CN106751998A - 一种无甲醛橱柜面板及其制备工艺 - Google Patents
一种无甲醛橱柜面板及其制备工艺 Download PDFInfo
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Abstract
本发明涉及面板板材技术领域,具体涉及一种无甲醛橱柜面板及其制备工艺。该制备工艺包括如下步骤:(1)板芯层的制备:将板芯层各原料进行热混合,干燥、冷却,再经挤压装置进行高温挤压成型,制得板芯层;(2)涂胶贴板面层:将步骤(1)制得的板芯层双面涂上胶粘剂,然后将板面层贴合在板芯层表面,进行压合处理,制得复合面板。本发明的制备工艺简单,操作简便,稳定性好,易于加工,可用于大规模生产,且采用的原料环保、无污染,无甲醛释放,制得的面板可用于橱柜等办公家具,对人体无伤害。
Description
技术领域
本发明涉及面板板材技术领域,具体涉及一种无甲醛橱柜面板及其制备工艺。
背景技术
随着人们生活水平的提高,对家具的质量和要求也随之提高,而木质板材是现有家具、橱柜、办公家具使用的主要材料,但人们对家具的要求已不仅局限于家具的美观度、实用性、防水性、防霉性、防火性、防虫蛀等,更多的是关注家具中是否含有污染物甲醛。装修材料、家具中的甲醛不仅不易散去,导致甲醛超标,对环境造成破坏,而且对人体造成极大的伤害,尤其会严重影响孕妇和小孩的健康和发育,容易导致胎儿畸形、小孩智力发育受阻、刺激成人呼吸道等。
而目前装修和家具使用的材料种类繁多,并非是材料的本身含有甲醛,而是因为材料中含有各种由甲醛制备而得的树脂粘和剂,如酚醛树脂等。
发明内容
为了克服现有技术中存在的缺点和不足,本发明的目的在于提供一种无甲醛橱柜面板的制备工艺,该制备工艺简单,操作简便,稳定性好,易于加工,可用于大规模生产。
本发明的另一目的在于提供一种无甲醛橱柜面板,该橱柜面板原料环保、无污染,无甲醛释放,可用于橱柜等柜类家具,实用性高,防水防霉性好,防虫蛀,且具有阻燃性,在厨房环境中不易引燃,安全,对人体无伤害。
本发明的目的通过下述技术方案实现:一种无甲醛橱柜面板的制备工艺,包括如下步骤:
(1)板芯层的制备:将板芯层各原料进行热混合,干燥、冷却,再经挤压装置进行高温挤压成型,制得板芯层;
(2)涂胶贴板面层:将步骤(1)制得的板芯层双面涂上胶粘剂,然后将板面层贴合在板芯层表面,进行压合处理,制得复合面板;
本发明通过采用上述制备工艺,操作简便,制备过程稳定性好,易于加工,制得的橱柜面板环保、无污染,无甲醛释放。
优选的,所述步骤(1)中,板芯层包括如下重量份原料:
木基材 60-80份
填充剂 30-40份
抗氧剂 1-2份
发泡剂 2-2.5份
阻燃剂 11-15份
稳定剂 6-10份
偶联剂 3-4份
润滑剂 2-2.5份
硬脂酸 4-6份。
本发明通过采用上述原料制备板芯层,环保、无污染,无甲醛释放,对人体无伤害,并通过严格控制各原料的用量,制得的板芯层实用性高,提高了板芯层的防水防霉性能、防虫蛀性能和阻燃性,可用于橱柜等柜类家具。
优选的,所述木基材为松木粉、杉木粉、樟木粉、水曲柳木粉、杨木粉、桦木粉、樱桃木粉、椴木粉、榆木粉、枫木粉、白榉木粉、红榉木粉、白橡木粉、红橡木粉、柚木粉、花梨木粉、胡桃木粉、白影木粉和红影木粉中的至少一种;所述填充剂为滑石粉、碳酸钙、硅灰石和胡桃壳中的至少一种。
本发明通过采用上述木基材,具有轻质、防虫蛀、不易腐蚀、稳定性好等特点、更为优选的,所述木基材是由松木粉、杉木粉、椴木粉和榆木粉以重量比1.4-2.2:2.4-3.2:0.8-1.2:1组成的混合物。
