CN111875879A - 一种复合板基材、复合板基材制备方法和装饰板 - Google Patents

一种复合板基材、复合板基材制备方法和装饰板 Download PDF

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CN111875879A
CN111875879A CN202010618717.8A CN202010618717A CN111875879A CN 111875879 A CN111875879 A CN 111875879A CN 202010618717 A CN202010618717 A CN 202010618717A CN 111875879 A CN111875879 A CN 111875879A
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黎国平
吴斌
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Jiangsu Langyue New Materials Technology Co Ltd
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Abstract

本申请涉及一种复合板基材、复合板基材制备方法和装饰板，旨在提供一种柔韧性好、强度高的新型基材。复合板基材由聚丙烯纤维、填充纤维、阻燃剂、偶联剂、无机填充料经热压制成，填充纤维为PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维中一种或多种；制备方法是：先将无机填充料、填充纤维、偶联剂混合；然后将混合填料与聚丙烯纤维共混；再将共混料铺装成带状后压制成型，分切得到料片；随后将多层料片层叠后，于温度165‑250℃、压力5‑20MPa条件下热压5‑30min，冷却，得基材半成品；最后将基材半成品修边，砂光成基材成品。本申请的基材具有尺寸稳定、开榫强度高的优点，可与三聚氰胺浸胶纸层、HPL层或PP装饰面层复合制成不同的装饰板。

Description

一种复合板基材、复合板基材制备方法和装饰板
技术领域
本申请涉及复合板的技术领域，尤其是涉及一种复合板基材、复合板基材制备方法和装饰板。
背景技术
基材作为复合板的主体结构层，其物理机械性对复合板的应用极为重要。目前，在复合板领域生产领域，以玻镁板基材最为常见。
例如，中国专利CN101871246B公开了一种玻镁板，由成型剂、增强材料、轻质填料、改性剂和水组成，其虽然在一定程度上提升了玻镁板基材的综合性能，但含有氯化镁的玻镁板基材存在的游离氯离子难以控制，会出现耐水性差，翘曲变形比较明显的现象，同时易吸潮返卤，在潮湿的环境下，会出现在物体表面出现水珠的情况，受潮后，物体会出现裂缝、最后慢慢脱落。
为解决上述技术问题，中国发明专利申请CN110746174A公开一种A级防火矿物质板及其制备方法：将2-15份硫酸镁与2-20份的水混合制成硫酸镁溶液，将10-90份植物纤维或颗粒与5-66份氧化镁、0-30份其他填充料及0.1-5份改性剂混合后，再与硫酸镁溶液搅拌混合均匀，而后经过铺模、冷压固化和养护即制得A级防火矿物质板。
但是，这类矿物质板本身的韧性差，弯折后极容易开裂，且上述专利申请公开的玻镁板基材的内结合强度最高只能达到1.5N/mm2，强度依然有待提升。为此，本申请提供一种韧性佳且强度高的新型基材。
发明内容
针对现有技术存在的不足，本申请的目的之一是提供一种复合板基材，其具有韧性佳、强度高的优势。
本申请的目的之二是提供一种复合板基材制备方法，采用该方法制得的复合板基材具有韧性佳、强度高的优势。
本申请的目的之三是提供一种装饰板，其具有韧性佳、强度高、不易开裂的优势。
本申请的目的是通过以下技术方案得以实现的：
一种复合板基材，由按质量百分比计的如下原料热压制成，
Figure BDA0002562309150000011
