CN112081299A - 一种软质墙板及其制作工艺 - Google Patents

一种软质墙板及其制作工艺 Download PDF

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CN112081299A
CN112081299A CN202010982110.8A CN202010982110A CN112081299A CN 112081299 A CN112081299 A CN 112081299A CN 202010982110 A CN202010982110 A CN 202010982110A CN 112081299 A CN112081299 A CN 112081299A
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艾华
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Anhui Ayalon New Material Technology Co ltd
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Abstract

本发明公开了一种软质墙板及其制作工艺，属于板材加工技术领域。本发明的软质墙板包括由外及内层叠分布的涂层、软质基板、布纤层、保温层和装饰层。层叠分布时，可将布纤层浸胶，提高软质基板和保温层之间竖向摩擦力的同时，又将两者在水平方向上牢固粘合，充分利用布纤层的附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果，还具有普通墙板的防潮防水性能，而软质基板和保温层叠加的缓冲能力，触感相对较好，杯子、手机、平板等物品横摔在墙板上时，不会导致摔碎。解决了现有的复合木墙板生产成本高、容易产生开胶和变形现象的不足以及耐冲击性欠佳的问题。

Description

一种软质墙板及其制作工艺
技术领域
本发明属于板材加工技术领域，更具体地说，涉及一种软质墙板及其制作工艺。
背景技术
近年来，室内装潢大量采用实木墙板、复合墙板、浸渍纸层压木质墙板(强化墙板)、木塑复合板等作墙面装饰材料。实木墙板需采用大量大口径原木作原材料，一般而言，实木墙板的木材利用率仅为30％～40％，需选用几十年甚至上百年的优质实木，原材料选用标准高，需要消耗大量的森林资源。因而，存在优质木材紧缺、木材利用率不高的问题。而消耗大量的森林资源会导致生态环境的破坏，这一问题也日益引起人们的重视。并且在使用上，实木墙板还存在易变形、易涨缩、不耐磨、且造价昂贵的缺陷，更难以解决防水、防潮、防虫蛀等问题，故影响了使用效果和使用寿命。
随着人们对墙板美观、实用和耐用耐磨等性能要求的不断提高，生产强度高、尺寸稳定性强、耐磨性高、使用寿命长而且美观实用的复合墙板逐渐成为墙板业发展的趋势。
现有的复合墙板表面耐冲击性及缓冲效果欠佳，尤其是在手机、平板广泛应用的当代社会，手机、平板等电子产品不小心摔到墙板上时，容易出现碎屏等隐患。
经检索，美国专利US2014/0109507A1，ENGINEERED WATERPROOFFLOORING ANDWALL COVERING PLANKS(工程防水地板和木质墙面装饰板)公开了将瓷砖、薄层石材、橡胶、装饰塑料板、漆布或装饰尼纶贴到WPC(木塑复合材料)底部，以此来提升触感舒适度和吸音性能的技术方案，这些材料必须使用热熔胶将其粘在WPC材料底部，加工自动化程度低，工序繁琐，无形中提高了产品加工成本。而且，还存在以下难以克服的缺陷：(1)表板和基板之间的粘合力较小，容易出现开胶现象；(2)墙板表面耐冲击性及缓冲效果欠佳。
