CN110891780B - 实木颗粒板 - Google Patents
实木颗粒板 Download PDFInfo
- Publication number
- CN110891780B CN110891780B CN201880046936.4A CN201880046936A CN110891780B CN 110891780 B CN110891780 B CN 110891780B CN 201880046936 A CN201880046936 A CN 201880046936A CN 110891780 B CN110891780 B CN 110891780B
- Authority
- CN
- China
- Prior art keywords
- solid wood
- intermediate foil
- core layer
- particle board
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
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Images
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Landscapes
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- Laminated Bodies (AREA)
Abstract
一种实木颗粒板(10),包括:芯层(2),该芯层(2)由树脂涂覆的具有大颗粒尺寸的实木颗粒形成;至少一个表面层(1,4),所述至少一个表面层(1,4)由树脂涂覆的实木颗粒形成,其中,所述至少一个表面层(1,4)包括颗粒尺寸小于芯层(2)的颗粒尺寸的实木颗粒;以及至少一个中间箔(3,5),所述至少一个中间箔(3,5)布置在表面层(1,4)与芯层(2)之间,其中,所述至少一个中间箔(3,5)的表面重量在5g/m2至600g/m2的范围内并且厚度在0.05mm至3mm的范围内。
Description
技术领域
本发明涉及实木颗粒板。实木颗粒板的示例可以包括由具有大碎片尺寸的实木颗粒构成的芯层,该芯层夹置在两个表面层之间,所述两个表面层由颗粒尺寸小于芯层的碎片尺寸的实木颗粒构成。
背景技术
目前特别是用在家具制造行业中的普通实木颗粒板包括多个实木颗粒层,其中,不同的层可以由不同尺寸的颗粒构成。具体地,表面层可以由细颗粒尺寸的实木颗粒构成,而芯层可以包含具有大颗粒尺寸的实木颗粒。然而,根据实木颗粒板的预期用途,板的相应层中的实木颗粒尺寸可以以不同的方式选择。例如,对于用在地板中或木质建筑行业中的结构板,尽管仍然需要提供适度光滑的表面,但是层的组成和数目可以根据相应的预期用途的需求来选择。在制造过程中,实木颗粒通常与粘结剂混合或涂覆有粘结剂,并且然后被放置以形成期望的层。然后,层在高压和高温下被压缩以形成颗粒板。
芯层的大的实木碎片被相对松散地压制,其中,在碎片之间形成有气穴,该芯层通常具有粗糙的表面纹理。因此,使用由较小颗粒构成的表面层来提供至少一个光滑且平坦的外表面。实木颗粒板通常以对称的方式构造,其包括奇数个层,所述奇数个层具有两个相应的外表面层和一个或更多个芯层。表面的质量对于家具制造行业特别重要。
为了确保板的低的总重量,期望使用相对薄的表面层。然而,一些较小的表面层颗粒可能会落到较大的芯层颗粒之间的间隙中,使得在薄的表面层的情况下表面粗糙度可能会增加。
发明内容
本发明的目的是提供一种具有平坦的表面的实木颗粒板。在本公开的上下文中,术语“实木颗粒板”用作关于至少部分地由实木颗粒制成的任何面板产品——比如说例如刨花板、OSB、碎片板、碎料板、华夫板等——的通用术语。此外,本公开的术语“实木颗粒板”还可以涵盖具有纤维基芯层和颗粒板表面层的板或可以例如包括被细颗粒板层覆盖的由木丝制成的芯的板。
