CN105667000B - 一种竹材、木材与泡沫铝复合夹芯板材及其制作方法 - Google Patents
一种竹材、木材与泡沫铝复合夹芯板材及其制作方法 Download PDFInfo
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Abstract
本发明公开了一种竹材、木材与泡沫铝复合夹芯板材及其制作方法。本发明竹材、木材与泡沫铝复合夹芯板材,它是由面层、芯层、底层三层粘合压制而成的复合板材;泡沫铝作为芯层,竹材和/或木材作为面层或底层;或者是,泡沫铝作为芯层,泡沫铝的一面贴竹材和/或木材,泡沫铝的另一面直接与薄钢板一次成型。本发明制作方法主要包括:对已制成的面层、底层材料的粘接面进行磨砂处理;对面层、底层板粘接面及芯层泡沫铝双面施胶;组坯;在压机上压制复合成型。本发明板材质量轻,且高比刚度、高阻尼减震性能,及吸声、电磁屏蔽等优势明显,可广泛用于家具板、地板、装潢、电磁屏蔽、隔声墙板等多种材料的基材。
Description
技术领域
本发明属于竹材加工、复合材料技术领域,具体涉及一种竹材、木材与泡沫铝复合夹芯板材及其制作方法。
背景技术
竹、木材作为与人们息息相关的优质材料,拥有易加工、强重比高、美丽花纹、光泽和颜色、吸收紫外线、反射红外线、良好触觉(远优于金属材料)、良好声学效果、良好的弹塑性、调温解湿、电绝缘、防火防腐等优良作用。在人类常用的钢、木、水泥、塑料四大主材中,只有竹、木材直接取自天然,因而具有生产成本较低、耗能较小、无毒害、无污染等特点。竹材、木材作为无可替代的低碳环保、环境友好型可持续材料,是目前使用最为广泛的材料之一,目前正在面临如何高效高值化利用的技术瓶颈,如何开拓竹、木材新的利用形式,促进竹木产业转型升级成为当前科研工作者共同的话题。
泡沫铝是一种多孔金属,与3D打印材料、离子液体、非晶合金和石墨烯等并称为未来最具潜力的十大新材料之一,由于内部存在大量孔隙,轻质、易加工、易安装(可两面蒙皮)、高比刚度、高阻尼减震性能及冲击能量吸收率等优点,同时具有优良电磁屏蔽性、吸声隔声、低热导率、低电导率等特殊优点,目前已广泛应用到轨道交通、航空航天、军事、汽车、绿色建筑化工和电讯等领域。其中,金属薄板——泡沫铝——金属薄板形成的“三明治”结构继承了泡沫铝的优异性能,并具有很高的抗弯强度,可用作新型建材、机车车辆的高刚度结构件等。
由于竹、木材是属于有机非金属材料,属于各向异性材料(非极性材料),给人以自然亲切温暖的感觉,目前主要用于建筑、装潢、家具、地板、客车底板、集装箱底板、结构用材等。泡沫铝作为一种新型金属材料属于各向同性材料(极性材料),经过发泡工艺而成,同时兼有金属和气泡特征,最有潜力的市场为泡沫铝隔音屏(用于高速公路、铁路、建筑)和泡沫铝夹心板(用于建筑、地铁、高速列车),而国外主要用于电磁屏蔽和吸、隔音材料。竹、木板材一般密度在0.6~0.8g/cm3,泡沫铝密度为金属铝密度的0.1~0.4倍(约0.3~0.9g/cm3),其抗弯比刚度为钢的1.5倍;二者组合密度梯度小强度大。此极性材料和非极性材料的组合体与同体积的金属钢材、竹木板材相比,具有质轻、易加工、易安装等优点,同时具有很好的物理力学性能和化学性能。二者的组合是复合材料应用领域的创新,使材料应用范围更加多元化,甚至可用于某些特殊领域。
发明内容
本发明的目的之一在于利用竹、木材和泡沫铝的上述优势,弥补各自劣势,扬长避短,采用合理的组坯方式及复合工艺(环氧树脂类胶黏剂)制造的一种兼具“泡沫铝”和“竹木”板材双重优点的竹材、木材与泡沫铝复合夹芯板材,该板材可用作家具板、地板、装潢、电磁屏蔽、隔声墙板等多种材料的基材,是一种具有高附加值和市场潜力的板材。
