CN108638622A - 一种复合板及其制备方法 - Google Patents
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Abstract
本发明涉及一种复合板及其制备方法,其中所述复合板包括:内层基材板和外层基材板;其中所述内层基材板和外层基材板之间设有保温层;所述内层基材板的外侧面还设有防火层板;以及所述外层基材板的外侧面还设有增强层板;本发明的复合板包括五层结构,不仅强度好,而且具备良好的保温性能和防火性能,能够达到制备房车车厢的要求;本发明的复合板制备方法对外层基材板和内层基材板均采用双面涂胶的方式,大大提高了复合板的制备效率,而且制备出的复合板质量高。
Description
技术领域
本发明涉及房车车厢制备领域,具体涉及一种复合板及其制备方法。
背景技术
复合板是由两种或两种以上不同性质的材料,通过物理或化学的方法,在宏观上组成具有新性能的材料。各种材料在性能上互相取长补短,产生协同效应,使复合板的综合性能优于原组成材料而满足各种不同的要求,目前广泛应用。
复合板中各层材料组合在一起的方法主要有热压和真空压两种不同的工艺方法,热压工艺方法中,涂胶粘合是必不可少的环节,目前大多数复合板的制备都采用单面涂胶方式,如溧阳二十八所系统装备有限公司于2016 年07月21日申请的专利号为201610579653 .9的发明专利:一种快速制作复合夹芯板的方法,就是采用单面涂胶的方式进行制备复合板的,但单面涂胶存在如下问题:1)需要进行二次涂胶动作,生产效率低;2)进行二次涂胶时,需将一次涂胶后粘合在一起的各层材料板一起移动至涂胶位置,以进行二次涂胶;由于胶水固化需要时间,如果一次涂胶并粘合后就进行二次涂胶,在一次涂胶后粘合在一起的各层材料板移动过程中,各层材料板很可能会因为胶固化不完全而发生松动或偏移,影响复合板制备强度;如果一次涂胶并粘合后,等待胶完全固化,又会拉长复合板制备周期,使得复合板制备效率极低。
发明内容
本发明的目的是提供一种复合板及其制备方法,以解决现有技术中存在的复合板制备效率低和制备强度低的技术问题。
为了解决上述技术问题,本发明提供了一种复合板,包括:内层基材板和外层基材板;其中所述内层基材板和外层基材板之间设有保温层;所述内层基材板的外侧面还设有防火层板;以及所述外层基材板的外侧面还设有增强层板。
进一步,所述保温层包括:预埋框架和填充于预埋框架内的挤塑聚苯乙烯泡沫塑料;以及所述防火层板的外侧面设有装饰层。
进一步,所述内层基材板采用素板或玻璃钢板;所述外层基材板采用素板;以及所述增强层板采用FRP玻璃钢板。
进一步,所述内层基材板和外层基材板的厚度均为3mm;所述保温层的厚度为25-30mm;所述防火层板的厚度为0.5-0.8mm;以及所述增强层板的厚度为1.2-2mm。
又一方面,本发明还提供了一种如前所述的复合板的制备方法,包括:对各层材料板进行预处理;将各层材料板叠合在一起,并压合,以得到半成品复合板;以及对半成品复合板进行切割,以得到成品复合板。
进一步,对各层材料板进行预处理的方法包括:裁剪FRP玻璃钢板、去除粘接在FRP玻璃钢板表面的杂物和灰尘,并用工业酒精清洗干净,以作为增强层板备用;以及制作预埋框架,并在预埋框架内填充挤塑聚苯乙烯泡沫塑料,以作为保温层。
进一步,将各层材料板叠合在一起,并压合的方法包括:对外层基材板进行双面涂胶,并在涂胶完成后,将该外层基材板叠至所述增强层板上;将所述保温层叠至该外层基材板上;对内层基材板进行双面涂胶,并在涂胶完成后,将该内层基材板叠至所述保温层上;将设有装饰层的防火层板叠至该内层基材板上;以及通过滚筒式压力机对叠合后的各层材料板进行压合。
进一步,所述外层基材板包括若干个大小相同的三厘素板;各三厘素板依次进行双面涂胶,并依次平铺在所述FRP玻璃钢板上。