Figure BDA0002562309150000021
所述填充纤维为PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维中一种或多种的混合物。
本申请与传统的玻镁板基材相比，不需要采用硫氧镁凝胶材料，因而不存在吸潮返卤问题。同时，本申请的复合板基材以聚丙烯纤维和填充纤维(所述填充纤维为PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维中一种或多种的混合物)为主原料热压制成，纤维之间相互交错/纠缠，一方面能够形成排气通道，利于空气排出，减少了中间层气孔，另一方面相互纠缠的纤维使得基材具有较高的内结合强度和优良的韧性，不易开裂。按照上述原料配比制得的基材具有韧性好和内结合强度高的优点。
进一步地，所述填充纤维的长度为3-200㎜。
通过采用上述技术方案，使得各组分更容易分散均匀，制得的基材尺寸稳定性好、内结合强度高。
进一步地，所述木纤维含水率＜8％。
通过采用上述技术方案，减少了因木纤维中水分汽化造成的气孔，利于提高基材内结合强度，提升了基材的抗开裂性能。
进一步地，所述填充纤维由PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维按质量比1：(0.5-1)：(0.5-1)：(0.5-1)混合而成。
掺加上述配比的填充纤维制得的基材综合性能更佳。
进一步地，所述木纤维为松木纤维、麻纤维、杨木纤维、椴木纤维、桦木纤维、水曲柳纤维、榉木纤维、色木槭纤维、柳桉木纤维、杉木纤维、柏木纤维、柞木纤维、樟木纤维、竹子纤维中一种或多种的混合物。
上述各种木纤维均具有可再生、易获取的优点，使得本申请方案容易实现。
进一步地，所述阻燃剂为无卤阻燃剂。
通过采用上述技术方案，使得基材具有良好的阻燃性能，且相较于含卤阻燃剂更为环保。
进一步地，所述阻燃剂为氢氧化镁、氢氧化铝或两者的混合物。
通过采用上述技术方案，不仅可以赋予基材良好的阻燃性，且基材热压成型过程中部分氢氧化镁、氢氧化铝受热分解时释放出结合水，吸收大量的潜热，可降低聚丙烯纤维、PET纤维、PE纤维的分子链在热压过程中的热解，利于提高基材的强度。
进一步地，所述无机填充料为碳酸钙、粉煤灰、膨润土或陶土。
通过采用上述技术方案，提高了基材的尺寸稳定性，使得基材不易收缩变形。碳酸钙作为无机填料添加时，在高温条件下可分解释放二氧化碳，还具有与阻燃剂协同提高基材阻燃性能的作用。
一种复合板基材的制备方法，包括如下步骤，
步骤一、将无机填充料、填充纤维、偶联剂混合，得混合填料；
步骤二、将混合填料与聚丙烯纤维共混，得共混料；
步骤三、将共混料铺装成带状后压制成型，然后分切呈片状，得料片；
步骤四、将多层料片层叠后，于温度165-250℃、压力5-20MPa条件下热压5-30min，冷却，得基材半成品；
步骤五、将基材半成品修边，砂光成基材成品。
通过采用上述技术方案，先分步将无机填充料、填充纤维、偶联剂和聚丙烯纤维混合，再压制成片状的料片，此时聚丙烯纤维和填充纤维已经初步形成的平面的网状结构，之后再将多层片料层叠，纤维料也相应形成空间立体网状结构，保留了足够的排气通道、且纤维相互纠缠，经热压可以快速排气减少了气孔、纤维材料互相粘结定型、冷却得到基材半成品，最后经修边和砂光即得基材成品，如此制得的基材具有尺寸稳定性好、开榫槽强度高的优势。加工过程中片材的厚度控制在1-20㎜范围，具体可以根据实际加工的产品不同进行选择。
一种装饰板，包括基材和装饰层，所述基材由按质量百分比计的如下原料热压制成，
Figure BDA0002562309150000031
所述填充纤维为PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维中一种或多种的混合物；所述装饰层为三聚氰胺浸胶纸层、HPL层或PP装饰面层。