本发明的上述目的是通过如下的技术方案来实现的:该竹材、木材与泡沫铝复合夹芯板材,它是由面层、芯层、底层三层粘合压制而成的复合板材;泡沫铝作为芯层,竹材和/或木材作为面层或底层;或者是,泡沫铝作为芯层,泡沫铝的一面贴竹材和/或木材,泡沫铝的另一面直接与薄钢板一次成型。
具体的,层与层之间的粘合采用环氧树脂类胶黏剂粘合压制而成一个整体。
具体的,所述面层、芯层、底层三层分别是竹板、泡沫铝、竹板。
具体的,所述面层、芯层、底层三层分别是木板、泡沫铝、木板。
具体的,所述面层、芯层、底层三层分别是竹板、泡沫铝、木板。
具体的,所述面层、芯层、底层三层分别是竹板、泡沫铝、薄钢板。
具体的,所述面层、芯层、底层三层分别是木板、泡沫铝、薄钢板。
具体的,所述面层或底层是一层较厚宽幅竹单板或木单板,或是几层的竹、木胶合板或是竹、木层积材。
该竹材、木材与泡沫铝复合夹芯板材还有另外一种结构形式,它是由面层、芯层、底层三层粘合压制而成的复合板材;泡沫铝一面直接与薄钢板一次成型作为芯层,竹材和/或木材作为面层或底层。
本发明的目的之二在于提供上述竹材、木材与泡沫铝复合夹芯板材的制作方法,它包括如下步骤:
(1)对已制成的面层、底层材料即竹板或木板的粘接一面进行磨砂处理,形成较毛糙表面,以增强环氧树脂类胶黏剂的渗透性,增强胶合强度;如果用到薄刚板,需用钢刷打磨薄刚板粘接面,形成毛糙表面;
(2)将环氧树脂类胶黏剂与固化剂以质量比1:1的比例配比,搅拌均匀后,均匀涂刷于面层、底层板的粘接面,芯层泡沫铝须双面均匀涂胶,施胶量为200g/cm2;
(3)以泡沫铝作为芯层,竹材和/或木材作为面层或底层组坯;或者是,泡沫铝作为芯层,泡沫铝的一面贴竹材和/或木材,泡沫铝的另一面直接与薄钢板一次成型组坯;面层、芯层、底层组坯方式为0°-90°-0°的交错组坯方式;
(4)在压机上压制复合成型步骤:
(a)加热预压阶段:压力为1.5~2.0MPa,时间为3~4min,温度为低于环氧树脂类胶黏剂的变性温度60~70℃;
(b)保压阶段:预压稳定后,升高压力至3MPa~10MPa,具体根据泡沫铝抗压强度及材料所需胶合强度配置,压力需控制在泡沫铝形变线弹性区内,时间为2.0~2.5min/mm板坯厚度,温度设定为60℃;
(c)降压定型阶段:根据保压压力大小分2~3段降压,卸板后用较重平板压好坯板,24h后堆垛使用。
本发明有效利用了非金属材料竹、木材板材及特殊金属材料泡沫铝的优良性能,经特殊工艺胶合而成,最大限度发挥了面层、底层材料(竹、木)自然温暖舒适的感官作用,芯层材料(泡沫铝)的减震、缓冲、轻质、吸声的优良性能;同时二者的结合能有效提高板材的抗弯、抗冲击性等力学特性,相比薄钢板来说,竹木材作为面层更轻质,且感官良好,又能很好的起到骨架作用,有效弥补泡沫铝的绝对刚度不足,而相比全竹、木板材或其他木质蜂窝板,泡沫铝作为芯层的质量更轻且高比刚度、高阻尼减震性能,及吸声、电磁屏蔽等优势更明显。二者组合可兼具泡沫铝和竹木板材双重优点,可广泛用于家具板、地板、装潢、电磁屏蔽、隔声墙板等多种材料的基材,是一种极具高附加值和市场潜力的板材。
附图说明
图1是本发明实施例1的结构示意图。
图2是本发明实施例2的结构示意图。
图3是本发明实施例3的结构示意图。
图4是本发明实施例4的结构示意图。
具体实施方式
