CN103568099B - 一种装饰板的制作方法 - Google Patents

一种装饰板的制作方法 Download PDF

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CN103568099B
CN103568099B CN201310178508.6A CN201310178508A CN103568099B CN 103568099 B CN103568099 B CN 103568099B CN 201310178508 A CN201310178508 A CN 201310178508A CN 103568099 B CN103568099 B CN 103568099B
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bond paper
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孙学民
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Jiangsu Tianrun Shengkai New Material Co.,Ltd.
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CHANGZHOU TIANRUN WOOD INDUSTRY Co Ltd
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Priority to CN201511006703.6A priority Critical patent/CN105599098A/zh
Priority to CN201511006701.7A priority patent/CN105398148A/zh
Priority to CN201511006705.5A priority patent/CN105599099A/zh
Priority to CN201511006702.1A priority patent/CN105442795B/zh
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Abstract

本发明涉及一种装饰板的制作方法，依次包括以下步骤：纤维的制备、胶粘剂的制备、施胶处理、预压热压、木皮处理、耐磨胶膜纸与表层胶膜纸的制备、压制装饰板。本发明所述的装饰板的制备方法具有以下技术效果：生产成本低；制作出的装饰板性能优异，耐水性、耐火性、抗菌性、耐污染能更佳；能耗低排放少；实木与康贝特结合一体,既有实木暖感,又有康贝特特有性能；采用耐磨纸表面,既不影响木材效果,又有超强耐刮耐磨性能,还可放弃传统油漆涂料表面处理；大胶量的浸胶表层纸紧紧连接木皮与芯材，结构更牢固。

Description

一种装饰板的制作方法
技术领域
本发明涉及装饰板的制作方法，尤其是一种复合实木康贝特的制作方法。
背景技术
康贝特又名抗倍特，复合实木康贝特是在高温高压下经溶解及不可逆时效硬化产生的一体成型装饰板材，其板材质稳定性高、防震防摔、耐寒耐热且有耐火防潮及耐烟烧特性，广泛应用于室内外装潢、厨房橱柜、办公家具、实验室等领域。复合实木康贝特作为一种特殊的高压装饰耐火板，成为建筑界惊为天人的超前概念建材，普遍应用于公共空间的柜体、墙面、装饰物等处，也成为设计师创作家具、饰物的灵感及最佳材料。
