CN103711410A - Integrally-formed high-pressure single-sided decorative door panel and manufacturing method thereof - Google Patents
Integrally-formed high-pressure single-sided decorative door panel and manufacturing method thereof Download PDFInfo
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Abstract
The invention discloses an integrally-formed high-pressure single-sided decorative door panel. The integrally-formed high-pressure single-sided decorative door panel comprises a base plate and a decorative layer compounded on the base plate. The base plate is made of at least one kraft paper impregnated with heat convertible resin. The decorative layer is made of decorative paper impregnated with heat convertible resin. The invention further discloses a manufacturing method of the integrally-formed high-pressure single-sided decorative door panel. Through the method, the integrally-formed high-pressure single-sided decorative door panel with the thickness of 1.8-3.5mm can be produced, has excellent surface performance and physical and chemical performance, and is waterproof, resistant to dry heat, anti-corrosive, resistant to high temperature, resistant to pollution, resistant to impact, resistant to scraping, good in tensile strength, cracking resistance, size stability and ageing resistance, and easy to clean.
Description
Technical field
The invention belongs to door trim panels, particularly relate to a kind of one-shot forming high pressure one side door trim panels and preparation method thereof.
Background technology
At present, the interior door of China mainly contains solid wood interior door, solid wood composite door, sandwich mold pressing hollow core flush door, steel wood composite door etc., and solid wood interior door is that natural wood is whole or splicing process is painted or coating carries out top finishing processing; Solid wood composite door adopts hardwood frame, and door core adopts splice plate or integrated timber to fill, and two sides is respectively with a medium density fibreboard, and surface adopts paint finishing or low pressure facing paper veneer; Sandwich mold pressing hollow core flush door is through mechanical compaction, to form with moulding and Wood-grain-imitating three centimetres or five centimetres of medium-density plate high-density fiber molded door dermatotomes by two, and surfacing divides sprays paint and PVC vacuum forming.Paint and coating contain volatile organic contaminant matter mostly, use or occupants's healthy meeting is caused to potential hazard to a certain degree, and Solid Door are because raw material check prince is higher; Low pressure facing paper veneer is the facing paper of a melamine-impregnated of hot pressing on medium density fibreboard or shaving board base material, and water-fast, high temperature resistant, scratch resistance, anti-fouling performance are poor, and under wet environment, expansion rate is high; PVC vacuum forming product is high, wear-resisting to equipment and base material quality requirement, scratch-resistant, heat-resisting quantity are poor.The door-plate of current material, because material is inflammable timber and timber derivative, does not carry out fire-retardant fireproof processing mostly, and fire safety performance is poor.
High pressure fire-retardant decorative laminated board is (to comprise overlay paper with stationery at present, decorate facial tissue and base paper) heat of immersion thermosetting resin produces by HTHP, be mainly used in furniture and interior decoration, in a great variety, surfacing also has Gao Guang, sub-light, the various ways such as relief surface, because resin content is high and adopt high-temperature high-pressure craft, surface compact, thereby fire-resistant, water-fast, dry heat resistance, corrosion-resistant, high temperature resistant, anti-pollution, impact resistance is good, tensile strength, resistance to cracking, dimensional stability, resistance to ag(e)ing is good, because the existence of N element in resin has certain stagnant combustion characteristic.The thermosetting resin that adopts has melamine resin, phenolic resins, in hot pressing, need with the moulding of stainless steel forming panel effects on surface, general thickness is that the high pressure fire-retardant decorative laminated board of 0.7--1.5mm is that one side is decorated, and need be pasted on the base materials such as medium density fibreboard, shaving board, woodwork plate and use; The high pressure fire-retardant decorative laminated board that 1.8--4.5mm is thick mostly is two-sided decoration, can independently use.As directly by high pressure fire-retardant decorative laminated board for common house ornamentation door, thickness is generally 38--42mm, the excessive and fire prevention from weight, soundproof effect are poor, price is also higher.The high-pressure decorating plate with special moulding that two thickness are 1.8--3.0mm as used is for panel material, and the middle fire-proof sound insulation material of filling, all will reach better effects at ornamental, fire line, sound-insulation and heat-insulation.But adopt the decorative panel of two-sided decoration, backing material has certain waste and smooth surface, is difficult for pasting, as carried out back sand hair by common decorative, because of thickness, to be difficult for greatly sand even and destroy first surface decorating layer, therefore needs the dipping compact technique that adopts back to exempt from sand to produce.
Summary of the invention
The object of the invention is to overcome the deficiency existing in existing house ornamentation door and house ornamentation door-plate production technology, a kind of fire-resistant, water-fast, moisture resistance, shock-resistant, anti-pollution, durable one-shot forming high pressure one side door trim panels attractive in appearance are provided, and the present invention also provides the production method of this door-plate.
For achieving the above object, the present invention adopts following technical scheme: a kind of one-shot forming high pressure one side door trim panels, comprise substrate and be compounded in the decorative layer on substrate, the kraft that substrate has flooded thermosetting resin by one deck is at least made, and decorative layer is made by the facing paper that has flooded thermosetting resin.
In decorative paper layer, be compounded with the overlay paper that one deck has flooded thermosetting resin.
