剪切设备完成该切割。为了改进强度，应该沿纵轴将所述竹条切割成优选约比2英寸长，如约3英寸，如约5英寸的条。尽管不想受理论的限制，不过认为当用圆盘条取向器对条进行取向时，较长的条长度将使条排列更紧密，并且不受理论的限制，认为更紧密排列的条将产生沿纵轴弹性系数更佳的最终木材复合板产品。
切割后，使所述竹条干燥(如下所述)和涂覆上常规聚合物树脂(如下所述)。优选实施方式中，采用含量约为2-12重量％(以竹木的重量为基准)的所述MDI(参见如下更详细定义)粘合剂树脂，而采用水基粘合剂树脂(如下)，则含量约为3-15重量％(以竹木的重量为基准)。
用于本发明时，通过使竹条与自然形成的硬或软木(如松木或白杨木)条混合，将取自竹茎内部的竹制成条复合板，优选为OSB板。为了最好结果获得良好的粘合性和板完整性，竹条的含量应该低于竹和非竹(硬和软)木条总重量的约90重量％，如低于约80重量％，如低于约75重量％，如低于约70重量％。
通常，将所述新的或回收的原木原料切割成本领域普通技术人员熟知的所需大小和形状的条、华夫刨花或片。当由所述竹条和自然形成的硬或软木的组合制造所述板时，可以分别干燥和用聚合物树脂粘合剂涂覆这两组分开的木材，然后在分别涂覆步骤后，将所述涂覆的硬/软木条与涂覆的竹条混合到一起。
对条进行切割后使它们在炉中干燥，然后涂上由一种或多种聚合热固性粘合剂树脂、蜡和其它添加剂制成的特殊制剂。所述粘合剂树脂和其它用于木材的各种添加剂在本文中称为涂料，即使所述粘合剂和添加剂是小颗粒的形式，如不会在木材上形成连续涂层的雾化颗粒或固体颗粒。通常，通过一种或多种喷雾、掺混或混合技术将所述粘合剂、蜡和任何其它添加剂施涂于木材，优选技术是当木条在鼓式掺混器中翻滚时将蜡、树脂和其它添加剂喷射到木条上。
用所需涂料和处理化学品涂布和处理后，这些涂覆条可用来形成多层垫，优选然后被压制成复合木材部件的3层垫。用以下方式完成所述成层。将涂覆片在传送带上铺开形成片的取向基本上与传送带呈一直线或与之平行的第一片或层，然后将第二片置于第一片上，第二片层的片的取向基本上与传送带垂直。最后，将第三片置于第二片上，第三片层的片的取向与第一片类似，基本上与传送带呈一直线，使得以这种方式堆叠的片层的各片的取向通常与邻片层垂直。或者，但较不优选，所有片层的各条取向为任意方向。可以采用公知多通道技术和条取向设备放置多个片或层。在3片或3层垫的情况下，第一和第三片是表面层，而第二片是芯层。所述各表面层具有外表面。
还可以在不同的相对方向上完成上述实例，从而第一片层的片的取向基本上与传送带垂直，然后，第二片置于第一片上，第二片层的片的取向基本上于传送带平行。本发明中，形成与传送带平行的板的纵向边，从而基本上与传送带平行取向的薄片将基本上与传送带平行取向和排列，最终基本上与最终木板产品的纵向边平行。最后，将片的取向与第一片类似，基本上与传送带垂直的第三片置于第二片上。
本发明中还有另一种可能的板构造。该构造中，根据上述方法构建一层或多层来形成足以形成复合木材部件的各层，然后在这些层上形成竹条层，所述竹条的取向方向基本上与纵向边平行，形成竹单板层。对该竹层中的竹条使用的粘合剂树脂如上所述，按以下各段中所述对该竹层和它伴有的木层进行加工。
各种常规聚合物树脂，优选热固性树脂，可以用作木片或木条的粘合剂。合适的聚合物粘合剂包括异氰酸酯树脂和水基粘合剂树脂，如脲-甲醛、聚乙酸乙烯酯(“PVA”)、苯酚甲醛、三聚氰胺甲醛、三聚氰胺脲甲醛(“MUF”)及其共聚物。异氰酸酯是优选的粘合剂，优选的异氰酸酯选自二苯甲烷-对，对’-二异氰酸酯类的聚合物，所述聚合物具有能与其它有机基团反应形成聚合物基团如聚脲，-NCON-，和聚氨酯，-NCOON-的NCO-官能团；优选含有约50重量％的4，4-二苯甲烷二异氰酸酯(“MDI”)的粘合剂或有其它异氰酸酯低聚物(“pMDI”)的混合物。合适的工业pMDI产品是购自犹他州盐湖城的猎人公司(Huntsman)的Rubinate 1840和宾夕法尼亚州匹兹堡市的北美拜耳公司(Bayer Corporation，North America)的Mondur 541。合适的工业MUF粘合剂是黛尼公司(Dynea corporation)的LS 2358和LS 2250产品。
粘合剂含量优选约为2-8重量％。通常采用蜡添加剂增强OSB板的抗渗水性。优选的蜡是疏松石蜡或乳液蜡。所述蜡固体的加入量优选约为0.1-3.0重量％(以木材的重量为基准)。
根据上述方法形成多层垫后，在热压机下将它们压制，使木材、粘合剂和其它添加剂熔合和粘合到一起形成各种厚度和尺寸的压实OSB板。高温还会使粘合剂材料固化。优选将本发明的板在约175-240℃的温度下压制2-15分钟。得到的复合板的密度约为35-55磅/英尺3(按ASTM标准D1037-98测量)。OSB板的厚度约为0.6cm(约1/4英寸)-5cm(约2英寸)，如约1.25-6cm，如约2.8-3.8cm。
本领域那些技术人员将意识到，在不脱离本发明主要发明原理的情况下，可以对上述实施方式作出改变。因此，应该理解，本发明不限于所公开的具体实施方式，而其意图是包括所附权利要求书所限定的本发明精神和范围内的各种修改。

