CN105563942B - 一种水晶彩板及其加工工艺 - Google Patents
一种水晶彩板及其加工工艺 Download PDFInfo
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Abstract
本发明涉及一种水晶彩板及其加工工艺,包括金属层,镀锌层,粘接层,聚对苯二甲酸乙二醇酯层,环氧树脂粘接层,背漆层,聚苯乙烯板层,发泡水泥层,复合彩膜以及保护层,镀锌层包括第一镀锌层和第二镀锌层,第一镀锌层通过镀锌形成于钢板层外表面,第二镀锌层通过镀锌形成于合金层外表面;聚对苯二甲酸乙二醇酯层包括第一聚对苯二甲酸乙二醇酯层和第二聚对苯二甲酸乙二醇酯层,背漆层辊涂在第二聚对苯二甲酸乙二醇酯层外,复合彩膜粘接在发泡水泥层上。本发明所生产的水晶彩板抗刮性能强,性价比高,可广泛用于大型公共建筑、公共厂房、活动板房、及集成房屋的室内外墙面和屋面。
Description
技术领域
本发明涉及板材构造以及制造工艺,具体涉及一种水晶彩板及其加工工艺。
背景技术
建筑节能保温是当前非常重要的问题,它是关系到低消耗能源,低碳,环保。市场上目前大多采用彩钢板。由于彩钢板在生产、运输、安装、使用等环节容易出现变形,要想满足要求,就需增加其横纵向强度相应也就增加了成本,这就限制或制约了推广和使用。为此,该技术领域需要一种既能强度达标又不增加太多成本的材料来进行替换,已成为当务之急。彩涂钢板是一种带有有机涂层的钢板。彩钢板分为单板、彩钢复合板、楼承板等。广泛使用于大型公共建筑、公共厂房、活动板房、及集成房屋的墙面和屋面。但是,目前市场上的彩钢板存在下述问题:1.尽管用量最大的建材用热镀锌基板产能很大,但缺少无锌花平整热镀锌钢卷及锌合金镀层钢卷等良好的基板;2.国产涂料品种、质量不能完全满足需求,进口涂料的高价格降低了竞争力,贴膜彩色板所需塑胶膜尚需依赖进口,缺少涂层厚、功能性、高强度、花色丰富的高档彩涂板;3.产品不够规范,造成资源严重浪费,产能4万吨/年以下的低产能机组过多,在产品质量和环境资源保护方面都存在问题;4、造价费用过高。而传统印刷VCM彩板表面光泽不高、透明性稍差、花纹图案在同一平面上没有立体及层次感,难以进入一二级高端市场。
发明内容
本发明的目的在于提供一种水晶彩板及其加工工艺,其抗刮性能强,光泽度好,不易生锈铝合金彩板,使用寿命长且强度高,具体技术方案如下:
一种水晶彩板,包括金属层,镀锌层,粘接层,聚对苯二甲酸乙二醇酯层,环氧树脂粘接层,背漆层,聚苯乙烯板层,发泡水泥层,复合彩膜以及保护层,其中,
所述金属层包括合金层和钢板层,所述合金层与钢板层之间通过环氧树脂粘接层固接;
所述合金层材料按照重量百分比含有如下组份:镁30%、铜0.03%、稀土0.1%、锂5%、镍7%、钒1%、硅7%、钼1%、钨1%、铁0.4%、钛9%、锰:0.03%、钴1%、其余为铝;
所述钢板层材料按照重量百分比含有如下组份:碳0.12%、镍2.23%、铜0.1%、硅0.41%、磷0.01%、硫0.02%、钒0.04%、铬0.1%、Als0.02%、钼0.1%、锰1.6%、钙0.001%、余量为铁;
所述镀锌层包括第一镀锌层和第二镀锌层,第一镀锌层通过镀锌形成于钢板层外表面,第二镀锌层通过镀锌形成于合金层外表面;