目前，康贝特的原材料是牛皮纸，它是由多层被酚醛树脂浸泡过的牛皮纸烘干后，再与经三聚氰胺处理过的色纸，在高温高压下制作而成的，其厚度由牛皮纸层叠数量决定。然而，现有工艺需要大量牛皮纸，生产前需要先进行造纸过程，造纸过程能耗高、污染重，对环境影响很大，同时也是康贝特生产成本高的主要原因。另外市场还未曾出现实木复合康贝特,一般是用装饰纸做表面,颜色比较冷,没有实木具有无污染、花纹自然、典雅应重、富质感性、弹性真实等特性。市场上有实木胶合板等人造板,但这些人造板不够耐水耐热耐冲击,不具备康贝特性能,另外表面大多用油漆保护,这样既操作麻烦也不耐刮擦。如何提供一种既简单又耐磨又有康贝特性能的实木复合康贝特，是本领域的技术难题。
发明内容
本发明要解决的技术问题是提供一种实木表面、高密度、高耐磨、成本低的装饰板的制作方法。
为解决上述技术问题，本发明所述的装饰板的制作方法，依次包括以下步骤：
（1）纤维的制备：将去皮的植物枝干水洗过后，削片、蒸煮、热磨制成均匀的纤维；
（2）施胶处理：先将步骤（1）制得的纤维先经过烘干，然后将胶粘剂以喷射方式与纤维混合均匀；
（3）预压热压：将施胶处理后的纤维再经过铺装、预压、热压制成半成品；预压可以使散乱纤维形成一体，以便压制；热压作用是胶黏剂部分反应，形成均匀坯体，方便后续使用。
（4）木皮处理：首先对原木进行截剖，成木方状，再通过蒸煮进行软化处理，然后将软化后的木方进行刨切并干燥、剪切成型；
（5）压制装饰板：将半成品的上表面依次设置上表层胶膜纸、木皮，将所述半成品的下表面设置耐磨胶膜纸，再经热压机热压成型制成装饰板。
所述胶粘剂的制备：按重量比取酚醛树脂80～90%、助剂10～20%混合均匀并加热到50℃制备成胶粘剂；所述助剂包括：重量百分比为5-20%的稀释剂、0.5-2%的碳黑与2-10%的高岭土，该稀释剂为甲醇和/或酒精。
所述步骤（2）中的纤维与胶粘剂的质量比为2：3至3：2，喷射压力为5-7MPA，这样压力能把液体胶黏剂雾化，保证胶黏剂与纤维充分混合均匀渗透。
所述步骤（3）中的预压温度为30-50℃，压力为2-3.5MPA，预压时间为15-25秒；热压温度为150-180℃，压力从最大压力5MPA逐渐递减为常压，热压时间为15-25秒。
所述步骤（4）中，所述截剖为将原木按所需长度截成木段，然后去皮再剖制木方，刨片厚度为0.5mm；所述蒸煮为将木方按树种、木方规格分别放入不同蒸煮池，放入时水温保持常温，然后升温至50℃蒸煮结束，升温速度为1℃/min；蒸煮处理后的木方及时放入刨切机前的贮木温水槽中保温，保温温度为40-50℃；所述干燥为将刨切后的木方放入滚筒干燥机进行干燥，干燥后的木方含水率在8-12%。
所述耐磨胶膜纸与表层胶膜纸的制备：用三聚氰胺-甲醛树脂分别浸渍18g/cm2的表层纸与28g/cm2的耐磨纸，浸渍后分别烘干剪切制成表层胶膜纸与耐磨胶膜纸。
所述三聚氰胺-甲醛树脂液包括：重量百分比为4.5%的柔韧剂、0.5%的润湿剂、0.5%的脱模剂，其余为三聚氰胺树脂；所述表层胶膜纸及耐磨胶膜纸的上胶量为200-300g/m2、挥发份为6-8%。上胶量要适宜，太小不够耐磨及粘结不好，太大胶流动不均匀造成表面痕迹，另外胶膜纸不容易保存。
所述步骤（5）中的热压温度为120-150℃，压力为7-9MPA，热压时间为80-100分钟。热压温度为120-150℃较适宜，温度太低，会导致固化不完全，不耐水；反之，温度过高，则易造成胶黏剂及纤维碳化，强度下降。压力为7-9MPA较适宜，压力太低，会造成密度不够，强度下降；反之，压力过高，则易导致产品密度太大，产品后续难加工，对设备伤害也明显。
本发明所述的装饰板的制备方法与现有技术相比具有的技术效果：
（1）生产成本低：由于直接采用纤维加工，省去了造牛皮纸的环节，简化了工艺，减少生产成本；
（2）装饰板性能优异：传统方法胶使用量一般都在13%以内，胶使用量大则无法混合均匀，一般产品密度不超过1.0g/cm3；本发明采用喷射方式加入胶粘剂可保证混合均匀，胶使用量可达40%以上，产品密度在1.45g/cm3以上；由于装饰板密度高，中间空隙被胶黏剂填充,其耐水性、耐火性、抗菌性、耐污染能更佳；
（3）能耗低排放少:由于原料是生物废弃物,而造纸使用的是大径材木料，造纸需要消耗大量水,而装饰板的水可以循环使用;制备装饰板时的前段热量可以供后面继续使用,整个过程能量排放极少；