根据本发明的实木颗粒板包括:芯层,该芯层可以例如由具有大颗粒尺寸的实木颗粒构成;以及至少一个表面层,所述至少一个表面层可以例如由颗粒尺寸小于芯层的颗粒尺寸的实木颗粒构成。因此,形成了具有光滑表面的轻质实木颗粒板。然而,本公开不限于这种碎片板,而是可以涵盖由不同类型的实木颗粒或木质纤维材料制成的其他类型的实木颗粒板。
通常,实木颗粒板以对称的方式形成有位于外侧的两个表面层以及夹置在这两个表面层之间的一个或更多个芯层。然而,可以设想的是,对于特定的应用,可以使用具有非对称构型并且仅具有一个表面层的实木颗粒板,使得芯层仅在芯层的侧面中的一个侧面上被单独的表面层覆盖。
在表面层与芯层之间布置有至少一个中间箔。中间箔层可以例如防止实木颗粒从表面层落到芯层中。因此,表面层的厚度相比于现有技术的颗粒板可以减小,同时确保了实木颗粒板的光滑且平坦的表面。
在制造期间,具有定位在芯层与表面层之间的中间箔的实木颗粒板可以在压力作用下利用例如热压制、冷压制或高频电流固化方法来固化。
因此,如上所限定的实木颗粒板即使在表面层相当薄的情况下也实现了由表面层均匀地覆盖粗糙的芯层(比如说例如碎片板、OSB或华夫板的芯层)。假使芯层由碎片、比如OSB基板或华夫基板制成,则通过现有技术方法极难实现这样的均匀覆盖。因此,根据实施方式,可以提供一种轻质的实木颗粒板,因为重的表面层的厚度可以由于中间箔的存在而减小。
此外,中间箔的存在允许减小所使用的表面层的量,而所制造的实木颗粒板可以仍然处于标准颗粒板或甚至高密度板的密度范围内。
中间箔具有下述附加效果:中间箔确保实木颗粒板的两个表面可以以相同的质量生产。在典型的现有技术实木颗粒板中,顶部表面倾向于具有较低的质量,并且通常使用较多的材料来形成顶部表面以实现给定的表面质量。因此,根据实施方式的实木颗粒板允许提高表面质量以用于具有高要求的应用,比如说例如薄箔或直接印花。
还发现,在与现有技术的实木颗粒板相比的情况下,在芯层与顶部表面层之间设置中间箔允许更快地制造实木颗粒板并且允许制造具有更高质量的边缘的实木颗粒板。这可能是由在热压制中作用在颗粒板板坯上的中间箔平衡力引起的,并且因此允许使放置的实木颗粒板板坯形成成品实木颗粒板的更快且质量更佳的压制步骤。此外,与没有中间箔的现有技术实木颗粒板相比,中间箔可以影响颗粒在热压制步骤期间的膨胀并且可以改善膨胀特性。
根据实施方式,中间箔可以是蒸气可渗透的。如果采用冷压制过程,则中间箔不必具有蒸气渗透性。然而,如果使用热压制,则蒸气可渗透的中间箔允许水分或蒸汽在热压制及后续冷却期间从芯层逸出。替代性地,可以使用不具有渗透性的热塑性中间箔,因为这种中间箔在热压制期间将会破裂或熔化,并且因此将不会形成对于蒸气从任何芯层或表面层逸出的障碍。
根据一些实施方式,可以提供一种实木颗粒板,其中,在该实木颗粒板的芯层与表面层中的一个表面层之间设置有仅一个中间箔。根据替代性实施方式,实木颗粒板可以包括两个中间箔,所述两个中间箔布置在芯层的相反的表面上。因此,对于一些应用,可以提供具有两个光滑表面的实木颗粒板。另外,可以通过在芯层的两侧设置两个中间箔来改善实木颗粒板的整体稳定性和机械性能。其中,可以根据成品实木颗粒板的期望机械性能来选择中间箔的厚度、密度和机械性能。
本发明的中间箔可以通过设置在芯层和表面层中的粘合剂粘附至芯层和表面层。因此,可以不必在中间箔上设置附加的粘合剂。此外,中间箔可以由各种材料、比如纸构成,特别地,中间箔可以是未经树脂浸渍的纸、带孔的塑料片材、织物或网状件。
本发明的中间箔的表面重量可以在5g/m2至600g/m2、优选地在5g/m2至200g/m2、最优选地在5g/m2至60g/m2的范围内并且厚度可以在0.05mm至3mm、优选地在0.05mm至2.5mm、最优选地在0.05mm至2.0mm的范围内。
