CN108215397A - 一种薄木饰面板及其制备方法 - Google Patents
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Abstract
本发明公开了一种薄木饰面板及其制备方法,属于装饰材料技术领域。本发明将将酚醛树脂,水,硅藻,改性竹炭纤维,纳米硅丙乳液,己二胺和硅烷偶联剂搅拌混合,即得改性酚醛树脂胶粘剂;将薄木皮板和基板烘干,得干燥薄木皮板和基板;将所得干燥薄木皮板和基板浸泡于异氰酸酯中,取出,得预处理薄木皮板和基板;依次按照薄木皮板‑改性酚醛树脂胶粘剂‑基板‑改性酚醛树脂胶粘剂‑薄木皮板顺序组坯,经过热压,冷却,即得薄木饰面板。本发明技术方案制备的薄木饰面板具有较高表面胶合质量,可有效减少饰面板出现翘曲变形。
Description
技术领域
本发明公开了一种薄木饰面板及其制备方法,属于装饰材料技术领域。
背景技术
以人造板(刨花板或中纤板)基材表面贴薄木的饰面板,采用冷压或热压工艺胶压后,由于薄木含水率变化产生木皮收缩以及环境温湿度的影响、薄木贴面装饰板在制造过程中工艺技术及工艺参数的影响以及受压贴后贴面装饰板(薄木饰面板)半成品进行养护处理的影响等,贴薄木后的饰面装饰板往往会出现干缩、弯曲、变形和面板开裂等缺陷,尤其以翘曲变形最为严重。这种现象如不加以控制,会直接造成薄木贴面装饰板涂装后产生翘曲变形现象。在家具生产过程中,人造板(刨花板或中纤板)贴薄木饰面装饰板用量很大,如果不能将装饰板件的质量加以控制,势必会影响到整个薄木贴面家具的使用寿命。而采用不同工艺生产的人造板(刨花板或中纤板)基材贴薄木饰面板件,翘曲变形的状况完全不同
传统工艺生产的薄木饰面板翘曲等问题产生的具体原因:(1)由于在热压前未对人造板基材或饰面单板材料(薄木)进行二次的含水率平衡处理,使得它们的内部含水率分布严重不均,易受热压过程中环境的影响而发生变化,含水率变化产生薄木收缩而变形,而贴面板件表面薄木的细微干缩湿胀也有可能造成薄木饰面家具的漆膜开裂,严重影响薄木装饰质量,降低其使用价值。(2)薄木热压或冷压过程中,由于受环境温湿度的影响,会造成贴面板硬化层(刨花板或中纤板制板时产生的预固化层,即硬化层)的应力分布严重不平衡。依据材料力学原理,材料内部的应力分布在平衡的条件下,才能表现出稳定的尺寸,一旦材料应力平衡状态遭到破坏,材料在宏观上就会表现为翘曲变形等缺陷。而传统的工艺由于只对人造板基材表面进行很薄的打磨砂光,基材表面仍保留有致密硬化层,压贴过程中起不到消除基材应力的作用,薄木饰面板内部硬化层的应力分布严重不平衡,所以贴面后的装饰板就会产生翘曲变形等缺陷。
因此,如何改善传统薄木饰面板翘曲变形的缺点,以获取更高综合性能的薄木饰面板,是其推广与应用于更广阔的领域,满足工业生产需求亟待解决的问题。
发明内容
本发明主要解决的技术问题是:针对传统薄木饰面板翘曲变形的缺点,提供了一种薄木饰面板及其制备方法。
为了解决上述技术问题,本发明所采用的技术方案是:
一种薄木饰面板,包括改性酚醛树脂胶粘剂、薄木皮板和基板,
所述改性酚醛树脂胶粘剂是由以下重量份数的原料组成:50~60份酚醛树脂,30~40份水,8~10份硅藻,8~10份改性竹炭纤维,10~20份聚乳酸微球,20~30份纳米硅丙乳液,8~10份己二胺,8~10份硅烷偶联剂;
所述薄木饰面板的制备步骤为:
(1)将薄木皮板和基板烘干,得干燥薄木皮板和基板;
(2)将上述所得干燥薄木皮板和基板浸泡于异氰酸酯中,取出,得预处理薄木皮板和基板;
(3)依次按照薄木皮板-改性酚醛树脂胶粘剂-基板-改性酚醛树脂胶粘剂-薄木皮板顺序组坯,经过热压,冷却,即得薄木饰面板。
所述薄木皮板为红木,紫檀木或黄花梨木中的任意一种;所述薄木皮板厚度为0.1-0.6mm。
所述基板为橡木,榉木或柚木中的任意一种;所述基板厚度为1-2cm。
