CN110014710A - 石塑面板、木质门扇复合结构及其制备方法 - Google Patents

石塑面板、木质门扇复合结构及其制备方法 Download PDF

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CN110014710A
CN110014710A CN201910316486.2A CN201910316486A CN110014710A CN 110014710 A CN110014710 A CN 110014710A CN 201910316486 A CN201910316486 A CN 201910316486A CN 110014710 A CN110014710 A CN 110014710A
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panel
stone
door leaf
wooden door
wooden
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吴水根
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JIANGSHAN OUPAI DOOR INDUSTRY Co Ltd
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JIANGSHAN OUPAI DOOR INDUSTRY Co Ltd
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Abstract

本发明提供了用于木质门扇表面的石塑面板、木质门扇复合结构及它们的制备方法。所述石塑面板依次包括：基材层、装饰层、耐磨层和UV涂层；其中，所述基材层包含聚氯乙烯树脂和碳酸钙颗粒。所述基材层由包含如下组成的混合料形成：聚氯乙烯树脂颗粒80～120重量份；碳酸钙颗粒100～300重量份；聚氯乙烯磨粉料20～60重量份；钙锌稳定剂3～6重量份；润滑剂1.1～3.0重量份；聚乙烯蜡0.4～0.8重量份；抗冲改性剂5～13重量份。该石塑面板具有材料密度和硬度大，抗划痕和耐磨性好，以及尺寸稳定性好的优点。

Description

石塑面板、木质门扇复合结构及其制备方法
技术领域
本发明涉及石塑面板(Stone plastic composite)，包括该石塑面板的木质门扇复合结构，以及它们的制备方法。
背景技术
目前免漆门门扇组成材料通常为：聚氯乙烯(PVC)膜、中密度纤维板(MDF)、单板层积材(LVL)或实木档材及内部填充物，通过冷压胶合形成整体。传统免漆门扇采用PVC膜覆贴于MDF表面，其表面耐磨、抗划痕、耐老化性能偏差，影响产品外观及使用寿命；门面板为中密度纤维板材料，湿度较大环境中使用易吸湿膨胀，造成变形甚至脱胶开裂，应用环境以及区域受到较大限制。
因此，迫切需要提供一种能解决传统免漆门扇表面耐磨性能、抗划痕、耐老化性能较差，易吸湿膨胀等问题，同时兼具较高防火性能的门扇材料。
石塑材料由于密度和硬度大，抗划痕且耐磨，通常用于地板类产品的制备，在木质门行业尚未有使用石塑材料的先例。
发明内容
本发明的目的在于提供一种用于木质门扇表面的石塑面板，通过包含特定配方的基材层，而具有材料密度和硬度大，抗划痕和耐磨性好，以及尺寸稳定性好的优点。
根据本发明的一个方面，提供一种用于木质门扇表面的石塑面板，依次包括：基材层、装饰层、耐磨层和UV涂层；其中，所述基材层包含聚氯乙烯树脂和碳酸钙颗粒。
优选地，所述基材层由包含如下组成的混合料形成：
基于所述基材层的总重量，所述基材层包含0～2％重量的颜料。
本发明的另一方面提供了上述石塑面板的制备方法，包括以下步骤：
步骤一、按照配比计量各种原材料，依次经过热混、冷混、冷却后形成均匀的混合料；
步骤二、将所述混合料进行加热挤出成型，并经过压延、定厚形成片材；
步骤三、在所述片材表面依次贴覆装饰层和耐磨层；
步骤四、对贴覆后的片材表面进行UV涂层涂覆，并进行固化；
步骤五、将固化后的片材，进行回火处理。