Described thermosetting resin is water soluble phenol resin, phenol modified urea-formaldehyde resins, melamine resin I, melamine resin II or cyanurotriamide modified urea resin;
The raw material consumption of described water soluble phenol resin is: the mol ratio of phenol and formaldehyde is 1:1.55, and rosin quality is 10% of resin total amount, and urea quality is 1% of resin total amount; Its preparation method is: (1) adds the formaldehyde of formaldehyde total amount 85% in reactor, then adds micro-(receiving) rice cellulose reinforcing agent of resin total amount 3～10%, is warming up to 40 ℃, adds rosin, liquefied carbolic acid, and with sheet alkali, adjusting pH value is 9.5～9.8; (2) continue to be warming up to 90～94 ℃, be incubated after approximately 40 minutes, be cooled to 50 ℃, add remaining formaldehyde, be warming up to 90 ℃, insulation: (3) survey cloud point in 20 ℃ of water, after going out cloud point, with improvement Ostwald viscosimeter, survey viscosity, during to 40～70mm/s, lower the temperature, add urea and water during to 75 ℃, adjusting theoretical solids content is 48%; (4) while continuing to be cooled to 50 ℃, adjust pH value to 9.0～10.0, blowing in the time of 45 ℃;
The raw material consumption of described phenol modified urea-formaldehyde resins is: phenol: urea: the mol ratio of formaldehyde is 1:2.4:6.0; Its preparation method is: (1) adds phenol to heat up in reactor, adds the formaldehyde of total amount 85%, stirs, and regulates pH to 8.5～8.8 of formalin with the NaOH of mass percentage concentration 30%; (2) heating is warming up to 90～92 ℃ for 30 minutes, under this temperature condition, is incubated 35 minutes; (3) be cooled to 60 ℃, add urea, be warming up to 85～88 ℃, be incubated 25 minutes, then add glacial acetic acid to regulate pH value to 5.2, when viscosity reaches 40～70mm/s, add remaining formolite reaction 10 minutes, then to add a certain amount of water adjustment resin theoretical solids content be 48%, after reaction, be cooled to below 45 ℃, obtain finished product;
The raw material consumption of described melamine resin I is: the mol ratio of melamine and formaldehyde is 1:3.0; Its preparation method is: (1) adds the formaldehyde measuring in reactor, and adding water adjustment concentration is 30%, and sodium hydrate aqueous solution adjust pH to 9.2～9.5 with mass percent 30%, are warming up to 40 ℃; (2) in reactor, add the melamine measuring,, while continuing to be warming up to 70 ℃, be incubated to solution and become clarification; (3) continue to be warming up to 90～94 ℃, be incubated after 40 minutes and start to survey water-insoluble in 20 ℃ of water, after going out cloud point, survey water tolerance, at glue: the ammonium dihydrogen phosphate (ADP) and the sodium pyrophosphate composite flame-retardant agent that add resin gross mass 6% when water reaches 1:5, cooling, during to 75 ℃, add water and ethanolic solution that mass ratio is 1:1, adjusting theoretical solids content is 45%, continues cooling; In the time of (4) 50 ℃, adjust pH value to 8.5 left and right, blowing in the time of 45 ℃;
The raw material consumption of described melamine resin II is: the mol ratio of melamine and formaldehyde is 1:1.65, the quality of caprolactam is 13.5% of melamine quality, the quality of diethylene glycol (DEG) is 18% of melamine quality, the quality of sucrose is 1.5% of melamine quality, and the quality of thiocarbamide is 2.2% of melamine quality; Its preparation method is: (1) adds the formaldehyde measuring in reactor, and adding water adjustment concentration is 30%, with liquid caustic soda adjust pH to 9.2～9.5, is warming up to 40 ℃; (2) in reactor, add melamine, thiocarbamide, the sucrose measuring, while continuing to be warming up to 70 ℃, solution becomes clarification; (3) continue to be warming up to 90～94 ℃, be incubated after 40 minutes, start to survey water-insoluble in 20 ℃ of water, after going out cloud point, survey water tolerance, at glue: add caprolactam when water reaches 1:6, cooling, during to 75 ℃, with diethylene glycol (DEG), adding the adjustment theoretical solids content of purifying waste water is 48%, continues cooling; In the time of (4) 50 ℃, adjust pH value to 8.5 left and right, blowing in the time of 45 ℃;
The raw material consumption of described cyanurotriamide modified urea resin is: the mol ratio of urea and formaldehyde is 1:1.90, the addition of melamine is 10% of formaldehyde amount, polyvinyl alcohol addition is 0.2% of resin total amount, the addition of hexa is 2.5% of resin total amount, and composite curing agent is the ammonium chloride of mass fraction 25%: the aqueous solution of urea: methenamine=25:40:35; Its preparation method is: (1) first adds formaldehyde in reactor, starts to heat up, and adds a urea of hexa, melamine, polyvinyl alcohol and urea total amount 75%; In (2) 30 minutes, be warming up to 85～88 ℃, be incubated 35 minutes, then adding glacial acetic acid catalyzer adjust pH is 6.5～6.8, when reaching 40～70mm/s, viscosity is cooled to 75～80 ℃, the secondary urea that adds urea gross weight 25%, adding the adjustment theoretical solids content of purifying waste water is 48%, reacts 10 minutes, be cooled to below 45 ℃, obtain liquid glue; (3) add the composite curing agent that accounts for liquid glue gross weight 1.5～3%, adjusting 100 ℃ of hardening times is 12～14 minutes, blowing.
The preparation method of described one-shot forming high pressure one side door trim panels, is comprised of following steps:
The preparation of a, dipping core paper: flood in the kraft as core paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～65%, after dipping, be dried, after dry, volatile ingredient is 7.0～9.5%, dry after length on request cut and obtain flooding core paper;
The preparation of b, dipping demoulding base stock: flood in the kraft as ground paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～70%, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 20.0～25.0%, then at back coated release agent, coating weight is 0.3～0.4Kg/ ㎡, be dried, after dry, volatile ingredient is 7.5～10.0%, dry after length on request cut and obtain flooding demoulding base stock;
The preparation of c, dipping decorative paper: by monochromatic paper or printing paper be impregnated into melamine resin I, cyanurotriamide modified urea resin flood for the first time, then will flood for the first time in any and dried monochromatic paper or printing paper adopt melamine resin I flood for the second time, dry, after twice dipping, the spread of resin is 95～120%, after dry, volatile ingredient is 7.5～9.5%, precuring degree is 35～45%, and the dry rear length requiring cuts and obtains pre-preg facing paper;
The preparation of d, dipping overlay paper: by overlay paper be impregnated in melamine resin II, flood and be dried dipping afterwards the spread of resin be 180～280%, after dry, volatile ingredient is 8.0～10.5%, precuring degree is 40～50%, and the dry rear length requiring cuts and obtains pre-preg overlay paper;
E, the dipping demoulding base stock that step a, b are prepared respectively and the dipping core paper pre-composing base base of arranging in pairs or groups, each substrate base is comprised of a dipping demoulding base stock and at least one dipping core paper, release agent coating is core paper dorsad, every one deck in batch (-type) hot press is mated formation from top to bottom in the following order: a dipping overlay paper, a dipping decorative paper, substrate base, another substrate base, another dipping decorative paper, another dipping overlay paper form 2 groups of slabs, and the release agent coating of two substrate bases contacts;
F, pack in hot press after mating formation and boost, heat up, temperature-rise period 15～20 minutes, reaches 130～135 ℃ in temperature, and pressure is to suppress 30～45 minutes under 16～23 Mpa conditions, pressurize cooling after compacting;
G, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane.
