CN112140667A - 一种防潮防霉耐腐蚀难燃人造板 - Google Patents
一种防潮防霉耐腐蚀难燃人造板 Download PDFInfo
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Abstract
本发明属于功能型木材技术领域，具体公开了一种防潮防霉耐腐蚀难燃人造板，包括阻燃芯层、粘接在阻燃芯层第一表面的第一复合层和粘结在阻燃芯层第二表面的第二复合层；所述第一复合层和第二复合层至少由乙烯树脂膜和第一单板层构成，所述乙烯树脂膜设置在第一单板层和阻燃芯层之间；所述乙烯树脂膜为PE膜或PVC膜，包含高密度成分和低密度成分，其中低密度成分含量为50‑80%wt；所述乙烯树脂膜还添加有防霉抗菌剂。本发明能够有效解决阻燃剂吸湿返卤的问题，潮湿环境下不会腐蚀金属部件；同时具有良好的防潮防霉性能。
Description
技术领域
本发明属于功能型木材技术领域，具体涉及一种防潮防霉耐腐蚀难燃人造板。
背景技术
建筑装饰材料依据国家标准GB 8624，将燃烧等级分为不燃、难燃、可燃和易燃级。木质建筑材料最高燃烧等级为难燃级，可燃、易燃级木质板材几乎无阻燃功能，因而难燃级人造板被广泛用于室内装修和家具制造。难燃级人造板按基材分为难燃胶合板、难燃细木工板、难燃纤维板、难燃刨花板、难燃木质地板等。
为了满足国家标准GB 8624难燃级要求，各类人造板之生产过程中通常施加磷、氮、硼系阻燃剂，起到阻止燃烧和抑烟效果。磷氮硼系材料是目前较环保、使用方便、烟毒低，且性价比高的木材高效阻燃剂，深受木质阻燃制品生产、经营和用户的青睐。胶合板、细木工板、木质复合地板通常通过单板阻燃剂浸渍，或阻燃剂混合于胶黏剂中，或2种方法复合使用，使产品达到难燃等级；纤维板、刨花板等通常使用阻燃胶与纤维、刨花单元均匀混合，再进行热压制成难燃人造板。
上述难燃人造板虽然具有良好的阻燃功能，但是在潮湿环境下磷、氮、硼系阻燃剂存在吸湿返卤问题，阻燃剂会顺着水分通道（木材导管，或细胞腔空隙）渗析出来，不仅影响其阻燃性能的发挥，还会对金属轻钢龙骨、螺钉产生锈蚀，若用于吊顶还存在难以预估的安全隐患；除了吸湿返卤问题外，现有的难燃人造板在潮湿环境下还容易发霉，严重影响使用寿命。因此，避免难燃板材于不利条件下应用的尴尬处境，强化其在潮湿环境下的质量保证，成为亟待解决的问题。
发明内容
为解决上述问题，本发明提供了一种防潮防霉耐腐蚀难燃人造板，能够有效解决阻燃剂吸湿返卤的问题，潮湿环境下不会腐蚀金属部件；同时具有良好的防潮防霉性能。
为达到上述目的，本发明采用的具体技术方案如下：
一种防潮防霉耐腐蚀难燃人造板，包括阻燃芯层、粘接在阻燃芯层第一表面的第一复合层和粘结在阻燃芯层第二表面的第二复合层；所述第一复合层和第二复合层至少由乙烯树脂膜和第一单板层构成，所述乙烯树脂膜设置在第一单板层和阻燃芯层之间；所述乙烯树脂膜为PE膜或PVC膜，包含高密度成分和低密度成分（即PE膜包含低密度聚乙烯和高密度聚乙烯，PVC膜包括低密度聚氯乙烯和高密度聚氯乙烯），其中低密度成分含量为50-80%wt；所述乙烯树脂膜还添加有防霉抗菌剂。
优选的，所述的第一复合层和/或第二复合层还包括第二单板层，所述的第二单板层设置在乙烯树脂膜和阻燃芯层之间。
优选的，所述防霉抗菌剂包括纳米硅和纳米银。
优选的，所述的人造板还在周向设有封边层，所述封边层的上下两端与乙烯树脂膜接合。
优选的，所述封边层为热熔胶层，所述热溶胶为EVA、PUR、PU等。
优选的，所述第一单板为木质单板，厚度为0.1-0.8mm；当第一复合层和/或第二复合层还包括第二单板层时，第二单板层也为木质单板，厚度为0.1-0.8mm；木质单板可以是天然装饰单板、重组装饰单板、染色单板、集成装饰单板等。
优选的，所述阻燃芯层为难燃级胶合板、难燃级细木工板、难燃级纤维板或者难燃级刨花板，厚度为3-25mm。