优选地，所述回火处理包括在80～95℃的热水和10～20℃的冷水下进行。。
根据本发明的又一方面提供了一种木质门扇复合结构，包括上木质门面板、下木质门面板、位于侧面的第一档材和位于内部的填充材料。所述上木质门面板和所述下木质门面板中的一者或两者为表面贴覆有上述石塑面板的木质板材。
可选地，所述上木质门面板和所述下木质门面板中的两者均可包括木质板材和贴覆在该木质板材表面上的上述石塑面板。或者，所述上木质门面板和所述下木质门面板中之一可包括木质板材和贴覆在该木质板材表面上的上述石塑面板，另一个面板则可包括木质板材和贴覆在该木质板材表面的贴皮面板。
优选地，所述填充料选自蜂窝纸、龙骨料、空心刨花板、中密度纤维板和指接实木。
根据本发明的又一方面，提供一种门扇复合结构的制备方法，由上述石塑面板、木质板材、档材、封边带和填充料经冷压胶合成型制得。
根据本发明的石塑面板通过特定的成分设计，并经过表面紫外回火处理，
能够与木质板材进行有效贴覆，从而赋予木质板材表面以石塑材料的特性。
具体地，根据本发明的石塑面板具有如下优点：1)由于石塑材料的密度和硬度大，能抗划痕、耐磨；2)极难溶于水，能防潮、防水、防腐、防霉变；3)尺寸性能稳定，热胀冷缩变化小，湿胀干缩变化小；4)较高阻燃性，能有效防止燃烧。
附图说明
参考随附的附图，本发明更多的目的、功能和优点将通过本发明实施方式的如下描述得以阐明，其中：
图1示意性示出了根据本发明的石塑面板的结构；
图2示意性示出了根据本发明的木质门扇复合结构的正视图；
图3为图2所示的木质门扇复合结构的内部结构图；
图4为图2所示的木质门扇复合结构沿B方向的剖面放大图。
具体实施方式
根据本发明提供的用于木质门扇表面的石塑面板，依次包括：基材层、装饰层、耐磨层和UV涂层。
其中，基材层包含聚氯乙烯树脂和碳酸钙颗粒。
优选地，基材层由包含如下组成的混合料形成：
基于上述混合料的总重量，混合料还包含0～2％重量的颜料。
以上聚氯乙烯树脂优选为SG-5型PVC。聚氯乙烯磨粉料是聚氯乙烯材料回收料经研磨粉碎后得到的粉状物。
上述碳酸钙颗粒优选为重质碳酸钙颗粒，更优选细度300目以上的方解石钙粉。
上述钙锌稳定剂的主要组分为钙锌有机酸盐，不含铅、镉、钡等重金属的无毒钙锌多功能复合稳定剂，例如可为钙锌复合热稳定剂WD-1。
上述润滑剂可包括PVC内外润滑剂ZB-60或ZB-74 0.6～1.0重量份，PVC润滑剂ZB-175或ZB-101 0.5～2重量份。
上述抗冲改性剂可包括CPE抗冲击改性剂氯化聚乙烯135-A 4～8重量份，ACR抗冲击改性剂ACR ZB-20或ZB-1 1～5重量份。
上述颜料可包括本领域的常用颜料，例如可包括炭黑、钛白粉、增白粉等，可根据所需颜色调整各种颜料间的配比，颜料的总重量不超过形成基材层的混合料总重量的2％。
优选地，基材层由包含如下组成的混合料形成：
上述石塑面板的厚度可为2.0～4.0mm，密度可为1200～2000Kg/m3。
参见图1，根据本发明的石塑面板由基材层、装饰层(印刷料，优选PVC彩膜)、耐磨层(约0.3mm，优选三氧化二铝层)和UV涂层(优选辊涂工艺)。
根据本发明的用于木质门扇表面的石塑面板的制备方法，包括以下步骤：
步骤一、按照配比计量各种原材料，依次经过热混、冷混、冷却后形成均匀的混合料；
步骤二、将所述混合料进行加热挤出成型，并经过压延、定厚形成片材；
步骤三、在所述片材表面依次贴覆装饰层和耐磨层；
步骤四、对贴覆后的片材表面进行UV涂层涂覆，并进行UV固化；
步骤五、将UV固化后的片材，进行回火处理。
步骤一中，各原材料按上述重量比计量，放入高速混合机中，优选在120～130℃下进行热混，使得原材料混合均匀，排除其中的水分；当混合料达到设置的热混温度时，及时在50～60℃下进行冷混，使得物料降温，防止结块和变色，形成混合均匀的混合料，直至混合料达到冷混设定温度后备用。
步骤二中，将混合料送入双螺杆挤出机，进行150～180℃加热挤出，由片材模具挤出成型，例如可用四辊压延机压延，对基材进行定厚。
步骤三中，对片材依次贴覆装饰层和耐磨层。其中，装饰层和耐磨层可为业内常用的装饰材料，例如分别可为PVC彩膜和氧化铝层。