通过采用上述技术方案，使得装饰板具有高度的尺寸稳定性、良好柔韧性和较高的内结合强度，在装饰板边缘进行开设榫槽或者铣出卡扣加工时，不易造成装饰板开裂报废。其中，三聚氰胺浸胶纸层，又称密胺纸，耐水性佳；HPL(High-pressure Laminate)又称热固性树脂浸渍纸高压层积板，具有良好的耐火性、丰富的色彩和纹理；PP装饰面层可以是PP透明料、PP印花膜等。本申请中装饰面层具体可以根据实际需要进行选择，能够得到不同装饰效果或风格的装饰板，其他类似具有装饰效果面层亦可以用于与本申请的基材进行复合得到不同的装饰板。
综上所述，本申请包括以下至少一种有益技术效果：
1、本申请的基材与传统的玻镁板基材相比，不需要采用硫氧镁凝胶材料，因而不存在吸潮返卤问题；同时，本申请的复合板基材以聚丙烯纤维和填充纤维(所述填充纤维为PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维中一种或多种的混合物)为主原料热压制成，纤维之间相互交错/纠缠，一方面能够形成排气通道，利于空气排出，减少了中间层气孔，另一方面相互纠缠的纤维使得基材具有较高的内结合强度，不易开裂；
2、本申请基材制备方法先分步将无机填充料、填充纤维、偶联剂和聚丙烯纤维混合，再压制成片状的料片，此时聚丙烯纤维和填充纤维已经初步形成的平面的网状结构，之后再将多层片料层叠，纤维料也相应形成空间立体网状结构保留了足够的排气通道，同时纤维相互纠缠，经热压可以快速排气减少了气孔、使纤维材料互相粘结定型，冷却得到基材半成品，最后经修边和砂光即得基材成品，如此制得的基材具有尺寸稳定性好、柔韧性佳、内结合强度高的优势；
3、选择三聚氰胺浸胶纸层、HPL层或PP装饰面层作为装饰面层与本申请公开的基材复合得到的装饰板不仅装饰效果佳，且具有尺寸稳定性好、柔韧性佳、内结合强度高的优点。
具体实施方式
实施例1-6：
实施例1-6均涉及一种复合板基材，由表1所示配比的原料经过热压制成。
表1.实施例1-6的原料配比表
Figure BDA0002562309150000041
其中，聚丙烯纤维和填充纤维的规格如表2-1所示，填充纤维的配比如表2-2所示，碳酸钙也可以用粉煤灰、膨润土、陶土等其他无机矿物填料代替。
表2-1.实施例1-6纤维规格及组成表
Figure BDA0002562309150000051
表2-2.实施例1-6填充纤维的组成配比表(按重量份计)
Figure BDA0002562309150000052
其中，木纤维选则含水率＜8％的松木纤维、麻纤维、杨木纤维、椴木纤维、桦木纤维、水曲柳纤维、榉木纤维、色木槭纤维、柳桉木纤维、杉木纤维、柏木纤维、柞木纤维、樟木纤维、竹子纤维中一种或多种的混合物均可，实施例4和实施例6中选择的均是竹木纤维。
实施例1-6中所用氢氧化镁、氢氧化铝、钛酸酯偶联剂、硅烷偶联剂和碳酸钙均是通过商业途径购买所得，具体规格如表3所示。
表3.实施例1-6原料规格信息表
原料 规格
氢氧化镁 纯度95％
氢氧化铝 纯度99％
钛酸酯偶联剂 工业级
硅烷偶联剂 纯度99％
碳酸钙 纯度：AR，99％
实施例1-6的制备方法基本相同，区别仅在于热压步骤的工艺参数不同。
复合板基材制备工艺步骤如下：
步骤一、按照表1配比称取各原料，先将称取的碳酸钙、填充纤维、偶联剂混合，得混合填料；
步骤二、将混合填料与聚丙烯纤维共混，得共混料；
步骤三、将共混料铺装成带状后，用压延辊压制成型，然后分切呈片状，得料片；
步骤四、将多层料片层叠后，进入热压机于温度165-250℃、压力5-20MPa条件下热压5-30min，冷却，得基材半成品；
步骤五、将基材半成品修边，砂光成基材成品。
实施例1-6复合板基材制备工艺的热压工艺参数如表4所示。
表4.实施例1-6热压工艺参数表
热压工艺参数 实施例1 实施例2 实施例3 实施例4 实施例5 实施例6
热压温度/℃ 165 195 220 250 200 180
热压压力/MPa 20 15 10 5 13 12.5
热压时间/min 5 13.5 18 30 15 17.5
实施例7-12：
实施例7-12均以实施例6为基础，与实施例6的区别仅在于：填充纤维的组成不同。具体实施例7-12填充纤维的组成见表5所示。