本发明采用的上述填充剂中,滑石粉具有较佳的滑腻感,化学性质不活泼,并具有优良的耐火性和电绝缘性;碳酸钙稳定性好,应用广泛、普遍,成本低;硅灰石具有优良的尺寸稳定性、韧性、硬度、电和热的绝缘性,能提高板芯层的耐化学、耐湿性能;胡桃壳是加工胡桃时产生的废料,含有大量木质树脂和角质蜡,不吸水,且成本低;通过采用上述填充剂,提高了板层的稳定性、耐化学性、耐湿性和绝缘性等性能,且大大地降低了生产成本。更为优选的,所述填充剂由滑石粉、碳酸钙、硅灰石和胡桃壳以重量比1.0-1.5:1-2:1.5-2.5:1组成的混合物。
优选的,所述偶联剂为硅烷类、钛酸酯类、铝酸酯类、磷酸酯类、铬络合类、木质素类、异氰酸盐、过氧化异丙苯、稀土类和锆类偶联剂中的至少一种;所述润滑剂为硬脂酸丁酯、油酰胺、硬脂酸酰胺、乙撑双硬脂酰胺、石蜡、聚乙烯蜡、氧化聚乙烯蜡和低分子量聚丙烯中的至少一种;所述硬脂酸为硬脂酸钠、硬脂酸镁、硬脂酸钙、硬脂酸锌、硬脂酸钾、硬脂酸铁和硬脂酸铝中的至少一种。
偶联剂在复合材料中能与增强材料表面的基团反应,也能与树脂反应,在材料和树脂之间形成一个能传递应力的界面层;本发明通过采用上述偶联剂,增强了材料与树脂之间粘合强度,提高了复合材料的性能,还可以防止与其它介质向界面渗透,改善了界面的状态,提高了制品的耐老化性能、耐应力性能和电绝缘性能。更为优选的,所述偶联剂由硅烷偶联剂、钛酸酯偶联剂和磷酸酯偶联剂以重量比1.4-2.2:0.8-1.2:1组成的混合物。
本发明采用的上述润滑剂,润滑效能高而持久,具有优良的耐热性和化学稳定性,在加工中不分解、不挥发,且不腐蚀设备,不污染其他材料,无毒性;通过采用上述润滑剂,在面板进行挤压成型时,提高了流动性,改善面板材料与挤压筒和模具的黏附性,防止并减少滞留物,防止发生热劣化,还能改善成品的外观和光泽,当多种润滑剂复合使用时,润滑效能大大提高。因而,更为优选的,所述润滑剂由硬脂酸丁酯、硬脂酸酰胺、聚乙烯蜡和乙撑双硬脂酰胺以重量比2.4-3.2:1.4-2.2:1: 0.8-1.2组成的混合物。
本发明通过采用上述硬脂酸,能提高板芯层的润滑性和稳定性,能防止后续加工过程中出现“焦化”现象,可作为稳定剂、润滑剂,应用范围广。更为优选的,所述硬脂酸为硬脂酸钠、硬脂酸钙、硬脂酸锌和硬脂酸钾以重量比1.5-2.5:1-2:1:0.5-1组成的混合物。
优选的,所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 80-100份
固化剂 10-15份
促进剂 5-10份
偶联剂 5-6份
稀释剂 5-10份
增塑剂 3-7份。
本发明通过采用上述原料制备胶粘剂,原料不含甲醛成分,采用的固化剂能缩短分子间距离,提高热稳定性和化学稳定性;采用的促进剂可加速胶粘剂的固化反应,缩短固化时间,降低固化温度;采用的偶联剂能与被粘物表面形成共价键,提高粘接界面的坚固性;采用的稀释剂能增加胶粘剂的流动性和渗透性;采用的增塑剂能增加树脂的流动性,有利于浸润、扩散与吸附,并能改善胶粘剂的弹性和耐寒性。通过严格控制各原料的用量,能提高胶粘剂的热稳定性、化学稳定性、弹性和粘接固定性。
优选的,所述树脂为新型醛脲树脂、环氧树脂、双酚A环氧树脂、丙烯酸树脂、萜烯树脂、密胺树脂、ABS树脂、聚酯树脂、聚氨酯树脂、聚酰胺树脂和聚氯乙烯树脂中的至少一种;所述增塑剂为邻苯二甲酸酯、磷酸酯、脂肪族二元酸酯、苯多酸酯、烷基磺酸酯、多元醇酯、偏苯三酸酯、环氧化合物和含氯增塑剂中的至少一种。
