CN108312261A - 一种再生重组厚芯竹胶合板及其制造方法 - Google Patents
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Abstract
本发明公开一种再生重组厚芯竹胶合板及其制造方法,再生重组厚芯竹胶合板,包括夹芯废板层以及依次对称铺设在夹芯废板层两侧的竹帘层和竹席层,夹芯废板层的主板体的四边上加工有倒角。其制造方法包括选料、预处理、斜角加工、铺装及重组加工。本发明中的再生重组厚芯竹胶合板及其制造方法,以废旧、废弃竹胶模板、竹胶合板或竹集成材为原料,经过筛选、锯切、斜角加工等工序获得的旧板坯料,在斜角处采用刨花填充热压成型获得板芯层,上下覆以竹帘、竹席并再次热压而成,通过刨花的填充、延展及粘结作用,使得芯层与边缘及芯层与表层无缝结合,使竹胶合板、竹胶膜板或竹集成材得以再生,且能达到相关产品标准要求。
Description
技术领域
本发明涉及竹胶合板、竹集成材制造技术领域,特别是涉及一种再生重组厚芯竹胶合板及其制造方法。
背景技术
竹胶合板、竹集成材材质坚韧、防潮耐腐、耐热耐寒、纹理美观,具有素雅、朴实的民族风格,其硬度及强度远高于木材,用途十分广泛,如用于车厢底板、建筑模板、室内棚顶材料、室内家具装饰装修等,尤其适用于室外高强、高耐场所,广受消费者喜欢。传统竹胶合板采用竹帘、竹席或竹帘纵横交错铺装,竹帘、竹席经施胶后难以分离,因此板材废旧后难于再利用。而新鲜竹材的砍伐成本越来越高,导致加工成本不断提升。废旧板材经过使用出现表面磨损、开胶甚至断裂、分层等导致使用性能下降,但其力学强度损失较小,许多旧竹胶合板或竹集成材仍保持较高强度。由于没有再利用途径,企业基本作为燃料燃烧,导致优质资源浪费。
发明内容
本发明的目的是提供一种再生重组厚芯竹胶合板及其制造方法,以解决上述现有技术存在的问题,使竹胶合板或竹胶膜板得以再生,再生重组厚芯竹胶合板的物理力学性能达到产品标准要求,加工成本显著减少,且变废为宝,综合利用了资源。
为实现上述目的,本发明提供了如下方案:本发明提供一种再生重组厚芯竹胶合板,包括竹席层、竹帘层和夹芯废板层,所述夹芯废板层的主板体的四边先进行斜角加工,两侧依次对称铺设所述竹帘层和竹席层,所述斜角处铺装有废旧竹刨花。
可选的,所述夹芯废板层以废旧、废弃竹胶模板或竹胶合板为原材料。
可选的,所述竹席层采用酚醛树脂浸渍竹席层,所述竹帘层采用酚醛树脂浸渍竹帘层。
可选的,所述倒角的斜角宽度为8-15cm。
可选的,在所述夹芯废板层倒角的斜角及四边延伸80-100mm铺装有刨花。
可选的,所述刨花铺设在纸质模具与挡板之间。
本发明还提供一种再生重组厚芯竹胶合板的制造方法,应用于上述的再生重组厚芯竹胶合板,包括以下步骤:(1)选料:夹芯废板层以废旧、废弃竹胶模板、竹胶合板或竹集成材为原料并进行初步筛选和分类;(2)废旧板预处理:对选好的原料进行表面砂光,去除表面污渍、灰尘及金属异物等,将所述原料四边破损部分锯除,并对预处理后的废旧板进行斜角加工;(3)干燥:将竹帘、竹席干燥至含水率8-12%;(4)施胶:分别对刨花、竹帘层、竹席层进行施胶,刨花采用搅拌法施胶、竹帘层和竹席层采用浸渍施胶,均采用酚醛树脂,施胶后陈放干燥备用;(5)板芯成型:在斜角处安放纸质模具,铺装刨花,并进行板芯热压成型;(6)板芯施胶:采用喷胶方式对板芯进行双面施胶;(7)热压重组成型:从下到上逐步铺装竹席层、竹帘层、夹芯废板层、竹帘层、竹席层,并进行热压重组;(8)后处理:对冷却后的热压板坯进行锯边、倒角、砂光,若产品整体使用可选择加固及封闭处理。
可选的,步骤(1)的选料过程中的初步筛选是对表面出现严重破损、分层或腐朽程度超过20%的废旧竹板材要剔除,然后按照原料的规格尺寸进行分组;步骤(4)-(7)中的重组加工,其加工过程为先将原料的边缘进行锯解、去除,露出内部新鲜的材面,然后在边缘铺装刨花再次热压。
可选的,将所述刨花铺装在纸质模具与挡板之间,热压后纸质模具直接与原料的板材融为一体;所述纸质模具为一次性模具。