优选的，所述乙烯树脂膜的厚度为0.02-0.10mm；当乙烯树脂膜的厚度≥
0.05mm时，所述乙烯树脂膜内含阻燃剂，如次磷酸铝、硼酸锌等；厚度0.05mm以下的乙烯树脂膜，其自身的燃烧性能几乎不影响该产品整体的燃烧性能。
优选的，所述第二单板层与阻燃芯层之间通过胶黏剂粘合，所述胶黏剂为三聚氰胺改性脲醛树脂、酚醛树脂、水性聚氨酯或者大豆蛋白胶黏剂。
本发明具有以下有益效果：
1、通过乙烯树脂膜的设置阻断空气中的水分向阻燃芯层渗透，同时也阻止了芯层内的阻燃剂向外渗析，所以不会对外部金属部件锈蚀，初步解决吸湿返卤的问题；乙烯树脂膜包含高密度成分和低密度成分，使其具备一定机械强度的同时兼具韧性，有利于乙烯树脂膜与其他板材的结合；更重要的是，高、低密度成分的混合有利于乙烯树脂膜中防霉抗菌剂的作用发挥，由于高密度区为结晶区，分子高度密实，容易把防霉抗菌剂包裹在内，防霉抗菌剂难以与霉菌细菌接触而失去其作用，低密度区为非结晶区，分子支链多，活性大，低密度区的存在为防霉抗菌剂提供了移动释放空间，在低密度成分不少于50%时，乙烯树脂膜具有良好的防霉抗菌功能，提升人造板的使用寿命。
2、采用纳米银和纳米硅作为防霉抗菌剂，一方面纳米银和纳米硅能够在乙烯树脂膜加工时起到诱导成核的作用，加快晶核形成，进而使结晶度下降，有利于乙烯树脂膜低密度区的形成，有效降低工艺难度；另一方面，纳米硅带有大量的负电荷，能够形成强大的吸附力，将霉菌、细菌进行汇集，然后通过纳米银的协同作用将霉菌和细菌杀死，这个过程中乙烯树脂膜低密度区为纳米银提供通路，纳米硅降低了纳米银捕获霉菌细菌的难度，因此可以实现快速杀菌，提升防霉抗菌效果。
3、通过在人造板周向设置上下两端与乙烯树脂膜接合的封边层，与乙烯树脂膜形成阻燃芯层的保护腔，完全避免水分进入阻燃芯层，使得芯层能够保持干燥，彻底解决吸湿返卤问题，增强内部螺钉、龙骨的耐腐蚀能力。更加优化的，封边层采用热熔胶涂覆得到，热熔胶与乙烯树脂膜相容性好，接合紧密，可以强化保护作用。
4、通过将木质单板的厚度控制在不超过0.8mm，使得木质单板与空气干湿度同步，即便有一定湿度也会随时逸散到空气中，减少了水分的滞留，结合上述阻燃芯层保持干燥以及乙烯树脂膜具备良好防霉抗菌功能，进一步提升人造板整体的防潮防霉能力。
5、本发明的防潮防霉耐腐蚀难燃人造板成本低，应用效果明显，阻燃性能达到B1级，抗霉菌功能达到1级，抗细菌功能达到Ⅰ级。
附图说明
图1：实施例1所述防潮防霉耐腐蚀难燃人造板的结构示意图。
图2：实施例2所述防潮防霉耐腐蚀难燃人造板的结构示意图。
图3：实施例4所述防潮防霉耐腐蚀难燃人造板的结构示意图。
图4：实施例5所述防潮防霉耐腐蚀难燃人造板的结构示意图。
图中：1-阻燃芯层，2a-第一复合层，2b-第二复合层，3-封边层，21-乙烯树脂膜，22-第一单板层，23-第二单板层。
具体实施方式
以下结合附图和具体实施例对本发明进行进一步的说明。
实施例1
一种防潮防霉耐腐蚀难燃人造板，如图1所示，包括阻燃芯层1、粘接在阻燃芯层1第一表面的第一复合层2a和粘结在阻燃芯层1第二表面的第二复合层2b；所述第一复合层2a和第二复合层2b由乙烯树脂膜21和第一单板层22构成，所述乙烯树脂膜21设置在第一单板层22和阻燃芯层1之间。其中：阻燃芯层1为厚度18mm的难燃B1级杨木胶合板；第一单板层22为厚度0.3mm的科技木单板；乙烯树脂膜21为厚度0.04mm的PE膜，包含高密度聚乙烯和低密度聚乙烯，其中低密度聚乙烯含量为65%wt，乙烯树脂膜21还添加有防霉抗菌剂，所述防霉抗菌剂为质量比为0.5:1纳米硅和纳米银，防霉抗菌剂的添加量为0.05%wt。
上述防潮防霉耐腐蚀难燃人造板的制造方法包括以下步骤：
a、芯层定厚砂光：使用多砂架砂光机对阻燃芯层1进行砂光，最后一道砂带为120~180目，砂光后厚度公差±0.2mm；