所述酚醛树脂为酚醛树脂2123,酚醛树脂2130或酚醛树脂2127中的任意一种。
所述硅藻为金藻或巨藻中的任意一种。
所述改性竹炭纤维改性过程为:将竹炭纤维与牛奶按质量比1:50~1:100搅拌混合,浸泡,过滤,得预处理竹炭纤维;按重量份数计,将20~30份预处理竹炭纤维和8~10份硅胶粉球磨混合,即得改性竹炭纤维。
所述聚乳酸微球制备过程为:将聚乳酸颗粒加热融化,得聚乳酸融化液;按重量份数计,依次取20~30份聚乳酸融化液,20~30份冰块,先将冰块粉碎,得碎冰粉末,将碎冰粉末加入聚乳酸融化液中搅拌,即得聚乳酸微球。
所述硅烷偶联剂型号为硅烷偶联剂KH-550,硅烷偶联剂KH-560或硅烷偶联剂KH-570中的任意一种。
所述异氰酸酯为二苯基甲烷二异氰酸酯,甲苯二异氰酸酯或异佛尔酮二异氰酸酯中的任意一种。
本发明的有益效果是:
(1)本发明通过添加聚乳酸微球,首先,在热压过程中,聚乳酸微球中包覆的水分释放,薄木皮板和基板中的异氰酸酯遇水发生反应,生成甲胺和二氧化碳,并释放大量的热量,一方面,生成的甲胺可促进酚醛树脂的固化交联,另一方面,生成大量热量为酚醛树脂固化提供能量,其次,在薄木板干燥收缩过程中,部分聚乳酸微球受力破裂,通过微球破裂,使体系内部的应力可通过微球破裂的瞬间得到释放,使体系内部的拉伸和收缩应力得以消除,使得薄木皮板与基板的干燥收缩程度趋于一致,避免因薄木皮板的收缩引起表面形成裂缝的问题,从而减少饰面板出现翘曲变形的问题;
(2)本发明通过添加改性竹炭纤维,首先,改性竹炭纤维中吸附的硅胶,一方面,硅胶可吸附空气中的一定量水分,可控制体系的含水率,从而避免体系因胀缩作用,引起表面形成裂缝的问题,从而减少饰面板出现翘曲变形的问题,另一方面,空气中的水分会与薄木板未反应的异氰酸酯在薄木皮板和基板胶合面发生反应,生成甲胺,进一步促进胶黏剂固化,提高表面胶合强度,其次,由于改性竹炭纤维中吸附硅胶,使得纤维韧性和强度都得到提升,一方面,提高表面胶合强度,另一方面,在薄木板干燥收缩过程中,改性竹炭纤维通过自生的曲伸,调节薄木皮板的胀缩,避免因薄木皮板的收缩,引起表面形成裂缝的问题,从而减少饰面板出现翘曲变形的问题。
具体实施方式
将竹炭纤维与牛奶按质量比1:50~1:100置于烧杯中,于转速为300~400r/min条件下,搅拌混合20~30min,停止搅拌,静置浸泡1~2h,得浸泡液,随后将浸泡液过滤,得预处理竹炭纤维;按重量份数计,将20~30份预处理竹炭纤维和8~10份硅胶粉置于混合球磨机中,于转速为400~500r/min条件下,球磨混合40~60min,即得改性竹炭纤维;将聚乳酸颗粒置于坩埚中,于温度为165~185℃条件下,加热至聚乳酸颗粒完全融化,得聚乳酸融化液;按重量份数计,依次取20~30份聚乳酸融化液,20~30份冰块,先将冰块置于冷冻粉碎机中粉碎40~60min,得碎冰粉末,将碎冰粉末加入聚乳酸融化液中,于转速为300~400r/min条件下,搅拌10~20min,即得聚乳酸微球;按重量份数计,依次取50~60份酚醛树脂,30~40份水,8~10份硅藻,8~10份改性竹炭纤维,10~20份聚乳酸微球,20~30份纳米硅丙乳液,8~10份己二胺,8~10份硅烷偶联剂加入混料机中,于转速为400~500r/min条件下,搅拌混合20~30min,即得改性酚醛树脂胶粘剂;将薄木皮板和基板烘干,得干燥薄木皮板和基板;将薄木皮板和基板浸泡于异氰酸酯中,浸泡1~2h,取出,得预处理薄木皮板和基板;依次按照薄木皮板-改性酚醛树脂胶粘剂-基板-改性酚醛树脂胶粘剂-薄木皮板组坯,得坯板,再将坯板置于热压机中,于温度为150~160℃,压力为3~5MPa条件下,热压5~10min后,冷却,即得薄木饰面板。所述薄木皮板为红木,紫檀木或黄花梨木中的任意一种。所述薄木皮板厚度为0.1-0.6mm。所述基板为橡木,榉木或柚木中的任意一种。所述基板厚度为1-2cm。所述酚醛树脂为酚醛树脂2123,酚醛树脂2130或酚醛树脂2127中的任意一种。所述硅藻为金藻或巨藻中的任意一种。所述硅烷偶联剂型号为硅烷偶联剂KH-550,硅烷偶联剂KH-560或硅烷偶联剂KH-570中的任意一种。所述异氰酸酯为二苯基甲烷二异氰酸酯,甲苯二异氰酸酯或异佛尔酮二异氰酸酯中的任意一种。