表5.实施例7-12中填充纤维组成表
Figure BDA0002562309150000061
实施例13：
按照实施例6的配比称取各原料，将各原料直接混合，然后铺入到模具中，用热压机在180℃、12.5MPa压力条件下热压17.5min，降温脱模得到基材半成品，然后修边、砂光得到基材成品。
对照例1：
与实施例6的区别仅在于：用等量聚丙烯纤维代替填充纤维。
对照例2：
与实施例6的区别仅在于：用等量聚丙烯纤维代替碳酸钙。
对照例3：
与实施例6的区别在于：聚丙烯纤维的掺加量为50％、填充纤维掺加量为40％，其他组分掺加量不变。
性能测试
A、参照GB/T17657-2013测定实施例1-13以及对照例1-3的内结合强度、静曲强度，测试结果记录如表6所示。
B、柔韧性测试
将宽度为5㎜的试样以1r/s的速度在φ4㎜抛光圆棒上连续紧密卷绕10圈，卷绕时试样承受的张力刚好使试样与圆棒接触，卷绕时避免试样受到拉伸和扭铰。卷绕后，用6倍放大镜检查试样是否开裂，重复试验≥10次，统计出现开裂的试样占比(开裂率)。
表6.内结合强度、柔韧性测试结果表(试样厚度5㎜)
试样 内结合强度/MPa 静曲强度/MPa 开裂率/％
实施例1 3.8 32 0
实施例2 4.0 33 0
实施例3 4.2 35 0
实施例4 4.3 33 0
实施例5 3.9 32 0
实施例6 4.4 36 0
实施例7 4.2 34 0
实施例8 4.3 35 0
实施例9 4.3 35 0
实施例10 4.3 35 0
实施例11 4.2 33 0
实施例12 4.0 32 0
实施例13 4.3 34 0
对照例1 3.4 26 1.2
对照例2 3.2 28 0.7
对照例3 3.7 30 0.2
由表6试验数据可知：本申请的基材内结合强度高达3.8-4.4MPa，静曲强度达32-36MPa，具有强度佳的特点。同时，本申请的基材可以在直径4㎜圆棒上卷绕10圈，而不出现可视的开裂，具有极佳的柔韧性。此外，对比实施例6和对照例1-3的试验数据可以发现，在本申请特定配比的基材内结合强度更高、柔韧性极佳。
C、参照GB/T17657-2013测定实施例1-13以及对照例1-3基材的吸水厚度膨胀率，测试结果记录如表7所示。
D、分别测试实施例1-13以及对照例1-3基材在不同温度环境下的尺寸变化率。尺寸测量方法参照GB/T17657-2013，试样初始尺寸50*50*5(25℃)，分别将试样于-20℃、80℃条件下放置6h后马上进行尺寸测量，计算处理后尺寸与初始尺寸之间的变化率。记录至少三次测量的尺寸变化率绝对值的平均值，以表示试样的尺寸稳定性。试验结果记录如表7所示。
表7.吸收厚度膨胀率及尺寸稳定性测试结果表(试样厚度5㎜)
Figure BDA0002562309150000081
由表6试验数据可知：本申请基材的吸水厚度膨胀率低至0.08-0.10％，80℃尺寸变化率低至0.02-0.03％、-20℃尺寸变化率低至0.01-0.02％，具有极佳的耐潮尺寸稳定性和耐高低温尺寸稳定性。此外，对比实施例6和对照例1-3的试验数据可以发现，在本申请特定配比的基材的耐潮尺寸稳定性、耐高低温尺寸稳定性更佳。
应用例14-16：
应用例14-16均涉及一种装饰板，以实施例6的复合板基材为基础，包括依次复合的装饰层、无纺布层、基材、无纺布层和平衡层。按照顺序将各层材料铺装于模具后，进入热压机于180-250℃、8-20MPa压力条件下热压50-1800s，冷却定型后取出切割，砂光得到装饰板。根据需要可在装饰板边缘铣出卡扣。其中装饰层可以选择含浸三聚氰胺-甲醛的三聚氰胺耐磨纸或三聚氰胺花纹纸，应用例14-16中选择的均是三聚氰胺花纹纸；两层无纺布层均选择的是PP无纺布；平衡层选择的是三聚氰胺耐磨纸；基材使用的均是实施例6的复合板基材。
应用例14-16的热压工艺参数如表8所示。
表8.应用例14-16热压工艺参数表
热压工艺参数 应用例14 应用例15 应用例16
热压温度/℃ 180 215 250
热压压力/MPa 20 14 8