所述聚对苯二甲酸乙二醇酯层包括第一聚对苯二甲酸乙二醇酯层和第二聚对苯二甲酸乙二醇酯层,所述粘接层包括第一粘接层和第二粘接层,所述第一聚对苯二甲酸乙二醇酯层通过第一粘接层粘接在第一镀锌层上,所述第二聚对苯二甲酸乙二醇酯层通过第二粘接层粘接在第二镀锌层上;
所述背漆层辊涂在第二聚对苯二甲酸乙二醇酯层外,所述背漆按照重量百分比含有如下组份:聚酯树脂51%,钛白粉7%,大分子环氧树脂15%,交联树脂16%,异氰酸酯3%,消泡剂2%,铬酸锶2%,流平剂1%,防沉剂2%,分散剂1%;
所述聚苯乙烯板层与第一聚对苯二甲酸乙二醇酯层之间采用结构胶固接;聚苯乙烯板层内沿横向和纵向设有多条玻璃纤维丝拉筋,其横向/纵向穿过聚苯乙烯板,两端在板边锚固;
所述聚苯乙烯板层按照重量含有如下组份:可发性聚苯乙烯珠粒48份,滑石粉1份,酚醛树脂43份,发泡剂1份,有机酸0.5份,可膨胀石墨5.5份,有机酸1份;
所述发泡水泥层设置于聚苯乙烯板层上表面,所述发泡水泥层材料按照重量百分比含有如下组份:425普通硅酸盐水泥57%,脱硫石膏9%,亚硝酸钠4%,粉煤灰13%,建筑石膏7%,铁粉2%,多元共聚物分散剂1%,消石灰7%,其中在发泡水泥层的长度和宽度方向均每间隔3cm设置有预应力钢绞线,横向和纵向的预应力钢绞线构成网状结构;
所述复合彩膜粘接在发泡水泥层上;
所述保护层为透明阻燃保护层,透明阻燃保护层设置于复合彩膜外并用于保护水晶彩板。
进一步地,所述第一粘接层和第二粘接层为环氧树脂系胶结剂。
进一步地,所述环氧树脂系胶结剂或环氧树脂粘接层按照重量百分比含有如下组份:
79%的第一组份:85份环氧树脂,2份触变剂,1份偶联剂,0.5份消泡剂,1份抗紫外线剂,5份阻燃剂,3份微晶纤维素,0.5份气相二氧化硅,2份玻璃纤维素;
21%的第二组份:30份聚硫醇,5份二乙烯三胺,5份三乙烯四胺,5份四乙烯五胺,25份促进剂,30份聚硫橡胶。
进一步地,还包括岩棉板,其设置于聚苯乙烯板中间,构成聚苯乙烯板的夹心层。
进一步地,所述透明阻燃保护层含有阻燃材料,阻燃材料优选硼类阻燃材料。
进一步地,所述阻燃材料按照重量百分比含有如下组份:二氧化硅15%,聚氯乙烯20%,聚丙烯树脂30%,磷酸三甲苯酯10%,苯胺甲基三乙氧基硅烷5%,对苯二甲酸二甲酯5%,己二酸二酰肼5%,磷酸三甲苯酯3%,聚乙烯醇3%,高铝微粉2%,矾土2%。
进一步地,所述第一聚对苯二甲酸乙二醇酯层与聚苯乙烯板层以及发泡水泥层之间均采用结构胶固接。
上述水晶彩板的制备方法,包括如下步骤:
(1)聚苯乙烯板中间夹心设置一层岩棉板;
(2)依照组份和配比轧制钢板,依照组份和配比铸造合金板,合金板和钢板长宽规格相同;
(3)采用环氧树脂胶将所述合金板和钢板粘接固定;
(4)整体加热粘接后的合金板和钢板至300-320摄氏度;
(5)迅速空冷至室温;
(6)对钢板以及合金板向外的面进行钝化处理;
(7)在钢板层的上表面镀锌,在合金层的下表面镀锌;
(8)按照组份和配比制造发泡水泥层的水泥板:在模具中横向和纵向每间隔3cm预设钢绞线,按照组份425普通硅酸盐水泥57%,脱硫石膏9%,亚硝酸钠4%,粉煤灰13%,建筑石膏7%,铁粉2%,多元共聚物分散剂1%,消石灰7%制得的浆料搅拌均匀后向模具灌浆,灌浆完毕后进行钢绞线的第一次预应力张拉,进行养护并进行钢绞线的第二次张拉后脱模形成预制水泥板;
