CN111909493B - 一种新型环保基材及其制备方法及新型环保基材复合板 - Google Patents
一种新型环保基材及其制备方法及新型环保基材复合板 Download PDFInfo
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Abstract
本发明涉及一种新型环保基材,由以下重量百分比的组分制备而成:PET纺纤维55%‑85%;填充纤维15%‑44%;阻燃剂0.1%‑2%;偶联剂0.001%‑2%;填充料0‑30%。其具有耐候性好、不易发生变形翘曲的优势。本发明还公开了一种新型环保基材的制备方法,包括以下步骤:将填充纤维、阻燃剂及偶联剂搅拌均匀,得一级混合物;将填充料与PET纺纤维搅拌均匀,得二级混合物;将一级混合物与二级混合物共混,铺装并压延成型,分切成片材;将片材层叠后进行热压成型,冷却后修边、砂光,得到环保基材。本发明公开通过将混合物压延成片材,将多层片材层叠后热压成型,可提高成型后的基材的强度。本发明中的新型环保基材可与防火板或PET透明料形成复合板,得到稳定性好、不易变形翘曲的新型的装饰板。
Description
技术领域
本发明涉及装饰面板的技术领域,尤其是涉及一种新型环保基材及其制备方法及新型环保基材复合板。
背景技术
聚酯纤维是由有机二元酸和二元醇缩聚而成的聚酯经纺丝所得的合成纤维,简称PET纤维,其最大的优点是抗皱性和保形性好,具有较高的强度与弹性恢复能力。现有很多企业以聚酯纤维为基础材料,制成了多种装饰面板,制成的装饰面板具有环保、可回收利用等优点。
现有申请公布号为CN107556619A的中国专利公开了一种用于制备汽车内外饰件的复合板材,包括粘结基体55%-70%、增强体25%-40%和助剂3%-7%,其中,粘结基体为聚丙烯纤维PP、聚乙烯纤维PE、聚酯纤维PET、尼龙纤维PA中的一种或多种,增强体为玻璃纤维、碳纤维或植物纤维中的一种或多种,助剂包括浸润液、氮磷阻燃剂和稳定剂,浸润液的配比为:硬脂酸30-40%、稀释剂59.2-69.8%、硅烷偶联剂0.2-0.8%。上述公开专利旨在进一步提高汽车内饰的综合性能,使产品具有轻量化和低VOC。
上述中的现有技术方案存在以下缺陷:上述公开专利中的复合板材虽然使产品具有轻量化和低VOC的优点,但作为一种板材,尤其是应用于地面、墙面装饰时,板材在长期使用后易发生吸水膨胀、变形翘曲等问题,因此,提供一种耐候性好、稳定性强、不易发生变形翘曲的环保基材是目前需要解决的一个问题。
发明内容
针对现有技术存在的不足,本发明的目的之一是提供一种新型环保基材,其具有耐候性好、不易发生变形翘曲的优势。
本发明的目的之二是提供一种新型环保基材的制备方法,通过压延成片材,将多层片材层叠后热压成型,提高成型后的基材的强度,使得基材不易发生变形翘曲。
本发明的目的之三是提供一种新型环保基材复合板,其可以由上述新型环保复合板与防火板、PET透明料进行贴合,得到稳定性好、不易变形翘曲的新型的装饰板。
本发明的发明目的一是通过以下技术方案得以实现的:
一种新型环保基材,由以下重量百分比的组分制备而成:
PET纺纤维 55%-85%;
填充纤维 15%-44%;
阻燃剂 0.1%-2%;
偶联剂 0.001%-2%;
填充料 0-30%。
通过采用上述技术方案,本方案选用PET纺纤维为基础材料,利用PET纺纤维的高强度和抗皱性提升基材的稳定性,使之不易发生变形翘曲;通过添加填充纤维,进一步增强基材的稳定性;通过添加阻燃剂,以降低基材的可燃性;利用偶联剂改善材料与材料之间的界面亲和力,促进各材料之间的浸润性和粘合性,进一步提高基材整体的稳定性;填充料可以选自碳酸钙、粉煤灰、膨润土和陶土中的一种或多种,利用填充料增加基材的体积,改善基材的强度。本方案利用各组分的协同作用,提高基材的整体稳定性,使得基材不易发生变形翘曲。
本发明在一较佳示例中可以进一步配置为:所述填充纤维选自PP纤维、玻璃纤维、碳纤维、PE纤维和木纤维中的一种或多种。
通过采用上述技术方案,PP纤维质轻、强度高、耐磨耐腐蚀,可增强基材的稳定性和耐磨性;玻璃纤维一方面可增强基材的整体稳定性,另一方面可增强基材的抗拉强度;利用碳纤维可增强基材的稳定性和耐高温性能;利用PE纤维可增强基材的强度和耐腐蚀性能;木纤维的结构具有毛细管作用,能够将基材内部的水分迅速传输到浆料表面和界面,使得基材内部的水分能够均匀分布,有效提高基材整体的稳定性。