（4）实木与康贝特结合一体,既有实木暖感,又有康贝特特有性能；
（5）采用耐磨纸表面,既不影响木材效果,又有超强耐刮耐磨性能,还可放弃传统油漆涂料表面处理；
（6）大胶量的浸胶表层纸紧紧连接木皮与芯材，结构更牢固。
具体实施方式
实施例1
本实施例的装饰板的制作方法，依次包括以下步骤：
（1）纤维的制备：采用树枝、树干或树杈为原材料，将去皮的树枝、树杈水洗过后，削片粉碎成5mm大小，然后蒸煮热磨制成均匀的纤维；
（2）施胶处理：先将步骤（1）制得的纤维先经过烘干，按重量比3:2称取纤维和胶粘剂备用，然后将胶粘剂以喷射方式逐步加入并与纤维混合均匀，其喷射压力为6MPA,喷嘴为4个；
所述胶粘剂的制备：按重量比取85%的酚醛树脂、12%的甲醇稀释剂、0.5%的碳黑、2.5%的高岭土，将稀释剂、碳黑、高岭土加入到酚醛树脂中，搅混合均匀并加热到50℃制备成胶粘剂；
（3）预压热压：将施胶处理后的纤维再经过铺装、预压、热压制成黑色半成品，其中，预压温度从初始50℃逐渐降低至30℃、压力3MPA、时间20秒；热压温度180℃，初始压力5MPA，压力逐渐递减为常压，时间20秒；
（4）木皮处理：首先对原木进行截剖，成木方状，再通过蒸煮进行软化处理，然后将软化后的木方进行刨切并干燥、剪切成型，其中，所述截剖为将原木按所需长度截成木段，然后去皮再剖制木方，刨片厚度为0.5mm；所述蒸煮为将木方按树种、木方规格分别放入不同蒸煮池，放入时水温保持常温，然后升温至50℃蒸煮结束，升温速度为1℃/min，蒸煮处理后的木方及时放入刨切机前的贮木温水槽中保温，保温温度为40-50℃，木方经过蒸煮处理后，提高了木材的可塑性；所述干燥为将刨切后的木方放入滚筒干燥机进行干燥，干燥后的木方含水率在8-12%。；
（5）压制装饰板：将半成品的上表面依次设置上表层胶膜纸、木皮，将半成品的下表面设置耐磨胶膜纸，再经热压机热压成型制成装饰板，其中，热压温度为150℃，压力为7MPA，热压时间100分钟；
所述耐磨胶膜纸与表层胶膜纸的制备：用三聚氰胺-甲醛树脂浸渍18g/cm2的表层纸与28g/cm2的耐磨纸，浸渍后烘干剪切制成表层胶膜纸与耐磨胶膜纸,其中，三聚氰胺-甲醛树脂液包括：重量百分比为4.5%的柔韧剂、0.5%的润湿剂、0.5%的脱模剂，其余为三聚氰胺树脂；制成的表层胶膜纸及耐磨胶膜纸的上胶量为300g/m2、挥发份为7%。
本实施例的装饰板按照《GB/T17657-1999人造板及饰面人造板理化性能试验方法》试验方法测定，结果：水煮增重0.45%，增厚0.50%，耐干热颜色没有变化，耐磨3500转，抗拉强度横向140Mpa，纵向133Mpa，甲醛释放量(干燥器法)0.47Mg/l。
符合《GB/T7911-1999热固性树脂浸渍高压装饰层积材标准》，即水煮增重小于2%，增厚小于2%，耐干热允许轻微变化，耐磨大于350转，抗拉强度横向大于70Mpa，纵向大于65Mpa，甲醛释放量(干燥器法)小于等于1.5Mg/l的标准。
实施例2
本实施例的装饰板的制作方法，依次包括以下步骤：
（1）纤维的制备：采用树枝、树杈为原材料，将去皮的树枝、树杈水洗过后，削片粉碎成5mm大小，然后蒸煮热磨制成均匀的纤维；
（2）施胶处理：先将步骤（1）制得的纤维先经过烘干，按重量比2:3称取纤维和胶粘剂备用，然后将胶粘剂以喷射方式逐步加入并与纤维混合均匀，其喷射压力为6MPA,喷嘴为3个；
所述胶粘剂的制备：按重量比取80%的酚醛树脂、16%的酒精稀释剂、1%的碳黑、3%的高岭土，将稀释剂、碳黑、高岭土加入到酚醛树脂中，搅混合均匀并加热到50℃制备成胶粘剂；
（3）预压热压：将施胶处理后的纤维再经过铺装、预压、热压制成白色半成品，其中，预压温度从初始50℃逐渐降低至30℃、压力2.5MPA、时间25秒；热压温度170℃，初始压力5MPA，压力逐渐递减为常压，时间25秒；
