CN105965622B - 耐光老化户外重组竹制造方法及产品 - Google Patents
耐光老化户外重组竹制造方法及产品 Download PDFInfo
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Abstract
本发明公开了一种耐光老化户外重组竹制造方法,本发明依次包括单元制备、浸胶、组坯、热压成型、锯切,此外本发明还包括对户外重组竹基材进行防霉剂处理以及对耐光老化户外重组竹的涂饰工艺。本发明具有优越的耐光防老化效果、防霉性和尺寸稳定性,其可以有效保护基材免受紫外线老化,提高了竹材户外使用寿命,扩大竹材的应用范围,提高竹制品的附加值,减少森林采伐量,具有优越的经济效益和生态效益。
Description
技术领域
本发明涉及一种竹制品的制造方法及产品,特别是一种耐光老化户外重组竹制造方法及产品,属于竹制品生产工艺技术领域。
背景技术
竹材由于其纹理美观、强重比高、可加工性强等优点,深受人们喜爱。近年来,由于传统建筑材料资源面临枯竭的危机,工信部和住建部等部门倡议大力发展生物质绿色建材,竹木建材成为建筑行业未来发展方向之一,是加快转型升级的必由之路。户外木地板、木质外墙装饰材料等户外产品也越来越受到消费者青睐。然而竹木材料户外利用时,其主要成分(纤维素、半纤维素、木质素及抽提物)对紫外线都有一定程度的吸收,从而导致分子结构会受到不同程度的破坏,其物理化学性能也会受到较大影响,如:颜色变化、开裂、光泽度下降和粗糙度增加等,开裂以及三大素的光降解会进一步加速竹制品的霉变和腐朽速度。这一系列的缺陷限制了竹材的户外应用范围,缩短了竹材户外使用寿命。因此,开发耐光老化竹制品十分必要。
国内外对木材料耐光老化方式主要分为两大类:木材涂饰处理和木材化学改性。这两大类中,无机及有机紫外吸收剂涂层是目前研究的热点。采用无机纳米紫外吸收剂涂层提高木竹材耐光老化性能已有大量报道,无机纳米紫外吸收剂具有较为良好的紫外光屏蔽能力及一定程度的抗菌性能,然而,无机纳米颗粒均匀分散难度大,经过表面改性处理的纳米颗粒可以达到较好的分散效果,但其同时降低了涂层对紫外光吸收能力。重组竹已成为竹材工业发展的主流品种。因此,本发明专注于耐光老化户外重组竹。
发明内容
本发明的目的在于:提供一种耐光老化户外重组竹制造方法及产品,本发明具有优越的耐光防老化效果、防霉性和尺寸稳定性,其可以有效保护基材免受紫外线老化,提高了竹材户外使用寿命,扩大竹材的应用范围,提高竹制品的附加值,减少森林采伐量,具有优越的经济效益和生态效益。
本发明是这样实现的:一种耐光老化户外重组竹制造方法,包括以下具体步骤;
1)单元制备:将毛竹锯截成竹筒,经剖分成竹片后,疏解制成竹束;
2)浸胶:将竹束干燥至含水率为6%-8%,再置于装有20%固含的酚醛树脂胶中浸渍,浸渍时间约为4-6分钟;
3)组坯:再将浸胶后的竹束干燥至含水率为11%-12%,然后按顺纹组坯,采用对称铺装,近青层朝外,竹黄面朝向中芯层,得到组坯板;
4)热压成型:对组坯板进行热压,热压板温度为55-60℃,热压温度为140℃,热压压力为3.5-4.0MPa,保温保压时间为1.5min/mm;卸板时,热压板温度为55-60℃,热压后得到厚度在22mm的板材;
