CN108297369B - 一种无甲醛高强度家居板材及其制备方法 - Google Patents
一种无甲醛高强度家居板材及其制备方法 Download PDFInfo
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- B32B27/00—Layered products comprising a layer of synthetic resin
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- C08J2327/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing chlorine atoms
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Abstract
本发明涉及家具及定制家居技术领域,具体涉及一种无甲醛高强度家居板材及其制备方法,其板材包括发泡聚氯乙烯板材;使用热压胶结材料,采用热压胶结技术,将0.2‑0.5mm厚度的铝合金板材复合发泡聚氯乙烯板材表面和底面,形成复合无甲醛家居板材;它利用煤、石油化工领域生产的重要树脂原料聚氯乙烯粉,以及有色金属工业重要的原材料铝合金,来设计制造家具板材;其相对于传统人造板,能提高板体强度和环保性能;其制成的铝合金/聚氯乙烯/铝合金复合家具用板材,具有无重金属、无甲醛、强度高、密度小,厚度可调节等优点,能够完全满足不同要求的家具制造和定制家居产品。
Description
【技术领域】
本发明涉及家具及定制家居技术领域,具体涉及一种用于铝合金/聚氯乙烯/铝合金复合的无甲醛高强度家居板材及其制备方法。
【背景技术】
现在市场上家具及定制家具领域常用的人造板板材,一般包括胶合板、刨花板、中密度纤维板等。
上述人造板板材由于工艺过程中需要加入脲醛胶,作为胶粘剂粘结木质材料,而脲醛胶的主要原材料包括尿素和甲醛。用上述人造板板材制成的家具,其在使用过程中板材不可避免的会释放出甲醛。甲醛是一种具有刺激性味道的致癌物质,长期使用木质人造板板材制成的家具,人们的健康会受到甲醛威胁。
针对实木材料制作的家具,也存在家具易变形,并且在环保呼声越来越大的今天,纯实木制作家具也有浪费森林资源的问题。
另外,对于大量使用的建筑装饰装修用铝塑复合板,其上下层为高强度铝合金板,中间为低密度聚乙烯板材(LDPE),其厚度一般只在5mm以内,广泛用于大楼外墙、帷幕墙板、旧楼改造翻新、室内墙壁及天花板装修、广告招牌、展示台架、净化防尘工程。但由于装修用的铝塑复合板厚度只有5mm,其抗扰强度不大,且中间夹芯层为密实的聚乙烯(PE),板材整体的密度较大,不适合制作家具。
【发明内容】
本发明的目的在于针对现有技术的缺陷和不足,提供一种无甲醛高强度家居板材及其制备方法,它利用煤、石油化工领域生产的重要树脂原料聚氯乙烯粉,以及有色金属工业重要的原材料铝合金,来设计制造家具板材;其相对于传统人造板,能提高板体强度和环保性能;其制成的铝合金/聚氯乙烯/铝合金复合家具用板材,具有无重金属、无甲醛、强度高、密度小,厚度可调节等优点,能够完全满足不同要求的家具制造和定制家居产品。
本发明所述的一种无甲醛高强度家居板材及其制备方法,其板材包括发泡聚氯乙烯板材;使用热压胶结材料,采用热压胶结技术,将0.2-0.5mm厚度的铝合金板材复合发泡聚氯乙烯板材表面和底面,形成复合无甲醛家居板材;
其制备方法采用如下的方法步骤:
步骤一:混合工艺,其采用如下步骤:
1)取制备发泡聚氯乙烯板材的原料;
发泡聚氯乙烯板材的各原料配比,其组成成份按重量份数:PVC,40-120份;有机锡稳定剂,1.5-3.2份;发泡调节剂,8-13.5份;发泡剂AC,0.5-0.9份;白色吸热发泡剂,0.5-2.4份;霍尼韦尔316A或OA6,0.65份;PE蜡,0.58份;无机填料,50-70份;回料或水口料,30-70份;颜料,20-40份;
