CN108839160B - 一种水热处理竹质粉末无胶模塑密实材的制备方法 - Google Patents
一种水热处理竹质粉末无胶模塑密实材的制备方法 Download PDFInfo
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Abstract
本发明公开了一种水热处理竹质粉末无胶模塑密实材的制备方法,包括以下步骤:竹片制备;水热处理;干燥、粉碎、计量;将竹质粉末预热处理;铺装;模压。使用本方法可制备各种异形模压制品,优点在于:绿色环保、无甲醛、密度高性能好,工艺简单、生产效率高,且大大提高竹材的利用率。利用本发明的工艺还可以用于雕刻类家具制品的加工,解决加工时间长、效率低的问题,大大扩大了竹材的应用领域。
Description
技术领域
本发明涉及竹木材加工领域,具体是一种水热处理竹质粉末无胶模塑密实材的制备方法,使用该方法生产的产品可用作模压异形工艺品、橱柜门板、室内家具制品等原材料。
背景技术
我国非木质无胶材料开发利用相对较多,而木质无胶材料成功的案例比较少,且木质无胶材料产品的性能还难以完全满足使用要求,多数无胶材料抗弯强度、内结合强度、吸水性能胶难达标,主要以木纤维为原料制备无胶材料。随着人们对环保要求也越来越高,无胶材料较受消费者的欢迎。但是,无胶材料距离大规模产业化还具有一段距离。当前利用竹木质材料自身化学成分在特定的工艺条件下制备无胶材料,依据成型技术可分为模压和热压,而热压成形技术依据构成单元处理方法可分为化学试剂活化法和天然物质转化法。传统的热压法制备无胶材料成型压力不能过大,过大的压力将导致材料的延展,因而密度相对较低,其次,无论是化学活化法还是天然物质转化法,均是通过改性产生自粘物质,产生的自粘物质其胶合性能低于常规胶粘剂。另外,传统的模压材料主要以木纤维、农作物秸秆、芦苇秆粉末等为主,木材生长周期长,植物纤维自身强度低,成型后物理性能不理想等缺点。因此,寻求一种工艺简单、成本低廉、生物降解,持续发展的高强度无胶材料的方法成为行业的热点。
发明内容
本发明的目的在于提供一种水热处理竹质粉末无胶模塑密实材的制备方法,以解决上述背景技术中提出的问题。
为实现上述目的,本发明提供如下技术方案:
一种水热处理竹质粉末无胶模塑密实材的制备方法,包括以下步骤:
S1,竹片制备:新鲜毛竹经截断、剖分、粗刨后制成长度为2000mm,宽度为8-15mm,厚度为3-6mm的去青粗刨竹片,并将其放入常温水池浸渍,增加水分有利于水热处理;
S2,水热处理:将竹片放入蒸煮罐中,采用程序控温对竹片进行水热处理,首先对水进行预热至60-80℃,将竹片放入罐体中恒温10-20min,再以3-5℃/min升温速率加热至150-170℃,保温2-4h,将罐内热水排放到保温储液槽中,排气后取出自然冷却;
S3,干燥、粉碎、计量:将水热处理后的竹片垂直将水沥干,并在通风处使其自然干燥至含水率10-12%,通过粉碎机将竹片粉碎至20-100目数,利用振动筛将竹粉分类堆垛,分为20目及以下、20-100目、100目以上,三种不同目数竹质粉末按混合比6∶2∶2或2∶2∶6比例配置,依据设计密度1.3-1.5g/cm3,模具尺寸计算所需粉末重量;
S4,将竹质粉末预热处理;
S5,铺装:将预热处理竹制粉末均匀铺装到封闭式模具;
S6,模压:将已经过预热处理的竹粉放入模具内,采用模压温度160-200℃、单位模压30-40Mpa、热塑时间10-60min,再冷却到80-100℃开模;