热压时间/s 50 1200 1800
应用例17-19：
应用例17-19均涉及一种装饰板，包括基材和HPL层，基材和HPL层之间通过双组份PU胶或PUR胶冷压复合而成。其中，基材选择的均是实施例6的复合板基材，应用例17-18均是通过PU胶复合，应用例19采用PUR胶复合。
制备工艺：
先三聚氰胺耐磨纸、三聚氰胺花纹纸、无纺布或酚醛胶浸胶的牛皮纸，在130-180℃、10-20MPa条件下高温热压15-90min制成HPL；然后，将HPL与基材使用双组份的PU胶或PUR胶冷压复合，复合压力为5-20MPa；待胶水完全固化后得半成品，经过切割修边即得装饰板。根据需要可在装饰板边缘铣出卡扣。
应用例17-19的HPL制备工艺参数和复合压力参数如表9所示。
表9.HPL制备工艺参数及复合压力参数
Figure BDA0002562309150000091
应用例20-22：
应用例20-22均涉及一种装饰板，包括依次设置的PP透明料层、PP印花膜层和基材层，其中基材层选用实施例6的复合板基材。
制备工艺：
将PP透明料、PP印花膜、基材铺设于模具，用热压机热压一次复合成型，热压温度为180-250℃、压力10-20MPa、热压时间15-60min。冷却定型后取出，养护至常温后经70-99℃回火，冷却制得半成品，再切割修边即得装饰板成品。根据需要可在装饰板边缘铣出卡扣。
应用例20-22的热压工艺参数如表10所示。
表10.应用例20-22的热压工艺参数表
热压工艺参数 应用例20 应用例21 应用例22
热压温度/℃ 180 215 250
热压压力/MPa 20 14 10
热压时间/min 15 30 60
上述实施例仅仅是对本申请的解释，其并不是对本申请的限制，本领域技术人员在阅读完本说明书后可以根据需要对上述实施例做出没有创造性贡献的修改，但只要在本申请的权利要求范围内都受到专利法的保护。

Claims (10)

1. 一种复合板基材，其特征在于：由按质量百分比计的如下原料热压制成，
聚丙烯纤维 55-85%
填充纤维 10-44%
阻燃剂 0.1-2%
偶联剂 0.001-2%
无机填充料 0-30%；
所述填充纤维为PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维中一种或多种的混合物。
2.根据权利要求1所述的复合板基材，其特征在于：所述填充纤维的长度为3-200㎜。
3.根据权利要求2所述的复合板基材，其特征在于：所述木纤维含水率＜8%。
4.根据权利要求3所述的复合板基材，其特征在于：所述填充纤维由PET纤维、PE纤维、玻璃纤维、碳纤维和木纤维按质量比1：（0.5-1）：（0.5-1）：（0.5-1）混合而成。
5.根据权利要求4所述的复合板基材，其特征在于：所述木纤维为松木纤维、麻纤维、杨木纤维、椴木纤维、桦木纤维、水曲柳纤维、榉木纤维、色木槭纤维、柳桉木纤维、杉木纤维、柏木纤维、柞木纤维、樟木纤维、竹子纤维中一种或多种的混合物。
6.根据权利要求1所述的复合板基材，其特征在于：所述阻燃剂为无卤阻燃剂。
7.根据权利要求6所述的复合板基材，其特征在于：所述阻燃剂为氢氧化镁、氢氧化铝或两者的混合物。
8.根据权利要求1所述的复合板基材，其特征在于：所述无机填充料为碳酸钙、粉煤灰、膨润土或陶土。
9.权利要求1所述的复合板基材的制备方法，其特征在于：包括如下步骤，
步骤一、将无机填充料、填充纤维、偶联剂混合，得混合填料；
步骤二、将混合填料与聚丙烯纤维共混，得共混料；
步骤三、将共混料铺装成带状后压制成型，然后分切呈片状，得料片；
步骤四、将多层料片层叠后，于温度165-250℃、压力5-20MPa条件下热压5-30min，冷却，得基材半成品；
步骤五、将基材半成品修边，砂光成基材成品。
10.一种装饰板，包括基材和装饰层，其特征在于：所述基材为权利要求1所述的复合板基材；所述装饰层为三聚氰胺浸胶纸层、HPL层或PP装饰面层。
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