Described in step f, heat up, the heat medium adopting in its temperature-rise period is high steam or superheated water; Described cooling, the cooling medium adopting in its temperature-fall period is water; The time of cooling is 30～40 minutes.
The preparation method of the release agent adopting in step b is: 40KgPAT3002 silicone release mixes and adds in stirred tank with 960Kg deionized water, add 2Kg silane type coupling agent as dispersing agent, slowly stir and within 30 minutes, put into stainless steel material storage barrel standing 6～8 hours.
The preparation method of described one-shot forming high pressure one side door trim panels, is comprised of following steps:
The preparation of a, dipping core paper: flood in the kraft as core paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～65%, after dipping, be dried, after dry, volatile ingredient is 7.0～9.5%, dry after length on request cut and obtain flooding core paper;
The preparation of b, dipping demoulding base stock: flood in the kraft as ground paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～70%, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 20.0～25.0%, then at back coated release agent, coating weight is 0.3～0.4Kg/ ㎡, be dried, after dry, volatile ingredient is 7.5～10.0%, dry after length on request cut and obtain flooding demoulding base stock;
The preparation of c, dipping decorative paper: by monochromatic paper or printing paper be impregnated into melamine resin I, cyanurotriamide modified urea resin flood for the first time, then will flood for the first time in any and dried monochromatic paper or printing paper adopt melamine resin I flood for the second time, dry, after twice dipping, the spread of resin is 95～120%, after dry, volatile ingredient is 7.5～9.5%, precuring degree is 35～45%, and the dry rear length requiring cuts and obtains pre-preg facing paper;
D, the dipping demoulding base stock that step a, b are prepared respectively and the dipping core paper pre-composing base base of arranging in pairs or groups, each substrate base is comprised of a dipping demoulding base stock and at least one dipping core paper, release agent coating is core paper dorsad, every one deck in batch (-type) hot press is mated formation from top to bottom in the following order: a dipping decorative paper, substrate base, another substrate base, another dipping decorative paper form 2 groups of slabs, and the release agent coating of two substrate bases contacts;
E, pack in hot press after mating formation and boost, heat up, temperature-rise period 15～20 minutes, reaches 130～135 ℃ in temperature, and pressure is to suppress 30～45 minutes under 16～23 Mpa conditions, pressurize cooling after compacting;
F, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane.
Described in step e, heat up, the heat medium adopting in its temperature-rise period is high steam or superheated water; Described cooling, the cooling medium adopting in its temperature-fall period is water; The time of cooling is 30～40 minutes.
The preparation method of the release agent adopting in step b is: 40KgPAT3002 silicone release mixes and adds in stirred tank with 960Kg deionized water, add 2Kg silane type coupling agent as dispersing agent, slowly stir and within 30 minutes, put into stainless steel material storage barrel standing 6～8 hours.
. the present invention adopts special release agent to be coated on dried dipping base stock back and makes demoulding base stock when base stock heat of immersion thermosetting resin, by thickness requirement, mix into substrate base from the dipping core paper of different numbers, and adopt thermosetting resin to use resin as combination with decorative surfaces as decorating facial tissue single-steeping and double-steeping, by the needs of product surface performance, adopt and maybe need not flood overlay paper as topping, using the Stainless Molding Board of different surface treatment as moulding form, in batch (-type) hot press, be pressed into product, in hot pressing, the base stock release layer of two groups of slabs directly contacts, do not need with the PP film of aluminium sheet or biaxial tension as isolated material, mat formation conveniently, fast, production efficiency is high, without process discarded object, reduce environment pollution.During its product following process, saw Hou Buxu back, limit sand hair, transverse tensile strength can obviously improve, can produce the door trim panels sheet material that 1.8--3.5mm is thick, there is good surface property and physicochemical property: water-fast, dry heat resistance, corrosion-resistant, high temperature resistant, anti-pollution, resistance to impact scraping are resistance to, tensile strength, resistance to cracking, dimensional stability, resistance to ag(e)ing are good, easy to clean.
The specific embodiment
An one-shot forming high pressure one side door trim panels, comprises substrate and is compounded in the decorative layer on substrate, and the kraft that substrate has flooded thermosetting resin by one deck is at least made, and decorative layer is made by the facing paper that has flooded thermosetting resin.
In decorative paper layer, be compounded with the overlay paper that one deck has flooded thermosetting resin.
