CN101500800A - 含有竹的板 - Google Patents

含有竹的板 Download PDF

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CN101500800A
CN101500800A CNA2006800364139A CN200680036413A CN101500800A CN 101500800 A CN101500800 A CN 101500800A CN A2006800364139 A CNA2006800364139 A CN A2006800364139A CN 200680036413 A CN200680036413 A CN 200680036413A CN 101500800 A CN101500800 A CN 101500800A
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bamboo
layer
plank
layers
composite wood
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O·尼安华
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Huber Engineered Woods LLC
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    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
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Abstract

本发明公开了一种木板，其包括：具有上和下表面层和芯层的复合木材部件；和一层或多层竹层，所述一层或多层竹层的厚度约为0.0625－0.5英寸，粘附于所述复合木材的上表面层。

Description

含有竹的板
发明背景
竹由于它的高强度、耐久性和极佳的尺寸稳定性，是一种在全亚洲广泛用作建筑材料的木质纤维素材料。在它被广泛使用和极佳的性能的条件下，存在用竹制成结构板的需求。
目前，这类竹制结构板通过将竹茎的外部或表面手工切割成竹条，然后编织(通常又是手工)成垫子而制成。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一起压制。
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该板中产生洞眼或其它缺陷，这会导致断裂。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，上述加工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
本发明包括一种木板，其包括：具有上和下表面层和芯层的复合木材部件；和一层或多层竹层，其厚度约为0.0625-0.5英寸，粘附于所述复合木材的上表面层。
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”指复合木屑板、硬纸板、中密度纤维板、胶合板，和条(strand)和层片单板复合物木板。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《可克-欧诗玛化学技术百科全书(Kirk-Othmer Encyclopedia of ChemicalTechnology)》的增补卷，第765-810，第6版，以其全文纳入本文作参考。
下面描述本发明的优选实施方式，其提供了一种木板，包括木材复合部件和一层或多层竹层。所述木材复合材料形成了所述板的内部，而一层或多层竹层由编织的竹片所形成。这样可以无需非常大量的编织竹片—而是将较少量的编织竹片粘贴到木材复合芯上，制成具有坚韧、耐久的竹表面的木板。这种板解决了上述结构竹板的缺点：所述板具有竹的耐久性；具体来讲，它具有竹的耐久性却没有内表面间隙和可能损害性能的其它缺陷。此外，减少竹片数量能缩短制造过程，制成较少使用石油基产品的板产品。
竹层
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。而且，由于存在用覆盖茎外部表面的蜡包覆的二氧化硅沉积的角质化层，竹茎外部的强度和硬度增加。因此，在大多数利用竹的方法中，茎外表面上或附近的竹具有优良的强度特性。与以前剥去角质化层，从而丢弃了茎的强度最大的部分的利用竹木技术不同，本发明中利用了角质化层，从而保留了竹的高强度特性。
总的来讲，竹中的纤维素纤维比大部分木类纤维更坚硬和更强，因此，含有竹的板具有比由其它类型木纤维制成的板高得多的强度与重量之比。
如本发明中所用的，将竹形成编织竹片。通过首先将竹切割成：(1)竹杆全长(距离通常为4-40英尺)或(2)更短段的竹条来形成这些竹片。可以手工或用机械剪切设备完成这种切割。将这些条手工编织到一起形成编织竹片。然后用异氰酸酯树脂涂覆所述竹片。优选所述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体(“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。苯酚-甲醛(“PF”)、三聚氰胺-甲醛、三聚氰胺-脲-甲醛(“MUF”)和其共聚物也适用。合适的工业MUF粘合剂是黛尼公司(Dynea corporation)的LS 2358和LS 2250产品。
以竹片的干重为基准计，树脂含量约为2-12重量％。涂上树脂后，任选地使竹片干燥。(通常，只使用异氰酸酯树脂时无需干燥)。可以在室温下或使用窑进行干燥，如果使用窑，则必须设定成不引起树脂固化的低温。如以下关于第一和第二制造方法更详细描述的，可以单独或与其它竹片组合使用所述竹片形成一层或多层竹层，置于复合木片上。
板的厚度可以在0.25-2.0英寸厚内变化，板的尺寸为4-8英尺。最薄的板可以用作工程木材I-托梁的腹板原料(web stock)。中等厚度的板可以用作壁板和底层地板。最厚的板可用于预制木构件应用。这些产品的另一种用途是作为装货容器和运输挂车的面板材料。
木材复合部件
优选所述木材复合部件由OSB材料制成。所述定向纤维板由纯的或混合的自然形成的硬或软木原材料得到，无论这类木材是干燥(含水量为2-12重量％)或绿色的(含水量为30-200重量％)。一般，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、薄片或片。
切割条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与传送带平行。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。
各种聚合树脂，优选热固性树脂，可以用作木材片或条的粘合剂。合适的聚合粘合剂包括异氰酸酯树脂、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”)和其共聚物。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。
所述粘合剂的含量优选约为2-15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35-48磅/英尺3(按ASTM标准D1037-98测量)。南方松的密度为40-48磅/英尺3和白杨的密度为35-42磅/英尺3。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。
接着，采用第一或第二方法生产最终的木板。在第一方法中，在涂覆片(如上)之前首先将一层或多层编织竹层置于传送带上，然后将涂覆片排列到编织竹层上，然后将第二组编织竹层置于片上。然后将该松散结构传送到热压机中，在该片上的树脂涂层和竹层形成粘合的情况下用热和压力压实。适用于本发明的第一方法如美国专利号6,737,155所述。
作为第一方法的另一方法，可以采用第二方法。在第二方法中，所述木材复合部件和竹层彼此粘附形成复合板。如通过将竹层与所述木材复合部件的表层的外表面粘结，如通过层压而使这类粘附产生。通过将编织竹层置于传送带上，将木材复合板置于所述编织竹层上使所述木材复合板的下表面与所述编织竹层接触，然后将另外的编织竹层置于所述木材复合板的上表面上而完成。在编织竹片上的树脂涂层能使所述编织竹片与木材复合部件的表层间发生粘合剂粘附。然后所述传送带将该竹-木材复合-竹垫送到压机中，在压机施加热和压力将所述各层压实成单个复合结构板。
此外，所述木板还可以存在于另一个实施方式中。在此实施方式中，所述木板包含不是1个而是2个木材复合部件。这种结构中，依次变换竹层、接着木材复合部件、接着竹层、接着木材复合部件、接着竹层。无论选择哪种方法或结构，所述竹层的厚度均约为0.0625-0.5英寸。
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 (9)