发明内容
1、要解决的问题
针对现有技术中复合墙板生产成本高、容易产生开胶和变形现象的不足以及耐冲击性欠佳的问题，本发明提供一种软质墙板及其制作工艺，通过软质基板和保温层叠加的缓冲效果和布纤层的附着能力，达到了抗开胶变形和提高缓冲能力的双重技术效果。
2、技术方案
为解决上述问题，本发明采用如下的技术方案。
一种软质墙板，包括由外及内层叠分布的涂层、软质基板、布纤层、保温层和装饰层。层叠分布时，可将布纤层浸胶，提高软质基板和保温层之间竖向摩擦力的同时，又将两者在水平方向上牢固粘合，充分利用布纤层的附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果，还具有普通墙板的防潮防水性能，而软质基板和保温层叠加的缓冲能力，触感相对较好，杯子、手机、平板等物品横摔在墙板上时，不会导致摔碎。
进一步的技术方案，软质基板为软质辊压成型渗胶板，即将软质基板的基料挤出后辊压时，基料中的胶液能够渗出，这样，在和布纤层叠加时，布纤层无需再行浸胶，从而节约了工序，提高了生产效率；所述保温层为岩棉板、聚苯板、酚醛板、聚合保温板、聚氨酯板或挤塑板，各种板材，尤其是聚苯板和酚醛板在保证保温效果的同时，容易汲取布纤层的胶液，从而达到三者牢固贴合的技术效果。
进一步的技术方案，软质辊压成型渗胶板外表面、布纤层的内外表面以及保温层的内表面设置有互相适配的啮合结构，充分利用布纤层容易随机变形的特点，提高三者之间的接触面，从而避免三者在水平方向上产生任何的位移而导致的开胶变形。
进一步的技术方案，啮合结构通过软质辊压成型渗胶板外表面的凹槽，布纤层内外表面的凸条以及保温层的外表面设置凹槽啮合式连接而成，操作方便，复合效果好。
进一步的技术方案，软质辊压成型渗胶板的组分中包括秸秆段、绿粉和PVC；充分利用广大农村闲置而不能充分利用的秸秆资源，尽可能的减少农村因秸秆焚烧而产生的空气污染，而且，秸秆颗粒的空芯结构，容易吸收胶液，并在其中暂存，避免胶液和其它组分过早接触而粘结成团而导致混料不均；绿粉为瓶装饮用水瓶体上的包装标签膜打磨而成的粉体，充分利用了装饮用水瓶体上的包装标签膜的闲置废弃资源，毕竟在装饮用水瓶体的回收过程中，其包装标签膜往往由于和瓶体的化学成分不一致而废弃，在本申请中，则可以充分利用，并和PVC颗粒混合使用。
进一步的技术方案，秸秆段为2～4mm段状颗粒，该长度范围的秸杆，可以实现在尽可能多的暂存胶液的同时，在墙板中还起到一定的植物钢筋的作用，让基板组分的结合更加牢固。
一种软质墙板的制作工艺，步骤为：
A、混料：将秸秆段、胶液、添加剂和其它组分后混匀；
B、加热：将混匀后的物料转入加热罐体进行加热成半流体的熔融状；
C、挤出：将半流体转入挤出机挤出呈条状体；
D、辊压：将条状体直接接入压辊单元辊压成片状的软质辊压成型渗胶板；辊压成型过程中，秸秆段中的胶液由于受到挤压而不断渗出，为下一步与布纤层的胶合奠定基础；
E、复合：将布纤层、保温层和装饰层依次复合在软质辊压成型渗胶板外表面，再喷涂涂层在软质辊压成型渗胶板内表面制作成软质墙板，布纤层和软质辊压成型渗胶板层叠的过程中，胶液可以再渗透布纤层，从而再将布纤层和保温层胶合在一起。
进一步的加工工艺，步骤A中先将秸秆段和胶液混合后，再按顺序混入添加剂和其它组分后混匀；秸秆段和胶液先行混合，这样，可以让胶液先行暂存于秸秆的空芯结构中，尤其是小麦的秸秆，其空心体积更大，胶液暂存量可更多，这样，后期的辊压成型中，胶液渗出量会更大。
