CN109322457A - 一种无机复合板材及其制造方法 - Google Patents
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Abstract
一种无机复合板材及其制造方法，所述无机复合板材的基材为6mm～15mm厚的硅酸钙晶粉板，所述硅酸钙晶粉板的两面使用环保热熔胶或热熔树脂贴1±0.1mm厚的防火板。本发明还包括一种所述无机复合板材的制造方法。本发明的板材具有生产成本低、尺寸稳定性好、不易变形、防火耐磨、保温良好、环保健康的优点，而且本发明的板材具有美观大方，视觉效果可替代石材、木材和布艺，然而与之相比又具有节约能源、环保生态的特点。
Description
技术领域
本发明涉及一种无机复合板材及其制造方法。
背景技术
目前，市场上的复合板种类主要有铝复合板、聚氨酯复合板、铜铝复合板、碳纤维复合板、ABS复合板、亚克力复合板等，这些板材或者具有生产成本高、难度大，或者尺寸稳定性不好，容易变形、脱层，或者保温性能差，或者含有有机材料不够安全环保，或者美观度不够等缺点。
其中，对于贴面复合材料，以木基贴面复合材料为主，而木基贴面复合材料有甲醛含量高、不够健康环保、阻燃性能不佳等缺点。
杨刚等人以脲醛树脂为胶黏剂，将15～30目(0.55～1.18mm)粒径的橡胶粉与木材纤维复合压制强化地板基材，再在2MPa热压压力、180℃热压温度和30s热压时间的工艺条件下用浸渍纸贴面制备成复合板材。由于脲醛树脂中含有游离甲醛，因而该复合材料不符合健康环保的理念，且木基材料自身又具有很强易燃性的特点。牛二彦等人以阻燃中密度纤维板(FR-MDF)为面板、发泡水泥板为芯板，制备阻燃发泡水泥复合板。该复合板虽然环保性能比较好，但由于发泡水泥强度不高，使得复合板抗折性能不高，且厚度较厚，这影响了作为装饰板材的美观质轻效果。且其表面材料阻燃中密度纤维板是以木质纤维或其他植物纤维为原料，加脲醛树脂胶粘剂，并施加FRW阻燃剂再经热压后制成的一种人造板材。虽然阻燃性能提高，但该板材的耐磨性能并不高。
现有贴皮复合板或者具有甲醛含量高、不环保、易燃烧的缺点，例如木基复合板；或者具有抗冲击、抗折性能不良、重量大、装饰效果不佳的缺点，例如中密度纤维板(FR-MDF)/发泡水泥复合板；或者保温性能不佳，例如金属复合板。
此外，复合板由于两种材料界面的存在，使得复合板容易产生变形。由此可见，当前复合板的性能提升空间很大。
发明内容
本发明所要解决的技术问题是，提供一种具有生产成本低、尺寸稳定性好、不易变形、基底材料为无机材料绝对防火、保温性能良好、表面贴皮避免使用油漆，从而基本无甲醛更环保特点的无机复合板材及其制造方法。
本发明解决其技术问题所采用的技术方案是：一种无机复合板材，基材为6mm～15mm厚的硅酸钙晶粉板，所述硅酸钙晶粉板的两面使用环保热熔胶或热熔树脂贴贴1±0.1mm厚的防火板。
进一步，所述硅酸钙晶粉板可用普通硅钙板或玻镁板等替代。
进一步，所述硅酸钙晶粉板由以下方法制备而成：首先对火电厂烟气进行脱硫脱硝除尘脱汞反应，然后将废液通过浓缩、结晶、离心、干燥得到含硫酸镁晶体，通过控制与粉煤灰、水渣粉、水泥用添加剂的不同配比制备得到不同性能晶粉板。当四者以2:1:1:1的重量比例混合时，所制得晶粉板性能最好。
进一步，所述无机复合板材的厚度为8mm～17mm。
进一步，所述无机复合板材的幅面尺寸规格为1.22m*2.44m或1.2m*2.4m。
一种所述无机复合板材的制造方法，包括以下步骤：
(1)对基材进行UV渗透，将基材表面灰尘凝固，提高附着力，为下一步涂胶、贴合工艺做准备；
(2)对基材表面及防火板背面涂胶、贴合，采用的胶为环保热熔胶或热熔树脂；
(3)完成单面复合后，对基材进行180°翻转，对基材另一面重复以上操作，完成基材双面贴合防火板工艺；