1.一种木板，包括：
具有上和下表面层和芯层的复合木材部件；和
一层或多层竹层，其厚度为约0.0625-0.5英寸，粘附于所述复合木材的上表面层。
2.如权利要求1所述的木板，其特征在于，包括与所述复合木材部件的下表面层粘附的一层或多层竹层。
3.如权利要求1所述的木板，其特征在于，所述复合木材部件是定向纤维板。
4.如权利要求1所述的木板，其特征在于，所述一层或多层竹层被层压到所述复合木材部件的上表面层上。
5.如权利要求1所述的木板，其特征在于，所述一层或多层竹层由编织竹制成。
6.如权利要求1所述的木板，其特征在于，所述一层或多层竹层由取自竹茎外部的竹条制成。
7.如权利要求1所述的木板，其特征在于，所述一层或多层竹层包括超过3层。
8.一种制备木板的方法，包括以下步骤：
提供复合木材部件，所述复合木材部件包括上表面层，所述上表面层具有外表面；
将竹茎切割成竹条；
将竹条编织成一层或多层竹垫；和
将一层或多层竹垫加到所述木材部件的上表面的外表面上。
9.如权利要求8所述的制备木板的方法，其特征在于，所述竹条从竹茎的外部切割而成。
CNA2006800364139A 2005-08-31 2006-08-11 含有竹的板 Pending CN101500800A (zh)

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