CN107053376A - 一种竹质游艇舷板材料的制造方法 - Google Patents
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Abstract
本发明公开了一种竹质游艇舷板材料的制造方法，该方法首先将毛竹截段、破蔑和四面刨加工，制成留青竹片；再经过炭化、干燥处理后，分别检测每根竹片的杨氏模量值，挑选出Ew＞12000 MPa的竹片，经测边涂胶、组坯、热压（加侧压）等工序制成单层竹板；其次，利用旋切机制备桉树单板，通过单板分级设备逐张检测，挑选出Ew＞12000 MPa的单板，干燥后备用；再次，自制水溶性酚醛树脂，用于浸渍玻璃纤维布，低温干燥后备用；将桉树单板涂胶，与玻璃纤维布和单层竹板按规定的组坯方式组坯，经热压等工序制成竹质游艇舷板材料。利用本发明方法生产出的竹质游艇舷板材料能满足高档游艇材料的性能及使用要求，具有广阔的发展前景。
Description
技术领域
本发明属于竹材加工领域，具体涉及一种竹质游艇舷板材料的制造方法。
背景技术
在我国大陆，随着近30年以来经济的高速发展和人民群众生活水平的提高，国内对游艇的需求在悄然增长，一股购买游艇热正在各地逐渐升温，越来越多的人把目光转向游艇开发。目前国内外使用的高档游艇均采用玻璃纤维增强塑料（简称玻璃钢）复合材料制造。这种材料存在成本高（15万元/吨）、废旧产品处理困难的问题，既难以燃烧，又不易分解，更无法回收利用，国外多采用堆积方式处理，占用了大量的土地。因此，必须开发出一种全新的低成本、可回收利用的环保游艇材料来替代目前大量使用的玻璃钢游艇材料。
发明内容
本发明的目的在于提供一种竹质游艇舷板材料的制造方法。利用本发明方法生产出的竹质游艇舷板材料能满足高档游艇材料的性能及使用要求，外观美丽自然，解决了目前高档游艇所采用的玻璃纤维增强塑料复合材料成本高，回收处理困难、产品外观单一的问题，并能够全面提升竹制品产业的科技含量和产品附加值，具有广阔的发展前景。
本发明提供了一种竹质游艇舷板材料的制造方法，该方法包括如下步骤：
1）按申请人发明的毛竹竹青板方材及其制造方法（专利授权号：ZL200810103115.8），具体工艺为：采伐新鲜毛竹，经截段、破蔑和四面刨加工，制成留青竹片；竹片再经过炭化、干燥处理后，分别检测每根竹片的杨氏模量值，挑选Ew＞12000 MPa的竹片备用；将挑选出的高杨氏模量值竹片经过测边涂胶、组坯、热压（加侧压）等工序制成单层竹板；该竹板的尺寸规格为2600mm×1300mm×6mm（长×宽×厚）；
2）利用旋切机制备桉树单板，单板的尺寸规格为1300mm×550mm×2.2mm（长×宽×厚），制备好的单板逐张通过单板分级设备的检测，将Ew＞12000 MPa的单板留下，送入干燥机干燥，备用；
3）自制水溶性酚醛树脂，参照国标GB/T14074.5-93的方法测定其固含量值，加水调制其固含量值为30%，加入贮存罐内，备用；
4）计算步骤3）调制的水溶性酚醛树脂的实际树脂量并以此为基准，在贮存罐内加入0.5～1.5wt%的硅烷偶联剂，调匀使用；
5）将剪成块状的玻璃纤维布放入贮存罐内浸泡10分钟，取出后沥干玻璃纤维布表面的胶滴，蹦紧四周后用夹子固定在木框上，送入干燥机进行低温干燥，备用；
6）取出步骤2）制备挑选出的桉树单板，通过涂胶机进行双面涂胶，完成后依图1规定的组坯方式进行组坯工作；组坯时自下而上的顺序为：步骤5）制备的浸渍玻璃纤维布、竹青朝下的单层竹板、双面涂胶后的桉树单板、竹青朝下的单层竹板、双面涂胶后的桉树单板、竹青朝上的单层竹板、双面涂胶后的桉树单板、竹青朝上的单层竹板以及步骤5）制备的浸渍玻璃纤维布；
7）把棉布条捆扎在木棍上，蘸取脱模剂涂刷在热压机相邻的两块热平板上，将组坯完毕的板材坯料送入热压机进行热压加工；