芯层的密度可以在500kg/m3以下,并且表面层的密度可以在700kg/m3以上。因此,可以提供轻质的实木颗粒板。由于中间箔的设置,即使在表面层相当薄的情况下也能够确保高的表面质量。
本发明还涉及一种用于生产实木颗粒板的方法。作为第一步骤,放置定尺寸成小颗粒尺寸的实木颗粒及粘合剂以形成第一表面层。在第一表面层上放置具有大颗粒尺寸的实木颗粒及粘合剂以形成芯层。接下来,在芯层的顶部上设置中间箔,其中,中间箔可以是蒸气可渗透的。可以将中间箔设置为连续的片材以允许连续的制造过程。在已经将中间箔安置到芯层上之后,放置颗粒尺寸小于芯层的颗粒尺寸的实木颗粒及粘合剂以形成至少一个表面层。最后,对放置的层进行压缩以形成实木颗粒板。
因此,通过设置中间箔防止了表面层的小颗粒进入芯层。另外,由于中间箔可以是蒸气可渗透的,因此可以使用常规的连续热压制过程来制造实木颗粒板,在该过程中,中间箔允许蒸汽和蒸气在压制和冷却期间穿过实木颗粒板。对于其他制造方法、比如说例如冷压制或高频电流固化,可以不必设置蒸气可渗透的中间箔。
其中,可以在执行放置实木颗粒的步骤之前用粘合剂涂覆实木颗粒。
根据实施方式,可以通过设置在芯层和表面层中的粘合剂将中间箔粘附至芯层和表面层。因此,不必在中间箔层上设置附加的粘合剂。
根据实施方式,在放置芯层的实木颗粒及粘合剂之前,可以将第一中间箔直接放置到第一表面层上,其中,可以将芯层放置在第一中间箔的顶部上。随后,可以在芯层的顶部上设置第二中间箔,并且可以在第二中间箔的顶部上放置第二表面层。
以这种方式,可以形成包括位于芯层的两侧的两个表面层的实木颗粒板,其中,在每个表面层与芯层之间定位有相应的中间箔。因此,可以提供用于需要具有两个高质量表面的板的应用的实木颗粒板。另外,在适当选择中间箔材料的情况下,可以通过在芯层的两侧添加两个中间箔层来改善实木颗粒板的机械性能。
附图描述
图1示出了本发明的第一实施方式的颗粒板的示意图。
图2示出了本发明的第二实施方式的颗粒板的示意图。
图3示出了双密度实木颗粒板的示例,其中,可以使用如图1或图2中所示的中间箔。
图4是在制造根据本发明的实施方式的实木颗粒板期间将粘合剂施加到中间箔层上的示意图。
具体实施方式
为了制造根据下面详细描述的实施方式中的一个实施方式的颗粒板,形成有粘合剂涂覆的实木颗粒的层。其中,不同的层通常包括具有不同性能的实木颗粒,并且所述层以彼此叠置的方式放置。在如下面所描述的实施方式中,在所放置的实木颗粒的两个层之间安置有至少一个中间箔。在形成颗粒层并且在两个颗粒层之间设置中间箔之后,进行至少一个固化或压制过程,所述至少一个固化或压制过程可以包括同时加热和压制。加热和压力使粘合剂活化并找出任何可获得的水分。粘合剂贯穿所有层进行粘结,然后凝固以提供实木颗粒之间以及实木颗粒与中间箔之间的牢固粘结。此外,应用压制以使层强化并且使实木颗粒板的内部结构演变,该内部结构包括实木颗粒板的最终密度轮廓。压制可以被执行为连续的过程,其中,连续地放置颗粒层并且将颗粒层连续地输送穿过热压制设备;或者压制可以被执行为分批过程,其中,将预定尺寸的层状颗粒结构安置在热压制设备中,在该热压制设备中,预定尺寸的层状颗粒结构在压制期间保持静止。
在压制之后,可以对实木颗粒板进行冷却和修整,以获得期望的长度和宽度。实木颗粒板可以形成为面板,但是也可以形成为模制的颗粒板产品、比如家具部件。此外,可以在进一步加工之前对实木颗粒板进行砂磨或刨削。可以在压制和冷却之后将其他层比如说例如装饰性外部层或其他支承层施加至实木颗粒板。
图1示出了本发明的第一实施方式的示意图。根据本实施方式的实木颗粒板10包括多个层,所述多个层从底部至顶部布置如下:底部表面层1、芯层2、中间箔3和顶部表面层4。
