CN106363761A - 一种竹麻复合板及其制备方法 - Google Patents
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Abstract
本发明公开了一种竹麻复合板及其制备方法，涉及人造板的竹基纤维复合材料领域，包括如下步骤：备料：对芯层和覆面层的材料进行浸渍或涂覆酚醛树脂胶并干燥好备用；铺料：将芯层和覆面层的材料按照一定顺序均匀铺至不锈钢板上；热压：将铺好的地板芯层、覆面层料连同底部的底板一起送入热压机进行热压，热压温度约140～160℃，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50℃，卸压出板得到板材，本方法制出的竹麻复合板，包括竹基纤维复合板材层，竹基纤维复合板材层的两侧中至少一侧覆有麻布覆面层，所述麻布覆面层2由1～2层麻布组成，解决了现有技术中竹基纤维复合板材很容易纵向通裂以及采用底板压出纹路成本高昂的问题。
Description
技术领域
本发明涉及人造板的竹基纤维复合材料领域，具体涉及一种竹麻复合板及其制备方法。
背景技术
专利申请号为CN200820078766.1、专利名为“一种具有网络状单板单元的人造板”的专利公布了竹基纤维复合材料的制造方法。
竹基纤维复合材料改变了以往重组竹采用的竹筒开条、剖篾去青、剖篾去黄、碾压之原料加工方式，将竹筒对剖后不去青、不去黄的状态下经过多次疏解，得到松散的片状竹束，不仅大大提高了原料的利用率，而且因胶液能浸透到每一根竹纤维，压出的竹基纤维复合板材具有强度高、耐候性好、节能环保等诸多优点。
近年来，以慈竹原料加工制成的竹基纤维复合板材以更高的强度和耐候性能得到了高端市场的青睐，被市场形象地誉称为“竹钢”，“竹钢”以其高耐磨性和耐候性已成功地应用于户外地板、高档景观建筑装修等。
本发明人拥有的公布号为CN202672610U的专利“一种新型户外竹地板”，公布了一种上表面或上表面和下表面采用三聚氰胺浸渍纸覆面、底板直接热压出表面立体纹路的户外竹地板，虽然改变了以往重组竹地板须采用加工手段加工出户外地板上、下表面沟槽纹路的制造方法，但存在覆面层与芯层粘接不牢、不锈钢模板昂贵、地板容易纵向裂开等问题，严重制约了“竹钢”户外地板的实际应用。
“竹钢”材料应用于高档景观建筑装修时，经常需要利用厚度较薄的热压板坯(厚度在15mm以下)，由于竹基纤维复合板材全部为纵向铺料，热压后板坯很容易出现纵向通裂现象，造成材料成品率不高；当应用于户外地板热压时，地板上、下表面需要用昂贵的不锈钢模板压出纹路，用以达到防滑的效果，但是每张不锈钢模板成本就高达数万元，严重增加了生产成本，降低了经济效益。
发明内容
本发明提供了一种竹麻复合板的制备方法，解决了现有技术中因竹基纤维复合板材全部为纵向铺料出现的热压后板坯很容易纵向通裂以及生产过程中采用不锈钢模板压出纹路成本高昂的问题。
为了解决上述技术问题，本发明采用的技术方案概述如下：
一种竹麻复合板，包括竹基纤维复合板材层，所述竹基纤维复合板材层的材质为浸渍过酚醛树脂胶的竹基纤维复合材料，竹基纤维复合板材层的上、下表面中至少有一面覆有麻布覆面层，所述麻布覆面层由1～2层麻布组成，所述麻布为浸渍过酚醛树脂胶的麻布。
更优的，所述竹基纤维复合板材层的厚度为8-35mm。
更优的，所述酚醛树脂胶为水溶性热固酚醛树脂胶。
一种竹麻复合板的制备方法，包括如下步骤：
(1)备料：a.芯层备料，将新鲜竹筒截断，经疏解工序加工成呈松散纤维状的竹束，将竹束干燥至含水率10％以下后再在竹束上浸渍或涂覆酚醛树脂胶至挂胶量10～25％，然后对竹束进行干燥，直至竹束含水率达8～15％；b.覆面层备料，将外购的麻布干燥至含水率10％以下，浸渍或涂覆酚醛树脂胶至挂胶量15～30％，再对浸渍或涂覆酚醛树脂胶后的麻布进行干燥，直至含水率为12～20％；
(2)铺料：按板坯密度1.1～1.3g/cm3称取原料重量，均匀铺在底板上，在铺料的上表层和/或下表层放置步骤(1)中备好的的麻布，放置的麻布为一层或两层，放置的麻布为覆面层，放置的竹束为地板芯层；
(3)热压：将步骤(2)铺好的地板芯层、覆面层料连同底部的底板一起送入热压机进行热压，热压温度约140～160℃，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50℃，卸压出板。