本发明采用的上述树脂,具有优良的粘附性和湿润性,制得的胶粘剂粘着力强,环保性好;其中,环氧树脂含有多种极性基团和活性很大的环氧基,木材、塑料等多种畸形材料具有很强的粘接力,胶接强度很高,稳定性好,通过与上述的其他原料及配比,使制得的胶粘剂具有优异的耐高温、耐低温、高强度、高柔性、耐老化、导电和导热等性能;聚氨酯树脂能提高与各种材料的粘接性,具有很高的反应性,使制得的胶粘剂具有耐冲击、耐低温、耐摩擦和耐油等性能;ABS树脂具有良好尺寸稳定性,突出的耐冲击性、耐热性、介电性、耐磨性,表面光泽性好,易涂装等优点,并具有较好的化学稳定性、抗冲击性、加工流动性和表面硬度;改性醛脲树脂具有较高的胶合强度,较好的防水、耐污染、耐腐蚀性等特点。更为优选的,所述树脂由环氧树脂、聚氨酯树脂和ABS树脂以重量比1.5-2.5:1-2:1组成的混合物,或所述树脂由环氧树脂、丙烯酸树脂和聚酰胺树脂以重量比1.5-2.5:1-2:1组成的混合物。
本发明采用的增塑剂,挥发性低,具有优良的耐候性、耐水性、相容性、阻燃性和热稳定性,增塑效果好;更为优选的,所述增塑剂为邻苯二甲酸酯增塑剂,所述邻苯二甲酸酯增塑剂为邻苯二甲酸二丁酯、邻苯二甲酸二辛酯、磷酸三苯酯、邻苯二甲酸丁苄酯、邻苯二甲酸二正辛酯、邻苯二甲酸二仲辛酯、邻苯二甲酸二环己酯、邻苯二甲酸二异丁酯、邻苯二甲酸二甲酯、邻苯二甲酸二乙酯、邻苯二甲酸二异壬酯和邻苯二甲酸二异癸酯中的至少一种;最为优选的,所述增塑剂由邻苯二甲酸二丁酯、邻苯二甲酸二辛酯和邻苯二甲酸二异癸酯以重量比1.4-2.2:0.8-1.2:1组成的混合物。
优选的,所述步骤(1)中,挤压装置的挤压筒温度为190-210℃,挤出口温度为175-185℃,挤压压力为15-18MPa。本发明通过严格控制挤压装置的挤压筒温度,使得原料分散均匀,提高制品质量;控制挤出口温度,比挤压筒温度有所降低,能更好地成型,且避免在挤压装置中持续的高温摩擦导致物料分解;控制挤压压力能保持制品的均匀性,挤压压力过高会使原料因推进过程的摩擦作用增大而升温,导致物料的分解或损坏,挤压压力过低会使成型效果不佳,制品质量低。
优选的,所述步骤(2)中,板面层为PVC层、PVDF层、PVDC层或PTFE层中的一种。
本发明采用的上述板面层,PVC层具有优异的稳定性和阻燃性,不易被酸碱腐蚀,耐热性佳,应用范围广;PVDF层具有极佳的耐腐蚀新、耐磨性、耐候性和耐热性,机械强度和韧度高;PVDC层具有耐燃、耐腐蚀、气密性好等优点;PTFE层具有优异的耐高温、耐低温、耐腐蚀和耐候性,润滑性能高,无毒害。通过采用上述板面层,对板芯层起保护作用,能提高面板成品的防水性、防腐蚀性、耐热性、阻燃性和稳定性。
优选的,所述步骤(2)中,压合压力为4000-5000kgf/cm2,压合温度为120-140℃,压合时间为2-4h。本发明通过严格控制板面层与板芯层的压合压力及压合温度,使得面板压合厚度均匀,无气泡出现,平坦性较佳。
本发明的另一目的通过下述技术方案实现:一种无甲醛橱柜面板,所述无甲醛橱柜面板根据上述的无甲醛橱柜面板的制备工艺制得。
本发明的有益效果在于:本发明的无甲醛橱柜面板制备工艺简单,操作简便,稳定性好,易于加工,制得的面板物料分散均匀,挤压过程不损伤物料,成型效果佳,压合过程无气泡出现,可用于大规模生产。
本发明的无甲醛橱柜面板,原料环保、无污染,无甲醛释放,对人体无伤害,可用于橱柜等柜类家具,实用性高,防水防霉性好,防虫蛀,且具有阻燃性,在厨房环境中不易引燃,安全。