进一步,所述内层基材板包括若干个大小相同的三厘素板或玻璃钢板;各三厘素板或玻璃钢板依次进行双面涂胶,并依次平铺在所述保温层上。
进一步,对半成品复合板进行切割的方法包括:通过雕刻机对半成品复合板进行切割。
本发明的有益效果是,本发明的复合板包括五层结构,不仅强度好,而且具备良好的保温性能和防火性能,能够达到制备房车车厢的要求;本发明的复合板制备方法对外层基材板和内层基材板均采用双面涂胶的方式,大大提高了复合板的制备效率,而且制备出的复合板质量高。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1是本发明的复合板的结构示意图。
其中:
内层基材板1、保温层2、预埋框架21、挤塑聚苯乙烯泡沫塑料22、外层基材板3、防火层板4、增强层板5、装饰层6。
具体实施方式
现在结合附图对本发明作进一步详细的说明。这些附图均为简化的示意图,仅以示意方式说明本发明的基本结构,因此其仅显示与本发明有关的构成。
实施例1
图1是本发明的复合板的结构示意图。
如图1所示,本实施例1提供了一种复合板,包括:内层基材板1和外层基材板3;其中所述内层基材板1和外层基材板3之间设有保温层2;所述内层基材板1的外侧面还设有防火层板4;以及所述外层基材板3的外侧面还设有增强层板5。
具体的,本实施例的复合板包括五层结构,内、外层基材板之间设置保温层,可以提高本复合板的保温性能,以适用于房车车厢、建筑墙体等;所述防火层板4适于在室内发生火灾时,能够阻止火势蔓延,使本复合板具备防火性能;在所述外层基材板3的外侧面还设有一层增强层板5,以提高本复合板的强度,提高抗压性能。
所述保温层2包括:预埋框架21和填充于预埋框架21内的挤塑聚苯乙烯泡沫塑料22;以及所述防火层板4的外侧面设有装饰层6。具体的,所述预埋框架21例如但不限于采用铝质框架或木质框架,在保温层2内安装预埋框架21,以提高保温层的强度,根据旅居房车的设计,尤其在需要加固的地方或者螺栓固定的地方安装所述预埋骨架21,以满足旅居房车的居住要求;因挤塑聚苯乙烯泡沫塑料22抗压强度高,导热性低,因此在预埋框架21之间填充挤塑聚苯乙烯泡沫塑料22,在获得良好的保温性能的同时,并进一步提高保温层的强度。
所述内层基材板1采用素板或玻璃钢板;所述外层基材板2采用素板;以及所述增强层板5采用FRP玻璃钢板。
具体的,因FRP玻璃钢板具有防水、防腐和抗老化的功能,且FRP玻璃钢板还具有较好的强度,因此将FRP玻璃钢板作为所述增强层使用。所述内层基材板1和外层基材板3的厚度均为3mm;所述保温层2的厚度为25-30mm;所述防火层板4的厚度为0.5-0.8mm;以及所述增强层板5的厚度为1.2-2mm。
优选的,所述保温层2的厚度为25mm,所述防火层板4的厚度为0.65mm;所述增强层板5的厚度为1.35mm或1.5mm或1.8mm或2mm。
实施例2
在实施例1的基础上,本实施例2提供了一种如实施例1所述的复合板的制备方法,包括:对各层材料板进行预处理;将各层材料板叠合在一起,并压合,以得到半成品复合板;以及对半成品复合板进行切割,以得到成品复合板。
具体的,制备本复合板所用的设备主要有:除尘设备、举升机、数控热熔胶固体发生器、数控高精密双面涂胶机、数控滚筒式压力机、压合输送辊道、自动卷板张紧机、横向加料系统、下片台、复合板流转小车、数控高精密龙门雕刻机。
具体的,本复合板采用热压粘合的方式制备,制备环境温度在20℃-25℃,湿度不低于40%RH;且制备本复合板的材料需在制备前存放空气中一天以上,以使材料充分吸收空气中的水分。
对各层材料板进行预处理的方法包括:裁剪FRP玻璃钢板、去除粘接在FRP玻璃钢板表面的杂物和灰尘,并用工业酒精清洗干净,以作为增强层板备用;以及制作预埋框架,并在预埋框架内填充挤塑聚苯乙烯泡沫塑料,以作为保温层。
