CN112140679B - 一种高抗冲型a级不燃高压装饰板及其制备方法 - Google Patents

一种高抗冲型a级不燃高压装饰板及其制备方法 Download PDF

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CN112140679B
CN112140679B CN202010932657.7A CN202010932657A CN112140679B CN 112140679 B CN112140679 B CN 112140679B CN 202010932657 A CN202010932657 A CN 202010932657A CN 112140679 B CN112140679 B CN 112140679B
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沈达
何伟
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Jiangsu Boda New Material Technology Co ltd
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Abstract

本发明涉及装饰材料技术领域，尤其涉及一种高抗冲型A级不燃高压装饰板及其制备方法。装饰板表面三聚氰胺甲醛树脂浸渍涂层在持续高温环境中的热收缩应力较大，极易造成整个装饰板表面开裂、有卷边，从而失去装饰效果。基于上述问题，本发明提供一种高抗冲型A级不燃高压装饰板，自上而下依次包括装饰层、缓冲层、无机板材、缓冲层、装饰层，装饰层由装饰纤维浸渍在改性三聚氰胺甲醛树脂中形成，改性三聚氰胺甲醛树脂中在使用过程中添加了一定含量的水性聚氨酯，有效降低了装饰板表面三聚氰胺甲醛树脂浸渍涂层的热收缩应力，大大提高了高抗冲型A级不燃高压装饰板在高温环境下的稳定性，且可实现单层多压，降低能源损耗，具有良好的应用前景。