在所描绘的实施方式中,表面层1和4由小实木颗粒形成以提供光滑的高质量表面。其中,表面层1和4两者可以由具有大致相同的尺寸和机械性能的实木颗粒构成,以确保实木颗粒板的平衡结构并且防止板内的变形和机械应力。成品实木颗粒板的表面层1和4的密度可以在700kg/m3以上,以确保整个实木颗粒板的足够的稳定性。
在所描绘的实施方式中,中间箔3布置在芯层2与顶部表面层4之间。中间箔3的表面重量可以在5g/m2至600g/m2、优选地在5g/m2至200g/m2、最优选地在5g/m2至60g/m2的范围内。中间箔3的厚度可以在0.05mm至3mm、优选地在0.05mm至2.0mm、最优选地在0.05mm至2.0mm的范围内。中间箔材料的关键特性可以在于,中间箔材料具有一定的蒸气渗透性,以确保热和蒸汽在热压制过程期间传递。可以使用葛尔莱阻力(Gurley resistance)以用于确定空气阻力的水平。例如,中间箔的空气阻力可以在1.1葛尔莱秒至12葛尔莱秒之间。优选地,该材料可以在高达约240℃的情况下机械稳定,以承受热压制过程而不被损坏。替代性地,中间箔可以设计成在压制或固化期间一旦实木颗粒在实木颗粒板的相应的层中的位置固定则中间箔被破坏或熔化。
各种材料可以构成中间箔3,比如纸、特别是未经树脂浸渍的纸、带孔的塑料片材、织物或网状件。在图1的第一实施方式中,在中间箔3上不必设置附加的粘合剂。然而,在另一实施方式中,可以利用粘合剂对中间箔3进行处理,以改善中间箔3与芯层2和表面层4的结合,如例如在图4中所示及在下面详细描述的。
由于中间箔3的设置,表面层4的厚度相比于常规的实木颗粒板可以减小,使得每一侧的每个表面层的厚度相当于整个板厚度的约8%,例如,对于11mm的板,每个表面层可以为0.7mm厚,或者对于40mm的板,每个表面层的厚度可以是2mm。因此,实木颗粒板的整体密度和重量可以减小,同时确保高的表面质量。
中间箔3安置在芯层2与顶部表面层4之间,并且因此防止实木颗粒从顶部表面层4移动到芯层2中,从而提供表面层2的光滑且平坦的表面。该实施方式可以用于各种应用,例如用于提供家具的无瑕疵外观。
由于中间箔3的使用,芯层2不需要用作细表面颗粒的承载部。因此,芯层2可以生产成相比于常规的实木颗粒板中的芯层具有甚至更低的密度,从而由于在芯层2中使用较大的实木颗粒而包括甚至更大的气穴。
图2示出了本发明的第二实施方式的示意图。与第一优选实施方式相比,第二实施方式的实木颗粒板11包括位于底部表面层1与芯层2之间的附加的中间箔5。
中间箔3和5优选地设置有相同的厚度、密度和机械性能,以确保实木颗粒板11的平衡结构,从而防止变形。由于所有层的对称布置,因而可以选择比第一实施方式中的中间箔3厚的中间箔3和5。优选地,中间箔3和5中的每一者的厚度在0.05mm至3mm、优选地在0.05mm至2.5mm、最优选地在0.05mm至2.0mm的范围内。
两个中间箔3和5的布置提供了表面层1和4的两个光滑且平坦的表面。这仅在顶部中间箔过厚的情况下是需要的,以保持板的稳定性并且以防止板由于设置单个厚的中间箔而弯曲。
本发明不限于上述实施方式,而是在不脱离本发明的范围的情况下可以将各种修改和/或添加合并在所描述的实施方式中。
例如,还可以将饰面薄板或其他材料施加在表面层1和/或表面层4的顶部上以提供装饰性表面。实木颗粒板还可以通过涂漆或油漆来进行最后修饰,或者可以利用耐火化学物质进行处理。此外,可以将其他材料像农业废弃物可以合并到实木颗粒板的层中。
根据上述实施方式的实木颗粒板可以以连续过程或者以分批过程来生产。根据连续制造方法的实施方式,可以用粘合剂涂覆实木颗粒。随后,可以将粘合剂涂覆的实木颗粒放置在输送带或类似物上,以形成第一表面层1和芯层2。然后可以将蒸气可渗透的中间箔3安置在芯层的顶部中,其中,例如中间箔3从辊子连续地供应。可以将较小的粘合剂涂覆的实木颗粒的顶部表面层4放置在中间箔3的顶部上。然后,可以将粘合剂涂覆的实木颗粒与设置在这些实木颗粒之间的中间箔3的最终堆叠件输送到连续热压制设备中,以用于形成成品实木颗粒板10。