具体的,制备前,对各层材料板进行预处理的方法包括:
步骤S1,预先备好符合制备要求的玻璃钢卷、三厘素板、挤塑聚苯乙烯泡沫塑料、热熔胶和制作预埋框架的材料等;
步骤S2,切割预埋框架的材料和挤塑聚苯乙烯泡沫塑料;
步骤S3,启动数控热熔胶固体发生器,进行加温;
步骤S4,裁剪FRP玻璃钢板,使用除尘设备,如滚刷和吸尘器去除需粘接在FRP玻璃钢板表面的杂物及灰尘,并用工业酒精清洗干净,保证所有粘接面无油、无尘、无水及其他污物;
步骤S5,根据图纸制作预埋框架并填充挤塑聚苯乙烯泡沫塑料。
其中预埋框架的位置用投影仪标记,制作时根据产品图纸和投影仪标记放置;如果预埋框架为木质的,则用直钉枪固定预埋框架。
将各层材料板叠合在一起,并压合的方法包括:对外层基材板进行双面涂胶,并在涂胶完成后,将该外层基材板叠至所述增强层板上;将所述保温层叠至该外层基材板上;对内层基材板进行双面涂胶,并在涂胶完成后,将该内层基材板叠至所述保温层上;将设有装饰层的防火层板叠至该内层基材板上;以及通过滚筒式压力机对叠合后的各层材料板进行压合。
所述外层基材板包括若干个大小相同的三厘素板;各三厘素板依次进行双面涂胶,并依次平铺在所述FRP玻璃钢板上。
所述内层基材板包括若干个大小相同的三厘素板或玻璃钢板;各三厘素板或玻璃钢板依次进行双面涂胶,并依次平铺在所述保温层上。
本实施例中内层基材板以三厘素板为例描述本复合板的制备方法;具体的,当数控热熔胶固体发生器加热温度到达热熔胶使用温度(应用温度):140-160℃时,即可进行叠合各层材料板,具体步骤如下:
步骤SS1,启动压合输送辊道,以将裁剪好的FRP玻璃钢板运输至横向加料系统的下方。
步骤SS2,通过举升机将层叠放置的若干三厘素板升至操作高度,人工将三厘素板逐张送入数控高精密双面涂胶机进行双面涂胶后,由横向加料系统驱动双面涂胶的三厘素板下移,以将该三厘素板叠放至FRP玻璃钢板上,压合输送辊道在该三厘素板叠放至FRP玻璃钢板上后,前移一个板位,以等待横向加料系统驱动下一张双面涂胶的三厘素板下移至FRP玻璃钢板上,然后压合输送辊道在前移一个板位,直至FRP玻璃钢板上铺满双面涂胶的三厘素板。
具体的,本实施例的热熔胶采用湿气固化反应型聚氨酯热熔胶,该热熔胶初粘性非常高,可以大大减少固化时间;同时在本步骤中,对作为外层基材板的三厘素板进行双面涂胶,可以大大简化复合板制备过程,即双面涂胶只需一次涂胶动作;而且与现有技术中的单面涂胶相比,不存在单面涂胶中二次涂胶时,需将一次涂胶后粘合在一起的各层材料板一起移动至涂胶位置,以进行二次涂胶的问题;因为胶水固化需要时间,如果一次涂胶并粘合后就进行二次涂胶,在一次涂胶后粘合在一起的各层材料板移动过程中,各层材料板很可能会因为胶固化不完全而发生松动或偏移,影响复合板制备质量;如果一次涂胶并粘合后,等待胶完全固化,又会拉长复合板制备周期,使得复合板制备效率极低;而双面涂胶就很好地解决了上述问题,尤其针对三层及三层以上的复合板结构,不仅能够大大提高复合板制备效率,还能确保复合板制备强度。
步骤SS3,压合输送辊道停止前进,并复位至起始位置,然后将保温层敷设在各双面涂胶的三厘素板上表面。
步骤SS4,启动压合输送辊道,将FRP玻璃钢板与保温层粘合的半成品工件运输至横向加料系统下方。
步骤SS5,人工将三厘素板逐张送入数控高精密双面涂胶机进行双面涂胶,横向加料系统驱动双面涂胶后的三厘素板下移,以将该三厘素板叠放至保温层上,压合输送辊道在该三厘素板叠放至保温层上后,前移一个板位,以等待横向加料系统驱动下一张双面涂胶的三厘素板下移至保温层上,然后压合输送辊道在前移一个板位,直至保温层上铺满双面面涂胶的三厘素板。
具体的,在本步骤中,对作为内层基材板的三厘素板进行双面涂胶,其好处与前述的外层基材板双面涂胶的好处一样,此处不再赘述。