本发明竹、木材与泡沫铝复合夹芯板材的制作过程是:首先将竹、木材(可以是宽幅面厚单板如无缝展开竹单板或胶合板、层积材等)按一定幅面规格锯制,厚度一般为5mm以上,作为面层或底层。准备同样幅面规格的泡沫铝板(金属骨架成份及孔结构可调节)作为芯层。对上述已制成的面层、底层材料即竹板或木板的粘接一面进行磨砂处理,形成较毛糙表面,以增强环氧树脂类胶黏剂的渗透性,增强胶合强度;如果用到薄刚板,需用钢刷打磨薄刚板粘接面,形成毛糙表面。用专用的环氧树脂类胶黏剂(双组份胶,即将环氧树脂类胶黏剂与固化剂以质量比1:1的比例配比,搅拌均匀后所得胶)分别均匀涂刷在面层、底层的粘接面上和芯层即泡沫铝板双面上;如果用到薄刚板,将双组份胶均匀涂刷在已打磨的薄刚板粘接面上。按照复合夹芯板材的各种结构类型组坯,在压机上将坯板压制成型(压力必须低于泡沫铝的破坏载荷,在泡沫铝形变线弹性区内),具体过程如下:
(a)加热预压阶段:压力为1.5~2.0MPa,时间为3~4min,温度为低于环氧树脂类胶黏剂的变性温度60~70℃;
(b)保压阶段:预压稳定后,升高压力至3MPa~10MPa,具体根据泡沫铝抗压强度及材料所需胶合强度配置,压力需控制在泡沫铝形变线弹性区内,时间为2.0~2.5min/mm板坯厚度,温度设定为60℃;
(c)降压定型阶段:根据保压压力大小分2~3段降压,卸板后用较重平板压好坯板,24h后堆垛使用。
较厚宽幅竹单板一般指无缝展开竹单板,即圆竹筒经去内、外节后,开展开缝,在高温蒸汽下蒸煮数分钟,待其达到玻璃化温度(软化)后,转移至专用装备中辊压、扎应力消除孔进行展平,并在冷却定型机上定型而成,厚度一般大于等于5mm(具体工艺参数涉及其他发明内容而不做阐述)。
木单板一般指宽幅实木板材或胶合板、层积材,即锯切或刨切的宽幅实木单板,或压制的规格厚度胶合板,或大规格方材锯切或刨切的宽幅木板材。
泡沫铝是在纯铝或铝合金中加入添加剂后,经过发泡工艺而成,密度0.3~1.0g/cm3,孔径0.3~7mm,孔隙率63%~90%,抗压强度3MPa~15MPa;密度、闭孔、通孔形式及幅面规格根据用途和复合工艺要求进行定制。
胶黏剂采用环氧树脂类胶黏剂,属于热固性树脂胶,搭配固化剂才能使用,并且需要混合均匀后才能完全固化,一般环氧树脂胶称为主剂,固化剂也叫硬化剂。能将极性材料金属泡沫铝和非极性材料竹、木材胶合良好粘合,并有较大的胶合强度,制品尺寸稳定、耐性良好和吸水率低。
实施例1:
参见图1,是本发明实施例1的结构示意图,它采用无缝展开竹单板1作为面层,泡沫铝2作为芯层,无缝展开竹单板3作为底层。其三层结构,表层(面层和底层)层宽度可根据幅面大小采用其他胶合工艺进行拼接,各层厚度可按使用途径进行调整,根据所选环氧树脂类胶黏剂的固化温度选择热压温度(也可根据板材用途来选择冷压),复合压力必须低于泡沫铝的破坏载荷。其表层是竹单板,花纹美观,触感舒适,具有较好的硬度和强度,芯层为泡沫铝兼具缓冲,吸声,隔热,防辐射等多重优点。
实施例2:
参见图2,是本发明实施例2的结构示意图,它采用宽幅木单板1作为面层,泡沫铝2作为芯层,宽幅木单板3作为底层。实施例2与实施例1组合方式及结构、性能优势均相似,主要区别在于表层材料的不同。
上述实施例1和实施例2中的表层,竹面板材和木面板材还可以根据需要进行搭配,即双竹层、双木层或一竹一木(表层材料可以是宽幅较厚单板或胶合板、层积材等,要求各项异性小,变形小)。
实施例3:
参见图3,是本发明实施例3的结构示意图,它采用无缝展开竹单板或宽幅木单板1作为面层,泡沫铝2作为芯层,薄钢板3作为底层(在泡沫铝制作时一次成型)。其一面为具有良好触感的竹、木层,温暖舒适;另一面为具有高强度及高硬度的薄钢板层,耐磨耐腐。根据表层使用环境选择使用面,方便调节,比如用作装饰墙板或家具面板,减震地板等,除了便于安装,还具有传统和现代相冲突的艺术感。