Described thermosetting resin is water soluble phenol resin, phenol modified urea-formaldehyde resins, melamine resin I, melamine resin II or cyanurotriamide modified urea resin;
The raw material consumption of described water soluble phenol resin is: the mol ratio of phenol and formaldehyde is 1:1.55, and rosin quality is 10% of resin total amount, and urea quality is 1% of resin total amount; Its preparation method is: (1) adds the formaldehyde of formaldehyde total amount 85% in reactor, then adds micro-(receiving) rice cellulose reinforcing agent of resin total amount 3～10%, is warming up to 40 ℃, adds rosin, liquefied carbolic acid, and with sheet alkali, adjusting pH value is 9.5～9.8; (2) continue to be warming up to 90～94 ℃, be incubated after approximately 40 minutes, be cooled to 50 ℃, add remaining formaldehyde, be warming up to 90 ℃, insulation: (3) survey cloud point in 20 ℃ of water, after going out cloud point, with improvement Ostwald viscosimeter, survey viscosity, during to 40～70mm/s, lower the temperature, add urea and water during to 75 ℃, adjusting theoretical solids content is 48%; (4) while continuing to be cooled to 50 ℃, adjust pH value to 9.0～10.0, blowing in the time of 45 ℃;
The quality index of gained water soluble phenol resin is: pH value 9.2～9.8, proportion 1.17～1.19g/cm
3, solid content is 45～48%, viscosity is 45～85mm/s;
The raw material consumption of described phenol modified urea-formaldehyde resins is: phenol: urea: the mol ratio of formaldehyde is 1:2.4:6.0; Its preparation method is: (1) adds phenol to heat up in reactor, adds the formaldehyde of total amount 85%, stirs, and regulates pH to 8.5～8.8 of formalin with the NaOH of mass percentage concentration 30%; (2) heating is warming up to 90～92 ℃ for 30 minutes, under this temperature condition, is incubated 35 minutes; (3) be cooled to 60 ℃, add urea, be warming up to 85～88 ℃, be incubated 25 minutes, then add glacial acetic acid to regulate pH value to 5.2, when viscosity reaches 40～70mm/s, add remaining formolite reaction 10 minutes, then to add a certain amount of water adjustment resin theoretical solids content be 48%, after reaction, be cooled to below 45 ℃, obtain finished product;
The raw material consumption of described melamine resin I is: the mol ratio of melamine and formaldehyde is 1:3.0; Its preparation method is: (1) adds the formaldehyde measuring in reactor, and adding water adjustment concentration is 30%, and sodium hydrate aqueous solution adjust pH to 9.2～9.5 with mass percent 30%, are warming up to 40 ℃; (2) in reactor, add the melamine measuring,, while continuing to be warming up to 70 ℃, be incubated to solution and become clarification; (3) continue to be warming up to 90～94 ℃, be incubated after 40 minutes and start to survey water-insoluble in 20 ℃ of water, after going out cloud point, survey water tolerance, at glue: the ammonium dihydrogen phosphate (ADP) and the sodium pyrophosphate composite flame-retardant agent that add resin gross mass 6% when water reaches 1:5, cooling, during to 75 ℃, add water and ethanolic solution that mass ratio is 1:1, adjusting theoretical solids content is 45%, continues cooling; In the time of (4) 50 ℃, adjust pH value to 8.5 left and right, blowing in the time of 45 ℃;
Gained melamine resin I quality index: pH value 8.3～8.6, proportion 1.21～1.25g/cm
3, solid content 43～48%, water tolerance 1:3.The curing compound I that adds resin quality 0.3% during use.Curing compound I is phthalic anhydride: triethanolamine: the solution that water is 1:1.5:2 (mass ratio).
The raw material consumption of described melamine resin II is: the mol ratio of melamine and formaldehyde is 1:1.65, the quality of caprolactam is 13.5% of melamine quality, the quality of diethylene glycol (DEG) is 18% of melamine quality, the quality of sucrose is 1.5% of melamine quality, and the quality of thiocarbamide is 2.2% of melamine quality; Its preparation method is: (1) adds the formaldehyde measuring in reactor, and adding water adjustment concentration is 30%, with liquid caustic soda adjust pH to 9.2～9.5, is warming up to 40 ℃; (2) in reactor, add melamine, thiocarbamide, the sucrose measuring, while continuing to be warming up to 70 ℃, solution becomes clarification; (3) continue to be warming up to 90～94 ℃, be incubated after 40 minutes, start to survey water-insoluble in 20 ℃ of water, after going out cloud point, survey water tolerance, at glue: add caprolactam when water reaches 1:6, cooling, during to 75 ℃, with diethylene glycol (DEG), adding the adjustment theoretical solids content of purifying waste water is 48%, continues cooling; In the time of (4) 50 ℃, adjust pH value to 8.5 left and right, blowing in the time of 45 ℃;
Gained resin quality index: pH value 8.3～8.6, proportion 1.23～1.25g/cm
3, solid content 44～47%, water tolerance 1:2.5～3.5.During use, add curing compound II adjust hardening time be 100 ℃ 12～14 minutes.Curing compound II is the mixture of p-methyl benzenesulfonic acid, morpholine and water, p-methyl benzenesulfonic acid: morpholine: the mass ratio of water is 1:2.2:4.84.
The raw material consumption of described cyanurotriamide modified urea resin is: the mol ratio of urea and formaldehyde is 1:1.90, the addition of melamine is 10% of formaldehyde amount, polyvinyl alcohol addition is 0.2% of resin total amount, the addition of hexa is 2.5% of resin total amount, and composite curing agent is the ammonium chloride of mass fraction 25%: the aqueous solution of urea: methenamine=25:40:35; Its preparation method is: (1) first adds formaldehyde in reactor, starts to heat up, and adds a urea of hexa, melamine, polyvinyl alcohol and urea total amount 75%; In (2) 30 minutes, be warming up to 85～88 ℃, be incubated 35 minutes, then adding glacial acetic acid catalyzer adjust pH is 6.5～6.8, when reaching 40～70mm/s, viscosity is cooled to 75～80 ℃, the secondary urea that adds urea gross weight 25%, adding the adjustment theoretical solids content of purifying waste water is 48%, reacts 10 minutes, be cooled to below 45 ℃, obtain liquid glue; (3) add the composite curing agent that accounts for liquid glue gross weight 1.5～3%, adjusting 100 ℃ of hardening times is 12～14 minutes, blowing.