步骤SS6,压合输送辊道停止前进,并复位至起始位置,然后将设有装饰层的防火层板敷设在各双面涂胶的三厘素板上表面。
步骤SS7,启动压合输送辊道继续向前运行,以将上述叠合好的各层材料板输送至数控滚筒式压力机位置,进行压合。
具体的,压合完成后,启动下片台顶升复合板流转小车升至数控滚筒式压力机出板高度,并通过压合输送辊道将压合后的半成品复合板滑入复合板流转小车平台之上,随后下片台下降至少一个复合板高度,以预备接收下一张半成品复合板。
具体的,复合板流转小车上堆叠10~13张半成品复合板后,更换复合板流转小车。
具体的,以上针对本复合板的制备过程均需隔离,即需在恒温恒湿的车间完成。
对半成品复合板进行切割的方法包括:通过雕刻机对半成品复合板进行切割。
具体的,雕刻过程在恒温恒湿车间外进行;用抽真空吊具将半成品复合板吊装至数控高精密龙门雕刻机的操作平台上,根据房车车厢图纸,对半成品复合板进行切割,得到成品复合板;采用数控高精密龙门雕刻机进行切割,切割精度高。
以上述依据本发明的理想实施例为启示,通过上述的说明内容,相关工作人员完全可以在不偏离本项发明技术思想的范围内,进行多样的变更以及修改。本项发明的技术性范围并不局限于说明书上的内容,必须要根据权利要求范围来确定其技术性范围。
Claims (10)
1.一种复合板,其特征在于,包括:
内层基材板和外层基材板;其中
所述内层基材板和外层基材板之间设有保温层;
所述内层基材板的外侧面还设有防火层板;以及
所述外层基材板的外侧面还设有增强层板。
2.根据权利要求1所述的复合板,其特征在于,
所述保温层包括:预埋框架和填充于预埋框架内的挤塑聚苯乙烯泡沫塑料;以及
所述防火层板的外侧面设有装饰层。
3.根据权利要求2所述的复合板,其特征在于,
所述内层基材板采用素板或玻璃钢板;
所述外层基材板采用素板;以及
所述增强层板采用FRP玻璃钢板。
4.根据权利要求3所述的复合板,其特征在于,
所述内层基材板和外层基材板的厚度均为3mm;
所述保温层的厚度为25-30mm;
所述防火层板的厚度为0.5-0.8mm;以及
所述增强层板的厚度为1.2-2mm。
5.一种如权利要求1所述的复合板的制备方法,其特征在于,包括:
对各层材料板进行预处理;
将各层材料板叠合在一起,并压合,以得到半成品复合板;以及
对半成品复合板进行切割,以得到成品复合板。
6.根据权利要求5所述的复合板的制备方法,其特征在于,
对各层材料板进行预处理的方法包括:
裁剪FRP玻璃钢板、去除粘接在FRP玻璃钢板表面的杂物和灰尘,并用工业酒精清洗干净,以作为增强层板备用;以及
制作预埋框架,并在预埋框架内填充挤塑聚苯乙烯泡沫塑料,以作为保温层。
7.根据权利要求6所述的复合板的制备方法,其特征在于,
将各层材料板叠合在一起,并压合的方法包括:
对外层基材板进行双面涂胶,并在涂胶完成后,将该外层基材板叠至所述增强层板上;
将所述保温层叠至该外层基材板上;
对内层基材板进行双面涂胶,并在涂胶完成后,将该内层基材板叠至所述保温层上;
将设有装饰层的防火层板叠至该内层基材板上;以及
通过滚筒式压力机对叠合后的各层材料板进行压合。
8.根据权利要求7所述的复合板的制备方法,其特征在于,
所述外层基材板包括若干个大小相同的三厘素板;
各三厘素板依次进行双面涂胶,并依次平铺在所述FRP玻璃钢板上。
9.根据权利要求7所述的复合板的制备方法,其特征在于,
所述内层基材板包括若干个大小相同的三厘素板或玻璃钢板;
各三厘素板或玻璃钢板依次进行双面涂胶,并依次平铺在所述保温层上。
10.根据权利要求8或9所述的复合板的制备方法,其特征在于,
对半成品复合板进行切割的方法包括:
通过雕刻机对半成品复合板进行切割。
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