具体实施方式
为了便于本领域技术人员的理解,下面结合实施例对本发明作进一步的说明,实施方式提及的内容并非对本发明的限定。
实施例1
一种无甲醛橱柜面板的制备工艺,包括如下步骤:
(1)板芯层的制备:将板芯层各原料进行热混合,干燥、冷却,再经挤压装置进行高温挤压成型,制得板芯层;
(2)涂胶贴板面层:将步骤(1)制得的板芯层双面涂上胶粘剂,然后将板面层贴合在板芯层表面,进行压合处理,制得复合面板。
所述步骤(1)中,板芯层包括如下重量份原料:
木基材 60份
填充剂 30份
抗氧剂 1份
发泡剂 2份
阻燃剂 11份
稳定剂 6份
偶联剂 3份
润滑剂 2份
硬脂酸 4份。
所述木基材为松木粉、樟木粉、水曲柳木粉或杨木粉;所述填充剂为滑石粉。
所述偶联剂为铝酸酯类偶联剂或木质素类偶联剂;所述润滑剂为聚乙烯蜡或油酰胺;所述硬脂酸为硬脂酸钠或硬脂酸镁。
所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 80份
固化剂 10份
促进剂 5份
偶联剂 5份
稀释剂 5份
增塑剂 3份。
所述树脂为新型醛脲树脂或双酚A环氧树脂;所述增塑剂为环氧化合物或偏苯三酸酯。
所述步骤(1)中,挤压装置的挤压筒温度为190℃,挤出口温度为175℃,挤压压力为15MPa。
所述步骤(2)中,板面层为PVDC层;压合压力为4000kgf/cm2,压合温度为120℃,压合时间为2h。
一种无甲醛橱柜面板,所述无甲醛橱柜面板根据上述的无甲醛橱柜面板制备工艺制得。
实施例2
本实施例与上述实施例1的区别在于:
所述步骤(1)中,板芯层包括如下重量份原料:
木基材 65份
填充剂 32份
抗氧剂 1.2份
发泡剂 2.1份
阻燃剂 12份
稳定剂 7份
偶联剂 3.2份
润滑剂 2.1份
硬脂酸 4.5份。
所述木基材为杉木粉、桦木粉、樱桃木粉或枫木粉;所述填充剂为碳酸钙。
所述偶联剂为钛酸酯类偶联剂或异氰酸盐偶联剂;所述润滑剂为硬脂酸丁酯或氧化聚乙烯蜡;所述硬脂酸为硬脂酸锌或硬脂酸铝。
所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 85份
固化剂 11份
促进剂 7份
偶联剂 5.2份
稀释剂 7份
增塑剂 4份。
所述树脂为萜烯树脂或密胺树脂;所述增塑剂为脂肪族二元酸酯或苯多酸酯。
所述步骤(1)中,挤压装置的挤压筒温度为195℃,挤出口温度为178℃,挤压压力为16MPa。
所述步骤(2)中,板面层为PVDF层;压合压力为4300kgf/cm2,压合温度为125℃,压合时间为2.5h。
实施例3
本实施例与上述实施例1的区别在于:
所述步骤(1)中,板芯层包括如下重量份原料:
木基材 70份
填充剂 35份
抗氧剂 1.5份
发泡剂 2.3份
阻燃剂 13份
稳定剂 68份
偶联剂 3.5份
润滑剂 2.3份
硬脂酸 5份。
所述木基材为椴木粉、白榉木粉、红榉木粉或柚木粉;所述填充剂为硅灰石。
所述偶联剂为硅烷类偶联剂或过氧化异丙苯;所述润滑剂为硬脂酸酰胺或聚乙烯蜡;所述硬脂酸为硬脂酸钙或硬脂酸钠。
所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 90份
固化剂 13份
促进剂 8份
偶联剂 5.5份
稀释剂 8份
增塑剂 5份。
所述树脂为环氧树脂、丙烯酸树脂或聚氯乙烯树脂;所述增塑剂为邻苯二甲酸酯或磷酸酯。
所述步骤(1)中,挤压装置的挤压筒温度为200℃,挤出口温度为180℃,挤压压力为17MPa。