可选的,斜角处刨花铺装量根据表面积和厚度,按设计密度0.95-1.15g/cm3进行铺装,所述刨花采用酚醛树脂,刨花施胶量为20-30%;步骤(4)中竹席层、竹帘层和夹芯废板层施胶,其中竹席施胶量23-30%、竹帘施胶量12-15%,刨花施胶量为20-30%;步骤(6)夹芯废板层双面施胶,施胶量为2.2kg/m2;步骤(7)中热压成型参数为:热压温度150-180℃、压力2.5-3.0MPa、热压时间20-30min,进行热压;步骤(8)对冷却后的热压板坯进行四面锯边,根据产品需要可进行倒角、表面砂光,四边固定及封闭处理。
本发明相对于现有技术取得了以下技术效果:
本发明中的再生重组厚芯竹胶合板及其制造方法,以废旧、废弃竹胶模板、竹胶合板或竹集成材为原料,经过挑选、锯切、砂光、斜角加工等工序加工的旧板为芯,在斜角处铺装刨花与上下层进行渐变过渡衔接,上下覆以竹帘、竹席并经热压而成,使废旧竹板材得以再生。再生重组厚芯竹胶合板的物理力学性能达到相关产品标准要求,加工成本显著减少,且变废为宝,综合利用了资源。企业可以以旧换新降低了部分生产成本。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动性的前提下,还可以根据这些附图获得其他的附图。
图1为本发明中再生重组厚芯竹胶合板的整体构造示意图;
图2为夹芯废板层的倒角处结构示意图;
图3为夹芯废板层的示意图;
其中,1竹席层;2竹帘层;3夹芯废板层;4挡板;5纸质模具;6刨花;7斜角。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明的目的是提供一种再生重组厚芯竹胶合板及其制造方法,以解决上述现有技术存在的问题,使竹胶合板、竹集成材或竹胶膜板得以再生,再生重组厚芯竹胶合板的物理力学性能达到产品标准要求,加工成本显著减少,且变废为宝,综合利用了资源。
本发明提供的再生重组厚芯竹胶合板,包括竹席层、竹帘层和夹芯废板层,夹芯废板层经斜角加工及刨花渐变过渡衔接,两侧对称依次铺设竹帘层和竹席层。采用废旧竹胶合板、竹集成材或竹胶膜板作为夹芯层做再生重组厚芯竹胶合板,大大节约了新竹帘、竹席的消耗,综合利用了资源,减少资源浪费。
为使本发明的上述目的、特征和优点能够更加明显易懂,下面结合附图和具体实施方式对本发明作进一步详细的说明。
请参考图1-3,其中,图1为本发明中再生重组厚芯竹胶合板的整体构造示意图;图2为夹芯废板层的倒角处结构示意图;图3为夹芯废板层的示意图。
本发明提供一种再生重组厚芯竹胶合板,包括竹席层1、竹帘层2和夹芯废板层3,夹芯废板层3两侧对称依次铺设竹帘层2和竹席层1,竹帘、竹席对称铺装起到尺寸稳定作用,竹席面层增加了表面可涂饰性及装饰效果,竹帘层2的纵向结构可增加再生重组厚芯竹胶合板力学强度。夹芯废板层3的主板体的四边上加工有斜角,在斜角处铺装刨花6,通过刨花6的填充、延展及粘结作用,使得芯层与表层及芯层与边缘无缝结合。夹芯废板层3以废旧、废弃竹胶模板、竹胶合板或竹集成材为原材料。竹席层1为酚醛树脂浸渍,竹帘层2为酚醛树脂浸渍。斜角7的宽度为8-15cm。在夹芯废板层3斜角7及四边延伸80-100mm铺装有刨花6。刨花6铺装在纸质模具5与挡板4之间。
本发明还提供一种再生重组厚芯竹胶合板的制造方法,应用于上述的再生重组厚芯竹胶合板,包括以下步骤:(1)选料:以废旧、废弃竹胶模板、竹刨花板或竹集成材为原料并进行初步筛选和分类;(2)预处理:对选好的原料进行表面砂光,去除表面污渍、灰尘及金属异物等,并去掉所述原料破损的四边;(3)斜角7加工:对预处理后的板芯进行斜角7加工;(4)竹帘、竹席干燥:将竹帘、竹席干燥至含水率8-12%;(5)施胶:将酚醛树脂稀释至12-18%,根据浸渍时间调整施胶量,竹席施胶量23-30%、竹帘施胶量12-15%,刨花采用拌胶方式,施胶量为20-30%,陈放干燥备用;(6)板芯铺装成型:将挡板4开启,在倒角处安放纸质模具5,铺装刨花6,并进行热压成型;(7)板芯施胶:采用喷胶方式对板芯进行双面施胶;(8)热压重组成型:将竹席铺装在底层、依次铺装竹帘、板芯、竹帘、竹席,并进行热压成型,热压温度150-180℃、压力2.5-3.0MPa、热压时间20-30min;(9)后处理:锯边、倒角、砂光,若产品整体使用可选择加固及封闭处理。