作为如上所述的方法的改型,可以在如上所述放置芯层颗粒之前或之后放置附加的实木颗粒层、比如说例如附加的表面层1。其中,可以在放置附加的底部表面层1之后设置第二中间箔5,然后将形成芯层2的颗粒放置到第二中间箔5上。
综上所述,如上所述的实施方式提供了一种实木颗粒板,其中,芯层可以由大实木颗粒形成以实现成品板的低密度,并且其中,至少一个表面层可以由较小的实木颗粒形成以实现至少一个光滑的表面。表面的质量通过在芯层与所述至少一个表面层之间设置中间箔来保证,其中,中间箔防止表面层的颗粒进入芯层中的任何运动,并且防止芯层的颗粒进入表面层中的任何运动。由于中间箔可以是蒸气可渗透的,因此中间箔可以不影响在实木颗粒板的制造期间的热压制过程。在热压制期间,中间箔使用附接至实木颗粒的粘合剂粘附至芯层和表面层的颗粒,使得通常不必在中间箔上设置另外的粘合剂涂层。
对于一些应用,提供具有两个高质量表面的实木颗粒板可能是有利的。在这种情况下,可以在芯层的两侧设置两个中间箔。另外,可以使用具有期望的机械性能的中间箔以用于例如加强实木颗粒板同时保持板的总体密度低。在这种情况下,可以使用两个中间箔以获得加强的实木颗粒板的平衡构型。
图3示出了另一种类型的实木颗粒板12的说明性示例,其中,可以使用如上所述的一个或两个中间箔。双密度实木颗粒板12包括如上所述夹置在第一表面层1与第二表面层4之间的芯层2。图4中所描绘的双密度实木颗粒板12除了上面针对实木颗粒板10、11所描述的特征外还具有多个不同的区域6、7,其中,高密度区域6与低密度区域7以交替的方式布置为例如低密度和高密度交替的纵向条带。与上面针对图1和图2的实木颗粒板10、11所描述的类似,可以在热压制或固化之前将一个或两个中间箔层安置在双密度实木颗粒板12的芯层2与相应的表面层1、4之间。因此,可以将如上所述的中间箔施加至各种不同类型的实木颗粒板,同时仍然实现确保实木颗粒板的高表面质量和轻质构型的技术效果。
图4是用于示出在如图2中所示的实木颗粒板11的实木颗粒层1、2、4的放置期间可以如何将附加的粘合剂施加至中间箔层3、5的示意图。
其中,中间箔3、5经由相应的辊子21供应。在第一表面层1沿着输送带22被运送时,在第一表面层1的放置的粘合剂涂覆的实木颗粒的顶部上设置第一中间箔层5。可以经由相应的喷射喷嘴20或类似物将附加的粘合剂施加至第一表面层1的顶部和第一中间箔层5的顶部。因此,第一中间箔的两个表面可以涂覆有适当的粘合剂以确保实木颗粒层1、2与中间箔5的牢固粘合,而每个表面层或芯层内的实木颗粒的粘合通过在放置各层之前已经涂覆到相应的实木颗粒上的粘合剂来保证。类似地,对于第二中间箔层3,可以设置喷射喷嘴20,以用于在将第二表面层4的实木颗粒放置在第二中间箔层3的顶部上之前用粘合剂涂覆放置的芯层2和第二中间箔层3的顶部。
示例
实木颗粒板组成的示例实施方式具有530kg/m3的总体板密度,在芯层中具有厚度在0.2mm与0.8mm之间且表面尺寸在宽度上为从2mm至120mm并且长度在50mm以上的颗粒,并且在表面层中具有通过1.6mm×1.6mm的网眼的较细的颗粒。对于芯层,可以使用标准聚合MDI作为粘合剂,并且粘合剂含量可以为3.2%。对于表面层,可以使用具有MR 0.95和含量为2.5%的三聚氰胺的传统MUF树脂作为粘合剂,并且粘合剂含量可以为14%。可以使用例如具有2葛尔莱秒的空气阻力的17g/m2的纸作为中间箔。
Claims (9)
1.一种实木颗粒板(10;11),包括:
芯层(2),所述芯层(2)由树脂涂覆的具有大颗粒尺寸的实木颗粒形成;