所述步骤(2)中,板面层为PVC层;压合压力为4500kgf/cm2,压合温度为130℃,压合时间为3h。
实施例4
本实施例与上述实施例1的区别在于:
所述步骤(1)中,板芯层包括如下重量份原料:
木基材 75份
填充剂 38份
抗氧剂 1.8份
发泡剂 2.4份
阻燃剂 14份
稳定剂 9份
偶联剂 3.8份
润滑剂 2.4份
硬脂酸 5.5份。
所述木基材为榆木粉、白橡木粉、红橡木粉或花梨木粉;所述填充剂为硅灰石。
所述偶联剂为磷酸酯类偶联剂或稀土类偶联剂;所述润滑剂为乙撑双硬脂酰胺或硬脂酸酰胺;所述硬脂酸为硬脂酸钾或硬脂酸镁。
所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 95份
固化剂 14份
促进剂 9份
偶联剂 5.8份
稀释剂 9份
增塑剂 6份。
所述树脂为ABS树脂或聚酯树脂;所述增塑剂为烷基磺酸酯或多元醇酯。
所述步骤(1)中,挤压装置的挤压筒温度为205℃,挤出口温度为183℃,挤压压力为17MPa。
所述步骤(2)中,板面层为PTFE层;压合压力为4800kgf/cm2,压合温度为135℃,压合时间为3.5h。
实施例5
本实施例与上述实施例1的区别在于:
所述步骤(1)中,板芯层包括如下重量份原料:
木基材 80份
填充剂 40份
抗氧剂 2份
发泡剂 2.5份
阻燃剂 15份
稳定剂 10份
偶联剂 4份
润滑剂 2.5份
硬脂酸 6份。
所述木基材为胡桃木粉、白影木粉或红影木粉;所述填充剂为胡桃壳。
所述偶联剂为铬络合类偶联剂或锆类偶联剂;所述润滑剂为石蜡或低分子量聚丙烯;所述硬脂酸为硬脂酸铁或硬脂酸铝。
所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 100份
固化剂 15份
促进剂 10份
偶联剂 6份
稀释剂 10份
增塑剂 7份。
所述树脂为聚氨酯树脂或聚酰胺树脂;所述增塑剂为含氯增塑剂。
所述步骤(1)中,挤压装置的挤压筒温度为210℃,挤出口温度为185℃,挤压压力为18MPa。
所述步骤(2)中,板面层为PTFE层;压合压力为5000kgf/cm2,压合温度为140℃,压合时间为4h。
实施例6
本实施例与上述实施例1的区别在于:
所述步骤(1)板芯层的原料中:
所述木基材是由松木粉、杉木粉、椴木粉和榆木粉以重量比1.4:3.2:1.2:1组成的混合物。
所述填充剂由滑石粉、碳酸钙、硅灰石和胡桃壳以重量比1.0:2:1.5:1组成的混合物。
所述偶联剂由硅烷偶联剂、钛酸酯偶联剂和磷酸酯偶联剂以重量比2.2:0.8:1组成的混合物。
所述润滑剂由硬脂酸丁酯、硬脂酸酰胺、聚乙烯蜡和乙撑双硬脂酰胺以重量比2.4:2.2:1: 0.8组成的混合物。
所述硬脂酸为硬脂酸钠、硬脂酸钙、硬脂酸锌和硬脂酸钾以重量比1.5:1:1:0.5组成的混合物。
所述步骤(2)胶粘剂的原料中:
所述树脂由环氧树脂、聚氨酯树脂和ABS树脂以重量比1.5:1:1组成的混合物,或所述树脂由环氧树脂、丙烯酸树脂和聚酰胺树脂以重量比1.5:1:1组成的混合物。
所述增塑剂为邻苯二甲酸酯增塑剂,所述邻苯二甲酸酯增塑剂由邻苯二甲酸二丁酯、邻苯二甲酸二辛酯和邻苯二甲酸二异癸酯以重量比2.2:0.8:1组成的混合物。
实施例7
本实施例与上述实施例2的区别在于:
所述步骤(1)板芯层的原料中:
所述木基材是由松木粉、杉木粉、椴木粉和榆木粉以重量比1.6:3.0:1.1:1组成的混合物。