步骤四中，在贴覆后的片材表面均匀地涂上一层UV涂料，可采用辊涂、喷涂、淋涂工艺，优选辊涂工艺。涂覆的UV涂层通常经紫外线照射并进入烘箱进行80～120℃烘烤来进行固化。优选地，重复两次辊涂、紫外照射和烘烤固化过程，以使涂料充分固化。
步骤五中，将固化后的片材分别送入80～95℃的热水与10～20℃的冷水中冷却。优选地，在冷却后，用冷风吹干片材表面的水，并放入常温常压下养生24～48h。
优选地，对养生放置后的片材进行分切包装。
由以上特定配方的混合料经过以上特定的方法步骤，制备得到的石塑面板控制厚度在2.0～4.0mm，既保持了石塑材料硬度、抗划痕和耐磨性等物理特性，又能够与木质门扇进行良好的贴合。
石塑面板通常色彩、纹理造型多样(例如石纹、木纹、锯纹等)，具有逼真的实木立体感效果，可为门扇造型提供多样化选择。石塑(SPC)面板表面造型可塑性强，相对传统的门扇可免去造型镂铣、喷漆等工艺，其加工工艺更加简单高效，加工过程更加环保节能。
本发明提供的木质门扇复合结构包括上木质门面板、下木质门面板、位于侧面的第一档材和位于内部的填充材料。其中，上木质门面板、下木质门面板中的一者或两者为表面贴覆有上述石塑面板的木质板材。
根据一种具体实施方式，上述上木质门面板和上述下木质门面板中之一可包括木质板材和贴覆在该木质板材表面上的上述石塑面板，另一个面板则可包括木质板材和贴覆在该木质板材表面的贴皮面板，即单面石塑复合门扇结构。由此制得的单面复合门扇结构可应用在门扇两面温湿度不一致的场所，石塑面板置于温度变化较大、高湿度区域，贴皮面板置于稳定室温、低湿度区域。
根据另一种具体实施方式，上述上木质门面板和下木质门面板中的两者均可包括木质板材和贴覆在该木质板材表面上的上述石塑面板，即双面石塑门面板。
上述木质门扇复合结构的四周还设置有封边带，例如5.0～7.0m的PVC封边带、铝制封边带等。优选地，在该门扇复合结构内部，在第一档材内侧设置有第二档材。第一档材和第二档材的材料可相同或不同，并且独立地可选自单板层积材、杉木、多层胶合板。
上述填充料可选自蜂窝纸、龙骨料、空心刨花板、中密度纤维板、指接实木。
上述木质门扇复合结构由上述石塑面板、木质板材、档材、封边带、填充料，通过冷压胶合形成。该木质板材优选为中密度纤维板。
上述冷压胶合过程中，使用比例为1:20～1:10的冷压胶和固化剂进行固化。该冷压胶通常为白乳胶，可为聚醋酸乙烯乳液，固化含量≥50％，粘度10000～18000MPa.S；固化剂为异氰酸酯胶，固化含量≥99％，粘度180～220MPa.S。冷压胶混合物的用胶量可为130～170g/m2。
具体地，根据实际门扇需求，对于选定尺寸的木质门面板，组框填充后，经冷压胶合成型。对成型的门扇复合结构进行精确的尺寸截切，再用封边带封边，开五金孔，清理，包装。
图2至图4示出了本发明的一个具体实施方式。其中，图2示出了木质门扇复合结构的正视图。图3为图2所示的木质门扇复合结构的内部结构图，图4为图2所示的木质门扇复合结构沿B方向的剖面放大图。具体地，该门扇结构包括第一石塑面板1、第一中密度纤维板(MDF)2、单板层基材(LVL)3、第二中密度纤维板4、第二石塑面板5、填充料蜂窝纸芯6、铝合金型材封边7、多层胶合板档材8、LVL锁垫木9，门吸垫木10，以及LVL合页垫木11。
根据本发明包括上述石塑面板取代传统免漆门中PVC膜与中密度纤维板复合贴皮的模压面板，直接采用工艺简单节能的冷压胶合。石塑面板的背面通过涂胶机或者人工涂冷压胶，施胶量为130～170g/m2。若为单面石塑门扇，非石塑面贴皮面板涂冷压胶，施胶量为130～170g/m2。利用液压式冷压机施加1.0～2.5MPa压力，保压2～4h(生产温度、胶水固化剂含量较低时，可适当延长加压时间)，进行冷压胶合成型。生产时，适合批量生产，提高生产效率，降低生产成本。
与传统PVC膜免漆门扇性能相比，根据本发明的包括石塑面板的门扇复合结构在以下性能方面具有显著改善：
1)耐划痕性能