(9)将聚酯层分别通过粘接层粘接到金属层的两面镀锌层上;
(10)在第二镀锌层上辊涂防水漆;
(11)使用结构胶粘接聚苯乙烯板和水泥板;
(12)将聚苯乙烯板的另一面通过结构胶粘接至第一聚酯层上;
(13)将复合彩膜敷设于发泡水泥层上;
(14)将透明阻燃保护层敷设于装饰层外;
(15)将步骤(14)所得板材在模腔中进行保压成型;
(16)整体加热至95-98摄氏度;
(17)空冷至室温得到水晶彩板。
进一步地,第一次预应力张拉力为双向80N,第二次预应力张拉力为双向197N。
与目前现有技术相比,本发明所生产的水晶彩板抗刮性能强,附着力好,光泽度好,不易脱色和褪色,装饰美观,使用寿命长,性价比高,可广泛用于大型公共建筑、公共厂房、活动板房、及集成房屋的室内外墙面和屋面。该具有一定强度的水晶彩板作为室外面的板体形成统一的整体。因此,该水晶彩板是集保温、防火、防老化、高强度于一身,在结构设计、材料的选择和工艺实现上都有很大创新,属于全新产品。通过工艺的创新设计,并通过工艺创新,采用全新工艺复合的水晶效果彩膜,使彩板表面具有如同水晶表面一样平整透明效果,实现彩板结构升级,提升彩板外观竞争力,弥补了传统彩板表面镜面效果差缺点,提升了产品档次及产品价值,使印刷彩板外观更高档,更奢华,更能满足用户日益提升的外观需求。
具体实施方式
下面对本发明进行详细描述,其为本发明多种实施方式中的一种优选实施例。
在一个优选实施例中,水晶彩板包括金属层,镀锌层,粘接层,聚对苯二甲酸乙二醇酯层,环氧树脂粘接层,背漆层,聚苯乙烯板层,发泡水泥层,复合彩膜以及保护层,其中,金属层包括合金层和钢板层,合金层与钢板层之间通过环氧树脂粘接层固接;合金层材料按照重量百分比含有如下组份:镁30%、铜0.03%、稀土0.1%、锂5%、镍7%、钒1%、硅7%、钼1%、钨1%、铁0.4%、钛9%、锰:0.03%、钴1%、其余为铝;钢板层材料按照重量百分比含有如下组份:碳0.12%、镍2.23%、铜0.1%、硅0.41%、磷0.01%、硫0.02%、钒0.04%、铬0.1%、Als0.02%、钼0.1%、锰1.6%、钙0.001%、余量为铁;镀锌层包括第一镀锌层和第二镀锌层,第一镀锌层通过镀锌形成于钢板层外表面,第二镀锌层通过镀锌形成于合金层外表面;聚对苯二甲酸乙二醇酯层包括第一聚对苯二甲酸乙二醇酯层和第二聚对苯二甲酸乙二醇酯层,粘接层包括第一粘接层和第二粘接层,第一聚对苯二甲酸乙二醇酯层通过第一粘接层粘接在第一镀锌层上,第二聚对苯二甲酸乙二醇酯层通过第二粘接层粘接在第二镀锌层上;背漆层辊涂在第二聚对苯二甲酸乙二醇酯层外,背漆按照重量百分比含有如下组份:聚酯树脂51%,钛白粉7%,大分子环氧树脂15%,交联树脂16%,异氰酸酯3%,消泡剂2%,铬酸锶2%,流平剂1%,防沉剂2%,分散剂1%;聚苯乙烯板层与第一聚对苯二甲酸乙二醇酯层之间采用结构胶固接;聚苯乙烯板层内沿横向和纵向设有多条玻璃纤维丝拉筋,其横向/纵向穿过聚苯乙烯板,两端在板边锚固;聚苯乙烯板层按照重量含有如下组份:可发性聚苯乙烯珠粒48份,滑石粉1份,酚醛树脂43份,发泡剂1份,有机酸0.5份,可膨胀石墨5.5份,有机酸1份;发泡水泥层设置于聚苯乙烯板层上表面,发泡水泥层材料按照重量百分比含有如下组份:425普通硅酸盐水泥57%,脱硫石膏9%,亚硝酸钠4%,粉煤灰13%,建筑石膏7%,铁粉2%,多元共聚物分散剂1%,消石灰7%,其中在发泡水泥层的长度和宽度方向均每间隔3cm设置有预应力钢绞线,横向和纵向的预应力钢绞线构成网状结构;复合彩膜粘接在发泡水泥层上;保护层为透明阻燃保护层,透明阻燃保护层设置于复合彩膜外并用于保护水晶彩板。
