CN107471772A - 一种热压成型装饰板及其生产方法 - Google Patents

一种热压成型装饰板及其生产方法 Download PDF

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CN107471772A
CN107471772A CN201710680275.8A CN201710680275A CN107471772A CN 107471772 A CN107471772 A CN 107471772A CN 201710680275 A CN201710680275 A CN 201710680275A CN 107471772 A CN107471772 A CN 107471772A
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fiber
hot
decorative panel
fibre
forming decorative
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曹晖
邹皞
丁剑武
方志登
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Foochow Fu Yao Mould Science And Technology Ltd
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Foochow Fu Yao Mould Science And Technology Ltd
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Abstract

本发明涉及一种热压成型装饰板及其生产方法，热压成型装饰板，其特征在于：包括中间层和叠设在中间层上、下表面的面层，所述中间层为废棉纤维与化纤纤维混合制成的无纺毡层，所述面层为麻纤维与化纤纤维混合制成的无纺毡层。该热压成型装饰板具有轻质、环保和优良的装饰性能，该生产方法工艺简单、制作成本低。

Description

一种热压成型装饰板及其生产方法
技术领域：
本发明涉及一种用于装饰板材料领域，具体地说，是涉及一种热塑性层毡复合材料及其制备方法，具有零甲醛、高强高模等优点。
背景技术：
随着社会生活质量水平的不断提高，人们对生活品质具有了更高的追求，也提高了对家居装潢要求。室内墙体和天花板的装饰也越来越受重视，内部装饰板成了优质选择，常规的内部装饰板包括利用包覆结合的水泥纤维板、熔融挤出板以及利用胶水粘合的石膏板、胶合板等。
然而，水泥纤维板质量重，界面相容性差；挤出板密度大且材质脆、易开裂；石膏板强度低，隔音效果差；胶合板易吸水翘曲变形、胶水会挥发甲醛等有害物质、发生霉变等，这些特点都可能影响用户的使用体验。
发明内容：
本发明的目的在于提供一种热压成型装饰板及其生产方法，该热压成型装饰板具有轻质、环保和优良的装饰性能，该生产方法工艺简单、制作成本低。
为实现本发明的目的，所采用的技术方案是：
一种热压成型装饰板，其特征在于：包括中间层和叠设在中间层上、下表面的面层，所述中间层为废棉纤维与化纤纤维混合制成的无纺毡层，所述面层为麻纤维与化纤纤维混合制成的无纺毡层。
进一步的，上述中间层为一层或两层以上的废棉纤维与化纤纤维混合制成的无纺毡层。
进一步的，上述废棉纤维与化纤纤维混合制成的无纺毡层的废棉纤维可以是制衣边角料、废旧衣服布料的一种或混合物；化学纤维可以是乙纶纤维、丙纶纤维、添加4080的涤纶纤维中的一种或混合物，毡材面密度为5000g/m2~7500 g/m2，是单层或者多层叠加；化学纤维的质量百分比为10%~40%；所述麻纤维可以是苎麻、亚麻、黄麻、剑麻纤维中的一种或混合物；化学纤维可以是乙纶纤维、丙纶纤维中的一种或混合物，麻纤维长度约为40mm~80mm，化学纤维的质量百分比为40%~70%。
本发明热压成型装饰板生产方法，包括如下步骤：
（1）将布料开松成纤维状，与热熔性化学纤维混合，在无纺布设备中梳理铺网或气流成网成型，经针刺成毡。布料纤维长度20mm~50mm，优选25mm~35mm。化学纤维长度30mm~80mm，优选40mm~60mm；种类优选丙纶纤维、添加4080的涤纶纤维。毡材面密度为5000g/m2~7500g/m2，优选5000g/m2~6000g/m2；化学纤维的质量百分比为10%~40%，优选15%。
（2）将麻纤维开松成纤维状，与热熔性化学纤维混合，在无纺布设备中铺网成型，经针刺成毡。麻纤维长度约为40mm~80mm，优选60~70mm；种类优选黄麻。化学纤维长度30mm~80mm，优选40mm~60mm；种类优选丙纶纤维。化学纤维的质量百分比为40%~70%，优选50%~55%。毡材面密度为300g/m2~1000g/m2。
（3）将步骤（2）制得的毡材层叠在步骤（1）制得的毡材的上、下两面，送入热压机中加热预成型，再转移到冷压机中保压冷却成型。热压温度为190℃~220℃；热压时间为60s~300s；保压时间为100s~1000s。乙纶纤维优选热压温度为190℃~200℃；其它纤维优选热压温度为200℃~210℃；优选热压时间为150s~200s，保压时间为500s~600s。
（4）步骤（3）所述热压方法可以是将步骤（1）制得的毡材先加热预成型后再在上、下两面叠加步骤（2）制得的毡材送入热压机进一步热压，再转移到冷压机中保压冷却成型。步骤（3）所用纤维为乙纶时，优选热压温度为180℃~190℃，其它纤维优选热压温度为190℃~200℃；层叠后优选热压温度为200℃~210℃；优选热压时间为120s~150s，保压时间为500s~600s。
