CN104385386A - 集装箱底板用全速生林材复合胶合板 - Google Patents
集装箱底板用全速生林材复合胶合板 Download PDFInfo
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Abstract
本发明集装箱底板用全速生林材复合胶合板,是采用我国产速生林为主要原料,用全速生林-国产桉木、杨木加工成木单板、毛竹加工成竹席或竹帘经干燥、整理、浸胶、涂胶,纵横交替布置,一次或二次组坯,多层复合,热压成型,表面覆膜,再进行纵横锯边、精锯、开榫、倒角处理,封边而得。本发明经科学结合优化,内部结构以速生林材料纵横组合,按力学性能比例搭配,特别是桉木、杨木单板通过浸胶使胶液渗透在单板木质纤维内使木质纤维组织达到胶织化,增加木单板强度。一次热压成型或二次热压成型,加工成强有力学性能的集装箱底板用胶合板,以解决世界硬质木材资源匮乏的不足。本发明提供的产品完全符合国家相关标准,完全满足集装箱使用要求。
Description
技术领域
本发明属于一种集装箱底板用胶合板,特别是采用我国产速生林为主要原料,经科学结合,优化加工成强有力学性能的单元材料而结合生产的集装箱底板用胶合板。
背景技术
集装箱由钢板、油漆和作为缓冲防震的底板——经胶合板组成。由于集装箱底板主要用于运输过程,必须具有良好的抗震、耐冲击、耐气候、耐老化等性能。因此,除了外观尺寸外,对用于集装箱底板的胶合板的胶合耐久性、静曲强度、弹性模量等物理性提出了很高的要求。过去的集装箱全木底板靠国外的硬质木材加工,或用国内的落叶松、阿必东,结合进口克隆木等木材结合,才构成集装箱木底板的物理力学性能,满足承载物体的需要。为满足产品物理性能指标的要求,集装箱底板用胶合板的木单板一般选用高密度硬阔叶材为原料。
根据国内外硬质木材开发利用资源越来越匮乏,国内又开发了竹木复合集装箱底板用胶合板,用部分竹材结合各种硬质杂木压制成集装箱底板用胶合板,以解决硬质木材价量、量少的问题。
发明内容
本发明的目的在于克服现有技术的不足之处,提供一种南方、北方大量生长和国家正在大力推广种植的速生林(桉树、杨树)、竹材,通过优化工艺复合成竹木材生产集装箱底板用胶合板。经采用新工艺新技术增强速生林材的强度,代替进口硬杂木和国产硬杂木。
本发明的技术方案是:采用我国产速生林为主要原料,用全速生林-国产桉木、杨木加工成木单板、毛竹加工成竹席或竹帘,经干燥、整理、浸胶、涂胶,纵横交替布置,一次或二次组坯,多层复合,热压成型,表面覆膜,再进行纵横锯边、精锯、开榫、倒角处理,封边而得。
所述全速生林、国产桉木、杨木,经旋切后成木单板,单板厚度为1.7-2.0mm。
所述竹帘、竹席用毛竹加工成,竹席厚度1.0mm-1.2mm,竹帘厚度为1.8mm-2.2mm,经干燥浸胶后二次干燥备用。
所述一次或二次组坯系指:
(1)一次组坯成型:
1) 将部分国产桉木单板经浸胶后滴干二次干燥,增加国产桉木单板强度;
2) 将部分国产桉木单板经涂胶,用于与浸胶的竹帘、竹席、单板的胶联复合;
3) 将浸胶干燥后单板、竹帘、竹席按集装箱底板力学性能分布方向进行比例搭配;
(2)二次组坯:将板坯按结构图层数复合,预压成坯板然后底板铺上浸渍覆膜纸将坯板铺在浸渍覆膜纸上,板面再铺上浸渍覆膜纸。
所述多层复合是指饰面为浸渍覆膜纸+竹席+九层纵向竹帘+两层横向竹帘+十层桉木单板,纵横搭配,或竹帘浸胶干燥后单板涂胶后及木单板浸胶干燥后,交替叠合,组成19-23层集装箱底板用胶合板。
所述表面覆膜是指用浸渍覆膜纸,即竹席浸胶后覆膜,或木单板上覆膜,或用克隆木单板贴面。
优化技术:竹帘、竹席采用酚醛树脂胶或共缩聚酚醛树脂胶浸胶,部分木单板浸胶强化木质纤维硬度。通过浸胶使胶液渗透木单板内使木质纤维通过胶织化达到加倍强度,将部分木单板涂胶作为单元结合,联接达到一定强度。