根据SPC石塑面板与传统PVC装饰膜相比，SPC石塑面板具有特定组成，且表面经过UV回火处理，强度、刚性都高于PVC装饰膜，表现出更好的耐划痕性能。按GB/T 17657-2013中4.39方法对SPC石塑面板与不同厚度的PVC装饰膜进行表面耐划性能测定，发现SPC石塑面板表面耐划痕全部符合标准要求，PVC装饰膜几乎不符合标准要求，SPC石塑面板表面耐划痕总体优于PVC装饰膜。
2)耐磨性能
SPC石塑材料表面有氧化铝耐磨层，与传统PVC装饰膜相比，呈现出了更好的耐磨性能。按《GB/T 29498-2013》标准对SPC石塑材料与不同厚度的PVC装饰膜进行表面耐磨性能测定，结果表明磨80转后均无露底现象，都符合标准要求。进一步测试，当大于600转后PVC装饰膜普遍出现露底现象，SPC石塑材料在大于5000转时开始出现耐磨层露底现象，说明SPC石塑材料表面耐磨性能总体优于PVC装饰膜。
3)吸水膨胀率
根据SPC石塑材料组成特性，代替了门皮的中密度纤维板，SPC石塑材料不存在木质纤维大分子，不含有类似羟基的亲水基团，且SPC石塑材料本身为非极性疏水材料，极难溶于水。按《GB/T 17657-2013，4.4》方法对厚度相近的SPC石塑面板与PVC贴皮模压面板进行吸水膨胀率测定。结果表明SPC石塑面板吸水膨胀率≤1.0％，PVC贴皮模压面板吸水膨胀率20.0～30.0％，SPC石塑材料吸水膨胀率性能上远优于传统的PVC贴皮模压面板。
4)尺寸变化稳定
SPC石塑材料加工工艺经过回火处理，减小或消除材料在加工过程时产生的内应力，降低材料脆性，同时保持较高的硬度。SPC石塑材料收缩率测试(标准：80℃，6小时)结果≤1‰,相对PVC膜≤4％的尺寸变化率，明显有更稳定的尺寸变化率。
5)有害物质含量
对包含SPC石塑面板的复合门扇按GB 18580-2017中1m3气候箱测定甲醛释放量，测定结果为0.049mg/m3远低于国家标准要求的0.124mg/m3；按《GB 18586-2001》测定可溶性重金属含量铅、镉，均未测出。SPC石塑材料面板门相关有害物质指标都远优于国家、行业标准要求。
6)阻燃性
按照《GB 8624-2012》建筑材料可燃性试验方法，测定包含SPC石塑面板的复合门扇的防火指标可达B1级，具有非常出色的防火性能，仅次于石材。SPC石塑材料本身不会燃烧且能有效阻燃。其次，包含SPC石塑面板的复合门扇独特的材料组成，在被动点燃时所产生的烟雾也绝对不会对人体产生伤害，不会产生有毒有害气体。
在下文中，将参考附图描述本发明的实施例。在附图中，相同的附图标记代表相同或类似的部件，或者相同或类似的步骤。
实施例1
1、石塑面板的制备
(1)由以下组成的混合料制备基材层：
SG-5型PVC 100kg，细度300目以上的重质碳酸钙200kg，PVC磨粉料40kg，钙锌稳定剂4kg，PVC内外润滑剂ZB-60 0.8kg，PE蜡0.6kg，CPE抗冲击改性剂氯化聚乙烯135-A 6kg，ACR抗冲击改性剂ACR ZB-20 3kg，PVC润滑剂ZB-175 1kg，炭黑0.6kg；
将上述原材料计重后放入高速混合机中，在125℃下进行热混，然后在55℃下进行冷混，冷却后形成混合料；
将混合料送入双螺杆挤出机，经150～180℃加热挤出，由片材模具挤出成型，再用四辊压延机压延，并对基材进行定厚为2mm，形成基材层。
(2)基材层的贴覆
对根据以上步骤(1)制得的基材层贴覆装饰层PVC彩膜和耐磨层氧化铝层，得到石塑面板。
2、门扇复合结构的制备
(1)根据门扇复合结构预定尺寸2100*800*40mm，选择符合尺寸要求的上述石塑面板和其它门扇复合结构的组成材料：厚度2mm石塑面板、厚度4mmMDF、30*27mmLVL、20*27mm多层胶合板档材、27mm蜂窝纸芯、0.8mm铝合金型材；
(2)门扇复合结构的组装：
a.按实际门扇尺寸2100*800*40mm要求，选择含水率为6％～12％的2400*30*27mmLVL，利用射钉枪机械装订组成边框；
b.选择含水率为5％～8％的2400*1200*4mm MDF，利用涂胶机单面均匀施冷压胶，施胶量为130～170g/m2，将边框、2150*20*27mm多层胶合板档全部固定于MDF的施胶面上；
c.选择厚度为27mm、孔径为17～19mm，含水率为8％～12％的蜂窝纸芯进行门内填充；