选料过程中的初步筛选主要针对表面分层、腐朽及边缘破损等,具体按表1进行,然后按照原料的规格尺寸进行分组;重组加工,其加工过程为先将原料的边缘进行锯解、去除,并对四边进行斜角加工,露出内部新鲜的材面,然后在边缘铺装刨花6进行热压成型。
刨花6铺装在纸质模具5与挡板4之间,热压后纸质模具5直接与原料的板材融为一体;纸质模具5选用一次性模具。
斜角7处刨花6铺装量根据表面积和厚度,按设计密度0.95-1.15g/cm3进行铺装,刨花6采用酚醛树脂,刨花6施胶量为20-30%;竹席层1、竹帘层2和夹芯废板层3施胶铺装过程中,竹席施胶量23-30%、竹帘施胶量12-15%;施胶采用喷胶方式,施胶量为2.2kg/m2,且其中的热压成型参数为,热压温度150-180℃、压力2.5-3.0MPa、热压时间20-30min,进行热压、锯边后还需要对重组厚芯竹胶合板进行再次倒角和表面砂光,对于整体使用的再生板可选择采用固定装置进行固定及封闭。
回收的废旧竹胶合板规格和质量参差不齐,为保障再生重组厚芯竹胶合板质量,首先要进行挑选、剔除和分类,对表面出现严重破损、分层或腐朽程度超过20%的胶合板要剔除,然后对符合要求的废旧竹板材进行按照规格尺寸进行分组,对表层进行砂光,去除表面水泥、灰尘等污渍。
具体的选用旧胶合板的质量要求见表1
表1废旧竹板材质量要求
表面破损 | 边缘破损 | 腐朽 | 表层开胶 | 分层 | 断裂 | 弯曲变形 | |
质量要求 | 允许 | 允许 | ≤总面积20% | 允许 | ≤总面积30% | 允许 | 不允许 |
废旧夹芯层直接与竹席热压将导致四边质量难以控制,而且胶合板幅面尺寸也产生了“缩水”。为了保持原有的幅面尺寸及边缘质量,在重组加工过程中,先将旧板芯的边缘进行锯解、去除,露出内部新鲜的材面,边缘铺装刨花6再次热压。
试验初试中发现采用直角边进行重组,再生重组厚芯竹胶合板中刨花6与旧板芯的结合处力学强度较低,材质过渡太明显,很容易导致断裂。为了进行缓慢过渡,将旧板芯四边先加工成一定长度的倒角,斜角7宽度一般为8-15cm。
为了增加成品的尺寸并增强旧板芯与重组厚芯竹胶合板整体连贯性,在斜角7及四边延伸100mm铺装刨花6。斜角7处刨花6的铺装是技术难点,本发明中采用纸质模具5,将刨花6铺装在其中,纸质模具5为一次性,直接与板材融为一体。
对旧板芯施胶采用喷胶方式,幅面为85cm×85cm×25mm(长×宽×厚),施胶量为每张板1.6kg,热压参数设定为160℃,压力3MPa,热压时间25min。
本发明中的再生重组厚芯竹胶合板的制造方法,其总体工艺流程还可以进行细化,具体为旧竹板→筛选→表面砂光→去四边→斜角7加工→施胶→陈放干燥→板芯成型→重组厚芯胶合板铺装→热压成型→锯边→倒角→砂光→封闭,从而能够使再生重组厚芯竹胶合板的物力力学性能达到相关产品标准要求。
性能测试
根据JG/T 156-2004《竹胶合板模板》或JG/T 428-2014《钢框组合竹胶合板模板》规定对板材进行测试,并与常规竹胶合板模板进行比较。具体见表2。
表2新旧板与性能比较
需要说明的是,本发明中的再生重组厚芯竹胶合板及其制造方法,只要与本发明中的制造方法及结构的基本原理相同,仅是某个步骤的简单的增删或者替换,也在本发明的保护范围内;另外,本发明中的关于斜角、施胶量等一系列参数的设置,仅是本发明中列举的可以实现的实施例,在具体的制造生产过程中,只要能满足相应的加工要求和最后能够保证再生重组厚芯竹胶合板的物力力学性能也可进行适当的调换,也落入本发明的保护范围内。
本发明中应用了具体个例对本发明的原理及实施方式进行了阐述,以上实施例的说明只是用于帮助理解本发明的方法及其核心思想;同时,对于本领域的一般技术人员,依据本发明的思想,在具体实施方式及应用范围上均会有改变之处。综上所述,本说明书内容不应理解为对本发明的限制。
Claims (10)