进一步的加工工艺，步骤D中，压辊单元为两组，第一组辊压出软质辊压成型渗胶板后，第二组将布纤层、保温层辊压在软质辊压成型渗胶板上；两步辊压，节奏紧凑，尽可能的避免渗出的胶液因留空而提前胶干。
进一步的加工工艺，压辊单元的上下压辊为热压辊，可让胶液保持一定高温而提高其流动性，尽可能的避免基料粘辊；而且间距可调，根据成品板的厚度需求进行适应性的调整。
3、有益效果
相比于现有技术，本发明的有益效果为：
(1)本发明的软质墙板，充分利用了布纤层浸胶后在水平和竖直两方向上的附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果，还具有普通墙板的防潮防水性能，而软质基板和保温层叠加的缓冲能力，触感相对较好，杯子、手机、平板等易碎物品横撤在墙板上时，不容易摔碎；
(2)本发明的软质墙板，其中的软质辊压成型渗胶板在辊压成型时，基料中的胶液能够渗出，这样，在和布纤层叠加时，布纤层无需再行浸胶，从而节约了工序，提高了生产效率；而且聚苯板或酚醛板在保证保温效果的同时，容易汲取布纤层的胶液，从而达到三者牢固贴合的技术效果；
(3)本发明的软质墙板，啮合结构的三层层状结构，充分利用布纤层容易随机变形的特点，提高三者之间的接触面，从而避免三者在水平方向上产生任何的位移而导致的开胶变形；
(4)本发明的软质墙板，充分利用广大农村闲置而不能充分利用的秸秆资源，尽可能的减少农村因秸秆焚烧而产生的空气污染，而且，秸秆颗粒的空芯结构，容易吸收胶液，并在其中暂存，避免胶液和其它组分过早接触而粘结成团而导致混料不均；而绿粉则充分利用了装饮用水瓶体上的包装标签膜的闲置资源，毕竟在装饮用水瓶体的回收过程中，其包装标签膜往往由于和瓶体的化学成分不一致而废弃，在本申请中，则可以充分利用，契合废弃资源循环利用的国内大环境政策需求，还降低了墙板的生产成本；
(5)本发明的软质墙板的制作工艺，秸秆段中的胶液由于受到挤压而不断渗出，为下一步与布纤层的胶合奠定基础，从而实现布纤层无需重复浸胶的技术目的，减少了操作工序，提高了生产效率；
(6)本发明的软质墙板的制作工艺，先将秸秆段和胶液混合后，再按顺序混入添加剂和其它组分后混匀；秸秆段和胶液先行混合，这样，可以让胶液先行暂存于秸秆的空芯结构中，尤其是小麦的秸秆，其空心体积更大，胶液暂存量可更多，这样，后期的辊压成型中，胶液渗出量会更大；
(7)本发明的软质墙板的制作工艺，两组式的压辊单元，第一组辊压出软质辊压成型渗胶板后，第二组将布纤层、保温层辊压在软质辊压成型渗胶板上；两步辊压，节奏紧凑，尽可能的避免渗出的胶液因留空而提前胶干；
(8)本发明的软质墙板的制作工艺，通压辊单元的上下压辊为热压辊，可让胶液保持一定高温而提高其流动性，尽可能的避免基料粘辊；而且间距可调，根据成品板的厚度需求进行适应性的调整；
(9)本发明的软质墙板及其制作工艺，秸秆为2～4mm段状颗粒，该长度范围的秸杆，可以实现在尽可能多的暂存胶液的同时，在墙板中还起到一定的植物钢筋的作用，让基板组分的结合更加牢固。
附图说明
图1为本发明的软质墙板使用状态结构示意图；
图2为本发明的层状啮合结构的软质墙板分拆后状态示意图。
图中：1、软质基板；2、布纤层；3、保温层；4、装饰层；5、涂层；11、凹槽；12、秸秆段；21、凸条。
具体实施方式
下面结合具体实施例和附图对本发明进一步进行描述。
实施例1
如图1所示，本实施例的软质墙板，包括由外及内层叠分布的涂层5、软质基板1、布纤层2、保温层3和装饰层4。层叠分布时，可将布纤层2浸胶，提高软质基板1和保温层3之间竖向摩擦力的同时，又将两者在水平方向上牢固粘合。