相对于现有技术，本发明所产生的有益效果：
1、麻布覆面压出的竹钢材料表面已有轻微的凹凸，能起到防滑效果，能直接作为户外地板的表面使用，不再需要用不锈钢模板在地板表面压出防滑的纹路或由后续的工序加工出上表面防滑纹路；
2、麻布有50％的横向纤维，克服了原本由于竹基纤维复合板材全部为纵向铺料的缺陷，麻布覆面压出的竹麻复合板没有以往头疼的纵向裂纹问题，大大提高了板坯的成品率；
3、麻布覆面的竹钢材料表面纹理规整，色泽均匀柔和，提升了材料的外观品相；
4、麻布属天然材料，秉承了“竹钢”天然、环保的特点，麻布价廉易得。
附图说明
下面结合附图对本发明作进一步说明。
图1是本发明的结构示意图；
图中标号分别为：1、竹基纤维复合板材层；2、麻布覆面层。
具体实施方式
下面结合附图和具体实施方式对本发明作进一步详细说明。本发明的实施方式包括但不限于下列实施例。
实施例1
一种竹麻复合板，其制备方法包括如下步骤：
(1)备料：a.芯层备料，将新鲜竹筒截断，经疏解工序加工成呈松散纤维状的竹束，将竹束干燥至含水率10％以下后再在竹束上浸渍或涂覆酚醛树脂胶至挂胶量10～25％，然后对竹束进行干燥，直至竹束含水率达8～15％；b.覆面层备料，将外购的麻布干燥至含水率10％以下，浸渍或涂覆酚醛树脂胶至挂胶量15～30％，再对浸渍或涂覆酚醛树脂胶后的麻布进行干燥，直至含水率为12～20％；
(2)铺料：按板坯密度1.1～1.3g/cm3称取原料重量，均匀铺在底板上，先在底板上铺步骤(1)中备好的竹束，然后在竹束在铺1-2层步骤(1)中备好的麻布，放置的麻布为覆面层，放置的竹束为地板芯层；
(3)热压：将步骤(2)铺好的地板芯层、覆面层料连同底部的底板一起送入热压机进行热压，热压温度约140～160℃，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50℃，卸压出板。
本实施例中所述酚醛树脂胶为水溶性热固酚醛树脂胶，采用本实施例方法制出的竹麻复合板，包括竹基纤维复合板材层1，所述竹基纤维复合板材层1的材质为浸渍过酚醛树脂胶的竹基纤维复合材料，竹基纤维复合板材层1的上表面或下表面覆有麻布覆面层2，所述麻布覆面层2由1～2层麻布组成，所述麻布为浸渍过酚醛树脂胶的麻布。
实施例2
一种竹麻复合板，其制备方法包括如下步骤：
(1)备料：a.芯层备料，将新鲜竹筒截断，经疏解工序加工成呈松散纤维状的竹束，将竹束干燥至含水率10％以下后再在竹束上浸渍或涂覆酚醛树脂胶至挂胶量10～25％，然后对竹束进行干燥，直至竹束含水率达8～15％；b.覆面层备料，将外购的麻布干燥至含水率10％以下，浸渍或涂覆酚醛树脂胶至挂胶量15～30％，再对浸渍或涂覆酚醛树脂胶后的麻布进行干燥，直至含水率为12～20％；
(2)铺料：按板坯密度1.1～1.3g/cm3称取原料重量，均匀铺在底板上，先在底板上铺1-2层步骤(1)中备好的麻布，再在麻布上铺步骤(1)中备好的竹束，最后在竹束在铺1-2层步骤(1)中备好的麻布，放置的麻布为覆面层，放置的竹束为地板芯层；
(3)热压：将步骤(2)铺好的地板芯层、覆面层料连同底部的底板一起送入热压机进行热压，热压温度约140～160℃，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50℃，卸压出板。
本实施例中所述酚醛树脂胶为水溶性热固酚醛树脂胶，采用本实施例方法制出的竹麻复合板如图1所示，包括竹基纤维复合板材层1，所述竹基纤维复合板材层1的材质为浸渍过酚醛树脂胶的竹基纤维复合材料，竹基纤维复合板材层1的上表面和下表面均覆有麻布覆面层2，所述麻布覆面层2由1～2层麻布组成，所述麻布为浸渍过酚醛树脂胶的麻布。
实施例3
采用实施例1提供的方法制备户外地板，其制备过程及结果如下：
(1)芯层备料：按户外地板长度截断新鲜的慈竹竹筒，经疏解工序加工成呈松散纤维状的竹束，竹束干燥至含水率10％以下，干竹束浸(涂)酚醛树脂胶至挂胶量10～25％，浸(涂)酚醛树脂胶后的竹束再干燥至含水率8～15％。所用的酚醛树脂胶为水溶性热固酚醛树脂胶。