5)锯切:将板材置于空气中静置一段时间后,经裁边、砂光槽形成户外重组竹基材。
上述的耐光老化户外重组竹制造方法中,还包括对户外重组竹基材进行防霉剂处理,所述的防霉剂处理采用防霉剂涂刷处理或防霉剂浸渍处理,所述的防霉剂涂刷处理是使用浓度为0.5%防霉剂涂饰竹质基材全部表面,涂刷次数1-3次;所述的防霉剂浸渍处理是将户外重组竹基材浸渍于浓度为0.1%-0.5%的防霉剂中,1MPa加压浸渍时间为5-30min。
前述的耐光老化户外重组竹制造方法中,还包括对耐光老化户外重组竹的涂饰工艺,依次包括以下步骤:
①砂光定厚:将户外重组竹基材砂光定厚;
②底漆涂饰:向户外重组竹基材涂覆2-3道UV固化底漆,每次涂饰量15-25g/m2,总涂饰量50g/m2;
③砂光底漆涂饰及砂光:向户外重组竹基材涂覆1-3道砂光底漆,每次涂饰量15-30g/m2,再对砂光底漆进行1-3道砂光;
④面漆涂饰:向户外重组竹基材涂覆3-4道耐光老化UV固化面漆,每次涂饰量15-30g/m2,总涂饰量60-90g/m2。
前述的耐光老化户外重组竹制造方法中,在步骤1和步骤2之间还包括竹束织帘处理,即采用人工或机械纺织成大幅竹束片,机械编织进给速度5m/min,下针间隙25mm。
前述的耐光老化户外重组竹制造方法中,在步骤2浸胶前还包括热处理,即将竹束置于水蒸气、惰性气体或油浴中进行热处理,处理温度160-220℃,处理时间0.5-6h。
前述的耐光老化户外重组竹制造方法中,步骤(2)中,将竹束浸渍的浸胶量控制在13%。
前述的耐光老化户外重组竹制造方法中,步骤(1)中,经剖分成竹片后去青,再疏解制成竹束。
前述的耐光老化户外重组竹制造方法中,步骤(1)中,所述的耐光老化UV固化面漆按重量百分比包括乙酸乙酯1%-2%、2'-(2'-羟基-3'-叔丁基-5'-甲基苯基)-5-氯苯并三唑1%-5%、无水酒精0.5%-1.5%、UV固化面漆90%-95%。
前述的耐光老化户外重组竹制造方法中,步骤(1)中,所述的耐光老化UV固化面漆按重量百分比包括乙酸乙酯1%、2'-(2'-羟基-3'-叔丁基-5'-甲基苯基)-5-氯苯并三唑5%、无水酒精1.5%、UV固化面漆92.5%。
采用前述的耐光老化户外重组竹制造方法的产品,包括由竹束拼接粘贴成的户外重组竹基材,户外重组竹基材上方设有2-3层UV固化底漆层,UV固化底漆层上方设有1-3层砂光底漆层,砂光底漆层上方设有2-4层UV固化面漆层。
上述的耐光老化户外重组竹制造方法的产品,户外重组竹基材上方设有3层UV固化底漆层,UV固化底漆层上方设有3层砂光底漆层,砂光底漆层上方设有4层UV固化面漆层。
与现有技术相比,本发明具有以下有益效果:
1)本发明对户外重组竹的制造方法的步骤和参数作了改进,改进后的工艺具有非常优越的耐光防老化的效果,保护基材免受紫外线老化,同时也具有强度大、硬度高、使用寿命长、尺寸稳定性好、层积工艺先进的特点。
2)本发明采用竹束作为地板的基础材料,大大减少了对竹子选材的要求,只要是有一定竹龄的竹子均可作为地板用材,由此可见,本发明可以有效地减少木材和竹材的浪费,节约木材和竹材资源,不仅具有优越的经济效益,而且环保节能具有可持续性发展。
3)本发明对户外重组竹基材进行防霉剂处理,所述的防霉剂处理采用防霉剂涂刷处理或防霉剂浸渍处理,因此极大地提高了户外重组竹的防霉性能,增加了本发明的应用范围和使用寿命。