本发明提供的产品已通过国家质量部门按国际方法检验,结果见表1。
部分结构经本公司按国标检验结果见表2。
本发明选用我国大量生长和国家正在大力推广种植的速生林(桉树、杨树)、竹材,充分发挥了我国种植速生林的优势,毛竹生长期为3-4年,广西桉木4-5年,杨树4-5年。本发明经科学结合优化,内部结构以速生林材料纵横组合,按力学性能比例搭配,特别是桉木、杨木单板通过浸胶使胶液渗透在单板木质纤维内使木质纤维组织达到胶织化,增加木单板强度。一次或二次热压成型,加工成强有力学性能的集装箱底板用胶合板。经采用新工艺新技术增强速生林材的强度,产品完全符合国家相关标准,完全满足集装箱使用要求。代替进口硬杂木和国产硬杂木,以解决世界硬质木材资源匮乏的不足,更经济,更环保。
附图说明
以下结合附图和实施例作详细说明。
图1为实施例1的组坯结构示意图。
图2为实施例2的组坯结构示意图。
图3为实施例3的组坯结构示意图。
图4为实施例4的组坯结构示意图。
图5为实施例5的组坯结构示意图。
图6为实施例6的组坯结构示意图。
图7为实施例7的组坯结构示意图。
图中所示:浸渍纸或覆膜纸1.1,竹席1.2,一层纵向竹帘2.1,一层横向竹帘2.2,三层纵向竹帘2.3,一层纵向胶单板3.1,一层横向胶单板3.2,上纵下横向中板的二夹板3.3,上横下纵向中板的二夹板3.4 ,一层纵向大单板3.5,饰面板之间为三夹板4.2,上、下纵向中板的三夹板4.1,上、中、下纵向中板的五夹板4.2,七夹板4.3。
具体实施方式
生产工艺描述:
本发明的集装箱底板用胶合板,层板对称布置,饰面为浸渍覆膜纸+竹席+九层纵向竹帘+两层横向竹帘+十层桉木单板,纵横搭配,或竹帘浸胶干燥后单板涂胶后及木单板浸胶干燥后,交替叠合组成19-23层集装箱底板用胶合板,一次热压成型或二次复合。表面可用浸渍覆贴面膜,即竹席浸胶后覆膜,或木单板上覆膜。
本发明中的层板是指饰面板、纵向竹帘、横向竹帘、木单板,总层数为19-23层和全桉木单板经浸胶和部分涂胶按纵横比例搭配19-23层。
木单板(速生林-广西桉木、杨木经旋切后的单板)干燥、整理、浸胶、涂胶。单板厚度为1.7-2.0mm,允许局部厚度误差±0.5mm,长度、宽度允许误差+10mm,不允许负公差。桉木单板一般材质达不到硬杂木强度,但通过浸胶后使木质纤维胶织化形成一个强硬的整体,替代了其它进口硬杂木和国产硬杂木。
毛竹加工成竹帘、竹席,竹席厚度1.0mm-1.2mm,竹帘厚度为1.8mm-2.2mm,经干燥浸胶后二次干燥备用。
浸胶用酚醛树脂胶(固体含量在23-26%),将竹席、竹帘或木单板装入吊笼内用电动葫芦吊入浸胶池中,浸胶10min吊起沥1min再吊入浸胶池中浸2min,吊起沥干,然后经网带烘干机在70℃温度下进行快速烘干。
将竹席、竹帘干燥(含水率达到6-8%之间)后浸胶经二次干燥到不粘手、不起泡,二次干燥后含水率控制在14%以内,木单板经干燥后,纵向木单板采用涂胶作联接,横向木单板经干燥浸胶后沥干二次干燥,含水率控制与竹帘二次干燥一样。
涂胶用酚醛树脂胶(固体含量为46%±2)或用共缩聚酚醛树脂胶(固体含量为46%±2),采用涂胶机涂胶。
热压成型,按例图结构层数组坯,面底加浸渍覆膜纸,经热压一次成型,或根据客户需要面底用克隆木饰面热压成型,再进行纵横锯边、精锯、开榫、倒角处理,经检验后得到合格产品。
为防止板材吸水膨胀,可对成品板进行封边,采用聚氨酯漆将板边四周封住。封边后包装。
实施例1
参见图1,饰面板为浸渍纸或覆膜纸1.1+竹席1.2+三层纵向竹帘2.3,饰面板之间为二夹板3.3+一层横向竹帘2.2+二夹板3.4 与三层纵向竹帘2.3交替布置,该二夹板3.3为上纵下横向中板的二夹板,二夹板3.4为上横下纵向中板的二夹板。