The preparation method of described one-shot forming high pressure one side door trim panels, is comprised of following steps:
The preparation of a, dipping core paper: flood in the kraft as core paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～65%, after dipping, be dried, after dry, volatile ingredient is 7.0～9.5%, dry after length on request cut and obtain flooding core paper;
The preparation of b, dipping demoulding base stock: flood in the kraft as ground paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～70%, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 20.0～25.0%, then at back coated release agent, coating weight is 0.3～0.4Kg/ ㎡, be dried, after dry, volatile ingredient is 7.5～10.0%, dry after length on request cut and obtain flooding demoulding base stock;
The preparation of c, dipping decorative paper: by monochromatic paper or printing paper be impregnated into melamine resin I, cyanurotriamide modified urea resin flood for the first time, then will flood for the first time in any and dried monochromatic paper or printing paper adopt melamine resin I flood for the second time, dry, after twice dipping, the spread of resin is 95～120%, after dry, volatile ingredient is 7.5～9.5%, precuring degree is 35～45%, and the dry rear length requiring cuts and obtains pre-preg facing paper;
The preparation of d, dipping overlay paper: by overlay paper be impregnated in melamine resin II, flood and be dried dipping afterwards the spread of resin be 180～280%, after dry, volatile ingredient is 8.0～10.5%, precuring degree is 40～50%, and the dry rear length requiring cuts and obtains pre-preg overlay paper;
E, the dipping demoulding base stock that step a, b are prepared respectively and the dipping core paper pre-composing base base of arranging in pairs or groups, each substrate base is comprised of a dipping demoulding base stock and at least one dipping core paper, release agent coating is core paper dorsad, every one deck in batch (-type) hot press is mated formation from top to bottom in the following order: a dipping overlay paper, a dipping decorative paper, substrate base, another substrate base, another dipping decorative paper, another dipping overlay paper form 2 groups of slabs, and the release agent coating of two substrate bases contacts;
G, pack in hot press after mating formation and boost, heat up, temperature-rise period 15～20 minutes, reaches 130～135 ℃ in temperature, and pressure is to suppress 30～45 minutes under 16～23 Mpa conditions, pressurize cooling after compacting;
F, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane.
Described in step g, heat up, the heat medium adopting in its temperature-rise period is high steam or superheated water; Described cooling, the cooling medium adopting in its temperature-fall period is water; The time of cooling is 30～40 minutes.
The preparation method of the release agent adopting in step b is: 40KgPAT3002 silicone release mixes and adds in stirred tank with 960Kg deionized water, add 2Kg silane type coupling agent as dispersing agent, slowly stir and within 30 minutes, put into stainless steel material storage barrel standing 6～8 hours.
After dry described in step a, volatile ingredient is 7.0～9.5%, and the weight percentage that the composition that its implication is volatilization accounts for dipping core paper is 7.0～9.5%.
After dry described in step b, volatile ingredient is 7.5～10.0%, and it is 7.5～10.0% that the composition that its implication is volatilization accounts for dipping base stock weight percentage.
After dry described in step c, volatile ingredient is 7.5～9.5%, and the weight percentage that the composition that its implication is volatilization accounts for the monochromatic paper of dipping or printing paper is 7.5～9.5%.
After dry described in step e, volatile ingredient is 8.0～10.5%, and the weight percentage that the composition that its implication is volatilization accounts for dipping overlay paper is 8.0～10.5%.
In step e, according to product surface, require difference, can not use dipping overlay paper.
In step e, different according to the thickness requirement of product, also can not use dipping core paper.
Embodiment 1:
One-shot forming high pressure one side door trim panels, comprises substrate and is compounded in the decorative layer on substrate.Decorative layer is selected the mould that dull surface surfacing, kenel are flap type when compacting.
The production method of this door-plate, detailed step is as follows:
The preparation of a, dipping core paper: quantitatively for 120g/ ㎡, width are that 960mm kraft is impregnated in cyanurotriamide modified urea resin, after dipping, the spread of resin is 58%, after dipping, be dried, volatile ingredient is 7.8%, cuts the dipping core paper that obtains 960 * 2100mm;
The preparation of b, dipping base stock: by quantitatively for 100g/ ㎡, width are that to be impregnated in water soluble phenol resin the spread of resin after dipping be 64% to 960mm kraft, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 23.0%, then at back coated release agent, coating weight is 0.32Kg/ ㎡, be dried, dry rear volatile ingredient is 8.6%, after being dried, cuts on request the dipping demoulding base stock that obtains 960 * 2100mm;
The preparation of c, dipping decorative paper: by the brown English walnut printing paper single-steeping cyanurotriamide modified urea resin dry, the double-steeping melamine resin I dry that are quantitatively 960mm for 100g/ ㎡, width, after twice dipping, the spread of resin is 115%, after dry, volatile ingredient is 9.0%, precuring degree is 42%, dry after length on request cut the pre-preg facing paper that obtains 960 * 2100mm;
The preparation of d, dipping overlay paper: will be quantitatively that the overlay paper that 28 g/ ㎡, width are 960mm is impregnated in melamine resin II and is dried, after dipping, the spread of resin is 230%, after dry, volatile ingredient is 9.8%, precuring degree is 42%, and the dry rear length requiring cuts the pre-preg overlay paper that obtains 960 * 2100mm;
E, the dipping demoulding base stock that step a, b are prepared respectively and 15 dipping core papers carry out pre-composing base base, release agent coating is core paper dorsad, every one deck in 7 layers of batch (-type) hot press is mated formation from top to bottom in the following order: dipping overlay paper, brown English walnut dipping decorative paper, 16 substrate bases, 16 substrate bases, brown English walnut dipping decorative paper, dipping overlay paper, the release agent coating of 2 group substrate bases contacts, and every one deck dress surface is that sub-light is processed, the matched molds mould of flap type is a set of.
F, pack in hot press after mating formation and boost, heat up, about 5min of heating up time, reaches 124 ℃ in temperature, and pressure is under 15Mpa condition, to suppress 13 minutes, pressurize cooling after compacting;
G, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane;
H, saw limit, by 940 * 2000mm breadth, carry out four sides and saw limit and process, obtain 14, brown English walnut door trim panels 7 cover.
Detection data to this product: 7 laminating machinees, 14, palm fibre English walnut one-shot forming high pressure one side door trim panels 7 cover, thickness is 1.8mm, record finished product: resistance to boiling water 2 hours, weightening finish 4.7%, thickens 3.6%, dry heat resistance is unchanged, endwise tensile strength is 138.8 MPa, transverse tensile strength 119.3 MPa, burst size of methanal: 1.0mg/L(40L dryer method).