第一粘接层和第二粘接层为环氧树脂系胶结剂。环氧树脂系胶结剂或环氧树脂粘接层按照重量百分比含有如下组份:79%的第一组份:85份环氧树脂,2份触变剂,1份偶联剂,0.5份消泡剂,1份抗紫外线剂,5份阻燃剂,3份微晶纤维素,0.5份气相二氧化硅,2份玻璃纤维素;21%的第二组份:30份聚硫醇,5份二乙烯三胺,5份三乙烯四胺,5份四乙烯五胺,25份促进剂,30份聚硫橡胶。
还包括岩棉板,其设置于聚苯乙烯板中间,构成聚苯乙烯板的夹心层,透明阻燃保护层含有阻燃材料,阻燃材料优选硼类阻燃材料。阻燃材料按照重量百分比含有如下组份:二氧化硅15%,聚氯乙烯20%,聚丙烯树脂30%,磷酸三甲苯酯10%,苯胺甲基三乙氧基硅烷5%,对苯二甲酸二甲酯5%,己二酸二酰肼5%,磷酸三甲苯酯3%,聚乙烯醇3%,高铝微粉2%,矾土2%。第一聚对苯二甲酸乙二醇酯层与聚苯乙烯板层以及发泡水泥层之间均采用结构胶固接。
此外,可以采用PET+印刷层+PETG+印刷层+PVC新型结构的复合彩膜,这种结构的彩膜可以提供如同水晶面板一样高光泽、高透明性、表面镜面效果及立体花纹的效果及层次感,使彩板表面看起来更高档,实现外观效果的升华,提升了彩板产品的档次和价值。与传统的印刷VCM彩板相比,外观更时尚、高档、视觉更具冲击力。与玻璃面板相比,成本有很大的优势,生产效率提升。
上面对本发明进行了示例性描述,显然本发明具体实现并不受上述方式的限制,只要采用了本发明的方法构思和技术方案进行的各种改进,或未经改进直接应用于其它场合的,均在本发明的保护范围之内。
Claims (6)
1.一种水晶彩板,其特征在于,包括金属层,镀锌层,粘接层,聚对苯二甲酸乙二醇酯层,环氧树脂粘接层,背漆层,聚苯乙烯板层,发泡水泥层,复合彩膜以及保护层,其中,
所述金属层包括合金层和钢板层,所述合金层与钢板层之间通过环氧树脂粘接层固接;
所述合金层材料按照重量百分比含有如下组份:镁30%、铜0.03%、稀土0.1%、锂5%、镍7%、钒1%、硅7%、铝1%、钨1%、铁0.4%、钛9%、锰:0.03%、钴1%、其余为铝;
所述钢板层材料按照重量百分比含有如下组份:碳0.12%、镍2.23%、铜0.1%、硅0.41%、磷0.01%、硫0.02%、钒0.04%、铬0.1%、Als0.02%、钼0.1%、锰1.6%、钙0.001%、余量为铁;
所述镀锌层包括第一镀锌层和第二镀锌层,第一镀锌层通过镀锌形成于钢板层外表面,第二镀锌层通过镀锌形成于合金层外表面;
所述聚对苯二甲酸乙二醇酯层包括第一聚对苯二甲酸乙二醇酯层和第二聚对苯二甲酸乙二醇酯层,所述粘接层包括第一粘接层和第二粘接层,所述第一聚对苯二甲酸乙二醇酯层通过第一粘接层粘接在第一镀锌层上,所述第二聚对苯二甲酸乙二醇酯层通过第二粘接层粘接在第二镀锌层上;
所述背漆层辊涂在第二聚对苯二甲酸乙二醇酯层外,所述背漆按照重量百分比含有如下组份:聚酯树脂51%,钛白粉7%,大分子环氧树脂15%,交联树脂16%,异氰酸酯3%,消泡剂2%,铬酸锶2%,流平剂1%,防沉剂2%,分散剂1%;