附图说明
图1是耐光老化户外重组竹地板的结构示意图。
具体实施方式
实施例:一种耐光老化户外重组竹制造方法,包括以下步骤:
1竹质基材制备工艺:
1)单元制备:纤维定向分离,将毛竹锯截成2.6m长的竹筒,经剖分成竹片后去青(如果需要保持竹青的颜色,则不需要去青步骤),疏解制成竹束。
2)竹束织帘:采用人工或机械编织成大幅竹束片。机械编织进给速度5m/min,下针间隙25mm。
3)竹束帘/竹束热处理:将竹束帘/竹束置于水蒸气或其他惰性气体中或油浴中进行热处理,处理温度160-220℃,处理时间0.5-6h。
4)浸胶:将干燥至含水率为6%-8%竹束帘/竹束置于装有20%固含的酚醛树脂胶中浸渍,浸渍时间约为4-6分钟。通过浸胶、淋胶时间控制浸胶量,浸胶量控制在13%左右。
5)组坯:将干燥至含水率为11%-12%的竹束帘/竹束按顺纹组坯,采用对称铺装,近青层朝外,竹黄面朝向中芯层。根据预设密度计算板坯质量,将称量好的竹束帘均匀、松散地铺装成板坯。
6)热压成型:采用“冷进冷出”工艺,热压温度为140℃,热压压力为3.5-4.0MPa,保温保压时间为1.5min/mm;卸板时,热压板温度为55-60℃,板材厚度为22mm。
7)锯切:将上述得到的板材置于空气中平衡一段时间后,经裁边、砂光、开槽(根据需要开槽这一步骤可以有或无)形成户外重组竹基材。
2基材防霉处理:
1)防霉剂配制:使用主要成分为C11H17NOSCl2(DCOIT)的微乳液配制浓度为0.5%、0.3%和0.1%防霉剂。
2)防霉剂处理工艺(2种:涂刷处理、浸渍处理):
①涂刷处理:使用浓度为0.5%防霉剂涂饰竹质基材全部表面(共六面)或者其中5面,涂刷次数1-3次。5面涂刷是指不涂刷正面(即装饰面,涂饰耐光老化涂料面),涂刷其余5个面。采用5面涂刷时,此步骤(防霉剂处理)可以在正面涂饰之后。
②浸渍处理:将竹质基材置于盛有上述防霉剂容器中浸渍,常压处理时,浸渍时间为1.5-10min,防霉剂浓度为0.3%;1MPa加压浸渍时间为5-30min,防霉剂浓度为0.1%。
3耐光老化涂饰处理:
1)UV固化底漆配制(2种:防霉性UV固化底漆、普通UV固化底漆):
①防霉性UV固化底漆配制:使用主要成分为C11H17NOSCl2(DCOIT)油性防霉剂与UV固化底漆配制,防霉剂浓度为0.25%。(用于防霉剂5面处理试材)
②普通UV底漆:市售。(用于表层已进行方面处理试材,即防霉剂6面涂刷处理或浸渍处理)
2)耐光老化UV固化面漆配制:乙酸乙酯、2'-(2'-羟基-3'-叔丁基-5'-甲基苯基)-5-氯苯并三唑、无水酒精、UV固化面漆比例为1%:5%:1.5%:92.5%。材料温度30-50℃,使用电动搅拌器搅匀,搅拌时间10min。
3)涂饰工艺(包括4个步骤):
①试材砂光定厚:将户外重组竹基材置于重型刷光机中刷光定厚。
②试材底漆涂饰:UV固化底漆涂饰处理,使用设备:滚涂机;UV固化底漆固化,使用设备:UV固化机。重复上述处理2-3次,每次涂饰量15-25g/m2,总涂饰量50g/m2。
③砂光底漆涂饰及砂光:砂光底漆涂饰处理,使用设备:滚涂机;砂光底漆固化,使用设备:UV固化机;砂光:砂去部分砂光底漆,使用设备:重型砂光机。重复上述处理1-3次,每次涂饰量15-30g/m2。