Claims (10)

1.一种含有从竹茎内部切割的竹条的木板。
2.如权利要求1所述的木板，其特征在于，还含有选自白杨木和松木的木条，其特征在于，所述竹条小于所有木条总重量的约90重量％，优选小于约80重量％，优选小于约75％。
3.如权利要求1所述的木板，其特征在于，所述条的厚度小于约0.2英寸，如约0.01-0.15英寸。
4.如权利要求1所述的木板，其特征在于，所述条的宽度大于约0.1英寸。
5.如权利要求1所述的木板，其特征在于，以竹木重量为基准计，所述木板还含有含量为约2-6重量％的MDI。
6.如权利要求1所述的木板，其特征在于，所述木板还含有含量为约3-10重量％的水基粘合剂树脂。
7.一种木板，含有：
(a)从竹茎内部切割的竹条；和
(b)选自白杨木和松木的木条；
其中(a)中竹条的重量小于(a)和(b)中的竹条和木条总重量的约90重量％，优选小于约80重量％，优选小于约75重量％。
8.如权利要求7所述的木板，其特征在于，所述竹条涂覆有MDI含量为约2-6重量％(以竹木重量为基准)的MDI粘合剂。
9.如权利要求7所述的木板，其特征在于，(a)和(b)中的所述条均以单一方向取向。
10.一种木板，所述木板具有平行的第一和第二纵向边，各板含有：
具有上表面层的复合木材部件；
位于所述上表面层上的竹单层，所述竹层由基本上以平行于纵向边的方向取向的竹条组成，其中所述竹条是从竹茎内部切割的。
CNA2006800364393A 2005-08-31 2006-08-11 含有内茎片的木板 Pending CN101277817A (zh)

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