本发明在一较佳示例中可以进一步配置为:所述填充纤维由玻璃纤维、木纤维和麻纤维组成,所述玻璃纤维、木纤维和麻纤维的重量比为(13-17):(3-7):(6.5-9)。
通过采用上述技术方案,选择特定比例的玻璃纤维、木纤维和麻纤维,使得制得的基材具有较高的稳定性,使之不易发生变形翘曲。
本发明在一较佳示例中可以进一步配置为:所述木纤维的含水率为0.5%-10%。
通过采用上述技术方案,特定的含水率能够增强木纤维的可塑性,增加了木纤维与其他掺料的接触面积,从而增强了木纤维与其他掺料的粘结牢固度,进而提升了基材的整体强度。
本发明在一较佳示例中可以进一步配置为:所述木纤维的长度为3mm-200mm。
通过采用上述技术方案,选择特定长度的木纤维,一定程度上提高基材整体的稳定性,使之不易发生变形翘曲。
本发明的发明目的二是通过以下技术方案得以实现的:
一种新型环保基材的制备方法,包括以下步骤:
S1、按配比,将填充纤维、阻燃剂及偶联剂搅拌均匀,得一级混合物;
S2、按配比,将填充料与PET纺纤维搅拌均匀,得二级混合物;
S3、将一级混合物与二级混合物共混,铺装并压延成型,分切成片材,片材厚度为1mm-20mm;
S4、将S3中得到的片材层叠后进行热压成型,冷却后修边、砂光,即得所述的新型环保基材。
通过采用上述技术方案,先利用压延技术排出片材中的气孔,减少成型后的片材中的气孔数量,降低了气孔对片材强度的影响;再将多层片材通过热压制成基材,使得制得的基材具有较高的稳定性。
本发明在一较佳示例中可以进一步配置为:所述S4中热压温度为200-280℃,压力为5-20Mpa,时间为5-30min。
通过采用上述技术方案,采用特定的温度、压力和时间,使得片材之间能够有效粘结成型,确保了制得的基材具有较高的稳定性。
本发明的发明目的三是通过以下技术方案得以实现的:
一种新型环保基材复合板,将所述的新型环保基材表面贴合面层形成复合板,所述面层为防火板和PET透明料中的任意一种。
通过采用上述技术方案,将基材与防火板或PET透明料等材料复合形成新型的装饰板,有效提高了装饰板的整体稳定性。
本发明在一较佳示例中可以进一步配置为:将三聚氰胺耐磨纸、三聚氰胺花纹纸、无纺布或酚醛胶浸胶的牛皮纸或羊皮纸,经高温高压成防火板,温度130-180℃,时间15-90min,压力10-20Mpa;
将防火板与新型环保基材使用PU胶或PUR胶冷压复合,压力5-20 Mpa,待胶水固化后切割修边,即得新型的防火板。
通过采用上述技术方案,利用PU胶或PUR胶将基材与防火板复合,有效提高了新型的防火板的整体稳定性。
本发明在一较佳示例中可以进一步配置为:将PET热转印花纹通过连续在线热转印至表面精砂至200目以上的新型环保基材,热转印温度100-180℃;将PET透明料和已热转印的新型环保基材按顺序进行铺装并热压成型,温度200-280℃,压力10-20 Mpa,时间15-30min,冷却定型后养生至常温;
经70-99℃回火冷却,得到新型的装饰板。
通过采用上述技术方案,将热转印后的基材与PET透明料复合,有效提高了装饰板的整体稳定性,使之不易发生变形翘曲。
综上所述,本发明包括以下至少一种有益技术效果:
1.本发明选用PET纤维为基础原料,并选用特定含水率和长度的木纤维,结合其他特定掺量的组分,有效增强了制得的基材的稳定性,制得的基材柔韧性好,可回收利用,稳定性强,不易发生变形和翘曲脆化;
2.本发明先制成片材,并利用压延排出片材中的气孔,降低气孔对片材强度的影响,再将多张片材层叠后利用热压技术制成基材,大大提升了制得的基材的整体强度和稳定性,使得基材长期使用后也不易发生变形翘曲等问题;
3.本发明在防火板和PET透明料上复合基材,有效提高了传统的防火板和PET透明料的整体强度和稳定性,使得复合有基材的防火板和PET透明料不易发生变形翘曲等问题。
具体实施方式
实施例1-实施例16
实施例1-实施例16公开的新型环保基材的组分和制备方法均相同,不同之处在于各组分的掺量和工艺参数不同,具体见表1,以实施例1为例进行说明新型环保基材的制备方法,具体如下:
S1、按配比称取各组分;
S2、将填充纤维、阻燃剂及偶联剂搅拌均匀,得一级混合物;
S2、将填充料与PET纺纤维搅拌均匀,得二级混合物;