(4)经压实、充分干燥后，即可对板材进行剪裁切割，根据产品要求进行封边工艺，即得到无机复合板。
步骤(1)中，在60～70℃预热条件下，对基材采用UV渗透固化方法，可大大减少污染，绿色环保。
步骤(2)中，采用边涂胶边贴合的方式，贴合过程使用贴面机完成。
步骤(2)和步骤(3)所述的贴合方式也可以是两面同时贴合。
本发明之无机复合板材，选择该基材做复合材料的原因如下，中间基材为首先对火电厂烟气进行脱硫脱硝除尘脱汞反应，然后将废液通过浓缩、结晶、离心、干燥得到含硫酸镁晶体，与粉煤灰、水渣粉及水泥用添加剂以2:1:1:1的重量比例混合制备得到晶粉板。该晶粉板与传统水泥、石材相比，具有环保、无废水、重量轻、成本低、保温性能好的特点；与木材和布艺材料相比，具有无燃烧、低成本、环保、无甲醛、无污染的特点。该板材的贴面材料为防火板。该材料具有抗冲击、耐磨损、耐污染、耐沸水、耐刮划及较好的尺寸稳定性的特点。
本发明之无机复合板材的制造方法，采用环保热熔胶或热熔树脂将防火板贴在晶粉板基底材料两面，使复合板不仅尺寸稳定、不易变形，而且复合板抗冲击、抗折、抗弯曲、耐磨损性能进一步增强。环保热熔胶对健康无害。该复合板实现了将防火性能优良的防火板与健康无机材料复合，能实现人们将环保、绿色、保温、健康、美观等优点集于一身的美好愿望。
概而言之，本发明的板材具有生产成本低、尺寸稳定性好、不易变形、防火耐磨、保温良好、环保健康的优点，而且本发明的板材具有美观大方，视觉效果可替代石材、木材和布艺，然而与之相比又具有节约能源、环保生态的特点。
附图说明
图1为本发明之无机复合板的制造方法的流程图。
具体实施方式
以下结合附图及实施例对本发明作进一步说明。
实施例1
本实施例之无机复合板材，基材为10mm厚的硅酸钙晶粉板，所述硅酸钙晶粉板的两面使用PUR热熔胶贴1mm厚的防火板。
所述硅酸钙晶粉板由以下方法制备而成：首先通过技术对火电厂烟气进行脱硫脱硝除尘脱汞反应，然后将废液通过浓缩、结晶、离心、干燥得到含硫酸镁晶体，通过控制与粉煤灰、水渣粉和水泥用添加剂以2:1:1:1的重量比例混合，得到的晶粉板。
所述无机复合板材的厚度为12mm。
所述无机复合板材的幅面尺寸规格为1.22m*2.44m。
参照图1，所述无机复合板材的制造方法，包括以下步骤：
(1)对基材进行UV渗透，将基材表面灰尘凝固，提高附着力，为下一步涂胶、贴合工艺做准备；
(2)对基材表面及防火板背面涂胶、贴合，采用的胶为PUR热熔胶；
(3)完成单面复合后，对基材进行180°翻转，对基材另一面重复以上操作，完成基材双面贴合防火板工艺；
(4)经压实、充分干燥后，即可对板材进行剪裁切割，根据产品要求进行封边工艺，即得到无机复合板。
步骤(1)中，在60～70℃预热条件下，对基材采用UV渗透固化方法，可大大减少污染，绿色环保。
步骤(2)中，由于采用的胶为PUR热熔胶，从涂抹到干燥固化过程仅有几秒钟，所以需要采用边涂胶边贴合的方式，贴合过程使用贴面机完成。
本发明的板材具有生产成本低、尺寸稳定性好、不易变形、防火耐磨、保温良好、环保健康的优点，而且本发明的板材具有美观大方，视觉效果可替代石材、木材和布艺，然而与之相比又具有节约能源、环保生态的特点。
该无机复合板物化检测性能如下：抗折强度：≥25MPa(GB/T17657-2013)；表面耐刮划性(金刚石划痕法)：表面2N有不明显轻微划痕(NEMALD3-2005)；导热系数：0.12w/m·k(GB10295)；耐高温性能：无变化(GB/T17657-2013)；耐沸水：表面无变化(GB/T17657-2013)；湿胀率：＜0.3％(GB/T17657-2013)；吸湿变形率：＜0.1％(GB/T17657-2013)；甲醛含量：0mg/l(GB18580-2001)。
实施例2