其中,在步骤S5和S6中,所述模具由阴模、阳模和脱模模具组成,模具加热冷却系统主要由加热系统和冷却系统组成,所述加热系统由导热油-高频加热联合装置提供,其主要优点是导热油及电热加热主要靠热传导从材料表面逐步向材料芯层传导,往往表层温度高于芯层,而通过高频联合加热加速芯层温度提高,使材料模压时温度更加均匀,所述高频加热的电磁波震荡频率6.78MHZ,高频电压3.8-9.5KV,高频发生器阳流2-3A,栅流0.4-0.6A,所述导热油加热温度40-300℃,所述冷却系统采用水冷方式。
进一步的,在步骤S4中,竹质粉末预热处理具体为:将混合均匀的竹质粉末放入蒸汽处理罐,蒸汽处理温度100-140℃,处理时间2-4h,处理湿度70-90%。
进一步的,在步骤S4中,竹质粉末预热处理具体为:将混合均匀的竹质粉末放入真空加热箱中,真空压力-0.04~-0.98,加热温度140-160℃,加热时间2-4h,通入氮气保护气体,防止粉末氧化热解,真空度降为0时,喷入水蒸气进行表面润湿。
与现有技术相比,本发明的有益效果是:
本发明对竹片进行高温高压水热处理,通过物理的方法,改善材料颜色及其表面活氧类自由基,促进粉末间无胶密实,通过水热处理降低粉末的物理力学性能,减少模压时反弹,进一步提高材料的密实化程度,处理后的竹质粉末具有较大的比表面积,采用模压的方式在温度和压力作用下,使其含有纤维素、半纤维素、木质素等基团之间产生延展、啮接、塑合,是一种具有密度高、各向同性、附加值高,力学性能较好的无胶模塑密实材。
使用本方法可制备各种异形模压制品,优点在于:绿色环保、无甲醛、密度高性能好,工艺简单、生产效率高,且大大提高竹材的利用率。
利用本发明的工艺还可以用于雕刻类家具制品的加工,解决加工时间长、效率低的问题,大大扩大了竹材的应用领域。
具体实施方式
下面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。
本发明实施例中,一种水热处理竹质粉末无胶模塑密实材的制备方法,包括以下步骤:
S1,竹片制备:新鲜毛竹经截断、剖分、粗刨后制成长度为2000mm,宽度为8-15mm,厚度为3-6mm的去青粗刨竹片,并将其放入常温水池浸渍,增加水分有利于水热处理;
S2,水热处理:将竹片放入蒸煮罐中,采用程序控温对竹片进行水热处理,首先对水进行预热至60-80℃,将竹片放入罐体中恒温10-20min,再以3-5℃/min升温速率加热至150-170℃,保温2-4h,将罐内热水排放到保温储液槽中,排气后取出自然冷却;
S3,干燥、粉碎、计量:将水热处理后的竹片垂直将水沥干,并在通风处使其自然干燥至含水率10-12%,通过粉碎机将竹片粉碎至20-100目数,利用振动筛将竹粉分类堆垛,分为20目及以下、20-100目、100目以上,三种不同目数竹质粉末按混合比6∶2∶2或2∶2∶6比例配置,依据设计密度1.3-1.5g/cm3,模具尺寸计算所需粉末重量;
S4,将竹质粉末预热处理;
S5,铺装:将预热处理竹制粉末均匀铺装到封闭式模具;
S6,模压:将已经过预热处理的竹粉放入模具内,采用模压温度160-200℃、单位模压30-40Mpa、热塑时间10-60min,再冷却到80-100℃开模。
进一步的,在步骤S2中,先将竹片粉碎至20-100目数,再进行水热处理,将竹粉放入蒸煮罐中,关闭罐门通入热水60-80℃,再以3-5℃/min升温速率加热至150-170℃,保温2-3h,排气后取出进行自然冷却,粉末水热处理由于颗粒较小,传热较快处理效果较好。
进一步的,在步骤S4中,竹质粉末预热处理具体为:将混合均匀的竹质粉末放入蒸汽处理罐,蒸汽处理温度100-140℃,处理时间2-4h,处理湿度70-90%。