(2)覆面层备料：将外购的麻布干燥至含水率10％以下，浸(涂)酚醛树脂胶至挂胶量15～30％，浸(涂)酚醛树脂胶后的麻布再干燥至含水率12～20％。所用的酚醛树脂胶为水溶性热固酚醛树脂胶。
(3)铺料：按板坯密度1.1～1.3g/cm3称取原料重量(含表面用麻布重量)，麻布可以是一层或两层。在底板上按板坯宽度均匀铺料，铺料的上表面放置2层浸胶干燥后的麻布。
(4)热压：将铺好的地板芯层、覆面层料连同底部的底板一起送入热压机进行热压，热压温度约140～160℃，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50°C，卸压出板。
(5)地板剖分：在双端锯上将板坯截成成品地板长度，在多片锯上按产品宽度剖分热压后的板坯。
制得的地板包括竹基纤维复合板材层1，竹基纤维复合板材层1的厚度为18mm，竹基纤维复合板材层1的上表面覆有麻布覆面层2，地板板坯取样检测的结果：密度1.2g/cm3，含水8％，静曲强度302MPa，28小时水煮-烘干试验后无剥离分层、厚度膨胀率3％。
实施例4
采用实施例2提供的方法制备景观装修用薄板坯(板坯厚度10mm以下)，其制备过程及结果如下：
(1)芯层备料：按户外地板长度截断新鲜的慈竹竹筒，经疏解工序加工成呈松散纤维状的竹束，竹束干燥至含水率10％以下，干竹束浸(涂)酚醛树脂胶至挂胶量10～25％，浸(涂)酚醛树脂胶后的竹束再干燥至含水率8～15％。所用的酚醛树脂胶为水溶性热固酚醛树脂胶。
(2)覆面层备料：将外购的麻布干燥至含水率10％以下，浸(涂)酚醛树脂胶至挂胶量15～30％，浸(涂)酚醛树脂胶后的麻布再干燥至含水率12～20％。所用的酚醛树脂胶为水溶性热固酚醛树脂胶。
(3)铺料：按板坯密度1.1～1.3g/cm3称取原料重量(含表面用麻布重量)，麻布可以是一层或两层。按板坯宽度均匀铺料，最上层为2层麻布，最下层为1层麻布层。
(4)热压：将铺好的料坯连同底板一起送入热压机进行热压，热压温度约140～160°C，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50℃，卸压出板。
制得的板坯包括竹基纤维复合板材层1，竹基纤维复合板材层1的厚度为7mm，竹基纤维复合板材层1的上表面和下表面均覆有麻布覆面层2，板坯取样检测的结果：密度1.2g/cm3，含水6％，静曲强度335MPa，28小时水煮-烘干试验后无剥离分层、厚度膨胀率2.8％。
如上所述即为本发明的实施例。本发明不局限于上述实施方式，任何人应该得知在本发明的启示下做出的结构变化，凡是与本发明具有相同或相近的技术方案，均落入本发明的保护范围之内。
Claims (4)
1.一种竹麻复合板，包括竹基纤维复合板材层(1)，其特征在于：所述竹基纤维复合板材层(1)的材质为浸渍过酚醛树脂胶的竹基纤维复合材料，竹基纤维复合板材层(1)的上、下表面中至少有一面覆有麻布覆面层(2)，所述麻布覆面层(2)由1～2层麻布组成，所述麻布为浸渍过酚醛树脂胶的麻布。
2.如权利要求1所述的一种竹麻复合板，其特征在于：所述竹基纤维复合板材层(1)的厚度为8-35mm。
3.如权利要求1所述的一种竹麻复合板，其特征在于：所述酚醛树脂胶为水溶性热固酚醛树脂胶。
4.如权利要求1或2或3所述的一种竹麻复合板的制备方法，其特征在于：包括如下步骤：
(1)备料：a.芯层备料，将新鲜竹筒截断，经疏解工序加工成呈松散纤维状的竹束，将竹束干燥至含水率10％以下后再在竹束上浸渍或涂覆酚醛树脂胶至挂胶量10～25％，然后对竹束进行干燥，直至竹束含水率达8～15％；b.覆面层备料，将外购的麻布干燥至含水率10％以下，浸渍或涂覆酚醛树脂胶至挂胶量15～30％，再对浸渍或涂覆酚醛树脂胶后的麻布进行干燥，直至含水率为12～20％；
(2)铺料：按板坯密度1.1～1.3g/cm3称取原料重量，均匀铺在底板上，在铺料的上表层和/或下表层放置步骤(1)中备好的的麻布，放置的麻布为一层或两层，放置的麻布为覆面层，放置的竹束为地板芯层；
(3)热压：将步骤(2)铺好的地板芯层、覆面层料连同底部的底板一起送入热压机进行热压，热压温度约140～160℃，热压压力3.5～5.5MPa，待酚醛树脂胶固化后，通水冷却至约50℃，卸压出板。
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