实例1
将竹炭纤维与牛奶按质量比1:100置于烧杯中,于转速为400r/min条件下,搅拌混合30min,停止搅拌,静置浸泡2h,得浸泡液,随后将浸泡液过滤,得预处理竹炭纤维;按重量份数计,将30份预处理竹炭纤维和10份硅胶粉置于混合球磨机中,于转速为500r/min条件下,球磨混合60min,即得改性竹炭纤维;将聚乳酸颗粒置于坩埚中,于温度为185℃条件下,加热至聚乳酸颗粒完全融化,得聚乳酸融化液;按重量份数计,依次取30份聚乳酸融化液,30份冰块,先将冰块置于冷冻粉碎机中粉碎60min,得碎冰粉末,将碎冰粉末加入聚乳酸融化液中,于转速为400r/min条件下,搅拌20min,即得聚乳酸微球;按重量份数计,依次取60份酚醛树脂,40份水,10份硅藻,10份改性竹炭纤维,20份聚乳酸微球,30份纳米硅丙乳液,10份己二胺,10份硅烷偶联剂加入混料机中,于转速为500r/min条件下,搅拌混合30min,即得改性酚醛树脂胶粘剂;将薄木皮板和基板烘干,得干燥薄木皮板和基板;将薄木皮板和基板浸泡于异氰酸酯中,浸泡2h,取出,得预处理薄木皮板和基板;依次按照薄木皮板-改性酚醛树脂胶粘剂-基板-改性酚醛树脂胶粘剂-薄木皮板组坯,得坯板,再将坯板置于热压机中,于温度为160℃,压力为5MPa条件下,热压10min后,冷却,即得薄木饰面板。所述薄木皮板为红木。所述薄木皮板厚度为0.6mm。所述基板为橡木。所述基板厚度为2cm。所述酚醛树脂为酚醛树脂2123。所述硅藻为金藻。所述硅烷偶联剂型号为硅烷偶联剂KH-550。所述异氰酸酯为二苯基甲烷二异氰酸酯。
实例2
将竹炭纤维与牛奶按质量比1:100置于烧杯中,于转速为400r/min条件下,搅拌混合30min,停止搅拌,静置浸泡2h,得浸泡液,随后将浸泡液过滤,得预处理竹炭纤维;按重量份数计,将30份预处理竹炭纤维和10份硅胶粉置于混合球磨机中,于转速为500r/min条件下,球磨混合60min,即得改性竹炭纤维;按重量份数计,依次取60份酚醛树脂,40份水,10份硅藻,10份改性竹炭纤维,30份纳米硅丙乳液,10份己二胺,10份硅烷偶联剂加入混料机中,于转速为500r/min条件下,搅拌混合30min,即得改性酚醛树脂胶粘剂;将薄木皮板和基板烘干,得干燥薄木皮板和基板;将薄木皮板和基板浸泡于异氰酸酯中,浸泡2h,取出,得预处理薄木皮板和基板;依次按照薄木皮板-改性酚醛树脂胶粘剂-基板-改性酚醛树脂胶粘剂-薄木皮板组坯,得坯板,再将坯板置于热压机中,于温度为160℃,压力为5MPa条件下,热压10min后,冷却,即得薄木饰面板。所述薄木皮板为红木。所述薄木皮板厚度为0.6mm。所述基板为橡木。所述基板厚度为2cm。所述酚醛树脂为酚醛树脂2123。所述硅藻为金藻。所述硅烷偶联剂型号为硅烷偶联剂KH-550。所述异氰酸酯为二苯基甲烷二异氰酸酯。
实例3
将聚乳酸颗粒置于坩埚中,于温度为185℃条件下,加热至聚乳酸颗粒完全融化,得聚乳酸融化液;按重量份数计,依次取30份聚乳酸融化液,30份冰块,先将冰块置于冷冻粉碎机中粉碎60min,得碎冰粉末,将碎冰粉末加入聚乳酸融化液中,于转速为400r/min条件下,搅拌20min,即得聚乳酸微球;按重量份数计,依次取60份酚醛树脂,40份水,10份硅藻,10份竹炭纤维,20份聚乳酸微球,30份纳米硅丙乳液,10份己二胺,10份硅烷偶联剂加入混料机中,于转速为500r/min条件下,搅拌混合30min,即得改性酚醛树脂胶粘剂;将薄木皮板和基板烘干,得干燥薄木皮板和基板;将薄木皮板和基板浸泡于异氰酸酯中,浸泡2h,取出,得预处理薄木皮板和基板;依次按照薄木皮板-改性酚醛树脂胶粘剂-基板-改性酚醛树脂胶粘剂-薄木皮板组坯,得坯板,再将坯板置于热压机中,于温度为160℃,压力为5MPa条件下,热压10min后,冷却,即得薄木饰面板。所述薄木皮板为红木。所述薄木皮板厚度为0.6mm。所述基板为橡木。所述基板厚度为2cm。所述酚醛树脂为酚醛树脂2123。所述硅藻为金藻。所述硅烷偶联剂型号为硅烷偶联剂KH-550。所述异氰酸酯为二苯基甲烷二异氰酸酯。