本实施例的软质墙板，软质基板1可以不使用任何的木材组分，其组分包括钙粉、绿粉、聚氯乙烯、回料和树脂粉等占比70％(重量比，以下同)左右，回料是指制板过程中的下角料，可以循环使用；绿粉为瓶装饮用水瓶体上的包装标签膜打磨而成的粉体，主要成分为聚氯乙烯，用作填充物，起到一定的软质的作用，占比15％左右，其它组分主要是添加剂，比如丙烯酰氨(ACR)、稳定剂钙锌复合热稳定剂、PE腊、SP60硬质酸、塑化剂、碳黑、石腊等；将以上组分混合后，经过加热、挤出、辊压成型、裁断等工序，即可制得软质基板1，然后，软质基板1、浸胶的布纤层2和保温层3进行叠加，最后用辊压式叠加，然后再附合装饰层4，即得本实施例的软质墙板。装饰层可以是带有木材仿真纹路的油漆层。保温层3可以是岩棉带YM型、聚合保温板AE型、聚苯板EP型、挤塑板XP型、聚氨酯板PU型、酚醛板PF型等。
本实施例的软质墙板，充分利用布纤层2的附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果，还具有普通墙板的防潮防水性能，而软质基板1和保温层3叠加的缓冲能力，触感相对较好，杯子、手机、平板等物品横摔在墙板上时，不会导致摔碎。经检测，各层间拉伸粘结强度≥0.2MPa；耐冲击性≥10J，检测标准JG/T 287-2013。
实施例2
本实施例的软质墙板，是在实施例1的基础上做进一步改进，软质基板1为软质辊压成型渗胶板，即将软质基板1的基料挤出后辊压时，基料中的胶液能够渗出，这样，在和布纤层2叠加时，布纤层2无需再行浸胶，从而节约了工序，提高了生产效率；所述保温层3为聚苯板或酚醛板，聚苯板或酚醛板在保证保温效果的同时，容易汲取布纤层2的胶液，从而达到三者牢固贴合的技术效果。软质辊压成型渗胶板上表面、布纤层2的上下表面以及保温层3的下表面设置有互相适配的啮合结构，充分利用布纤层2容易随机变形的特点，提高三者之间的接触面，从而避免三者在竖直方向上产生任何的位移而导致的开胶变形。如图2所示，啮合结构通过配合使用的软质辊压成型渗胶板上表面的凹槽11，布纤层2上下表面的凸条21以及保温层3的下表面设置凹槽11协作而成，当然，也可以是通常的榫接结构。
本实施例的软质墙板，如图2所示，组分中可以添加10～30％的秸秆段12，以充分利用广大农村闲置而不能充分利用的秸秆资源，尽可能的减少农村因秸秆焚烧而产生的空气污染，并降低了墙板的生产成本，而且，秸秆颗粒的空芯结构，混合过程中容易吸收胶液，并在其中暂存，避免胶液和其它组分过早接触而粘结成团而导致混料不均。
本实施例的软质墙板的制作工艺为：
A、混料：将秸秆段12、胶液、添加剂和其它组分后混匀；
B、加热：将混匀后的物料转入加热罐体进行加热成半流体的熔融状；
C、挤出：将半流体转入挤出机挤出呈条状体；
D、辊压：将条状体直接接入压辊单元辊压成片状的软质辊压成型渗胶板；辊压成型过程中，秸秆段12中的胶液由于受到挤压而不断渗出，为下一步与布纤层2的胶合奠定基础；
E、复合：将布纤层2、保温层3和装饰层4依次复合在软质辊压成型渗胶板外表面，再喷涂涂层5在软质辊压成型渗胶板内表面制作成软质墙板，布纤层2和软质辊压成型渗胶板层叠的过程中，胶液可以再渗透布纤层2，从而再将布纤层2和保温层3胶合在一起。
经检测，本实施例的软质墙板，各层间拉伸粘结强度≥0.25MPa；耐冲击性≥12J。
实施例3
本实施例的软质墙板及其制作工艺，在实施例2的基础上做进一步改进，可以步骤A中先将秸秆段12和胶液混合后，再按顺序混入添加剂和其它组分后混匀；秸秆段12和胶液先行混合，这样，可以让胶液先行暂存于秸秆的空芯结构中，尤其是小麦的秸秆，其空心体积更大，胶液暂存量可更多，这样，后期的辊压成型中，胶液渗出量会更大。