所述填充剂由滑石粉、碳酸钙、硅灰石和胡桃壳以重量比1.1:1.8:1.7:1组成的混合物。
所述偶联剂由硅烷偶联剂、钛酸酯偶联剂和磷酸酯偶联剂以重量比2.0:0.9:1组成的混合物。
所述润滑剂由硬脂酸丁酯、硬脂酸酰胺、聚乙烯蜡和乙撑双硬脂酰胺以重量比2.6:2.0:1: 0.9组成的混合物。
所述硬脂酸为硬脂酸钠、硬脂酸钙、硬脂酸锌和硬脂酸钾以重量比1.8:1.2:1:0.6组成的混合物。
所述步骤(2)胶粘剂的原料中:
所述树脂由环氧树脂、聚氨酯树脂和ABS树脂以重量比1.8:1.2:1组成的混合物,或所述树脂由环氧树脂、丙烯酸树脂和聚酰胺树脂以重量比1.8:1.2:1组成的混合物。
所述增塑剂为邻苯二甲酸酯增塑剂,所述邻苯二甲酸酯增塑剂由邻苯二甲酸二丁酯、邻苯二甲酸二辛酯和邻苯二甲酸二异癸酯以重量比2.0:0.9:1组成的混合物。
实施例8
本实施例与上述实施例3的区别在于:
所述步骤(1)板芯层的原料中:
所述木基材是由松木粉、杉木粉、椴木粉和榆木粉以重量比1.8:2.8:1:1组成的混合物。
所述填充剂由滑石粉、碳酸钙、硅灰石和胡桃壳以重量比1.2:1.5:2.0:1组成的混合物。
所述偶联剂由硅烷偶联剂、钛酸酯偶联剂和磷酸酯偶联剂以重量比1.8:1.0:1组成的混合物。
所述润滑剂由硬脂酸丁酯、硬脂酸酰胺、聚乙烯蜡和乙撑双硬脂酰胺以重量比2.8:1.8:1: 1.0组成的混合物。
所述硬脂酸为硬脂酸钠、硬脂酸钙、硬脂酸锌和硬脂酸钾以重量比2.0:1.5:1:0.7组成的混合物。
所述步骤(2)胶粘剂的原料中:
所述树脂由环氧树脂、聚氨酯树脂和ABS树脂以重量比2.0:1.5:1组成的混合物,或所述树脂由环氧树脂、丙烯酸树脂和聚酰胺树脂以重量比2.0:1.5:1组成的混合物。
所述增塑剂为邻苯二甲酸酯增塑剂,所述邻苯二甲酸酯增塑剂由邻苯二甲酸二丁酯、邻苯二甲酸二辛酯和邻苯二甲酸二异癸酯以重量比1.8:1.0:1组成的混合物。
实施例9
本实施例与上述实施例4的区别在于:
所述步骤(1)板芯层的原料中:
所述木基材是由松木粉、杉木粉、椴木粉和榆木粉以重量比2:2.6:0.9:1组成的混合物。
所述填充剂由滑石粉、碳酸钙、硅灰石和胡桃壳以重量比1.3:1.2:2.2:1组成的混合物。
所述偶联剂由硅烷偶联剂、钛酸酯偶联剂和磷酸酯偶联剂以重量比1.6:1.1:1组成的混合物。
所述润滑剂由硬脂酸丁酯、硬脂酸酰胺、聚乙烯蜡和乙撑双硬脂酰胺以重量比3.0:1.6:1: 1.1组成的混合物。
所述硬脂酸为硬脂酸钠、硬脂酸钙、硬脂酸锌和硬脂酸钾以重量比2.3:1.8:1:0.8组成的混合物。
所述步骤(2)胶粘剂的原料中:
所述树脂由环氧树脂、聚氨酯树脂和ABS树脂以重量比2.3:1.8:1组成的混合物,或所述树脂由环氧树脂、丙烯酸树脂和聚酰胺树脂以重量比2.3:1.8:1组成的混合物。
所述增塑剂为邻苯二甲酸酯增塑剂,所述邻苯二甲酸酯增塑剂由邻苯二甲酸二丁酯、邻苯二甲酸二辛酯和邻苯二甲酸二异癸酯以重量比1.6:1.1:1组成的混合物。
实施例10
本实施例与上述实施例5的区别在于:
所述步骤(1)板芯层的原料中:
所述木基材是由松木粉、杉木粉、椴木粉和榆木粉以重量比2.2:2.4:0.8:1组成的混合物。
所述填充剂由滑石粉、碳酸钙、硅灰石和胡桃壳以重量比1.5:1:2.5:1组成的混合物。
所述偶联剂由硅烷偶联剂、钛酸酯偶联剂和磷酸酯偶联剂以重量比1.4:1.2:1组成的混合物。
所述润滑剂由硬脂酸丁酯、硬脂酸酰胺、聚乙烯蜡和乙撑双硬脂酰胺以重量比3.2:1.4:1: 1.2组成的混合物。