S3、将一级混合物与二级混合物共混,铺装成棉絮带状,并使用压延辊压延成型,分切成厚度为5mm的片材;
S4、将S3中得到的片材多张层叠后,送入热压机进行热压成型,热压温度230℃,压力15Mpa,时间15min,冷却后修边、砂光,得到新型环保基材。
表1:实施例1-实施例14新型环保基材的各组分掺量及工艺参数
实施例1-实施例14中填充纤维均由重量配比为15:5:8的玻璃纤维、木纤维和麻纤维组成。
实施例15
本实施例与实施例3的区别仅在于:填充纤维中玻璃纤维、木纤维和麻纤维的重量配比为13:3:9。
实施例16
本实施例与实施例3的区别仅在于:填充纤维中玻璃纤维、木纤维和麻纤维的重量配比为17:7:6.5。
实施例17
本实施例与实施3的区别仅在于:步骤S3:将一级混合物与二级混合物共混,铺装成棉絮带状,并使用压延辊压延成型,根据实际需求分切成不同规格的片材,直接送入热压机进行热压成型,热压温度230℃,压力15Mpa,时间15min,冷却后修边、砂光,即得新型环保基材。
对照例1-对照例6
对照例1-对照例6中新型环保基材的组分和制备方法与实施例3均相同,不同之处在于各组分的掺量和工艺参数不同,具有见表2:
对照例7
本对照例与实施例3的区别仅在于:填充纤维中玻璃纤维、木纤维和麻纤维的重量配比为10:9:4。
对照例8
以对比文件(CN107556619A)中实施例1制得的复合板材作为本对照例。
各实施例和各对照例中组分的来源见表3:
应用例1
一种具有防火板表面的新型环保基材复合板,包括实施例3中的新型环保基材以及贴合在新型环保基材表面的防火板,将三聚氰胺耐磨纸、三聚氰胺花纹纸、无纺布或酚醛胶浸胶的牛皮纸或羊皮纸,经高温高压制成防火板,温度150℃,时间60min,压力18Mpa;利用PU胶或PUR胶将新型环保基材与防火板冷压复合,压力15Mpa;待胶水完全固化后切割修边,得到具有防火板表面的新型环保基材复合板。该复合板具有较高的强度,不易发生变形或翘曲,边缘直接铣出卡扣或铣槽后可直接进行施工,简化了传统的防火板需要胶粘的施工流程,提高了施工效率。
应用例2
一种具有PET透明料的新型环保基材复合板,包括实施例3中的新型环保基材以及贴合在新型环保基材表面的PET透明料,先将新型环保基材表面精砂至200目,再将PET热转印花纹通过连续在线热转印至新型环保基材表面,热转印温度160℃,将PET透明料和已热转印的基材按顺序铺装送入热压机热压成型,温度260℃,压力18 Mpa,时间25min,冷却定型后养生至常温,经85℃回火冷却,切割修边,得到具有PET透明料的新型环保基材复合板。该复合板具有较高的强度,不易发生变形或翘曲,边缘直接铣出卡扣或铣槽后可直接进行施工,简化了施工流程,可将该复合板应用于地面或墙面装饰。
针对各实施例和各对照例中制得的新型环保基材进行性能测试,测试过程如下:
一、吸水厚度膨胀率测定
参照GB/T 17657-2013《人造板及饰面人造板理化性能试验方法》第4.4节对各试板进行测定。
二、尺寸稳定性测定
参照GB/T 17657-2013《人造板及饰面人造板理化性能试验方法》第4.33节对各试板进行测定,记录各试板的厚度变化率。
三、静曲强度测定
参照GB/T 17657-2013《人造板及饰面人造板理化性能试验方法》第4.7节对各试板进行测定。
四、甲醛含量测定
参照GB/T 17657-2013《人造板及饰面人造板理化性能试验方法》第4.58节对各试板进行测定。
五、柔韧性测定
选择一根直径为4cm的抛光圆棒,将各基材制成宽度为5mm和厚度为5mm的长条形试板,将各试板分别缠绕在抛光圆棒上,缠绕10圈,抛光圆棒卷绕的速度为3r/s。本试验中,各实施例和各对照例分别选取10块试板,卷绕完成后,用放大倍数为10倍的放大镜观察试板表面是否有开裂现象,并记录发生开裂的试板的占比。
六、内结合强度
参照GB/T 17657-2013《人造板及饰面人造板理化性能试验方法》第4.11节测试各试板的内结合强度,
测试结果见表4:
由表4可知,与对照例8相比,实施例1-实施例17中试板的吸水厚度膨胀率低于对照例8,且实施例1-实施例17中试板的尺寸稳定性、静曲强度、柔韧性和内结合强度均优于对照例8,表明本发明公开的新型环保基材具有较优的耐候性和稳定性,不易发生变形和翘曲。