（4）木皮处理：首先对原木进行截剖，成木方状，再通过蒸煮进行软化处理，然后将软化后的木方进行刨切并干燥、剪切成型，其中，所述的截剖为将原木按所需长度截成木段，然后去皮再剖制木方，刨片厚度为0.5mm；所述蒸煮为将木方按树种、木方规格分别放入不同蒸煮池，放入时水温保持常温，然后升温至50℃蒸煮结束，升温速度为1℃/min，蒸煮处理后的木方及时放入刨切机前的贮木温水槽中保温，保温温度为40-50℃，木方经过蒸煮处理后，提高了木材的可塑性；所述的干燥为将刨切后的木方放入滚筒干燥机进行干燥，干燥后的木方含水率在8-12%。；
（5）压制装饰板：将半成品的上表面依次设置上表层胶膜纸、木皮，将半成品的下表面设置耐磨胶膜纸，再经热压机热压成型制成装饰板，其中，热压温度为135℃，压力为8MPA，热压时间为100分钟；
所述耐磨胶膜纸与表层胶膜纸的制备：用三聚氰胺-甲醛树脂浸渍18g/cm2的表层纸与28g/cm2的耐磨纸，浸渍后烘干剪切制成表层胶膜纸与耐磨胶膜纸,其中，三聚氰胺-甲醛树脂液包括：重量百分比为4.5%的柔韧剂、0.5%的润湿剂、0.5%的脱模剂，其余为三聚氰胺树脂；制成的表层胶膜纸及耐磨胶膜纸的上胶量为250g/m2、挥发份为7.5%。
同法测定结果为：水煮增重0.56%，增厚0.67%，耐干热颜色没有变化，耐磨3100转，抗拉强度横向137Mpa，纵向130Mpa，甲醛释放量(干燥器法)0.39Mg/l。
符合《GB/T7911-1999热固性树脂浸渍高压装饰层积材标准》。
实施例3
本实施例的装饰板的制作方法，依次包括以下步骤：
（1）纤维的制备：采用树枝、树杈为原材料，将去皮的树枝、树杈水洗过后，削片粉碎成5mm大小，然后蒸煮热磨制成均匀的纤维；
（2）施胶处理：先将步骤（1）制得的纤维先经过烘干，按重量比1:1称取纤维和胶粘剂备用，然后将胶粘剂以喷射方式逐步加入并与纤维混合均匀，其喷射压力为6MPA,喷嘴为4个；
所述胶粘剂的制备：按重量比取87%的酚醛树脂、10%的甲醇酒精混合液稀释剂、0.7%的碳黑、2.3%的高岭土，其中甲醇酒精重量比为1:1，将稀释剂、碳黑、高岭土加入到酚醛树脂中，混合均匀并加热到50℃制备成胶粘剂；
（3）预压热压：将施胶处理后的纤维再经过铺装、预压、热压制成白色半成品，其中，预压温度从初始50℃逐渐降低至30℃、压力3.5MPA、时间15秒；热压温度175℃，初始压力5MPA，压力逐渐递减为常压，时间15秒；
（4）木皮处理：首先对原木进行截剖，成木方状，再通过蒸煮进行软化处理，然后将软化后的木方进行刨切并干燥、剪切成型，其中，所述截剖为将原木按所需长度截成木段，然后去皮再剖制木方，刨片厚度为0.5mm；所述蒸煮为将木方按树种、木方规格分别放入不同蒸煮池，放入时水温保持常温，然后升温至50℃蒸煮结束，升温速度为1℃/min，蒸煮处理后的木方及时放入刨切机前的贮木温水槽中保温，保温温度为40-50℃，木方经过蒸煮处理后，提高了木材的可塑性；所述干燥为将刨切后的木方放入滚筒干燥机进行干燥，干燥后的木方含水率在8-12%。；
（5）压制装饰板：将所述半成品的上表面依次设置上表层胶膜纸、木皮，将所述半成品的下表面设置耐磨胶膜纸，再经热压机热压成型制成装饰板，其中，热压温度为120℃，压力为9MPA，热压时间80分钟；
所述耐磨胶膜纸与表层胶膜纸的制备：用三聚氰胺-甲醛树脂浸渍18g/cm2的表层纸与28g/cm2的耐磨纸，浸渍后烘干剪切制成表层胶膜纸与耐磨胶膜纸,其中，三聚氰胺-甲醛树脂液包括：重量百分比为4.5%的柔韧剂、0.5%的润湿剂、0.5%的脱模剂，其余为三聚氰胺树脂；制成的表层胶膜纸及耐磨胶膜纸的上胶量为204g/m2、挥发份为6.5%；
同法测定结果为：水煮增重0.43%，增厚0.47%，耐干热颜色没有变化，耐磨3000转，抗拉强度横向160Mpa，纵向150Mpa，甲醛释放量(干燥器法)0.67Mg/l。