进一步的,在步骤S4中,竹质粉末预热处理具体为:将混合均匀的竹质粉末放入真空加热箱中,真空压力0~-0.98,加热温度140-160℃,加热时间2-4h,通入氮气保护气体,防止粉末氧化热解,真空度降为0时,喷入水蒸气进行表面润湿。
进一步的,在步骤S5和S6中,所述模具由阴模、阳模和脱模模具组成,模具加热冷却系统主要由加热系统和冷却系统组成,所述加热系统由导热油-高频加热联合装置提供,其主要优点是导热油及电热加热主要靠热传导从材料表面逐步向材料芯层传导,往往表层温度高于芯层,而通过高频联合加热加速芯层温度提高,使材料模压时温度更加均匀,所述高频加热的电磁波震荡频率6.78MHZ,高频电压3.8-9.5KV,高频发生器阳流2-3A,栅流0.4-0.6A,所述导热油加热温度40-300℃,所述冷却系统采用水冷方式。
实施例1
本发明实施例中,一种水热处理竹质粉末无胶模塑密实材的制备方法,包括以下步骤:
S1,竹片制备:选取新鲜毛竹经截断、剖分、粗刨后制成长度为2000mm,宽度为12mm,厚度为6mm去青粗刨竹片,并将其放入常温水池浸渍,增加水分有利于水热处理;
S2,水热处理:将竹片放入蒸煮罐中,采用程序控温对竹片进行水热处理,首先对水进行预热至80℃,将竹片放入罐体中恒温20min,再以3℃/min升温速率加热至160℃,保温2h,将罐内热水排放到保温储液槽中,排气后取出自然冷却;
S3,干燥、粉碎、计量:将水热处理后的竹片垂直将水沥干,并在通风干燥处使其自然干燥至含水率10-12%,通过粉碎机将竹片粉碎,利用振动筛将竹粉分类堆垛,分为20目及以下、20-100目、100目以上,三种不同目数竹质粉末已混合比6∶2∶2比例配置,依据设计密度1.4g/cm3,设计模具制样尺寸长30cm,宽6cm,厚度2cm,计算所需粉末重量为504g;
S4,竹质粉末预热处理:将混合均匀的竹质粉末放入蒸汽处理罐,蒸汽处理温度140℃,处理时间2h,处理湿度90%;
S5,铺装:将预热处理竹制粉末均匀铺装到封闭式模具;
S6,模压:将已经过预热处理的竹粉迅速放入模具内,高频电磁波震荡频率6.78MHZ,高频电压3.8KV,高频发生器阳流2-3A,栅流0.4-0.6A,导热油油炉加热温度210℃;采用模压温度180℃、单位模压30Mpa、热塑时间20min,热塑时间到后进行冷却至80℃,期间采用分段式泄压至单位压力3MPa,待冷却至80℃后完全泄压开模。
实施例2
本发明实施例中,一种水热处理竹质粉末无胶模塑密实材的制备方法,包括以下步骤:
S1,竹片制备:新鲜毛竹经截断、剖分、粗刨后制成长度为2000mm,宽度为15mm,厚度为5mm去青粗刨竹片,自然干燥;
S2,先将竹片粉碎至20-100目数,进行水热处理,将竹粉放入蒸煮罐中,关闭罐门通入热水80℃,再以5℃/min升温速率加热至150-170℃,保温2h,排气后取出进行自然冷却,干燥;
S3,干燥、粉碎、计量:将水热处理后的竹粉自然干燥至含水率10-12%,利用振动筛将竹粉分类堆垛,分为20目及以下、20-100目、100目以上,三种不同目数竹质粉末已混合比2∶2∶6比例配置,依据设计密度1.2g/cm3,设计模具制样尺寸长30cm,宽30cm,厚度4cm,计算所需粉末重量为4320g;
S4,预热处理:将混合均匀的竹质粉末放入真空加热箱中,真空压力-0.80,加热温度15℃,加热时间2h,通入氮气保护气体,防止粉末氧化热解,真空度降为0时,喷入水蒸气进行表面润湿,该方法能较好的控制其含水率;
S5,铺装:将预热处理竹制粉末均匀铺装到封闭式模具;