所述聚苯乙烯板层与第一聚对苯二甲酸乙二醇酯层之间采用结构胶固接;聚苯乙烯板层内沿横向和纵向设有多条玻璃纤维丝拉筋,其横向/纵向穿过聚苯乙烯板,两端在板边锚固;
所述聚苯乙烯板层按照重量含有如下组份:可发性聚苯乙烯珠粒48份,滑石粉1份,酚醛树脂43份,发泡剂1份,有机酸0.5份,可膨胀石墨5.5份,有机酸1份;
所述发泡水泥层设置于聚苯乙烯板层上表面,所述发泡水泥层材料按照重量百分比含有如下组份:425普通硅酸盐水泥57%,脱硫石膏9%,亚硝酸钠4%,粉煤灰13%,建筑石膏7%,铁粉2%,多元共聚物分散剂1%,消石灰7%,其中在发泡水泥层的长度和宽度方向均每间隔3cm设置有预应力钢绞线,横向和纵向的预应力钢绞线构成网状结构;
所述复合彩膜粘接在发泡水泥层上;
所述保护层为透明阻燃保护层,透明阻燃保护层设置于复合彩膜外并用于保护水晶彩板。
2.如权利要求1所述的水晶彩板,其特征在于,所述第一粘接层和第二粘接层为环氧树脂系胶结剂。
3.如权利要求2所述的水晶彩板,其特征在于,所述环氧树脂系胶结剂或环氧树脂粘接层按照重量百分比含有如下组份:79%的第一组份:85份环氧树脂,2份触变剂,1份偶联剂,0.5份消泡剂,1份抗紫外线剂,5份阻燃剂,3份微晶纤维素,0.5份气相二氧化硅,2份玻璃纤维素;21%的第二组份:30份聚硫醇,5份二乙烯三胺,5份三乙烯四胺,5份四乙烯五胺,25份促进剂,30份聚硫橡胶。
4.如权利要求3所述的水晶彩板,其特征在于,还包括岩棉板,其设置于聚苯乙烯板中间,构成聚苯乙烯板的夹心层。
5.如权利要求4所述水晶彩板的制备方法,其特征在于,包括如下步骤:
(1)聚苯乙烯板中间夹心设置一层岩棉板;
(2)依照组份和配比轧制钢板,依照组份和配比铸造合金板,合金板和钢板长宽规格相同;
(3)采用环氧树脂胶将所述合金板和钢板粘接固定;
(4)整体加热粘接后的合金板和钢板至300-320摄氏度;
(5)迅速空冷至室温;
(6)对钢板以及合金板向外的面进行钝化处理;
(7)在钢板层的上表面镀锌,在合金层的下表面镀锌;
(8)按照组份和配比制造发泡水泥层的水泥板:在模具中横向和纵向每间隔3cm预设钢绞线,按照组份425普通硅酸盐水泥57%,脱硫石膏9%,亚硝酸钠4%,粉煤灰13%,建筑石膏7%,铁粉2%,多元共聚物分散剂1%,消石灰7%制得的浆料搅拌均匀后向模具灌浆,灌浆完毕后进行钢绞线的第一次预应力张拉,进行养护并进行钢绞线的第二次张拉后脱模形成预制水泥板;
(9)将聚酯层分别通过粘接层粘接到金属层的两面镀锌层上;
(10)在第二镀锌层上辊涂防水漆;
(11)使用结构胶粘接聚苯乙烯板和水泥板;
(12)将聚苯乙烯板的另一面通过结构胶粘接至第一聚酯层上;
(13)将复合彩膜敷设于发泡水泥层上;
(14)将透明阻燃保护层敷设于装饰层外;
(15)将步骤(14)所得板材在模腔中进行保压成型;
(16)整体加热至95-98摄氏度;
(17)空冷至室温得到水晶彩板。
6.如权利要求5所述的水晶彩板的制备方法,其特征在于,第一次预应力张拉力为双向80N,第二次预应力张拉力为双向197N。
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