Description

一种高抗冲型A级不燃高压装饰板及其制备方法
技术领域
本发明涉及装饰材料技术领域，尤其涉及一种高抗冲型A级不燃高压装饰板及其制备方法。
背景技术
装饰板是用多种专用的纸张经改性的三聚氰胺树脂和酚醛树脂浸渍处理，高温高压层压制成的热固性层积板，在装饰材料市场上占有一定比例。浸渍用甲醛树脂是由三聚氰胺与甲醛在催化剂作用下缩聚而成的无色甲阶树脂水溶液，其能形成耐水、耐热、耐磨、耐污染腐蚀、富有光泽的树脂保护膜。三聚氰胺甲醛树脂是热固性树脂，是具有交联网络状的高分子化合物，具有良好的机械性能、电学性能和粘结性。但是交联后的三聚氰胺甲醛树脂性脆、耐冲击性能较差，特别是其在持续高温环境中的热收缩应力较大，容易造成装饰板开裂。
当冬季来临，中国北方城市室内集中供暖的方式一般采用暖气片，当室内平均温度达到16-24℃时，暖气片的温度在55-70℃，这时，靠近暖气的地方，A级高压装饰不燃板表面的三聚氰胺甲醛树脂浸渍涂层的热收缩应力较大，极易造成整个装饰板侧面开裂，严重时会导致装饰板整个表面与基材分层，从而失去装饰效果。另外，中国发明专利CN106379021 A公开了一种无机高压防火耐磨装饰板及其生产方法，其在无机板材表面覆涂酚醛树脂作为无机和装饰层的粘结剂。其酚醛树脂的颜色为红褐色，随着时间的推移及空气潮湿度的变化酚醛树脂很容易随着无机板材中的碱性物质迁移到装饰层表面形成黄变，从而影响装饰效果。
目前，有报道在三聚氰胺甲醛树脂使用过程中添加己内酰胺、对甲苯黄酰胺、聚乙烯醇、淀粉、α-纤维素等改善三聚氰胺甲醛树脂的脆性和耐冲击性能并取得了一定效果(何乃叶.低压短周期浸渍用三聚氰胺甲醛树脂改性研究[D].东北林业大学,2010.)，但是，目前人们对如何降低三聚氰胺甲醛树脂装饰涂层的热收缩应力的研究鲜有报道。
发明内容
针对现有技术中存在的问题，本发明要解决的技术问题是：装饰板表面三聚氰胺甲醛树脂浸渍涂层在持续高温环境中的热收缩应力较大，极易造成整个装饰板表面开裂，从而失去装饰效果。
本发明解决其技术问题所采用的技术方案是：本发明提供一种高抗冲型A级不燃高压装饰板，其自上而下依次包括装饰层、缓冲层、无机板材、缓冲层、装饰层。
具体地，所述装饰层由装饰纤维纸浸渍在改性三聚氰胺甲醛树脂中形成，所述装饰纤维纸的上胶量为75-140wt.％，挥发份为6-8wt.％。
具体地，所述改性三聚氰胺甲醛树脂按照以下步骤制备：
将甲醛与三聚氰胺按摩尔比1.1-1.7:1投料，以水为溶剂，将溶液pH调节至9.0-9.5，加入增塑剂，搅拌均匀，将反应溶液升温至114±2℃，反应10-15min，直至反应溶液变得澄清，然后降温至102±2℃，当反应溶液的水倍数为1.0-1.2时，立即将反应溶液温度降至50-60℃，然后加入水性聚氨酯，持续搅拌至反应溶液降温至常温，即得到固含量为35-55％的改性三聚氰胺甲醛树脂。
具体地，所述增塑剂的添加量为反应溶液总质量的1-50％。
具体地，所述水性聚氨酯的添加量为反应溶液总质量的1-50％。
具体地，所述水性聚氨酯为聚酯型水性聚氨酯、聚醚型水性聚氨酯、聚碳型水性聚氨酯中的一种或几种。
具体地，所述增塑剂为己内酰胺、双氰胺、硫脲、二甘醇、1,4-丁二醇中一种或几种。
具体地，所述缓冲层是由抗冲击纤维浸渍在酚醛树脂中形成，抗冲击纤维的上胶量为35-65wt.％，挥发份为6-8wt.％。
具体地，所述抗冲击纤维为牛皮纸、碳纤维、无纺布中的一种或几种。
具体地，所述无机板材是通过涂布的方式在无机不燃板材双面涂覆丙烯酸树脂胶黏剂形成，胶黏剂的涂布量为10-100g/m2。
具体地，所述无机不燃板材为硅酸钙板、玻镁板、硅酸铝棉板、无石棉纤维水泥板中的一种或几种。
具体地，所述的一种高抗冲型A级不燃高压装饰板，按照以下步骤制备：
所述高抗冲型A级不燃高压装饰板按由上往下的顺序将装饰层、缓冲层、无机板材、缓冲层、装饰层进行排叠后进入多层高压压机进行压制成型，单位压力6.5-10MPa，板芯温度到达135℃降温成型，即得到高抗冲型A级不燃高压装饰板。
本发明的有益效果是：
(1)本发明所制备改性三聚氰胺甲醛树脂中添加了水性聚氨酯成分，水性聚氨酯的柔性链段不仅可以降低三聚氰胺甲醛树脂分子间的作用力，而且在三聚氰胺甲醛树脂交联固化时具有阻聚作用，降低三聚氰胺甲醛树脂的固化速率，可以有效改善改性三聚氰胺甲醛树脂的热收缩率，从而使得本发明所制备高抗冲型A级不燃高压装饰板侧面在持续高温或湿热环境下不易开裂，测试结果显示，本发明所制备的高抗冲型A级不燃高压装饰板在温度-18℃下放置2h后立即转入110℃下放置2h，连续3次冷热循环后，其表面及侧面均未出现开裂现象；