b、组坯：按“第一单板层22、乙烯树脂膜21、阻燃芯层1、乙烯树脂膜21、第一单板层22”结构组坯，并用塑料气枪钉固定；
c、热压：压贴工艺为压力0.3~1.0Mpa，温度130~150℃，时间1~4min。；
d、养生：按1米高度左右堆放，养生期冬季1周，夏季15天。
e、裁边：按规定尺寸裁切，尺寸公差符合相关国家标准要求。
f、检验、打包：按相关国家标准检验外观质量、内在理化性能，并打包。
实施例2
一种防潮防霉耐腐蚀难燃人造板，如图2所示，包括阻燃芯层1、粘接在阻燃芯层1第一表面的第一复合层2a和粘结在阻燃芯层1第二表面的第二复合层2b；所述第一复合层2a和第二复合层2b由第一单板层22、设置在第一单板层22和阻燃芯层1之间的乙烯树脂膜21以及设置在乙烯树脂膜21和阻燃芯层1之间的第二单板层23构成。其中：阻燃芯层1为厚度17mm的难燃B1级杉木细木工板；第一单板层22和第二单板层23为厚度0.15mm的奥古曼天然单板；乙烯树脂膜21为厚度0.03mm的PVC膜，包含高密度聚氯乙烯和低密度聚氯乙烯，其中低密度聚氯乙烯含量为75%wt，乙烯树脂膜21还添加有防霉抗菌剂，所述防霉抗菌剂为质量比为0.5:1纳米硅和纳米银，防霉抗菌剂的添加量为0.05%wt。
上述防潮防霉耐腐蚀难燃人造板的制造方法包括以下步骤：
a、复合层组坯：按“第一单板层22+乙烯树脂膜21+第二单板层23”结构进行第一复合层2a以及第二复合层2b的组坯，并用塑料气枪钉固定；
b、复合层热压：压贴工艺为压力0.3~1.0Mpa，温度130~150℃，时间1~4min ；
c、芯层定厚砂光：使用多砂架砂光机对对阻燃芯层1进行砂光，最后一道砂带为120~180目，砂光后厚度公差±0.2mm；
d、芯层涂胶：阻燃芯层1双面涂胶，胶黏剂为三聚氰胺改性脲醛树脂、酚醛树脂、水性聚氨酯或者大豆蛋白胶黏剂，涂胶量80~150g/m2；
e、二次组坯：按“第一复合层2a+阻燃芯层1+第二复合层2b”结构组坯，并送预压机冷压；
f、二次热压：热压工艺为压力0.5~1.0Mpa，温度100~120℃，时间3~5min；
g、养生：按1米高度左右堆放，养生期冬季1周，夏季15天。
h、裁边：按规定尺寸裁切，尺寸公差符合相关国家标准要求。
j、检验、打包：按相关国家标准检验外观质量、内在理化性能，并打包。
实施例3
一种防潮防霉耐腐蚀难燃人造板，基本构造同实施例1，区别仅在于：本实施例乙烯树脂膜21的厚度为0.10mm，乙烯树脂膜21内含有阻燃剂次磷酸铝，次磷酸铝的添加量为0.8%wt；本实施例的制造方法同实施例1。
实施例4
一种防潮防霉耐腐蚀难燃人造板，如图3所示，基本构造同实施例1，区别仅在于：所述的人造板还在周向设有封边层3，所述封边层3的上下两端与乙烯树脂膜21接合，封边层3与上下两层乙烯树脂膜21将阻燃芯层1包裹在内，避免了阻燃芯层1的吸湿，封边层3为热熔胶层，本实施例中，热熔胶为PU；本实施例的制造方法除在热压与养生之间增加一步热熔胶封边固化外同实施例1。
实施例5
一种防潮防霉耐腐蚀难燃人造板，如图4所示，基本构造同实施例2，区别仅在于：所述的人造板还在周向设有封边层3，所述封边层3的上下两端与乙烯树脂膜21接合，封边层3与上下两层乙烯树脂膜21将阻燃芯层1以及第二单板层23包裹在内，避免了阻燃芯层1的吸湿，封边层3为热熔胶层，本实施例中，热熔胶为EVA；本实施例的制造方法除在二次热压与养生之间增加一步热熔胶封边固化外同实施例2。
对比例1
一种防潮防霉耐腐蚀难燃人造板，基本构造同实施例1，区别仅在于：PE膜中低密度聚乙烯的含量为49%wt。
对比例2
一种防潮防霉耐腐蚀难燃人造板，基本构造同实施例2，区别仅在于：PVC膜中低密度聚氯乙烯的含量为49%wt。
对实施例1-5以及对比例1-2进行性能测试，测试项目和测试方法如下：