1.一种再生重组厚芯竹胶合板,其特征在于:包括竹席层、竹帘层和夹芯废板层,所述夹芯废板层的主板体的四边上加工有斜角,所述夹芯废板层两侧对称依次铺设所述竹帘层和竹席层,所述斜角处铺有废旧竹刨花。
2.根据权利要求1所述的一种再生重组厚芯竹胶合板,其特征在于:所述夹芯废板层以废旧、废弃竹胶模板、竹集成材或竹胶合板为原材料。
3.根据权利要求1所述的一种再生重组厚芯竹胶合板,其特征在于:所述竹席层采用酚醛树脂浸渍竹席层,所述竹帘层采用酚醛树脂浸渍竹帘层。
4.根据权利要求1所述的一种再生重组厚芯竹胶合板,其特征在于:所述斜角的宽度为8-15cm。
5.根据权利要求4所述的一种再生重组厚芯竹胶合板,其特征在于:在所述夹芯废板层的斜角及四边延伸80-100mm铺装有废旧竹刨花。
6.根据权利要求5所述的一种再生重组厚芯竹胶合板,其特征在于:所述刨花铺装在纸质模具与挡板之间。
7.一种再生重组厚芯竹胶合板的制造方法,应用于权利要求1-6中任一项所述的再生重组厚芯竹胶合板,其特征在于:
包括以下步骤:(1)选料:夹芯废板层以废旧、废弃竹胶模板、竹胶合板或竹集成材为原料并进行初步筛选和分类;(2)废旧板预处理:对选好的原料进行表面砂光,去除表面污渍、灰尘及金属异物等,将所述原料四边破损部分锯除,并对预处理后的废旧板进行斜角加工;(3)干燥:将竹帘、竹席干燥至含水率8-12%;(4)施胶:分别对刨花、竹帘层、竹席层进行施胶,刨花采用搅拌法施胶、竹帘层和竹席层采用浸渍施胶,均采用酚醛树脂,施胶后陈放干燥备用;(5)板芯成型:在斜角处安放纸质模具,铺装刨花,并进行板芯热压成型;(6)板芯施胶:采用喷胶方式对板芯进行双面施胶;(7)热压重组成型:从下到上逐步铺装竹席层、竹帘层、夹芯废板层、竹帘层、竹席层,并进行热压重组;(8)后处理:对冷却后的热压板坯进行锯边、倒角、砂光,若产品整体使用可选择加固及封闭处理。
8.根据权利要求7所述的再生重组厚芯竹胶合板的制造方法,其特征在于:步骤(1)的选料过程中的初步筛选是对表面出现严重破损、分层或腐朽程度超过20%的废旧竹板材要剔除,然后按照原料的规格尺寸进行分组;步骤(4)-(7)中的重组加工,其加工过程为先将原料的边缘进行锯解、去除,露出内部新鲜的材面,然后在边缘铺装刨花再次热压。
9.根据权利要求8所述的再生重组厚芯竹胶合板的制造方法,其特征在于:将所述刨花铺装在纸质模具与挡板之间,热压后纸质模具直接与原料的板材融为一体;所述纸质模具为一次性模具。
10.根据权利要求9所述再生重组厚芯竹胶合板的制造方法,其特征在于:斜角处刨花铺装量根据表面积和厚度,按设计密度0.95-1.15g/cm3进行铺装,所述刨花采用酚醛树脂,刨花施胶量为20-30%;步骤(4)中竹席层、竹帘层和刨花施胶,其中竹席施胶量23-30%、竹帘施胶量12-15%,刨花施胶量为20-30%;步骤(6)中夹芯废板层双面施胶,施胶量为2.2kg/m2;步骤(7)中的热压成型参数为:热压温度150-180℃、压力2.5-3.0MPa、热压时间20-30min;步骤(8)对冷却后的热压板坯进行四面锯边,根据产品需要可进行倒角、表面砂光,四边固定及封闭处理。
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CN103770167A (zh) * | 2014-01-20 | 2014-05-07 | 仁化县奥达胶合板有限公司 | 一种竹束胶合板生产工艺 |
CN205875599U (zh) * | 2016-07-15 | 2017-01-11 | 宜华生活科技股份有限公司 | 一种木质基材覆面地板 |
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CN113459543A (zh) * | 2021-05-25 | 2021-10-01 | 杨维武 | 一种弯折摩擦式复合材料板生产装置 |
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