d.选择含水率为5％～8％的2400*1200*4mm MDF，利用涂胶机单面均匀施冷压胶，施胶量为130～170g/m2，MDF的施胶面全面覆于边框上；
e.选择两块尺寸相同的2380*920*2mmMDF和石塑面板，利用涂胶机在非装饰层面均匀施加冷压胶，施胶量为130～170g/m2，两块石塑面板分别覆于MDF上；
f.对半成品进行冷压胶合，选择液压式冷压机施加1.0～2.5MPa压力，保压2～4h，进行冷压胶合成型；
g.按实际门扇尺寸2100*800*40mm要求进行尺寸精截，选择40*0.8mm铝合金型材进行45°切角封边；
h.按所需尺寸要求进行五金开孔，清洁包装。
如图2至图4所示，该双面SPC石塑门扇包括厚度2mm石塑面板(1,5)、厚度4mm MDF(2,4)、30*27mm LVL(3)、20*27mm多层胶合板档材(8)、27mm蜂窝纸芯(6)、0.8mm铝合金型材封边(7)。
实施例2
以与实施例1相同的方法制备门扇结构，不同之处在于，将实施例1中双面SPC石塑材料门扇结构改为单面SPC石塑材料门扇结构，由贴皮面板代替其中一面SPC石塑面板，其中，贴皮面板为PVC贴皮面板。
性能测试
对根据实施例1和2制得的SPC石塑材料门扇结构测定耐划痕性能、耐磨性能、吸水膨胀率、尺寸变化稳定性和有害物质含量。结果示于以下表1中。
表1
由以上实施例1和2以及表1的数据可看出，根据本发明的SPC石塑材料门扇结构具有优异的耐划痕性能、耐磨性能、吸水膨胀率、尺寸变化稳定性，且有害物质含量低。
结合这里披露的本发明的说明和实践，本发明的其他实施例对于本领域技术人员都是易于想到和理解的。说明和实施例仅被认为是示例性的，本发明的真正范围和主旨均由权利要求所限定。

Claims (10)

1.一种用于木质门扇表面的石塑面板，其特征在于，所述石塑面板依次包括：基材层、装饰层、耐磨层和UV涂层；
其中，所述基材层包含聚氯乙烯树脂和碳酸钙颗粒。
2.根据权利要求1所述的用于木质门扇表面的石塑面板，所述基材层由包含如下组成的混合料形成：
3.根据权利要求2所述的用于木质门扇表面的石塑面板，基于所述混合料的总重量，所述混合料还包含0～2％重量的颜料。
4.根据权利要求1至3中任一项所述的用于木质门扇表面的石塑面板的制备方法，其特征在于，包括以下步骤：
步骤一、按照配比计量各种原材料，依次经过热混、冷混、冷却后形成均匀的混合料；
步骤二、将所述混合料进行加热挤出成型，并经过压延、定厚形成片材；
步骤三、在所述片材表面依次贴覆装饰层和耐磨层；
步骤四、贴覆后的片材表面进行UV涂层涂覆，并进行固化；
步骤五、将固化后的片材，进行回火处理。
5.根据权利要求4所述的制备方法，所述回火处理包括在80～95℃的热水和10～20℃的冷水下进行。
6.一种木质门扇复合结构，其特征在于，包括上木质门面板、下木质门面板、位于侧面的第一档材和位于内部的填充材料，所述上木质门面板和所述下木质门面板中的一者或两者为表面贴覆有根据权利要求1至5中任一项所述的石塑面板的木质板材。
7.根据权利要求6所述的门扇复合结构，所述上木质门面板和所述下木质门面板中的一个为表面贴覆有根据权利要求1至5中任一项所述的石塑面板的木质板材，另一个为表面贴覆有贴皮面板的木质板材。
8.根据权利要求6所述的门扇复合结构，所述上木质门面板和所述下木质门面板分别为表面贴覆有根据权利要求1至5中任一项所述的石塑面板的木质板材。
9.根据权利要求6至8中任一项所述的门扇复合结构，所述填充料选自蜂窝纸、龙骨料、空心刨花板、中密度纤维板和指接实木。
10.一种门扇复合结构的制备方法，由根据权利要求1至5中任一项所述的石塑面板、木质板材、档材、封边带和填充料经冷压胶合成型制得。
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CN114775949A (zh) * 2022-04-25 2022-07-22 浙江晶通新材料集团有限公司 抗老化装饰板材、地板及板材制造方法

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