符合《GB/T7911-1999热固性树脂浸渍高压装饰层积材标准》。
实施例4
本实施例的装饰板的制作方法，依次包括以下步骤：
（1）纤维的制备：采用树枝、树杈为原材料，将去皮的树枝、树杈水洗过后，削片粉碎成5mm大小，然后蒸煮热磨制成均匀的纤维；
（2）施胶处理：先将步骤（1）制得的纤维先经过烘干，按重量比3:2称取纤维和胶粘剂备用，然后将胶粘剂以喷射方式逐步加入并与纤维混合均匀，其喷射压力为6MPA,喷嘴为4个；
所述胶粘剂的制备：按重量比取86%的环氧树脂、10%的甲醇稀释剂、0.5%的碳黑、3.5%的高岭土，将稀释剂、碳黑、高岭土加入到酚醛树脂中，搅混合均匀并加热到50℃制备成胶粘剂；
（3）预压热压：将施胶处理后的纤维再经过铺装、预压、热压制成黑色半成品，其中，预压温度从初始50℃逐渐降低至30℃、压力3.5MPA、时间18秒；热压温度180℃，初始压力5MPA，压力逐渐递减为常压，时间18秒；
（4）木皮处理：首先对原木进行截剖，成木方状，再通过蒸煮进行软化处理，然后将软化后的木方进行刨切并干燥、剪切成型，其中，所述截剖为将原木按所需长度截成木段，然后去皮再剖制木方，刨片厚度为0.5mm；所述蒸煮为将木方按树种、木方规格分别放入不同蒸煮池，放入时水温保持常温，然后升温至50℃蒸煮结束，升温速度为1℃/min，蒸煮处理后的木方及时放入刨切机前的贮木温水槽中保温，保温温度为40-50℃，木方经过蒸煮处理后，提高了木材的可塑性；所述干燥为将刨切后的木方放入滚筒干燥机进行干燥，干燥后的木方含水率在8-12%。；
（5）压制装饰板：将半成品的上表面分别设置上表层胶膜纸、木皮，下表面设置耐磨胶膜纸，再经热压机热压成型制成装饰板，其中，热压温度为150℃，压力为7MPA，热压时间100分钟；
所述耐磨胶膜纸与表层胶膜纸的制备：用三聚氰胺-甲醛树脂浸渍18g/cm2的表层纸与28g/cm2的耐磨纸，浸渍后烘干剪切制成表层胶膜纸与耐磨胶膜纸,其中，三聚氰胺-甲醛树脂液包括：重量百分比为4.5%的柔韧剂、0.5%的润湿剂、0.5%的脱模剂，其余为三聚氰胺树脂；制成的表层胶膜纸及耐磨胶膜纸的上胶量为300g/m2、挥发份为6.5%。
同法测定结果为：水煮增重0.48%，增厚0.57%，耐干热颜色没有变化，耐磨3000转，抗拉强度横向136Mpa，纵向131Mpa，甲醛释放量(干燥器法)0.42Mg/l。
符合《GB/T7911-1999热固性树脂浸渍高压装饰层积材标准》。

Claims (1)

1.一种装饰板的制作方法，其特征在于包括以下步骤：
（1）纤维的制备：将去皮的植物枝干水洗过后，削片、蒸煮、热磨制成均匀的纤维；
（2）施胶处理：先将步骤（1）制得的纤维先经过烘干，然后将胶粘剂以喷射方式与纤维混合均匀；
（3）预压热压：将施胶处理后的纤维再经过铺装、预压、热压制成半成品；
（4）木皮处理：首先对原木进行截剖，成木方状，再通过蒸煮进行软化处理，然后将软化后的木方进行刨切并干燥、剪切成型；
（5）压制装饰板：将半成品的上表面依次设置上表层胶膜纸、木皮，将半成品的下表面设置耐磨胶膜纸，再经热压机热压成型制成装饰板；
胶粘剂的制备：按重量比取酚醛树脂80-90%、助剂10-20%混合均匀并加热到50℃制备成胶粘剂；所述助剂包括：重量百分比为5-20%的稀释剂、0.5-2%的碳黑与2-10%的高岭土，该稀释剂为甲醇；
耐磨胶膜纸与上表层胶膜纸的制备：用三聚氰胺-甲醛树脂分别浸渍18g/cm2的上表层纸与28g/cm2的耐磨纸，浸渍后分别烘干剪切制成上表层胶膜纸与耐磨胶膜纸；
所述三聚氰胺-甲醛树脂液包括：重量百分比为4.5%的柔韧剂、0.5%的润湿剂、0.5%的脱模剂，其余为三聚氰胺树脂；上表层胶膜纸及耐磨胶膜纸的上胶量为200-300g/m2、挥发份为6-8%。
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