Embodiment 2:
In the present embodiment, one-shot forming high pressure one side door trim panels, comprises substrate and is compounded in the decorative layer on substrate.Decorative layer is selected the mould of pitted skin surface effect, barrier when compacting.
The production method of this door-plate, detailed step is as follows:
The preparation of a, dipping core paper: quantitatively for 140g/ ㎡, width are that 550mm kraft is impregnated into water soluble phenol resin, after dipping, the spread of resin is 61%, after dipping, be dried, volatile ingredient is 8.7%, cuts the dipping core paper that obtains 550 * 820mm;
The preparation of b, dipping base stock: will be quantitatively for 140g/ ㎡, width are that 550mm kraft is impregnated in water soluble phenol resin, after dipping, the spread of resin is 66%, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 22.0%, then at back coated release agent, coating weight is 0.36Kg/ ㎡, is dried, after dry, volatile ingredient is 8.9%, after being dried, cuts on request the dipping demoulding base stock that obtains 550 * 820mm;
The preparation of c, dipping decorative paper: by the monochromatic paper single-steeping of the cream colour melamine resin I dry, the double-steeping melamine resin I dry that are quantitatively 550mm for 110g/ ㎡, width, after twice dipping, the spread of resin is 110%, after dry, volatile ingredient is 8.8%, precuring degree is 39%, dry after length on request cut the pre-preg facing paper that obtains 550 * 820mm;
D, the dipping demoulding base stock that step a, b are prepared respectively and 11 dipping core papers carry out pre-composing base base, release agent coating is core paper dorsad, every one deck in 7 layers of batch (-type) hot press is mated formation from top to bottom in the following order: the ground paper (release agent coating is facing paper dorsad) of the ground paper (release agent coating is facing paper dorsad) of cream-coloured dipping decorative paper, 12 substrates, 12 substrates, cream-coloured dipping decorative paper, every one deck dress surface is for pitted skin is processed, the matched molds mould of grid type is a set of, 2 groups of slabs.
E, pack in hot press the 5min that boosts, heats up into after mating formation, in temperature, reach 127 ℃, pressure is to suppress 13.5min under 15.2Mpa condition, pressurize cooling after compacting;
F, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane;
G, saw limit, by 520 * 780mm breadth, carry out four sides and saw limit and process, obtain 14 of cream-coloured pitted skin grid type high pressure one side door trim panels.
Detection data to this product: 7 laminating machinees, 14, one-shot forming high pressure one side door trim panels 7 cover, color is cream colour, surfacing is pitted skin, kenel is grid, thickness is 2.0mm, records finished product: resistance to boiling water (2 hours) weightening finish 3.9%, thickens 3.1%, dry heat resistance is unchanged, endwise tensile strength is 154.3 MPa, transverse tensile strength 138.7 MPa, burst size of methanal: 0.84mg/L(40L dryer method).
embodiment 3:
One-shot forming high pressure one side door trim panels, comprises substrate and is compounded in the decorative layer on substrate.Decorative layer is selected the mould that high finish surface effect, kenel are triumphal arch when compacting.
The production method of door-plate, detailed step is as follows:
The preparation of a, dipping core paper: quantitatively for 120g/ ㎡, width are that 850mm kraft is impregnated in phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 53%, after dipping, be dried, volatile ingredient is 7.9%, cuts the dipping core paper that obtains 850 * 2060mm;
The preparation of b, dipping base stock: by quantitatively for 120g/ ㎡, width are that to be impregnated in water soluble phenolic phenolic resins the spread of resin after dipping be 63% to 850mm kraft, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 21.0%, then at back coated release agent, coating weight is 0.33Kg/ ㎡, be dried, dry rear volatile ingredient is 8.7%, after being dried, cuts on request the dipping demoulding base stock that obtains 850 * 2060mm;
The preparation of c, dipping decorative paper:
By the monochromatic paper single-steeping of the cream colour melamine resin I dry, the double-steeping melamine resin I dry that are quantitatively 850mm for 85g/ ㎡, width, after twice dipping, the spread of resin is 95%, after dry, volatile ingredient is 8.5%, precuring degree is 45%, dry after length on request cut the pre-preg facing paper that obtains 850 * 2060mm;
The preparation of d, dipping overlay paper
To be quantitatively that the overlay paper that 2 2g/ ㎡, width are 950mm is impregnated in melamine resin II and is dried, after dipping, the spread of resin is 220%, after dry, volatile ingredient is 9.2%, precuring degree is 45%, and the dry rear length requiring cuts the pre-preg overlay paper that obtains 950 * 2060mm;
E, by step a, the dipping demoulding base stock that b is prepared respectively and 12 dipping core papers carry out pre-composing base base (release agent coating is core paper dorsad), with c, dipping decorative paper prepared by d, dipping overlay paper every one deck in 7 layers of batch (-type) hot press is mated formation from top to bottom in the following order: dipping overlay paper, Bai Fengmu dipping decorative paper, 13 substrate bases, 13 substrate bases, Bai Fengmu dipping decorative paper, dipping overlay paper, the release agent coating of 2 group substrate bases contacts, every one deck dress surface is that high light is processed, the matched molds mould of triumphal arch type is a set of, 2 groups of slabs.
After mating formation, pack in hot press and boost, heat up, about 5min of heating up time, reaches 127 ℃ in temperature, and pressure is under 14.5Mpa condition, to suppress 13 minutes, pressurize cooling after compacting;
G, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane;
H, saw limit, by 920 * 2020mm breadth, carry out four sides and saw limit and process, obtain 14, one-shot forming high pressure one side door trim panels 7 cover.
Detection data to this product: 7 laminating machinees, 14, high light colourless maple one-shot forming high pressure one side door trim panels 7 cover, thickness is 1.8mm, record finished product: resistance to boiling water (2 hours) weightening finish 4.9%, thicken 4.1%, dry heat resistance is unchanged, and endwise tensile strength is 134.3 MPa, transverse tensile strength 120.6 MPa, burst size of methanal: 1.1mg/L(40L dryer method).