木单板(速生林-桉木、杨木经旋切后的单板)干燥、整理、浸胶、涂胶。单板厚度为1.7-2.0mm,允许局部厚度误差±0.5mm,长度、宽度允许误差+10mm,不允许负公差。
毛竹加工成竹帘、竹席,竹席厚度1.0mm-1.2mm,竹帘厚度为1.8mm-2.2mm,经干燥浸胶后二次干燥备用。
浸胶用酚醛树脂胶(固体含量在23-26%),将竹席、竹帘或木单板装入吊笼内用电动葫芦吊入浸胶池中,浸胶10min吊起沥1min再吊入浸胶池中浸2min,吊起沥干,然后经网带烘干机在70℃温度下进行快速烘干。
将竹席、竹帘干燥(含水率达到6-8%之间)后浸胶经二次干燥到不粘手、不起泡,二次干燥后含水率控制在14%以内,木单板经干燥后,纵向木单板采用涂胶作联接,横向木单板经干燥浸胶后沥干二次干燥,含水率控制与竹帘二次干燥一样。
涂胶用酚醛树脂胶(固体含量为46%±2)或用共缩聚酚醛树脂胶(固体含量为46%±2),采用涂胶机涂胶。
本结构采用热进冷出的生产工艺,压板温度升至135℃后将板坯迅速推进压板内,快速将上下压板闭合,计时保温在140℃左右,板坯采用单位压力2.6-2.8mPa/cm2,保温保压时间根据板坯厚度定在35-40min,保温保压时间到后打开冷却水降温,20min时间降到40℃以下出板。
实施例2
参见图2,饰面板为浸渍纸或覆膜纸1.1+竹席1.2+一层纵向竹帘2.1+一层纵向胶单板3.1,饰面板之间为一层纵向竹帘2.1+一层横向胶单板3.2+一层纵向竹帘2.1+一层纵向胶单板3.1+一层横向竹帘2.2与一层横向胶单板3.2+一层纵向竹帘2.1+一层纵向胶单板3.1+一层纵向竹帘2.1 +一层横向胶单板3.2交替布置。
此结构采用热进冷出的生产工艺,工艺方法同实施例1。
实施例3
参见图3,饰面板为浸渍纸或覆膜纸1.1+一层纵向大单板3.5,饰面板之间为三夹板4.1与一层纵向竹帘2.1+一层纵向涂胶单板3.1+一层纵向竹帘2.1+一层纵向涂胶单板3.1+一层纵向竹帘2.1交替布置,该三夹板4.1为上、下纵向中板的三夹板,其中横向单板为浸胶单板。前处理工艺同实施例1。
此结构采用热进冷出的生产工艺,将浸胶干燥后的竹帘、木单板和涂胶木单板按力学分布方向比例和板坯厚度要求搭配组成坯板,经冷压机预压成板坯,或用热压机压成基板经定厚砂光后,根据客户要求的饰面材料进行热压成型。
实施例4
参见图4,饰面板为浸渍纸或覆膜纸1.1+竹席1.2+三层纵向竹帘2.3,饰面板之间为五夹板4.2与三层纵向竹帘2.3交替布置,该五夹板4.2为上、中、下纵向中板的五夹板,其中横向单板为浸胶单板。前处理工艺同实施例1。
此结构采用热进冷出的生产工艺,压板温度升至135℃后将板坯迅速推进压板内,快速将上下压板闭合,计时保温在140℃左右,板坯采用单位压力2.6-2.8mPa/cm2,保温保压时间根据板坯厚度定在35-40min,保温保压时间到后打开冷却水降温,20min时间降到40℃以下出板。
实施例5
参见图5,饰面板为浸渍纸或覆膜纸1.1+一层纵向大单板3.5+一层纵向涂胶单板3.1+一层纵向竹帘2.1+一层纵向涂胶单板3.1,饰面板之间为一层纵向涂胶单板3.1和一层纵向竹帘2.1纵横交叠后与一层横向竹帘2.2交替布置。前处理工艺同实施例1。
此结构采用热进冷出的生产工艺,压板温度升至135℃后将板坯迅速推进压板内,快速将上下压板闭合,计时保温在140℃左右,板坯采用单位压力2.6-2.8mPa/cm2,保温保压时间根据板坯厚度定在35-40min,保温保压时间到后打开冷却水降温,20min时间降到40℃以下出板。
实施例6
参见图6,饰面板为浸渍纸或覆膜纸1.1+一层纵向大单板3.5,饰面板之间为一层纵向竹帘2.1和一层纵向涂胶单板3.1纵横交叠后与五夹板4.2交替布置,该五夹板4.2为上、中、下纵向中板的五夹板,其中横向单板为浸胶单板。前处理工艺同实施例1。