8）将热压成型的竹质游艇舷板材料的毛坯板取出，送入锯板机加工成规格板材料；再送入砂光机进行双面定厚砂光，完成后利用毛刷分别在舷板材料上涂刷桐油，经反复涂刷-干燥-涂刷-干燥后，制成竹质游艇舷板材料。
所述步骤2）中的单板分级设备为美国Metriguard公司生产的2800型单板分级设备。
所述步骤3）中自制水溶性酚醛树脂的配方为：苯酚、甲醛和NaOH的质量比为1:2.78:0.29，固化物含量54%，游离甲醛含量<0.155%，树脂pH值8.75。
所述步骤4）中加入的硅烷偶联剂数量以贮存罐内实际加入的胶量为基准计算，而贮存罐内实际加入的胶量=贮存罐内胶总重×贮存罐内胶的固含量（%）；
所述步骤4）中加入的硅烷偶联剂为KH-550（a—氨基丙基三甲氧基硅烷），加入硅烷偶联剂的目的是提高玻璃纤维与分级竹板之间的胶合强度。
所述步骤5）中玻璃纤维布是由南京中材科技股份有限公司生产的EW90无碱玻璃纤维平纹布，其拉伸断裂强力（N/25mm）：经向≥4500N；纬向≥3000N；
所述步骤5）中取出沥干后玻璃纤维布表面的胶滴，蹦紧四周后用夹子固定在木框上的目的是防止浸胶玻璃纤维布在低温干燥的过程中，因收缩不均或折叠而造成浸胶玻璃纤维布表面不平整，影响下一步的组坯工作；
所述步骤5）中取出沥干后玻璃纤维布，送入干燥机进行低温干燥，干燥温度控制在85～95℃，干燥时间控制在以玻璃纤维布表面上的浸渍胶不再粘手为准。
所述步骤6）中将步骤2）挑选出的优质桉树单板，通过涂胶机进行双面涂胶，涂胶量控制在190～230g/m2。
所述步骤7）在竹质游艇舷板材料的热压前，必须在热压机的热平板上涂刷脱模剂，有利于成品竹质游艇舷板材料的脱模，防止粘板现象发生；同时还必须控制脱模剂的用量，防止脱模剂用量过多污染成品竹质游艇舷板材料的表面。
本发明的优点在于：
利用本发明方法生产出的竹质游艇舷板材料能满足高档游艇材料的性能及使用要求，外观美丽自然，解决了目前高档游艇所采用的玻璃纤维增强塑料复合材料存在的成本高，回收处理困难、产品外观单一的问题，并能够全面提升竹制品产业的科技含量和产品附加值，具有广阔的发展前景。
附图说明
图1为本发明实施例竹质游艇舷板材料组坯结构示意图；1为浸渍玻璃纤维布；2为单层竹板（竹青朝上）；3为单层竹板（竹青朝下）；4为涂胶桉树单板。
具体实施方式
为进一步公开而不是限制本发明，以下结合实例对本发明作进一步的详细说明。
实施例1
一种竹质游艇舷板材料的制造方法的具体步骤为：
1）采伐新鲜毛竹，经截段、破蔑和四面刨加工，制成留青竹片；竹片再经过炭化、干燥处理后，分别检测每根竹片的杨氏模量值，挑选Ew＞12000 MPa的竹片备用；将挑选出的高杨氏模量值竹片经过测边涂胶、组坯、热压（加侧压）等工序制成单层竹板；该竹板的尺寸规格为2600mm×1300mm×6mm（长×宽×厚）；
2）利用旋切机制备桉树单板，单板的尺寸规格为1300mm×550mm×2.2mm（长×宽×厚），制备好的单板逐张通过单板分级设备的检测，将Ew＞12000 MPa的单板留下，送入干燥机干燥，备用；
3）自制水溶性酚醛树脂，参照国标GB/T14074.5-93的方法测定其固含量值，加水调制其固含量值为30%，加入贮存罐内，备用；水溶性酚醛树脂的原料：苯酚、甲醛、NaOH的质量比为1:2.78:0.29，固化物含量54%，游离甲醛含量<0.155%，树脂pH值8.75；
4）计算步骤3）调制的水溶性酚醛树脂的实际树脂量并以此为基准，在贮存罐内加入1.0%的硅烷偶联剂，调匀使用；
5）将剪成块状的玻璃纤维布放入贮存罐内浸泡10分钟，取出后沥干玻璃纤维布表面的胶滴，蹦紧四周后用夹子固定在木框上，送入干燥机进行90℃干燥，备用；
6）取出步骤2）制备挑选出的桉树单板，通过涂胶机进行双面涂胶，涂胶量为210g/m2，完成后依图1规定的组坯方式进行组坯工作；
7）把棉布条捆扎在木棍上，蘸取脱模剂涂刷在热压机相邻的两块热平板上。将组坯完毕的板材坯料送入热压机进行热压加工；