所述硬脂酸为硬脂酸钠、硬脂酸钙、硬脂酸锌和硬脂酸钾以重量比2.5:2:1:1组成的混合物。
所述步骤(2)胶粘剂的原料中:
所述树脂由环氧树脂、聚氨酯树脂和ABS树脂以重量比2.5:2:1组成的混合物,或所述树脂由环氧树脂、丙烯酸树脂和聚酰胺树脂以重量比2.5:2:1组成的混合物。
所述增塑剂为邻苯二甲酸酯增塑剂,所述邻苯二甲酸酯增塑剂由邻苯二甲酸二丁酯、邻苯二甲酸二辛酯和邻苯二甲酸二异癸酯以重量比1.4:1.2:1组成的混合物。
实施例1-10制得的无甲醛橱柜面板的性能测试如下表所示:
测试项目 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | 实施例6 | 实施例7 | 实施例8 | 实施例9 | 实施例10 |
甲醛释放量(mg/m3) | 0.02 | 0.02 | 0.01 | 0.02 | 0.03 | 0.01 | 0.006 | 0.002 | 0.005 | 0.008 |
阻燃性 | B | A2 | A1 | A2 | B | A2 | A1 | A1 | A1 | A2 |
硬度(JH) | 1235 | 1280 | 1300 | 1250 | 1220 | 1280 | 1460 | 1580 | 1390 | 1350 |
防水防腐蚀性 | 7 | 8 | 9 | 7 | 7 | 8 | 9 | 9 | 9 | 8 |
测试条件:
(1)甲醛释放量:利用甲醛测试仪精确测试甲醛释放量,根据国家标准规定,板材中甲醛释放量应小于0.20 mg/m3,测得的甲醛释放量越低,则说明该面板的甲醛含量越低。
(2)阻燃性测试:通过采用水平或垂直燃烧测试法,对实施例1-10制得的面板进行阻燃性测试,阻燃等级越高,则该面板的阻燃性越大,其中,阻燃等级如下表所示:
等级 | A1 | A2 | B | C | D | E | F |
燃烧性 | 不燃 | 不燃 | 难燃 | 难燃 | 可燃 | 可燃 | 易燃 |
从上表可以看出,本发明制得的面板的阻燃性能较佳,均处于B等级以上。
(3)硬度测试:采用詹氏硬度,用压力器将直径11.28毫米的钢珠压入面板中,深度达钢珠高度一半时所需要的荷载,詹氏硬度越大,则该面板的硬度越大。
(4)防水、防腐蚀性测试:将实施例1-10制得的面板进行喷淋或浸泡处理,并记录喷淋或浸泡前后的面板重量差,重量差越小,防水防腐蚀等级越高,则该面板的防水防腐蚀性能越优,测试结果如下表所示:
等级 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
重量差(g) | <400 | <350 | <300 | <250 | <200 | <150 | <100 | <70 | <50 |
由上述测试结果可知,本发明制得的面板的甲醛含量均不超标,且甲醛释放量极低,基本达到无甲醛释放的效果,表明通过本发明的无甲醛面板原料和制备工艺制得的面板符合国家标准,且甲醛含量极、几乎为零,环保、对环境无污染,对人体健康无伤害;本发明制得的面板的阻燃等级均达到B等级以上,基本已达到A等级,表明制得的面板阻燃性较优;本发明制得的面板硬度可达到1200JH以上,硬度较大;本发明制得的面板经喷淋或浸泡后,重量差小于70g,具有优异的防水防腐蚀性能。
上述实施例为本发明较佳的实现方案,除此之外,本发明还可以其它方式实现,在不脱离本发明构思的前提下任何显而易见的替换均在本发明的保护范围之内。
Claims (10)