对比例:上海某实业有限公司生产的薄木饰面板。
将实例1至3所得的薄木饰面板及对比例产品进行性能检测,具体检测方法如下:
1.胶合质量:按照GB/T15104装饰单板贴面人造板的要求,对饰面板进行浸渍剥离及表面胶合强度等性能进行检测;
2.翘曲变形:按照GB/T15140检测试件翘曲度。
胶合质量具体检测结果如表1所示:
表1
检测项目 | 实例1 | 实例2 | 实例3 | 对比例 |
浸渍剥离长度/mm | 2.3 | 3.4 | 3.8 | 6.8 |
表面胶合强度/MPa | 2.13 | 1.84 | 1.65 | 0.65 |
翘曲变形具体检测结果如表2所示:
表2
检测项目 | 实例1 | 实例2 | 实例3 | 对比例 |
翘曲度/% | 0.45 | 0.73 | 0.94 | 2.46 |
由表1和表2检测结果可知,本发明技术方案制备的薄木饰面板具有较高表面胶合质量,可有效减少饰面板出现翘曲变形,在装饰材料行业的发展中具有广阔的前景。
Claims (9)
1.一种薄木饰面板,包括改性酚醛树脂胶粘剂、薄木皮板和基板,其特征在于:
所述改性酚醛树脂胶粘剂是由以下重量份数的原料组成:50~60份酚醛树脂,30~40份水,8~10份硅藻,8~10份改性竹炭纤维,10~20份聚乳酸微球,20~30份纳米硅丙乳液,8~10份己二胺,8~10份硅烷偶联剂;
所述薄木饰面板的制备步骤为:
(1)将薄木皮板和基板烘干,得干燥薄木皮板和基板;
(2)将上述所得干燥薄木皮板和基板浸泡于异氰酸酯中,取出,得预处理薄木皮板和基板;
(3)依次按照薄木皮板-改性酚醛树脂胶粘剂-基板-改性酚醛树脂胶粘剂-薄木皮板顺序组坯,经过热压,冷却,即得薄木饰面板。
2.根据权利要求1所述一种薄木饰面板,其特征在于:所述薄木皮板为红木,紫檀木或黄花梨木中的任意一种;所述薄木皮板厚度为0.1-0.6mm。
3.根据权利要求1所述一种薄木饰面板,其特征在于:所述基板为橡木,榉木或柚木中的任意一种;所述基板厚度为1-2cm。
4.根据权利要求1所述一种薄木饰面板,其特征在于:所述酚醛树脂为酚醛树脂2123,酚醛树脂2130或酚醛树脂2127中的任意一种。
5.根据权利要求1所述一种薄木饰面板,其特征在于:所述硅藻为金藻或巨藻中的任意一种。
6.根据权利要求1所述一种薄木饰面板,其特征在于:所述改性竹炭纤维改性过程为:将竹炭纤维与牛奶按质量比1:50~1:100搅拌混合,浸泡,过滤,得预处理竹炭纤维;按重量份数计,将20~30份预处理竹炭纤维和8~10份硅胶粉球磨混合,即得改性竹炭纤维。
7.根据权利要求1所述一种薄木饰面板,其特征在于:所述聚乳酸微球制备过程为:将聚乳酸颗粒加热融化,得聚乳酸融化液;按重量份数计,依次取20~30份聚乳酸融化液,20~30份冰块,先将冰块粉碎,得碎冰粉末,将碎冰粉末加入聚乳酸融化液中搅拌,即得聚乳酸微球。
8.根据权利要求1所述一种薄木饰面板,其特征在于:所述硅烷偶联剂型号为硅烷偶联剂KH-550,硅烷偶联剂KH-560或硅烷偶联剂KH-570中的任意一种。
9.根据权利要求1所述一种薄木饰面板,其特征在于:所述异氰酸酯为二苯基甲烷二异氰酸酯,甲苯二异氰酸酯或异佛尔酮二异氰酸酯中的任意一种。
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