2)采用热冷混合机组进行混料,投料顺序如下:PVC、有机锡稳定剂、PE蜡、加工助剂、无机填料、颜料,形成混合原始料;
其中加工助剂为:发泡调节剂、发泡剂AC、白色吸热发泡剂、霍尼韦尔316A或OA6及回料或水口料;
3)步骤2)中的混合原始料的投料量为热冷混合机组中的热混筒有效容积的60%;
4)在热冷混合机组中,高速热混温度控制在110~120℃范围内进行5~10 min,冷却混合水温在15~20℃以下,冷混的物料 5~10 min后在35~40℃时从混合机组放出;
步骤二:挤出工艺,其采用如下步骤:
1)将步骤一中混合机组中放出的冷混的物料,至挤出机中;
2)控制挤出机各区间的温度,挤出机一区155±5℃、二区165±5℃、三区170±5℃,四区180±5℃;过渡体170±5℃;口模175±5;模唇175±5℃;冷却定型装置一区恒温控制,二三四区冷却控制,模具各区冷却温度控制在 5~40℃;
3)控制挤出机螺杆转速,根据厚度不同设置不同的挤出速度,10mm-18mm厚度的板材挤出速度为0.65-0.8m/min;
步骤三:牵引机冷却工艺,其采用如下步骤:
1)步骤二中经过挤出机加工后形成的熔体再至牵引机中;
2)牵引机的衣架式挤出机头结构中,机头内部流道由歧管区、扇形区、阻流区和模唇区组成;机头内部流道从上往下依次为歧管区、扇形区、阻流区和模唇区;
3)熔体流入歧管后,被歧管均匀分配到整个扇形区内,保证料流在进入模唇区时的同向性,同时为控制口模中熔体的压力,设置阻流区降低熔体压力,保证料流速度的一致,形成发泡聚氯乙烯板材板材;
4)流道各部分长短设计应满足特定压缩比要求,保证物料不会发泡过度;
步骤四:切割工艺:步骤三中的发泡聚氯乙烯板材板材冷却后,采用自动机械切割成2800mm*1220mm的尺寸的板材;
步骤五:复合工艺,其采用如下步骤:
1)在热压平板机上依次放置铝合金板材、PP/PE高分子薄膜、切割成2800mm*1220mm的尺寸的发泡聚氯乙烯板材、PP/PE高分子薄膜、铝合金板材;
2)热压平板机上下压板温度控制在160-180℃,热压15s-30s,完成铝合金/聚氯乙烯/铝合金家居板材的复合,形成复合无甲醛家居板材。
进一步地,步骤一中的无机填料为:工业碳酸钙、高岭土、滑石粉或长石粉。
进一步地,所述PVC为聚氯乙烯粉,聚氯乙烯粉的适用的型号包括SG-5~SG-8,其分子量分布范围为40000-70000。
进一步地,所述发泡聚氯乙烯板材,其组成成份按重量份数的配比为:PVC,100份;有机锡稳定剂,2.2份;发泡调节剂,11.5份;发泡剂AC,0.7份;白色吸热发泡剂,1.4份;霍尼韦尔316A或OA6,0.65份;PE蜡,0.58份;轻质碳酸钙填料,50-70份;回料或水口料,40份;颜料,30份。
进一步地,所述热压胶结材料为PE/PP复合高分子薄膜。
本发明有益效果为:本发明所述的一种无甲醛高强度家居板材及其制备方法,它利用煤、石油化工领域生产的重要树脂原料聚氯乙烯粉,以及有色金属工业重要的原材料铝合金,来设计制造家具板材;其相对于传统人造板,能提高板体强度和环保性能;其制成的铝合金/聚氯乙烯/铝合金复合家具用板材,具有无重金属、无甲醛、强度高、密度小,厚度可调节等优点,能够完全满足不同要求的家具制造和定制家居产品。
【具体实施方式】
下面将以具体实施例来详细说明本发明,其中的示意性实施例以及说明仅用来解释本发明,但并不作为对本发明的限定。
本具体实施方式所述的一种无甲醛高强度家居板材及其制备方法,其板材包括发泡聚氯乙烯板材;使用热压胶结材料,采用热压胶结技术,将0.2-0.5mm厚度的铝合金板材复合发泡聚氯乙烯板材表面和底面,形成复合无甲醛家居板材;
其制备方法采用如下的方法步骤:
步骤一:混合工艺,其采用如下步骤:
1)取制备发泡聚氯乙烯板材的原料;
发泡聚氯乙烯板材的各原料配比,其组成成份按重量份数:PVC,40-120份;有机锡稳定剂,1.5-3.2份;发泡调节剂,8-13.5份;发泡剂AC,0.5-0.9份;白色吸热发泡剂,0.5-2.4份;霍尼韦尔316A或OA6,0.65份;PE蜡,0.58份;无机填料,50-70份;回料或水口料,30-70份;颜料,20-40份;