S6,模压:将已经过预热处理的竹粉放入模具内,导热油油炉加热温度250℃;模压温度200℃、单位模压25Mpa、热塑时间40min,热塑时间到后进行冷却至60℃,期间采用分段式泄压。
本发明对竹片进行高温高压水热处理,通过物理的方法,改善材料颜色及其表面活氧类自由基,促进粉末间无胶密实,通过水热处理降低粉末的物理力学性能,减少模压时反弹,进一步提高材料的密实化程度,处理后的竹质粉末具有较大的比表面积,采用模压的方式在温度和压力作用下,使其含有纤维素、半纤维素、木质素等基团之间产生延展、啮接、塑合,是一种具有密度高、各向同性、附加值高,力学性能较好的无胶模塑密实材。
使用本方法可制备各种异形模压制品,优点在于:绿色环保、无甲醛、密度高性能好,工艺简单、生产效率高,且大大提高竹材的利用率。
利用本发明的工艺还可以用于雕刻类家具制品的加工,解决加工时间长、效率低的问题,大大扩大了竹材的应用领域。
以上的仅是本发明的优选实施方式,应当指出,对于本领域的技术人员来说,在不脱离本发明构思的前提下,还可以作出若干变形和改进,这些也应该视为本发明的保护范围,这些都不会影响本发明实施的效果和专利的实用性。
Claims (3)
1.一种水热处理竹质粉末无胶模塑密实材的制备方法,其特征在于,包括以下步骤:
S1,竹片制备:新鲜毛竹经截断、剖分、粗刨后制成长度为2000mm,宽度为8-15mm,厚度为3-6mm的去青粗刨竹片,并将其放入常温水池浸渍;
S2,水热处理:将竹片放入蒸煮罐中,采用程序控温对竹片进行水热处理,首先对水进行预热至60-80℃,将竹片放入罐体中恒温10-20min,再以3-5℃/min升温速率加热至150-170℃,保温2-4h,将罐内热水排放到保温储液槽中,排气后取出自然冷却;
S3,干燥、粉碎、计量:将水热处理后的竹片垂直将水沥干,并在通风处使其自然干燥至含水率10-12%,通过粉碎机将竹片粉碎至20-100目数,利用振动筛将竹粉分类堆垛,分为20目及以下、20-100目、100目以上,三种不同目数竹质粉末按混合比6∶2∶2或2∶2∶6比例配置,依据设计密度1.3-1.5g/cm3,模具尺寸计算所需粉末重量;
S4,将竹质粉末预热处理;
S5,铺装:将预热处理竹制粉末均匀铺装到封闭式模具;
S6,模压:将已经过预热处理的竹粉放入模具内,采用模压温度160-200℃、单位模压30-40Mpa、热塑时间10-60min,再冷却到80-100℃开模;
其中,在步骤S5和S6中,所述模具由阴模、阳模和脱模模具组成,模具加热冷却系统主要由加热系统和冷却系统组成,所述加热系统由导热油-高频加热联合装置提供;
所述高频加热的电磁波震荡频率6.78MHZ,高频电压3.8-9.5KV,高频发生器阳流2-3A,栅流0.4-0.6A;
所述导热油加热温度40-300℃;
所述冷却系统采用水冷方式。
2.根据权利要求1所述的水热处理竹质粉末无胶模塑密实材的制备方法,其特征在于,在步骤S4中,竹质粉末预热处理具体为:将混合均匀的竹质粉末放入蒸汽处理罐,蒸汽处理温度100-140℃,处理时间2-4h,处理湿度70-90%。
3.根据权利要求1所述的水热处理竹质粉末无胶模塑密实材的制备方法,其特征在于,在步骤S4中,竹质粉末预热处理具体为:将混合均匀的竹质粉末放入真空加热箱中,真空压力-0.04~-0.98,加热温度140-160℃,加热时间2-4h,通入氮气保护气体,真空度降为0时,喷入水蒸气进行表面润湿。
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