CN108590241A - 一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴 - Google Patents

一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴 Download PDF

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CN108590241A
CN108590241A CN201810750163.XA CN201810750163A CN108590241A CN 108590241 A CN108590241 A CN 108590241A CN 201810750163 A CN201810750163 A CN 201810750163A CN 108590241 A CN108590241 A CN 108590241A
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cellular
polyurethane
integral bathroom
fibrous
polyurethane cellular
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李加春
毛华星
周兴超
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Zhejiang Shan Sheng Molding Science And Technology Ltd
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Abstract

本发明公开了一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴，该整体卫浴是由防水底板、墙板及顶板固定密封围合而成的房体结构，顶板和防水底板分别开设排气口和排水口，所述防水底板、墙板及顶板均为聚氨酯蜂窝复合材料板材，该聚氨酯蜂窝复合材料板材包括在蜂窝材料外由内至外依次包裹覆盖纤维材料层、聚氨酯材料层和表面保护层。本技术方案所用的聚氨酯蜂窝复合材料板材内部的蜂窝结构材料可以增加板材的支撑强度，满足作为墙体、底板的轻重量要求，在蜂窝结构材料的外层包裹纤维材料层能够提升内部蜂窝结构材料的抗冲击能力，再通过工艺制作将聚氨酯材料层发泡使玻纤材料层和蜂窝结构材料粘连，实现板材的整体成型，大大简化了复合板材的制作工艺步骤，在最外层通过表面保护层可以实现在潮湿环境中的防水和耐腐蚀效果。