2)采用热冷混合机组进行混料,投料顺序如下:PVC、有机锡稳定剂、PE蜡、加工助剂、无机填料、颜料,形成混合原始料;
其中加工助剂为:发泡调节剂、发泡剂AC、白色吸热发泡剂、霍尼韦尔316A或OA6及回料或水口料;
3)步骤2)中的混合原始料的投料量为热冷混合机组中的热混筒有效容积的60%;
4)在热冷混合机组中,高速热混温度控制在110~120℃范围内进行5~10 min,冷却混合水温在15~20℃以下,冷混的物料 5~10 min后在35~40℃时从混合机组放出;
步骤二:挤出工艺,其采用如下步骤:
1)将步骤一中混合机组中放出的冷混的物料,至挤出机中;
2)控制挤出机各区间的温度,挤出机一区155±5℃、二区165±5℃、三区170±5℃,四区180±5℃;过渡体170±5℃;口模175±5;模唇175±5℃;冷却定型装置一区恒温控制,二三四区冷却控制,模具各区冷却温度控制在 5~40℃;
3)控制挤出机螺杆转速,根据厚度不同设置不同的挤出速度,10mm-18mm厚度的板材挤出速度为0.65-0.8m/min;
步骤三:牵引机冷却工艺,其采用如下步骤:
1)步骤二中经过挤出机加工后形成的熔体再至牵引机中;
2)牵引机的衣架式挤出机头结构中,机头内部流道由歧管区、扇形区、阻流区和模唇区组成;机头内部流道从上往下依次为歧管区、扇形区、阻流区和模唇区;
3)熔体流入歧管后,被歧管均匀分配到整个扇形区内,保证料流在进入模唇区时的同向性,同时为控制口模中熔体的压力,设置阻流区降低熔体压力,保证料流速度的一致,形成发泡聚氯乙烯板材板材;
4)流道各部分长短设计应满足特定压缩比要求,保证物料不会发泡过度;
步骤四:切割工艺:步骤三中的发泡聚氯乙烯板材板材冷却后,采用自动机械切割成2800mm*1220mm的尺寸的板材;
步骤五:复合工艺,其采用如下步骤:
1)在热压平板机上依次放置铝合金板材、PP/PE高分子薄膜、切割成2800mm*1220mm的尺寸的发泡聚氯乙烯板材、PP/PE高分子薄膜、铝合金板材;
2)热压平板机上下压板温度控制在160-180℃,热压15s-30s,完成铝合金/聚氯乙烯/铝合金家居板材的复合,形成复合无甲醛家居板材。
作为本发明的一种优选,步骤一中的无机填料为:工业碳酸钙、高岭土、滑石粉或长石粉。
作为本发明的一种优选,所述PVC为聚氯乙烯粉,聚氯乙烯粉的适用的型号包括SG-5~SG-8,其分子量分布范围为40000-70000。
作为本发明的一种优选,所述发泡聚氯乙烯板材,其组成成份按重量份数的配比为:PVC,100份;有机锡稳定剂,2.2份;发泡调节剂,11.5份;发泡剂AC,0.7份;白色吸热发泡剂,1.4份;霍尼韦尔316A或OA6,0.65份;PE蜡,0.58份;轻质碳酸钙填料,50-70份;回料或水口料,40份;颜料30份。
作为本发明的一种优选,所述热压胶结材料为PE/PP复合高分子薄膜。
本发明中,首先是发泡聚氯乙烯板材的制备,用聚氯乙烯粉(PVC)为主要材料,添加各种无机填料(包括:工业碳酸钙、高岭土、滑石粉或长石粉等)、各种塑料助剂及稳定剂,然后再加入发泡剂、发泡调节剂,在一定条件下通过挤出和发泡成发泡聚氯乙烯板材;然后将发泡制成的发泡聚氯乙烯板材,在其正反面上通过热压胶结(采用高分子薄膜)技术,将0.2-0.5mm厚度以内的铝合金板材,复合在生产的发泡聚氯乙烯板材两面,制成铝合金/聚氯乙烯/铝合金复合无甲醛高强度家居板材。
本发明,铝合金板材,指0.2-0.5mm厚度范围的高强度纯铝合金板材。
本发明中,发泡聚氯乙烯板材中的颜料,根据所需要的颜色,采用不同颜色的颜料,从而可以制备出不同色彩的发泡聚氯乙烯板材。
本发明中,无机填料为:工业碳酸钙、高岭土、滑石粉或长石粉。
本发明中,PVC为聚氯乙烯粉,聚氯乙烯粉的适用的型号包括SG-5~SG-8,其分子量分布范围为40000-70000。