1.一种无甲醛橱柜面板的制备工艺,其特征在于:包括如下步骤:
(1)板芯层的制备:将板芯层各原料进行热混合,干燥、冷却,再经挤压装置进行高温挤压成型,制得板芯层;
(2)涂胶贴板面层:将步骤(1)制得的板芯层双面涂上胶粘剂,然后将板面层贴合在板芯层表面,进行压合处理,制得复合面板。
2.根据权利要求1所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述步骤(1)中,板芯层包括如下重量份原料:
木基材 60-80份
填充剂 30-40份
抗氧剂 1-2份
发泡剂 2-2.5份
阻燃剂 11-15份
稳定剂 6-10份
偶联剂 3-4份
润滑剂 2-2.5份
硬脂酸 4-6份。
3.根据权利要求2所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述木基材为松木粉、杉木粉、樟木粉、水曲柳木粉、杨木粉、桦木粉、樱桃木粉、椴木粉、榆木粉、枫木粉、白榉木粉、红榉木粉、白橡木粉、红橡木粉、柚木粉、花梨木粉、胡桃木粉、白影木粉和红影木粉中的至少一种;所述填充剂为滑石粉、碳酸钙、硅灰石和胡桃壳中的至少一种。
4.根据权利要求2所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述偶联剂为硅烷类、钛酸酯类、铝酸酯类、磷酸酯类、铬络合类、木质素类、异氰酸盐、过氧化异丙苯、稀土类和锆类偶联剂中的至少一种;所述润滑剂为硬脂酸丁酯、油酰胺、硬脂酸酰胺、乙撑双硬脂酰胺、石蜡、聚乙烯蜡、氧化聚乙烯蜡和低分子量聚丙烯中的至少一种;所述硬脂酸为硬脂酸钠、硬脂酸镁、硬脂酸钙、硬脂酸锌、硬脂酸钾、硬脂酸铁和硬脂酸铝中的至少一种。
5.根据权利要求1所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述步骤(2)中,胶粘剂包括如下重量份原料:
树脂 80-100份
固化剂 10-15份
促进剂 5-10份
偶联剂 5-6份
稀释剂 5-10份
增塑剂 3-7份。
6.根据权利要求5所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述树脂为新型醛脲树脂、环氧树脂、双酚A环氧树脂、丙烯酸树脂、萜烯树脂、密胺树脂、ABS树脂、聚酯树脂、聚氨酯树脂、聚酰胺树脂和聚氯乙烯树脂中的至少一种;所述增塑剂为邻苯二甲酸酯、磷酸酯、脂肪族二元酸酯、苯多酸酯、烷基磺酸酯、多元醇酯、偏苯三酸酯、环氧化合物和含氯增塑剂中的至少一种。
7.根据权利要求1所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述步骤(1)中,挤压装置的挤压筒温度为190-210℃,挤出口温度为175-185℃,挤压压力为15-18MPa。
8.根据权利要求1所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述步骤(2)中,板面层为PVC层、PVDF层、PVDC层或PTFE层中的一种。
9.根据权利要求1所述的一种无甲醛橱柜面板的制备工艺,其特征在于:所述步骤(2)中,压合压力为4000-5000kgf/cm2,压合温度为120-140℃,压合时间为2-4h。
10.一种无甲醛橱柜面板,其特征在于:所述无甲醛橱柜面板根据权利要求1-9任一项所述的无甲醛橱柜面板制备工艺制得。
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