本发明之无机复合板材，基材为12mm厚的硅酸钙晶粉板，所述硅酸钙晶粉板的两面使用PUR热熔胶贴1mm厚的防火板。
所述硅酸钙晶粉板由以下方法制备而成：首先通过技术对火电厂烟气进行脱硫脱硝除尘脱汞反应，然后将废液通过浓缩、结晶、离心、干燥得到含硫酸镁晶体，通过控制与粉煤灰、水渣粉和水泥用添加剂以2:1:1:1的重量比例混合，得到的晶粉板。
所述无机复合板材的厚度为14mm。
所述无机复合板材的幅面尺寸规格为1.2m*2.4m。
本发明之无机复合板材的制造方法，包括以下步骤：
(1)对基材进行UV渗透，将基材表面灰尘凝固，提高附着力，为下一步涂胶、贴合工艺做准备；所述基材为硅酸钙晶粉板；
(2)对基材表面及防火板背面涂胶、贴合，采用的胶为PUR热熔胶；
(3)完成单面复合后，对基材进行180°翻转，对基材另一面重复以上操作，完成基材双面贴合防火板工艺；
(4)经压实、充分干燥后，即可对板材进行剪裁切割，根据产品要求进行封边工艺，即得到无机复合板。
步骤(1)中，在60～70℃预热条件下，对基材采用UV渗透固化方法，可大大减少污染，绿色环保。
步骤(2)中，由于采用的胶为PUR热熔胶，从涂抹到干燥固化过程仅有几秒钟，所以需要采用边涂胶边贴合的方式，贴合过程使用贴面机完成。
本发明的板材具有生产成本低、尺寸稳定性好、不易变形、防火耐磨、保温良好、环保健康的优点，而且本发明的板材具有美观大方，视觉效果可替代石材、木材和布艺，然而与之相比又具有节约能源、环保生态的特点。
该无机复合板物化检测性能如下：抗折强度：≥28MPa(GB/T17657-2013)；表面耐刮划性(金刚石划痕法)：表面2N有不明显轻微划痕(NEMALD3-2005)；导热系数：0.12w/m·k(GB10295)；耐高温性能：无变化(GB/T17657-2013)；耐沸水：表面无变化(GB/T17657-2013)；湿胀率：＜0.3％(GB/T17657-2013)；吸湿变形率：＜0.1％(GB/T17657-2013)；甲醛含量：0mg/l(GB18580-2001)。
Claims (8)
1.一种无机复合板材，其特征在于：基材为6mm～15mm厚的硅酸钙晶粉板，所述硅酸钙晶粉板的两面使用环保热熔胶或热熔树脂贴1±0.1mm厚的防火板。
2.根据权利要求1所述的无机复合板材，其特征在于：所述硅酸钙晶粉板用普通硅钙板或玻镁板替代。
3.根据权利要求1所述的无机复合板材，其特征在于：所述硅酸钙晶粉板由以下方法制备而成：首先对火电厂烟气进行脱硫脱硝除尘脱汞反应，然后将废液通过浓缩、结晶、离心、干燥得到含硫酸镁晶体，通过控制与粉煤灰、水渣粉、水泥用添加剂的不同配比制备得到不同性能晶粉板。
4.根据权利要求1或2所述的无机复合板材，其特征在于：所述无机复合板材的厚度为8mm～17mm。
5.根据权利要求1或2所述的无机复合板材，其特征在于：所述无机复合板材的幅面尺寸规格为1.22m*2.44m或1.2m*2.4m。
6.一种如权利要求1所述的无机复合板材的制造方法，其特征在于，包括以下步骤：
(1)对基材进行UV渗透，将基材表面灰尘凝固，提高附着力，为下一步涂胶、贴合工艺做准备；
(2)对基材表面及防火板背面涂胶、贴合，采用的胶为环保热熔胶或热熔树脂；
(3)完成单面复合后，对基材进行180°翻转，对基材另一面重复以上操作，完成基材双面贴合防火板工艺；
(4)经压实、充分干燥后，对板材进行剪裁切割，根据产品要求进行封边工艺，即得到无机复合板。
7.根据权利要求6所述的无机复合板材的制造方法，其特征在于，步骤(1)中，在60～70℃预热条件下，采用UV渗透固化方法。
8.根据权利要求6或7所述的无机复合板材的制造方法，其特征在于，步骤(2)中，采用边涂胶边贴合的方式，贴合过程使用贴面机完成。
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