本发明中,稳定剂,考虑到环保无铅,选用有机锡稳定剂。
本发明中,发泡剂及发泡调节剂,选用白色发泡剂,配合塑化慢熔体大的发泡调节剂,其他助剂视工艺需求添加。
本发明所述的一种无甲醛高强度家居板材及其制备方法,它利用煤、石油化工领域生产的重要树脂原料聚氯乙烯粉,以及有色金属工业重要的原材料铝合金,来设计制造家具板材;其相对于传统人造板,能提高板体强度和环保性能;其制成的铝合金/聚氯乙烯/铝合金复合家具用板材,具有无重金属、无甲醛、强度高、密度小,厚度可调节等优点,能够完全满足不同要求的家具制造和定制家居产品。
以上所述仅是本发明的较佳实施方式,故凡依本发明专利申请范围所述的特征及原理所做的等效变化或修饰,均包括于本发明专利申请范围内。
Claims (3)
1.一种无甲醛高强度家居板材的制备方法,依次采用如下步骤:
步骤一:混合工艺,依次采用如下步骤:
1)取制备发泡聚氯乙烯板材的原料;
发泡聚氯乙烯板材的各原料配比份按重量份数:PVC,100份;有机锡稳定剂,2.2份;发泡调节剂,11.5份;发泡剂AC,0.7份;白色吸热发泡剂,1.4份;霍尼韦尔316A或OA6,0.65份;PE蜡,0.58份;轻质碳酸钙填料,50-70份;回料或水口料,40份;颜料,30份;
其中,所述PVC为聚氯乙烯粉,聚氯乙烯粉的适用的型号为SG-8,其分子量分布范围为40000-70000;
2)采用热冷混合机组进行混料,投料顺序如下:PVC、有机锡稳定剂、PE蜡、加工助剂、无机填料、颜料,形成混合原始料;
其中加工助剂为:发泡调节剂、发泡剂AC、白色吸热发泡剂、霍尼韦尔316A或OA6及回料或水口料;
3)步骤2)中的混合原始料的投料量为热冷混合机组中的热混筒有效容积的60%;
4)在热冷混合机组中,高速热混温度控制在110~120℃范围内进行5~10min,冷却混合水温在15~20℃,冷混的物料5~10min后在35~40℃时从所述热冷混合机组放出;
步骤二:挤出工艺,依次采用如下步骤:
1)将步骤一中从所述热冷混合机组冷混的物料放出至挤出机中;
2)控制挤出机各区间的温度,挤出机一区155±5℃、二区165±5℃、三区170±5℃,四区180±5℃;过渡体170±5℃;口模175±5℃;模唇175±5℃;冷却定型装置一区恒温控制,二、三、四区冷却控制,模具各区冷却温度控制在5~40℃;
3)控制挤出机螺杆转速,根据厚度不同设置不同的挤出速度,10mm-18mm厚度的板材挤出速度为0.65-0.8m/min;
步骤三:牵引机冷却工艺,依次采用如下步骤:
1)步骤二中经过挤出机加工后形成的熔体再至牵引机中;
2)在牵引机的衣架式挤出机头结构中,机头内部流道由歧管区、扇形区、阻流区和模唇区组成;机头内部流道从上往下依次为歧管区、扇形区、阻流区和模唇区;
3)熔体流入歧管后,被歧管均匀分配到整个扇形区内,保证料流在进入模唇区时的同向性,同时为控制口模中熔体的压力,设置阻流区降低熔体压力,保证料流速度的一致,形成发泡聚氯乙烯板材;
4)流道各部分长短设计应满足特定压缩比要求,保证物料不会发泡过度;
步骤四:切割工艺:步骤三中的发泡聚氯乙烯板材冷却后,采用自动机械切割成2800mm*1220mm的尺寸的板材;
步骤五:复合工艺,依次采用如下步骤:
1)在热压平板机上依次放置铝合金板材、PP/PE高分子薄膜、切割成2800mm*1220mm的尺寸的发泡聚氯乙烯板材、PP/PE高分子薄膜、铝合金板材;
2)热压平板机上下压板温度控制在160-180℃,热压15s-30s,完成铝合金/聚氯乙烯/铝合金家居板材的复合,形成复合无甲醛家居板材。
2.根据权利要求1所述无甲醛高强度家居板材的制备方法,其特征在于:步骤一中的无机填料为:工业碳酸钙、高岭土、滑石粉或长石粉。
3.根据权利要求1所述无甲醛高强度家居板材的制备方法,其特征在于:所述热压胶结材料为PE/PP复合高分子薄膜。
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