（5）如需改善板材表面形态，成型时可以在表面添加乙纶无纺布或膜。
步骤（2）所述麻纤维经预处理，添加接枝试剂、防霉剂和抗老化剂等，以提高产品的附加值；步骤（2）所述化学纤维在制备中经预处理，在原料中添加接枝试剂再制成纤维，以提高最终产品的物理力学性能。
本发明采用热模+冷模压制成型方法，适合制造多种纤维、不同纤维含量组成的板件，通过控制模具温度、压力、时间，以及压板间距，可生产密度在0.4 g/m3~1.0 g/m3之间的增强纤维板，具有很强的灵活性和较高的经济效益。
本发明产品及上述方法的第一个创新点在于：在原料方面选用自然界丰富的天然高分子──麻纤维为面层毡材的增强纤维材料，改善产品机械性能。植物纤维纤维密度小使材料达到轻量化的效果，并减小对石油产品的消耗。芯层利用废棉纤维来源广的特点，降低产品成本，麻纤维机械性能好、密度小，热塑性化学纤维加工性能好，可应用于建筑装饰领域。
第二个创新点是利用梳理铺网/气流成网+针刺工艺使多种纤维之间的产生缠结，克服长纤维均匀混合困难的问题，提高发挥长纤维对产品机械性能的提高作用。
第三个创新点是利用表层麻毡和芯层的乙纶/丙纶、表面部分熔融的低熔点涤纶等的粘接，形成较强的各层内部粘结、表/芯材料粘结。
附图说明：
图1、图2 为本发明产品的结构示意图。
具体实施方式：
下面结合实施例对本发明方法作进一步的详细说明。需要特别说明的是，本发明的保护范围应当包括但不限于本实施例所公开的技术内容。
实施例１
（1）将布料开松，得到布料纤维（20mm~30mm）；低熔点涤纶纤维（30mm ~50mm）开松后与布料纤维按质量比例25%：75%混合，经气流成网、两道针刺成5000g/m2的毡材1。
（2）将黄麻纤维（40mm~60mm）开松，与开松后的丙纶纤维（50mm~ 60mm）按照按质量比例45%：55%混合，经梳理铺网、两道针刺成500g/m2的毡材2。
（3）将毡材1的上、下两面分别叠层毡材2，放入205℃平板压机中加热压制150s，转移至冷压机中保压200s，开模取料得到厚度为13mm板材。
实施例2
（1）将布料开松，得到布料纤维（20mm~30mm）；低熔点涤纶纤维（30mm ~50mm）开松后与布料纤维按质量比例20%：80%混合，经气流成网、两道针刺成3000g/m2的毡材1。
（2）将黄麻纤维（40mm~60mm）开松，与开松后的丙纶纤维（50mm~ 60mm）按照按质量比例50%：50%混合，经梳理铺网、两道针刺成400g/m2的毡材2。
（3）将两层毡材1层叠后，在其上、下两面分别叠层毡材2，放入205℃平板压机中加热压制180s，转移至冷压机中保压200s，开模取料得到厚度为15mm板材。
实施例3
（1）将布料开松，得到布料纤维（30mm~50mm）；丙纶纤维（40mm ~60mm）开松后与布料纤维按质量比例10%：90%混合，经气流成网、两道针刺成2000g/m2的毡材1。
（2）将黄麻纤维（40mm~60mm）开松，与开松后的丙纶纤维（40mm ~60mm）按照按质量比例50%：50%混合，经梳理铺网、两道针刺成400g/m2的毡材2。
（3）将三层毡材1层叠后，在其上、下两面分别叠层毡材2，放入200℃平板压机中加热压制160s，转移至冷压机中保压200s，开模取料得到厚度为15mm板材。
实施例4
（1）将布料开松，得到布料纤维（30mm~50mm）；低熔点涤纶纤维（30mm ~50mm）开松后与布料纤维按质量比例25%：75%混合，经气流成网、两道针刺成5500g/m2的毡材1。
（2）将黄麻纤维（40mm~60mm）适当开松并喷洒硅烷偶联剂，干燥后与开松后的丙纶纤维（40mm ~60mm）按照按质量比例50%：50%混合，经梳理铺网、两道针刺成400g/m2的毡材2。
（3）将三层毡材1层叠后，在其上、下两面分别叠层毡材2，放入205℃平板压机中加热压制180s，转移至冷压机中保压200s，开模取料得到厚度为14mm板材。
实施例5
（1）将布料开松，得到布料纤维（30mm~50mm）；低熔点涤纶纤维（30mm ~50mm）开松后与布料纤维按质量比例25%：75%混合，经气流成网、两道针刺成5500g/m2的毡材1。
（2）将聚丙烯与马来酸酐接枝聚丙烯按质量比例95%：5%熔融共混，并添加质量比例0.5%的抗氧剂，进而纺成改性丙纶纤维（40mm ~60mm）。
将黄麻纤维（40mm~60mm）适当开松后与丙纶纤维按照按质量比例50%：50%混合，经梳理铺网、两道针刺成400g/m2的毡材2。
（3）将三层毡材1层叠后，在其上、下两面分别叠层毡材2，放入200℃平板压机中加热压制180s，转移至冷压机中保压200s，开模取料得到厚度为14mm板材。
本发明所制备的环保型增强纤维材料，其重要特点是材料具有轻质、环保和优良装饰性能，因此对该材料的环保性和物理力学性能进行了测定。
本发明充分利用天然植物纤维和化学纤维开发零甲醛、轻量化、高强高模的复合材料。
本发明的显著优点：
机械强度高、寸稳定性好、不吸水翘曲变形、握钉不开裂、无酚醛等胶水、节约优质原料、降低成本。
1、利用植物纤维的高模高强特性，改善产品机械性能；
2、利用植物纤维密度小的特点，达到轻量化的效果，并减小对石油产品的消耗；
3、利用针刺使纤维之间的产生缠结，提高产品机械性能；
4、利用芯层废棉纤维来源广的特点，降低产品成本；
5、利用表层麻毡提高装潢品质；
6、利用表层麻毡中熔融的聚丙烯和芯层表面部分熔融的低熔点PET等的粘接，形成较强的表、芯材料粘接。
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 (10)