与对照例1相比,实施例1-实施例17中的试板呈现出更优的耐候性和稳定性,表明参照本发明公开的掺量进行制备新型环保基材,使得制得的新型环保基材具有较优的耐候性和稳定性,使得新型环保基材不易发生变形或翘曲。
与对照例2至对照例7相比,实施例3中的试板表现出更优的耐候性和稳定性,表明参照本发明公开的掺量和比例进行添加填充纤维,以及参照本发明公开的规格进行添加木纤维,参照本发明公开的工艺参数进行制备新型环保基材,一定程度上能够增强新型环保基材的耐候性和稳定性,降低新型环保基材发生变形或翘曲的可能性。
本具体实施方式的实施例均为本发明的较佳实施例,并非依此限制本发明的保护范围,故:凡依本发明的结构、形状、原理所做的等效变化,均应涵盖于本发明的保护范围之内。
Claims (6)
1.一种新型环保基材,其特征在于:由以下重量百分比的组分制备而成:
PET纺纤维 55%-85%;
填充纤维 15%-44%;
阻燃剂 0.1%-2%;
偶联剂 0.001%-2%;
填充料 0-30%;
所述填充纤维由玻璃纤维、木纤维和麻纤维组成,所述玻璃纤维、木纤维和麻纤维的重量比为(13-17):(3-7):(6.5-9);
所述木纤维的含水率为0.5%-10%;
所述木纤维的长度为3mm-200mm;
新型环保基材的制备包括以下步骤:
S1、按配比,将填充纤维、阻燃剂及偶联剂搅拌均匀,得一级混合物;
S2、按配比,将填充料与PET纺纤维搅拌均匀,得二级混合物;
S3、将一级混合物与二级混合物共混,铺装并压延成型,分切成片材,片材厚度为1mm-20mm;
S4、将S3中得到的片材层叠后进行热压成型,冷却后修边、砂光,即得所述的新型环保基材;
所述S4中热压温度为200-280℃,压力为5-20Mpa,时间为5-30min。
2.权利要求1所述的一种新型环保基材的制备方法,其特征在于:包括以下步骤:
S1、按配比,将填充纤维、阻燃剂及偶联剂搅拌均匀,得一级混合物;
S2、按配比,将填充料与PET纺纤维搅拌均匀,得二级混合物;
S3、将一级混合物与二级混合物共混,铺装并压延成型,分切成片材,片材厚度为1mm-20mm;
S4、将S3中得到的片材层叠后进行热压成型,冷却后修边、砂光,即得所述的新型环保基材。
3.根据权利要求2所述的一种新型环保基材的制备方法,其特征在于:所述S4中热压温度为200-280℃,压力为5-20Mpa,时间为5-30min。
4.一种新型环保基材复合板,其特征在于:将权利要求1所述的新型环保基材表面贴合面层形成复合板,所述面层为防火板和PET透明料中的任意一种。
5.根据权利要求4所述的一种新型环保基材复合板,其特征在于:将三聚氰胺耐磨纸、三聚氰胺花纹纸、无纺布或酚醛胶浸胶的牛皮纸或羊皮纸,经高温高压成防火板,温度130-180℃,时间15-90min,压力10-20Mpa;
将防火板与新型环保基材使用PU胶或PUR胶冷压复合,压力5-20 Mpa,待胶水固化后切割修边,即得新型的防火板。
6.根据权利要求4所述的一种新型环保基材复合板,其特征在于:将PET热转印花纹通过连续在线热转印至表面精砂至200目以上的新型环保基材,热转印温度100-180℃;将PET透明料和已热转印的新型环保基材按顺序进行铺装并热压成型,温度200-280℃,压力10-20 Mpa,时间15-30min,冷却定型后养生至常温;经70-99℃回火冷却,得到新型的装饰板。
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Denomination of invention: A novel environmentally friendly substrate and its preparation method, as well as a novel environmentally friendly substrate composite board Granted publication date: 20220513 Pledgee: Bank of China Limited Dingmaoqiao Branch, Zhenjiang Pledgor: Jiangsu Langyue New Material Technology Co.,Ltd. Registration number: Y2024980007549 |