Claims (9)
1. an one-shot forming high pressure one side door trim panels, comprises substrate and is compounded in the decorative layer on substrate, it is characterized in that: the kraft that substrate has flooded thermosetting resin by one deck is at least made, and decorative layer is made by the facing paper that has flooded thermosetting resin.
2. one-shot forming high pressure one side door trim panels as claimed in claim 1, is characterized in that: in decorative paper layer, be compounded with the overlay paper that one deck has flooded thermosetting resin.
3. one-shot forming high pressure one side door trim panels as claimed in claim 1 or 2, is characterized in that: described thermosetting resin is water soluble phenol resin, phenol modified urea-formaldehyde resins, melamine resin I, melamine resin II or cyanurotriamide modified urea resin;
The raw material consumption of described water soluble phenol resin is: the mol ratio of phenol and formaldehyde is 1:1.55, and rosin quality is 10% of resin total amount, and urea quality is 1% of resin total amount; Its preparation method is: (1) adds the formaldehyde of formaldehyde total amount 85% in reactor, then adds micro-(receiving) rice cellulose reinforcing agent of resin total amount 3～10%, is warming up to 40 ℃, adds rosin, liquefied carbolic acid, and with sheet alkali, adjusting pH value is 9.5～9.8; (2) continue to be warming up to 90～94 ℃, be incubated after approximately 40 minutes, be cooled to 50 ℃, add remaining formaldehyde, be warming up to 90 ℃, insulation: (3) survey cloud point in 20 ℃ of water, after going out cloud point, with improvement Ostwald viscosimeter, survey viscosity, during to 40～70mm/s, lower the temperature, add urea and water during to 75 ℃, adjusting theoretical solids content is 48%; (4) while continuing to be cooled to 50 ℃, adjust pH value to 9.0～10.0, blowing in the time of 45 ℃;
The raw material consumption of described phenol modified urea-formaldehyde resins is: phenol: urea: the mol ratio of formaldehyde is 1:2.4:6.0; Its preparation method is: (1) adds phenol to heat up in reactor, adds the formaldehyde of total amount 85%, stirs, and regulates pH to 8.5～8.8 of formalin with the NaOH of mass percentage concentration 30%; (2) heating is warming up to 90～92 ℃ for 30 minutes, under this temperature condition, is incubated 35 minutes; (3) be cooled to 60 ℃, add urea, be warming up to 85～88 ℃, be incubated 25 minutes, then add glacial acetic acid to regulate pH value to 5.2, when viscosity reaches 40～70mm/s, add remaining formolite reaction 10 minutes, then to add a certain amount of water adjustment resin theoretical solids content be 48%, after reaction, be cooled to below 45 ℃, obtain finished product;
The raw material consumption of described melamine resin I is: the mol ratio of melamine and formaldehyde is 1:3.0; Its preparation method is: (1) adds the formaldehyde measuring in reactor, and adding water adjustment concentration is 30%, and sodium hydrate aqueous solution adjust pH to 9.2～9.5 with mass percent 30%, are warming up to 40 ℃; (2) in reactor, add the melamine measuring,, while continuing to be warming up to 70 ℃, be incubated to solution and become clarification; (3) continue to be warming up to 90～94 ℃, be incubated after 40 minutes and start to survey water-insoluble in 20 ℃ of water, after going out cloud point, survey water tolerance, at glue: the ammonium dihydrogen phosphate (ADP) and the sodium pyrophosphate composite flame-retardant agent that add resin gross mass 6% when water reaches 1:5, cooling, during to 75 ℃, add water and ethanolic solution that mass ratio is 1:1, adjusting theoretical solids content is 45%, continues cooling; In the time of (4) 50 ℃, adjust pH value to 8.5 left and right, blowing in the time of 45 ℃;
The raw material consumption of described melamine resin II is: the mol ratio of melamine and formaldehyde is 1:1.65, the quality of caprolactam is 13.5% of melamine quality, the quality of diethylene glycol (DEG) is 18% of melamine quality, the quality of sucrose is 1.5% of melamine quality, and the quality of thiocarbamide is 2.2% of melamine quality; Its preparation method is: (1) adds the formaldehyde measuring in reactor, and adding water adjustment concentration is 30%, with liquid caustic soda adjust pH to 9.2～9.5, is warming up to 40 ℃; (2) in reactor, add melamine, thiocarbamide, the sucrose measuring, while continuing to be warming up to 70 ℃, solution becomes clarification; (3) continue to be warming up to 90～94 ℃, be incubated after 40 minutes, start to survey water-insoluble in 20 ℃ of water, after going out cloud point, survey water tolerance, at glue: add caprolactam when water reaches 1:6, cooling, during to 75 ℃, with diethylene glycol (DEG), adding the adjustment theoretical solids content of purifying waste water is 48%, continues cooling; In the time of (4) 50 ℃, adjust pH value to 8.5 left and right, blowing in the time of 45 ℃;
The raw material consumption of described cyanurotriamide modified urea resin is: the mol ratio of urea and formaldehyde is 1:1.90, the addition of melamine is 10% of formaldehyde amount, polyvinyl alcohol addition is 0.2% of resin total amount, the addition of hexa is 2.5% of resin total amount, and composite curing agent is the ammonium chloride of mass fraction 25%: the aqueous solution of urea: methenamine=25:40:35; Its preparation method is: (1) first adds formaldehyde in reactor, starts to heat up, and adds a urea of hexa, melamine, polyvinyl alcohol and urea total amount 75%; In (2) 30 minutes, be warming up to 85～88 ℃, be incubated 35 minutes, then adding glacial acetic acid catalyzer adjust pH is 6.5～6.8, when reaching 40～70mm/s, viscosity is cooled to 75～80 ℃, the secondary urea that adds urea gross weight 25%, adding the adjustment theoretical solids content of purifying waste water is 48%, reacts 10 minutes, be cooled to below 45 ℃, obtain liquid glue; (3) add the composite curing agent that accounts for liquid glue gross weight 1.5～3%, adjusting 100 ℃ of hardening times is 12～14 minutes, blowing.