阻燃性能：依据GB8624-2012建筑材料及制品燃烧性能分级检测；
防霉抗菌性能：LY/T 1926-2010 抗菌木（竹）质地板中抗菌性能检验方法与抗菌效果，以及抗霉菌性能检测方法及效果分级检测；
实地应用检验：产品于2020年浙江省梅雨季节里（2020.5.29日始），在绍兴的一家装饰工地进行防潮防霉耐腐蚀实地应用检验，具体应用方法为：先将轻钢龙骨固定于四周墙面和吊顶处，然后通过螺钉把人造板固定在轻钢龙骨上，直到出梅日，观察板材有无霉变和阻燃剂渗析现象。
性能测试结果如下：
综上，本发明有效解决了难燃板材在潮湿环境下的吸湿返卤和发霉问题，强化了难燃板材在潮湿环境下的质量保证。
本具体实施方式仅仅是对本发明的解释，并不是对本发明的限制，本领域技术人员在阅读了本发明的说明书之后所做的任何改变，只要在本发明权利要求书的范围内，都将受到专利法的保护。
Claims (10)
1.一种防潮防霉耐腐蚀难燃人造板，其特征在于：包括阻燃芯层（1）、粘接在阻燃芯层（1）第一表面的第一复合层（2a）和粘结在阻燃芯层（1）第二表面的第二复合层（2b）；所述第一复合层（2a）和第二复合层（2b）至少由乙烯树脂膜（21）和第一单板层（22）构成，所述乙烯树脂膜（21）设置在第一单板层（22）和阻燃芯层（1）之间；所述乙烯树脂膜（21）为PE膜或PVC膜，包含高密度成分和低密度成分，其中低密度成分含量为50-80%wt；所述乙烯树脂膜（21）还添加有防霉抗菌剂。
2.根据权利要求1所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述的第一复合层（2a）和/或第二复合层（2b）还包括第二单板层（23），所述的第二单板层（23）设置在乙烯树脂膜（21）和阻燃芯层（1）之间。
3.根据权利要求1或2所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述防霉抗菌剂包括纳米硅和纳米银。
4.根据权利要求1或2所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述的人造板还在周向设有封边层（3），所述封边层（3）的上下两端与乙烯树脂膜（21）接合。
5.根据权利要求4所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述封边层（3）为热熔胶层。
6.根据权利要求1所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述第一单板层（22）为木质单板，厚度为0.1-0.8mm。
7.根据权利要求2所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述第一单板层（22）和第二单板层（23）为木质单板，厚度为0.1-0.8mm。
8.根据权利要求1或2所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述阻燃芯层（1）为难燃级胶合板、难燃级细木工板、难燃级纤维板或者难燃级刨花板，厚度为3-25mm。
9.根据权利要求1所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述乙烯树脂膜（21）的厚度为0.02-0.10mm；当乙烯树脂膜（21）的厚度≥0.05mm时，所述乙烯树脂膜（21）内含阻燃剂。
10.根据权利要求2所述的防潮防霉耐腐蚀难燃人造板，其特征在于：所述第二单板层（23）与阻燃芯层（1）之间通过胶黏剂粘合，所述胶黏剂为三聚氰胺改性脲醛树脂、酚醛树脂、水性聚氨酯或者大豆蛋白胶黏剂。
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