Description

一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴
技术领域
本申请的技术方案属于家庭卫浴设备技术领域，具体涉及一种利用聚氨酯蜂窝纤维复合材料构成的整体卫浴。
背景技术
整体卫浴产品是由日本在20世纪60年代提出的一种卫浴产品设计方案，其诞生是伴随压模技术发展而产生的一种工业化设计卫浴产品。其采用压模工艺构建一体化防水底盘、墙板、顶板后通过密封固定连接构成的卫浴结构。由于整体卫浴底板是通过模压形成的整体构造，其在防水、防漏上的优势被充分展现，并且其生产过程采用模块化、批量压制工艺流程，使其在各种环境中都可以采用模块化拼装方式实现卫浴装修，该工艺已经逐渐取代传统水泥防水再通过贴附瓷砖美化的卫浴装修方式。经过几十年的发展，日本90％以上的酒店和70％以上的住宅都是采用了整体卫浴，在欧、美、澳等劳动力昂贵的发达国家，安装简单、节省人工的整体卫浴也占据着较大的市场份额。我国从90年代起将整体卫浴引入国内，国内酒店、医院、船舶、快装房已大量使用了整体卫浴。随着精装修住宅越来越普及，以及产业化、低碳环保住宅的国家政策导向相继出台，整体卫浴在中国普通家庭的普及会越来越广。
整体卫浴所具备的突出优点在于：(1)杜绝渗漏，一体成型防水底盘，防水反沿和流水坡度设计消除了渗漏隐患；(2)结构牢固可靠，其与建筑构架分开独立，能够实现强壮的负重支撑；(3)出众的保温隔热效果，材料中层蜂窝结构中空材料，隔断内外室环境；(4)根据需求定制内饰材料，效果美观大气、舒适性强，装潢方案灵活多元；(5)不需做防水处理，本身具有流水坡度，实际安装中只需要调整水平即可，无需进一步的防水处理；(6)安装简便，由于其整体结构，在现场底盘安装时，可以直接叠放在基层上予以固定；(7)缩短制作和装修工期，整体卫浴的施工不受季节影响，与湿作业相比，工期大大缩短；(8)集成排水，采用一体式排水地漏，现场只需连接排水管就可以实现下水。
整体卫浴在各行业开始普及应用同时，在某些特殊行业和环境中的直接套用仍然存在一定的性能局限性和兼容性问题。例如在海上船舶、潮湿环境地区，整体卫浴构架材质的防腐、防水性能要求更高，传统材质如石膏板易霉变发涨；另外如在北方冬季，卫浴保温性能将提出更高要求；此外用户对整体卫浴的材质轻量化需求也日益增强，传统的FRP、SMC、石材、石膏板等材质性能开始不能全面满足市场需求了。如何利用现有材料领用发展的最新方向，结合整体卫浴加工工艺、满足不同环境中的使用要求，对不同复合材料的结构和构造进行改进、改造以满足制作整体卫浴要求已经成为卫浴领域发展的前沿。
为此，本申请的技术方案结合聚氨酯蜂窝纤维复合材料制造工艺和结构，利用其轻质、防水防腐、高阻燃、高隔温、低节拍高产出的诸多优势，对其结构构造进行了改进，实现了新型整体卫浴制品的开发和研制。
发明内容
本发明的目的在于提出一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴，该整体卫浴产品可以利用发泡成型技术生产整体卫浴的各个部件，其强度高、防水性能强、密封严密，同时具备耐高温、重量轻的特点，在整体卫浴技术上实现了革命性进步。
实现上述发明目的技术方案为，一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴，该整体卫浴是由防水底板、墙板及顶板固定密封围合而成的房体结构，顶板和防水底板分别开设排气口和排水口，所述防水底板、墙板及顶板均为聚氨酯蜂窝复合材料板材，该聚氨酯蜂窝复合材料板材包括在蜂窝材料外由内至外依次包裹覆盖纤维材料层、聚氨酯材料层和表面保护层。本技术方案所用的聚氨酯蜂窝复合材料板材最内部的蜂窝结构材料可以增加板材的支撑强度，也可满足作为墙体、底板的轻重量要求，在蜂窝结构材料的外层包裹纤维材料层能够提升内部蜂窝结构材料的抗冲击能力，再通过工艺制作将聚氨酯材料层发泡使玻纤材料层和蜂窝结构材料粘连，实现板材的整体成型，大大简化了复合板材的制作工艺步骤，在最外层通过表面保护层可以实现在潮湿环境中的防水和耐腐蚀效果。
在上述整体卫浴的结构中，墙板通过嵌插密封固定方式实现与防水底板和顶板的密封固定。该方式大大简化了装配过程，在实际环境中只要将墙板底部直接嵌插在防水底板的边缘，同样将顶板嵌插在墙板顶部即可以实现整体卫浴的安装。
为了实现相邻墙板在装配整体卫浴中的密封连接，相邻墙板之间通过密封角条实现密封固定连接，由此可以任意调节整体卫浴的形状，增加了装配结构的灵活性。
制作聚氨酯蜂窝复合材料板材的蜂窝材料是铝蜂窝芯、芳纶蜂窝芯、塑料蜂窝芯、纸蜂窝芯中的一种。上述不同蜂窝材料的窝芯都具备强大支撑作用，能够满足作为支撑主体的强度需求。
覆盖蜂窝材料窝芯的纤维材料层是玻纤布、玻纤毡、碳维布中的一种。其主要作用是能够将其内部的窝芯包裹限定在一定的空间范围内，同时也实现了减轻内部所受冲击力的效果。蜂窝材料与纤维材料层通过胶粘或装订方式实现覆盖层叠。
利用聚氨酯发泡材料层作为聚氨酯材料层的最大优势在于可以在制作工艺上采用发泡工艺进行一次定型，提高了生产效率、降低了制作成本。通常聚氨酯材料层通过喷涂方式实现覆盖。
表面保护层是零发泡聚氨酯层、彩钢板层、不锈钢层、陶瓷层、塑料薄膜中的一种。其主要作用是进行表面美观、防护，减少腐蚀。
上述整体卫浴结构中，地板上开有排水口，地面设计带有流水坡度，实际安装只需调整水平即可，不需要做防水；顶板开有排气口，可安装排风扇、浴霸、灯具等；侧墙根据需求位置安装衣物挂钩、电源插座、衣物架等。
该聚氨酯蜂窝复合材料板材的制备步骤如下：
(1)将裁切合适的蜂窝材料铺设于工作台后在其表面粘帖或装订纤维材料层；
(2)将上步覆盖了维材料层的产品置入喷涂机中，在纤维材料层表面均匀喷涂聚氨酯材料，再送入模压模具的模腔中合模保压固化成型，固化成型过程的温度设置为90-130℃，压力80-220bar,保压时间100-300s；
(3)完成上步的保压固化成型后开模获得整体卫浴基板并进行整型修边；
(4)对上步完成整型修边的卫浴基板表面进行表面保护层贴覆，获得最终整体卫浴的聚氨酯蜂窝复合材料板材。
本技术方案利用聚氨酯蜂窝纤维复合材料及其制造工艺，结合其轻质、防水防腐、高阻燃、高隔温、低成本、高产出等优点开发出整体卫浴制品，其将是未来整体卫浴市场的新换代产品。
附图说明
图1为本申请的由聚氨酯蜂窝纤维复合材料构成的整体卫浴结构示意图；
图2为聚氨酯蜂窝复合材料板材的结构示意图；
图中，1、顶板；2、排气口；3、墙板；4、防水底板；5、排水口；6、密封角条；7、表面保护层；8、蜂窝材料；9、纤维材料层；10、聚氨酯材料层。
具体实施方式
以下结合附图及实施例对本申请的技术方案作进一步详细说明，附图中整体卫浴仅为一种实施方式，实际使用中并不限于附图中的类型。
如图1所示的由聚氨酯蜂窝纤维复合材料构成的整体卫浴,该整体卫浴是由防水底板4、墙板3及顶板1固定密封围合而成的房体结构，顶板和防水底板分别开设排气口2和排水口5，所述防水底板、墙板及顶板均为聚氨酯蜂窝复合材料板材，该聚氨酯蜂窝复合材料板材包括在蜂窝材料8外由内至外依次包裹覆盖纤维材料层9、聚氨酯材料层10和表面保护层7,如图2所示。墙板通过嵌插密封固定方式实现与防水底板和顶板的密封固定，相邻墙板之间通过密封角条6实现密封固定连接。安装时，首先放置防水底板并调整至水平状态，再依次在防水底板边缘插装墙板，并在相邻的墙板边角处用角条连接密封安装；最后盖上顶板紧固即可完成主体安装。整个安装步骤和过程简单、方便，简化了卫生间的复杂装修工程。顶板上的排气口可安装排风扇、浴霸、灯具等，侧墙根据位置需求安装衣物挂钩、电源插座、衣物架等。
聚氨酯蜂窝复合材料板材中，蜂窝材料是铝蜂窝芯、芳纶蜂窝芯、塑料蜂窝芯、纸蜂窝芯中的一种；纤维材料层是玻纤布、玻纤毡、碳维布中的一种；聚氨酯材料层采用聚氨酯发泡材料层；表面保护层是零发泡聚氨酯层、彩钢板层、不锈钢层、陶瓷层、塑料薄膜中的一种。
聚氨酯蜂窝复合材料板材的具体制备步骤如下：
(1)将裁切合适的蜂窝材料铺设于工作台后在其表面粘帖或装订纤维材料层；
(2)将上步覆盖了维材料层的产品置入喷涂机中，在纤维材料层表面均匀喷涂聚氨酯材料，再送入模压模具的模腔中合模保压固化成型，固化成型过程的温度设置为90-130℃，压力80-220bar,保压时间100-300s；
(3)完成上步的保压固化成型后开模获得整体卫浴基板并进行整型修边；
(4)对上步完成整型修边的卫浴基板表面进行表面保护层贴覆获得最终整体卫浴的聚氨酯蜂窝复合材料板材。
本申请的整体卫浴强度高、防水性能强、密封严密，同时具备耐高温、重量轻的特点，在整体卫浴技术上实现了革命性进步。
本发明中的具体实施例仅仅是对本发明的解释，其并不是对本发明的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本发明的权利要求范围内都受到专利法的保护。