实施例4:
参见图4,是本发明实施例4的结构示意图,它采用无缝展开竹单板或宽幅木单板1作为面层,泡沫铝2、薄钢板3(在泡沫铝制作时一次成型)作为芯层,无缝展开竹单板或宽幅木单板4作为底层。表层是具有良好触感的竹、木层,温暖舒适;芯层泡沫铝和薄钢板具有很强的骨架作用,板材结构更稳定,力学性能更优质。可广泛应用于轻承载型装饰板,减震地板及特高级材料领域(如动车车厢、航空等)。
同时,此夹芯结构的芯层材料还可根据特殊需要选择其他泡沫金属,如泡沫铜、泡沫铁等。
Claims (7)
1.一种竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:
该复合夹芯板材是由面层、芯层、底层三层粘合压制而成的复合板材;
泡沫铝作为芯层,竹材和/或木材作为面层或底层;
或者是,泡沫铝作为芯层,泡沫铝的一面贴竹材和/或木材,泡沫铝的另一面直接与薄钢板一次成型;
所述复合夹芯板材的制造方法包括以下步骤:
(1)对制成的面层、底层材料即竹板或木板的粘接一面进行磨砂处理,形成较毛糙表面,以增强环氧树脂类胶黏剂的渗透性,增强胶合强度;如果用到薄刚板,需用钢刷打磨薄刚板粘接面,形成毛糙表面;
(2)将环氧树脂类胶黏剂与固化剂以质量比1:1的比例配比,搅拌均匀后,均匀涂刷于面层、底层板的粘接面,芯层泡沫铝须双面均匀涂胶,施胶量为200g/cm2;
(3)以泡沫铝作为芯层,竹材和/或木材作为面层或底层组坯;或者是,泡沫铝作为芯层,泡沫铝的一面贴竹材和/或木材,泡沫铝的另一面直接与薄钢板一次成型组坯;面层、底层厚度大于等于5mm;面层、芯层、底层组坯方式为0°-90°-0°的交错组坯方式;
(4)在压机上复合压制成型步骤:
(a)加热预压阶段:压力为1.5~2.0MPa,时间为3~4min,温度为低于环氧树脂类胶黏剂的变性温度60~70℃;
(b)保压阶段:预压稳定后,升高压力至3MPa~10MPa,具体根据泡沫铝抗压强度及材料所需胶合强度配置,压力需控制在泡沫铝形变线弹性区内,时间为2.0~2.5min/mm板坯厚度,温度设定为60℃;
(c)降压定型阶段:根据保压压力大小分2~3段降压,卸板后用较重平板压好坯板,24h后堆垛使用。
2.根据权利要求1所述竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:层与层之间的粘合采用环氧树脂类胶黏剂粘合压制而成一个整体。
3.根据权利要求1所述竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:所述面层、芯层、底层三层分别是木板、泡沫铝、木板。
4.根据权利要求1所述竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:所述面层、芯层、底层三层分别是竹板、泡沫铝、木板。
5.根据权利要求1所述竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:所述面层、芯层、底层三层分别是竹板、泡沫铝、薄钢板。
6.根据权利要求1所述竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:所述面层、芯层、底层三层分别是木板、泡沫铝、薄钢板。
7.根据权利要求1所述竹材、木材与泡沫铝复合夹芯板材的制造方法,其特征在于:所述面层板或者是一层较厚宽幅竹单板或木单板,或者是几层的竹、木胶合板或竹、木层积材。
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