经检测，本实施例的软质墙板，各层间拉伸粘结强度≥0.3MPa；耐冲击性≥15J。
实施例4
本实施例的软质墙板及其制作工艺，在实施例3的基础上做进一步改进，步骤D中，压辊单元为两组，第一组辊压出软质辊压成型渗胶板后，第二组将布纤层2、保温层3辊压在软质辊压成型渗胶板上；两步辊压，节奏紧凑，尽可能的避免渗出的胶液因留空而提前胶干。压辊单元的上下压辊为热压辊，可让胶液保持一定高温而提高其流动性，尽可能的避免基料粘辊；而且间距可调，根据成品板的厚度需求进行适应性的调整。
经检测，本实施例的软质墙板，各层间拉伸粘结强度≥0.3MPa；耐冲击性≥15J。
实施例5
本实施例的软质墙板及其制作工艺，在实施例4的基础上做进一步改进，将秸杆截断为2～4mm段状颗粒使用，该长度范围的秸杆，可以实现在尽可能多的暂存胶液的同时，在墙板中还起到一定的植物钢筋的作用，让基板组分的结合更加牢固。
经检测，本实施例的软质墙板，各层间拉伸粘结强度≥0.4MPa；耐冲击性≥18J。
本发明所述实例仅仅是对本发明的优选实施方式进行描述，并非对本发明构思和范围进行限定，在不脱离本发明设计思想的前提下，本领域工程技术人员对本发明的技术方案作出的各种变形和改进，均应落入本发明的保护范围。

Claims (10)

1.一种软质墙板，其特征在于，包括由外及内层叠分布的涂层(5)、软质基板(1)、布纤层(2)、保温层(3)和装饰层(4)。
2.根据权利要求1所述的软质墙板，其特征在于：所述软质基板(1)为软质辊压成型渗胶板；所述保温层(3)为岩棉板、聚苯板、酚醛板、聚合保温板、聚氨酯板或挤塑板。
3.根据权利要求2所述的软质墙板，其特征在于：所述软质辊压成型渗胶板外表面、布纤层(2)的内外表面以及保温层(3)的内表面设置有互相适配的啮合结构。
4.根据权利要求2所述的软质墙板，其特征在于：所述啮合结构通过软质辊压成型渗胶板外表面的凹槽(11)，布纤层(2)内外表面的凸条(21)以及保温层(3)的外表面设置凹槽(11)啮合式连接而成。
5.根据权利要求2所述的软质墙板，其特征在于，所述软质辊压成型渗胶板的组分中包括秸秆段(12)、绿粉和PVC；所述绿粉为瓶装饮用水瓶体上的包装标签膜打磨而成的粉体。
6.根据权利要求5所述的软质墙板，其特征在于，所述秸秆段(12)为2～4mm段状颗粒。
7.一种软质墙板的制作工艺，其特征在于，步骤为：
A、混料：将秸秆段(12)、胶液、添加剂和其它组分后混匀；
B、加热：将混匀后的物料转入加热罐体进行加热成半流体的熔融状；
C、挤出：将半流体转入挤出机挤出呈条状体；
D、辊压：将条状体直接接入压辊单元辊压成片状的软质辊压成型渗胶板；
E、复合：将布纤层(2)、保温层(3)和装饰层(4)依次复合在软质辊压成型渗胶板外表面，再喷涂涂层(5)在软质辊压成型渗胶板内表面制作成软质墙板。
8.根据权利要求7所述的软质墙板的制作工艺，其特征在于：步骤A中先将秸秆段(12)和胶液混合后，再按顺序混入添加剂和其它组分后混匀。
9.根据权利要求7所述的软质墙板的制作工艺，其特征在于：步骤D中，压辊单元为两组，第一组辊压出软质辊压成型渗胶板后，第二组将布纤层(2)、保温层(3)辊压在软质辊压成型渗胶板上。
10.根据权利要求7所述的软质墙板的制作工艺，其特征在于：所述压辊单元的上下压辊为热压辊，而且间距可调。
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