4. the preparation method of one-shot forming high pressure one side door trim panels as claimed in claim 2, is characterized in that being comprised of following steps:
The preparation of a, dipping core paper: flood in the kraft as core paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～65%, after dipping, be dried, after dry, volatile ingredient is 7.0～9.5%, dry after length on request cut and obtain flooding core paper;
The preparation of b, dipping demoulding base stock: flood in the kraft as ground paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～70%, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 20.0～25.0%, then at back coated release agent, coating weight is 0.3～0.4Kg/ ㎡, be dried, after dry, volatile ingredient is 7.5～10.0%, dry after length on request cut and obtain flooding demoulding base stock;
The preparation of c, dipping decorative paper: by monochromatic paper or printing paper be impregnated into melamine resin I, cyanurotriamide modified urea resin flood for the first time, then will flood for the first time in any and dried monochromatic paper or printing paper adopt melamine resin I flood for the second time, dry, after twice dipping, the spread of resin is 95～120%, after dry, volatile ingredient is 7.5～9.5%, precuring degree is 35～45%, and the dry rear length requiring cuts and obtains pre-preg facing paper;
The preparation of d, dipping overlay paper: by overlay paper be impregnated in melamine resin II, flood and be dried dipping afterwards the spread of resin be 180～280%, after dry, volatile ingredient is 8.0～10.5%, precuring degree is 40～50%, and the dry rear length requiring cuts and obtains pre-preg overlay paper;
E, the dipping demoulding base stock that step a, b are prepared respectively and the dipping core paper pre-composing base base of arranging in pairs or groups, each substrate base is comprised of a dipping demoulding base stock and at least one dipping core paper, release agent coating is core paper dorsad, every one deck in batch (-type) hot press is mated formation from top to bottom in the following order: a dipping overlay paper, a dipping decorative paper, substrate base, another substrate base, another dipping decorative paper, another dipping overlay paper form 2 groups of slabs, and the release agent coating of two substrate bases contacts;
F, pack in hot press after mating formation and boost, heat up, temperature-rise period 15～20 minutes, reaches 130～135 ℃ in temperature, and pressure is to suppress 30～45 minutes under 16～23 Mpa conditions, pressurize cooling after compacting;
G, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane.
5. the preparation method of one-shot forming high pressure one side door trim panels according to claim 4, is characterized in that: described in step f, heat up, the heat medium adopting in its temperature-rise period is high steam or superheated water; Described cooling, the cooling medium adopting in its temperature-fall period is water; The time of cooling is 30～40 minutes.
6. the preparation method of the one-shot forming high pressure one side door trim panels as described in claim 4 or 5, it is characterized in that: the preparation method of the release agent adopting in step b is: 40KgPAT3002 silicone release mixes and adds in stirred tank with 960Kg deionized water, add 2Kg silane type coupling agent as dispersing agent, slowly stir and within 30 minutes, put into stainless steel material storage barrel standing 6～8 hours.
7. the preparation method of one-shot forming high pressure one side door trim panels as claimed in claim 1, is characterized in that being comprised of following steps:
The preparation of a, dipping core paper: flood in the kraft as core paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～65%, after dipping, be dried, after dry, volatile ingredient is 7.0～9.5%, dry after length on request cut and obtain flooding core paper;
The preparation of b, dipping demoulding base stock: flood in the kraft as ground paper layer is impregnated into any in water soluble phenol resin and phenol modified urea-formaldehyde resins, after dipping, the spread of resin is 55～70%, after dipping, carry out preliminarily dried, after dry, volatile ingredient is 20.0～25.0%, then at back coated release agent, coating weight is 0.3～0.4Kg/ ㎡, be dried, after dry, volatile ingredient is 7.5～10.0%, dry after length on request cut and obtain flooding demoulding base stock;
The preparation of c, dipping decorative paper: by monochromatic paper or printing paper be impregnated into melamine resin I, cyanurotriamide modified urea resin flood for the first time, then will flood for the first time in any and dried monochromatic paper or printing paper adopt melamine resin I flood for the second time, dry, after twice dipping, the spread of resin is 95～120%, after dry, volatile ingredient is 7.5～9.5%, precuring degree is 35～45%, and the dry rear length requiring cuts and obtains pre-preg facing paper;
D, the dipping demoulding base stock that step a, b are prepared respectively and the dipping core paper pre-composing base base of arranging in pairs or groups, each substrate base is comprised of a dipping demoulding base stock and at least one dipping core paper, release agent coating is core paper dorsad, every one deck in batch (-type) hot press is mated formation from top to bottom in the following order: a dipping decorative paper, substrate base, another substrate base, another dipping decorative paper form 2 groups of slabs, and the release agent coating of two substrate bases contacts;
E, pack in hot press after mating formation and boost, heat up, temperature-rise period 15～20 minutes, reaches 130～135 ℃ in temperature, and pressure is to suppress 30～45 minutes under 16～23 Mpa conditions, pressurize cooling after compacting;
F, when temperature be down to 40 ℃ following after release, ejecting plate unloads the goods from the airplane.
8. the preparation method of one-shot forming high pressure one side door trim panels according to claim 7, is characterized in that: described in step e, heat up, the heat medium adopting in its temperature-rise period is high steam or superheated water; Described cooling, the cooling medium adopting in its temperature-fall period is water; The time of cooling is 30～40 minutes.
9. the preparation method of one-shot forming high pressure one side door trim panels as claimed in claim 7 or 8, it is characterized in that: the preparation method of the release agent adopting in step b is: 40KgPAT3002 silicone release mixes and adds in stirred tank with 960Kg deionized water, add 2Kg silane type coupling agent as dispersing agent, slowly stir and within 30 minutes, put into stainless steel material storage barrel standing 6～8 hours.
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