1.一种热压成型装饰板，其特征在于：包括中间层和叠设在中间层上、下表面的面层，所述中间层为废棉纤维与化纤纤维混合制成的无纺毡层，所述面层为麻纤维与化纤纤维混合制成的无纺毡层。
2.根据权利要求1所述的热压成型装饰板，其特征在于：所述中间层为一层或两层以上的废棉纤维与化纤纤维混合制成的无纺毡层。
3.根据权利要求1所述的热压成型装饰板，其特征在于：所述废棉纤维与化纤纤维混合制成的无纺毡层的废棉纤维是制衣边角料、废旧衣服布料的一种或混合物；化学纤维是乙纶纤维、丙纶纤维、添加4080的涤纶纤维中的一种或混合物，毡材面密度为5000g/m2~7500g/m2，是单层或者多层叠加；化学纤维的质量百分比为10%~40%；所述麻纤维是苎麻、亚麻、黄麻、剑麻纤维中的一种或混合物；化学纤维是乙纶纤维、丙纶纤维中的一种或混合物，麻纤维长度约为40mm~80mm，化学纤维的质量百分比为40%~70%。
4.一种热压成型装饰板的生产方法，其特征在于：包括如下步骤：
（1）将布料开松成纤维状，与化学纤维混合，在无纺布设备中上网成型，针刺成毡；
（2）将麻纤维开松成纤维状，与化学纤维混合，在无纺布设备中上网成型，针刺成毡；
（3）将步骤（2）制得的毡材层叠在步骤（1）制得的毡材的上、下两面，送入热压机中加热预成型，再转到冷压机中保压冷却成型。
5.根据权利要求4所述的热压成型装饰板的生产方法，其特征在于：步骤（1）所述布料是制衣边角料、废旧衣服布料的一种或混合物；化学纤维是乙纶纤维、丙纶纤维、添加4080的涤纶纤维中的一种或混合物，毡材面密度为5000g/m2~7500 g/m2，是单层或者多层叠加；化学纤维的质量百分比为10%~40%。
6.根据权利要求4所述的热压成型装饰板的生产方法，其特征在于：步骤（2）所述麻纤维是苎麻、亚麻、黄麻、剑麻纤维中的一种或混合物；化学纤维是乙纶纤维、丙纶纤维中的一种或混合物，麻纤维长度约为40mm~80mm，化学纤维的质量百分比为40%~70%。
7.根据权利要求4所述的热压成型装饰板的生产方法，其特征在于：步骤（2）所述麻纤维经预处理，添加接枝试剂、防霉剂和抗老化剂，以提高产品的附加值。
8.根据权利要求4所述的热压成型装饰板的生产方法，其特征在于：步骤（2）所述化学纤维在制备中经预处理，在原料中添加接枝试剂再制成纤维，以提高最终产品的物理力学性能。
9.根据权利要求4所述的热压成型装饰板的生产方法，其特征在于：步骤（3）所述热压温度为190℃~220℃；热压时间为60s~300s；保压时间为100s~1000s。
10.根据权利要求4所述的热压成型装饰板的生产方法，其特征在于：步骤（3）所述热压方法是三层毡材直接热压或者将步骤（1）制得的毡材先加热预成型后再叠加步骤（2）制得的毡材送入热压机进一步热压。
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Application publication date: 20171215