④试材面漆涂饰:耐光老化UV固化面漆涂饰处理,使用设备:滚涂机;耐光老化UV固化面漆固化,使用设备:UV固化机,固化时紫外辐射量是底漆固化的两倍。重复上述处理3-4次,每次涂饰量15-30g/m2,总涂饰量60-90g/m2。
实施例2:采用上述的耐光老化户外重组竹制造方法的产品,如附图1所示,包括由竹束1拼接粘贴成的户外重组竹基材2,户外重组竹基材2上方设有2-3层UV固化底漆层3,UV固化底漆层3上方设有1-3层砂光底漆层4,砂光底漆层4上方设有2-4层UV固化面漆层5。
Claims (1)
1.耐光老化户外重组竹制造方法,其特征在于:包括以下具体步骤;
1)单元制备:将毛竹锯截成竹筒,经剖分成竹片后去青,疏解制成竹束;
2)浸胶:将竹束干燥至含水率为6%-8%,再置于装有20%固含的酚醛树脂胶中浸渍,浸渍时间约为4-6分钟,将竹束浸渍的浸胶量控制在13%;
3)组坯:再将浸胶后的竹束干燥至含水率为11%-12%,然后按顺纹组坯,采用对称铺装,近青层朝外,竹黄面朝向中芯层,得到组坯板;
4)热压成型:对组坯板进行热压,热压温度为140℃,热压压力为3.5-4.0MPa,保温保压时间为1.5min/mm;卸板时,热压板温度为55-60℃,热压后得到厚度在22mm的板材;
5)锯切:将板材置于空气中静置一段时间后,经裁边、砂光槽形成户外重组竹基材;
还包括对耐光老化户外重组竹的涂饰工艺,依次包括以下步骤:
①砂光定厚:将户外重组竹基材砂光定厚;
②底漆涂饰:向户外重组竹基材涂覆2-3道UV固化底漆,每次涂饰量15-25g/m2,总涂饰量50g/m2;
③砂光底漆涂饰及砂光:向户外重组竹基材涂覆1-3道砂光底漆,每次涂饰量15-30g/m2,再对砂光底漆进行1-3道砂光;
④面漆涂饰:向户外重组竹基材涂覆3-4道耐光老化UV固化面漆,每次涂饰量15-30g/m2,总涂饰量60-90g/m2;所述的耐光老化UV固化面漆按重量百分比包括乙酸乙酯1%-2%、2'-(2'-羟基-3'-叔丁基-5'-甲基苯基)-5-氯苯并三唑1%-5%、无水酒精0.5%-1.5%、UV固化面漆90%-95%;
还包括对户外重组竹基材进行防霉剂处理,所述的防霉剂处理采用防霉剂涂刷处理或防霉剂浸渍处理,所述的防霉剂涂刷处理是使用浓度为0.5%防霉剂涂饰竹质基材全部表面,涂刷次数1-3次;所述的防霉剂浸渍处理是将户外重组竹基材浸渍于浓度为0.1%-0.5%的防霉剂中,1MPa加压浸渍时间为5-30min;
在步骤1和步骤2之间还包括竹束织帘处理,即采用人工或机械纺织成大幅竹束片,机械编织进给速度5m/min,下针间隙25mm;
在步骤2浸胶前还包括热处理,即将竹束置于水蒸气、惰性气体或油浴中进行热处理,处理温度160-220℃,处理时间0.5-6h;
耐光老化户外重组竹制造方法的产品,包括由竹束(1)拼接粘贴成的户外重组竹基材(2),户外重组竹基材(2)上方设有3层UV固化底漆层(3),UV固化底漆层(3)上方设有3层砂光底漆层(4),砂光底漆层(4)上方设有4层UV固化面漆层(5)。
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