此结构采用热进冷出的生产工艺,将浸胶干燥后的竹帘、木单板和涂胶木单板按力学分布方向比例和板坯厚度要求搭配组成坯板,经冷压机预压成板坯,或用热压机压成基板经定厚砂光后,根据客户要求的饰面材料进行热压成型。
实施例7
参见图7,饰面板为一层纵向大单板3.5+一层纵向涂胶单板3.1+一层纵向浸胶单板3.1,饰面板之间为两张七夹板4.3交替布置,该七夹板为上、下纵向中板的纵横交叠七夹板,其中纵向底板、横向单板为浸胶单板。前处理工艺同实施例1。
将各种单板复合,经冷压机预压成坯板,然后按热进冷出的生产工艺,压板温度升至135℃后将板坯迅速推进压板内,快速将上下压板闭合,计时保温在140℃左右,板坯采用单位压力2.6-2.8mPa/cm2,保温保压时间根据板坯厚度定在35-40min,保温保压时间到后打开冷却水降温,20min时间降到40℃以下出板。
检验结果
以上范例通过生产后取样,经国家人造板检测机构报告,检测出的物理力学性能合格,各项技术指标均超过国家标准要求的20-27%以上,样品密度大于17%,所以全速生林材可以完全代替进口和国产的其它硬杂木的作用,可解决木材资源匮乏的不足。
取样检测结果见表1、表2。
表1:国家林业局南京人造板质量监督检验站检验报告
表2:公司检验报告
Claims (8)
1.一种集装箱底板用全速生林材复合胶合板,其特征在于:采用我国产速生林为主要原料,用全速生林-国产桉木、杨木加工成木单板、毛竹加工成竹席或竹帘,经干燥、整理、浸胶、涂胶,纵横交替布置,一次或二次组坯,多层复合,热压成型,表面覆膜,再进行纵横锯边、精锯、开榫、倒角处理,封边而得。
2.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于:所述全速生林、国产桉木、杨木,经旋切后成木单板,单板厚度为1.7-2.0mm。
3.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于:所述竹帘、竹席用毛竹加工成,竹席厚度1.0mm-1.2mm,竹帘厚度为1.8mm-2.2mm,经干燥浸胶后二次干燥备用。
4.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于:所述浸胶、涂胶,采用酚醛树脂胶或共缩聚酚醛树脂胶。
5.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于所述一次或二次组坯系指:
(1)一次组坯成型:
1) 将部分国产桉木单板经浸胶后滴干二次干燥,增加国产桉木单板强度;
2) 将部分国产桉木单板经涂胶,用于与浸胶的竹帘、竹席、单板的胶联复合;
3) 将浸胶干燥后单板、竹帘、竹席按集装箱底板力学性能分布方向进行比例搭配;
(2)二次组坯:将板坯按结构图层数复合,预压成坯板然后底板铺上浸渍覆膜纸将坯板铺在浸渍覆膜纸上,板面再铺上浸渍覆膜纸。
6.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于:所述多层复合是指饰面为浸渍覆膜纸+竹席+九层纵向竹帘+两层横向竹帘、十层桉木单板,纵横搭配,或竹帘浸胶干燥后单板涂胶后及木单板浸胶干燥后,交替叠合,组成19-23层集装箱底板用胶合板。
7.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于:所述表面覆膜是指用浸渍覆膜纸,即竹席浸胶后覆膜,或木单板上覆膜,或用克隆木单板贴面。
8.如权利要求1所述的集装箱底板用全速生林材复合胶合板,其特征在于:所述封边是指用聚氨酯漆将板边四周封住。
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