8）将热压成型的竹质游艇舷板材料的毛坯板取出，送入锯板机加工成规格板材料；再送入砂光机进行双面定厚砂光，完成后利用毛刷分别在舷板材料上涂刷桐油，经5次涂刷-干燥-涂刷-干燥后，制成竹质游艇舷板材料。
本发明提供一种竹质游艇舷板材料的制造方法。该方法具有操作简单、易学的特点。利用本发明方法生产出的竹质游艇舷板材料能满足高档游艇材料的性能及使用要求，外观美丽自然，解决了目前高档游艇所采用的玻璃纤维增强塑料复合材料存在的成本高，回收处理困难、产品外观单一的问题，并能够全面提升竹制品产业的科技含量和产品附加值，具有广阔的发展前景。
以上所述仅为本发明的较佳实施例，凡依本发明申请专利范围所做的均等变化与修饰，皆应属本发明的涵盖范围。
Claims (7)
1.一种竹质游艇舷板材料的制造方法，其特征在于，包括如下步骤：
1）采伐新鲜毛竹，经截段、破蔑和四面刨加工，制成留青竹片；竹片再经过炭化、干燥处理后，分别检测每根竹片的杨氏模量值，挑选Ew＞12000 MPa的竹片备用；将挑选出的高杨氏模量值竹片经过测边涂胶、组坯、热压制成单层竹板；该单层竹板的尺寸规格为： 长2600mm×宽1300mm×厚6mm；
2）利用旋切机制备桉树单板，单板的尺寸规格为长1300mm×宽550mm×厚2.2mm，制备好的单板逐张通过单板分级设备的检测，将Ew＞12000 MPa的单板留下，送入干燥机干燥，备用；
3）制备水溶性酚醛树脂，参照国标GB/T14074.5-93的方法测定其固含量值，加水调制其固含量值为30%，加入贮存罐内，备用；
4）计算步骤3）调制的水溶性酚醛树脂的实际树脂量并以此为基准，在贮存罐内加入0.5～1.5wt%的硅烷偶联剂，调匀使用；
5）将剪成块状的玻璃纤维布放入贮存罐内浸泡10分钟，取出后沥干玻璃纤维布表面的胶滴，蹦紧四周后用夹子固定在木框上，送入干燥机进行低温干燥，备用；
6）取出步骤2）制备挑选出的桉树单板，通过涂胶机进行双面涂胶；然后按照自下而上的顺序：步骤5）制备的浸渍玻璃纤维布、竹青朝下的单层竹板、双面涂胶后的桉树单板、竹青朝下的单层竹板、双面涂胶后的桉树单板、竹青朝上的单层竹板、双面涂胶后的桉树单板、竹青朝上的单层竹板以及步骤5）制备的浸渍玻璃纤维布进行组坯工作；
7）把棉布条捆扎在木棍上，蘸取脱模剂涂刷在热压机相邻的两块热平板上，将步骤6）组坯完毕的板材坯料送入热压机进行热压加工；
8）将步骤7）热压成型的竹质游艇舷板材料的毛坯板取出，送入锯板机加工成规格板材料；再送入砂光机进行双面定厚砂光，完成后利用毛刷分别在舷板材料上涂刷桐油，经反复涂刷-干燥-涂刷-干燥后，制成竹质游艇舷板材料。
2.根据权利要求1所述的一种竹质游艇舷板材料的制造方法, 其特征在于：步骤2）中所述的单板分级设备为美国Metriguard公司生产的2800型单板分级设备。
3.根据权利要求1所述的一种竹质游艇舷板材料的制造方法, 其特征在于：步骤3）中所述的水溶性酚醛树脂的配方为：苯酚、甲醛和NaOH的质量比为1:2.78:0.29，固化物含量54%，游离甲醛含量<0.155%，树脂pH值8.75。
4.根据权利要求1所述的一种竹质游艇舷板材料的制造方法, 其特征在于：步骤4）中所述的硅烷偶联剂为KH-550。
5.根据权利要求1所述的一种竹质游艇舷板材料的制造方法, 其特征在于：步骤5）中所述的玻璃纤维布是由南京中材科技股份有限公司生产的EW90无碱玻璃纤维平纹布，其拉伸断裂强力为N/25mm，经向≥4500N；纬向≥3000N。
6.根据权利要求1所述的一种竹质游艇舷板材料的制造方法, 其特征在于：步骤5）中所述的低温干燥，干燥温度控制在85～95℃，干燥时间控制在以玻璃纤维布表面上的浸渍胶不再粘手为准。
7.根据权利要求1所述的一种竹质游艇舷板材料的制造方法, 其特征在于：步骤6）中双面涂胶的涂胶量控制在190～230g/m2。
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