Claims (10)

1.一种由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，该整体卫浴是由防水底板(4)、墙板(3)及顶板(1)固定密封围合而成的房体结构，顶板和防水底板分别开设排气口(2)和排水口(5)，所述防水底板、墙板及顶板均为聚氨酯蜂窝复合材料板材，该聚氨酯蜂窝复合材料板材包括在蜂窝材料(8)外由内至外依次包裹覆盖纤维材料层(9)、聚氨酯材料层(10)和表面保护层(7)。
2.根据权利要求1所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，墙板通过嵌插密封固定方式实现与防水底板和顶板的密封固定。
3.根据权利要求1所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，相邻墙板之间通过密封角条(6)实现密封固定连接。
4.根据权利要求1所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，蜂窝材料是铝蜂窝芯、芳纶蜂窝芯、塑料蜂窝芯、纸蜂窝芯中的一种。
5.根据权利要求1所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，纤维材料层是玻纤布、玻纤毡、碳维布中的一种。
6.根据权利要求1所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，聚氨酯材料层是聚氨酯发泡材料层。
7.根据权利要求1所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，表面保护层是零发泡聚氨酯层、彩钢板层、不锈钢层、陶瓷层、塑料薄膜中的一种。
8.根据权利要求1、4或5所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，蜂窝材料与纤维材料层通过聚氨酯材料的发泡、渗透、浸润、固化方式实现层叠固化成型。
9.根据权利要求1或6所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，聚氨酯材料层通过喷涂方式实现覆盖。
10.根据1-6任一权利要求所述的由聚氨酯蜂窝纤维复合材料构成的整体卫浴，其特征在于，该聚氨酯蜂窝复合材料板材的制备步骤如下：
(1)将裁切合适的蜂窝材料铺设于工作台后在其表面装订纤维材料层；
(2)将上步覆盖了纤维材料层的产品置入喷涂机中，在纤维材料层表面均匀喷涂聚氨酯材料，再送入模压模具的模腔中合模保压固化成型，固化成型过程的温度设置为90-130℃，压力80-220bar,保压时间100-300s；
(3)完成上步的保压固化成型后开模获得整体卫浴基板并进行整型修边；
(4)对上步完成整型修边的卫浴基板表面进行表面保护层贴覆或安装，获得最终整体卫浴的聚氨酯蜂窝复合材料板材。
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