至少一个表面层(1,4),所述至少一个表面层(1,4)由树脂涂覆的实木颗粒形成,其中,所述至少一个表面层(1,4)包括颗粒尺寸小于所述芯层(2)的颗粒尺寸的实木颗粒;以及
至少一个中间箔(3,5),所述至少一个中间箔(3,5)布置在表面层(1,4)与所述芯层(2)之间,其中,所述中间箔(3,5)由未经树脂浸渍的纸或者带孔的塑料片材形成,并且其中,所述至少一个中间箔(3,5)的表面重量在5g/m2至600g/m2的范围内并且厚度在0.05mm至3mm的范围内。
2.根据权利要求1所述的实木颗粒板(10;11),其中,
所述至少一个中间箔(3,5)是蒸气可渗透的。
3.根据权利要求1或2所述的实木颗粒板(11),其中,
所述实木颗粒板(11)包括两个表面层(1,4)和两个中间箔(3,5),所述两个中间箔(3,5)布置在所述芯层(2)的相反的表面上。
4.根据权利要求1或2所述的实木颗粒板(10;11),其中,
所述至少一个中间箔(3,5)通过设置在所述芯层(2)中和/或所述表面层(1,4)中的粘合剂粘附至所述芯层(2)和所述表面层(1,4)。
5.根据权利要求1或2所述的实木颗粒板(10;11),其中,
所述芯层(2)的密度在500kg/m3以下,并且所述至少一个表面层(1,4)的密度在700kg/m3以上。
6.一种用于生产实木颗粒板(10;11)的方法,所述方法包括:
放置具有小颗粒尺寸的实木颗粒及粘合剂以形成第一表面层(1);
放置颗粒尺寸大于所述第一表面层的颗粒尺寸的实木颗粒及粘合剂以形成芯层(2);
在所述芯层(2)的顶部上设置中间箔(3),其中,所述中间箔(3,5)由未经树脂浸渍的纸或者带孔的塑料片材形成,并且其中,所述中间箔(3,5)的表面重量在5g/m2至600g/m2的范围内并且厚度在0.05mm至3mm的范围内;
放置颗粒尺寸小于所述芯层(2)的颗粒尺寸的实木颗粒及粘合剂以形成至少一个第二表面层(4);以及
对放置的层进行压缩以形成实木颗粒板(10)。
7.根据权利要求6所述的用于生产实木颗粒板(10;11)的方法,所述方法还包括:
在执行放置实木颗粒的步骤之前用粘合剂涂覆所述实木颗粒。
8.根据权利要求6或7所述的用于生产实木颗粒板(10;11)的方法,其中,
通过设置在所述芯层(2)和所述表面层(1,4)中的所述粘合剂将所述中间箔(3)粘附至所述芯层(2)和所述表面层(1,4)。
9.根据权利要求6或7所述的用于生产实木颗粒板(10;11)的方法,所述方法还包括:
在放置所述芯层(2)的所述实木颗粒和所述粘合剂之前,在所述第一表面层(1)上放置第一中间箔(5),其中,随后将所述芯层(2)放置在所述第一中间箔(5)的顶部上;
在所述芯层(2)的顶部上设置第二中间箔(3);以及
在所述第二中间箔(3)的顶部上放置第二表面层(4)。
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RU2020107168A3 (zh) | 2021-10-08 |
RU2765643C2 (ru) | 2022-02-01 |
SE1750950A1 (en) | 2019-01-20 |
PL3655244T3 (pl) | 2022-08-01 |
EP3655244A1 (en) | 2020-05-27 |
WO2019015916A1 (en) | 2019-01-24 |
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CA3066528A1 (en) | 2019-01-24 |
EP3655244B1 (en) | 2022-05-11 |
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