(2)本发明所制备的高抗冲型A级不燃高压装饰板，工艺简便，密度小，板型平整，表面纹理丰富，不易产生黄变，加工裁切时不易崩口，冷热循环无开裂；同时还具有较好的阻燃性、抗冲击性能和耐水性能；
(3)本发明采用无色且具有耐酸碱性的丙烯酸树脂双面涂布无机不燃板材不仅可以达到较好的粘结效果，还能阻止无机不燃板材中的碱性物质的迁移至装饰层表面形成黄变。
具体实施方式
现在结合实施例对本发明作进一步详细的说明。
本发明以下实施例和对比例所采用的装饰层由装饰纤维纸浸渍在改性三聚氰胺甲醛树脂中形成，所述装饰纤维纸的上胶量为75-140wt.％，挥发份为6-8wt.％。
本发明以下实施例和对比例所采用的改性三聚氰胺甲醛树脂按照以下步骤制备：
将甲醛与三聚氰胺按摩尔比1.1-1.7:1投料，以水为溶剂，将溶液pH调节至9.0-9.5，加入增塑剂，增塑剂的添加量为反应溶液总质量1-50％，搅拌均匀，将反应溶液升温至114±2℃，反应10-15min，直至反应溶液变得澄清，然后降温至102±2℃，当反应溶液的水倍数为1.0-1.2时，立即将反应溶液温度降至50-60℃，然后加入水性聚氨酯，水性聚氨酯的添加量为反应溶液总质量的1-50％，持续搅拌至反应溶液降温至常温，即得到固含量为35-55％的改性三聚氰胺甲醛树脂。
本发明以下实施例和对比例所采用的水性聚氨酯为亨缌克PU3747、亨缌克PU3645、亨缌克PU3946或亨缌克PU3553。
本发明以下实施例和对比例所采用的增塑剂为己内酰胺、双氰胺、硫脲、二甘醇、1,4-丁二醇中一种或几种。
本发明以下实施例和对比例所采用的缓冲层是由抗冲击纤维浸渍在酚醛树脂中形成，抗冲击纤维的上胶量为35-65wt.％，挥发份为6-8wt.％。
本发明以下实施例和对比例所采用的抗冲击纤维为牛皮纸、碳纤维、无纺布中的一种或几种。
本发明以下实施例和对比例所采用的无机板材是通过涂布的方式在无机不燃板材双面涂覆丙烯酸树脂胶黏剂形成，胶黏剂的涂布量为10-100g/m2。
本发明以下实施例和对比例所采用的无机不燃板材为硅酸钙板、玻镁板、硅酸铝棉板、无石棉纤维水泥板中的一种或几种。
实施例1
自上而下按照顺序将装饰层、缓冲层、无机板材、缓冲层、装饰层复合，自上而下装饰层的厚度为0.06mm，缓冲层的厚度为0.04mm，无机板材的厚度为4mm，缓冲层的厚度为0.04mm，装饰层的厚度为0.06mm，然后置于多层高压压机进行压制成型，单位压力6.5MPa，热压机升温时间15min，保压保温时间35min，保压冷却时间30min，板芯温度到达135℃降温成型，待板芯温度降至50℃以下后卸压、卸机，板坯经过锯边工序处理后得到高抗冲型A级不燃高压装饰板。
实施例2
自上而下按照顺序将装饰层、缓冲层、无机板材、缓冲层、装饰层复合，自上而下装饰层的厚度为0.2mm，缓冲层的厚度为0.3mm，无机板材的厚度为25mm，缓冲层的厚度为0.3mm，装饰层的厚度为0.2mm，然后置于多层高压压机进行压制成型，单位压力8MPa，热压机升温时间20min，保压保温时间40min，保压冷却时间45min，板芯温度到达135℃降温成型，待板芯温度降至50℃以下后卸压、卸机，板坯经过锯边工序处理后得到高抗冲型A级不燃高压装饰板。
实施例3
自上而下按照顺序将装饰层、缓冲层、无机板材、缓冲层、装饰层复合，自上而下装饰层的厚度为0.1mm，缓冲层的厚度为0.2mm，无机板材的厚度为8mm，缓冲层的厚度为0.2mm，装饰层的厚度为0.15mm，然后置于多层高压压机进行压制成型，单位压力10MPa，热压机升温时间17min，保压保温时间38min，保压冷却时间40min，板芯温度到达135℃降温成型，待板芯温度降至50℃以下后卸压、卸机，板坯经过锯边工序处理后得到高抗冲型A级不燃高压装饰板。
对比例1同实施例3，不同之处在于：改性三聚氰胺甲醛树脂制备过程中未添加水性聚氨酯。
对比例2同实施例3，不同之处在于：改性三聚氰胺甲醛树脂制备过程中将水性聚氨酯替换为水性丙烯酸酯。
性能测试：
实施例1-3以及对比例1-2所制备高抗冲型A级不燃高压装饰板按照NEMA LD-20053.8抗落球冲击测试其抗冲击性能，按照NEMA LD-20053.5测试其耐沸水性能，按照GB8624-2012测试其阻燃性能，通过在-18℃下放置2h后立即转入110℃下放置2h，连续3次的测试方法观察装饰板侧面开裂情况评价其冷热循环性能的优劣，具体测试结果如表1所示：
表1
Figure BDA0002670783220000061
以上述依据本发明的理想实施例为启示，通过上述的说明内容，相关工作人员完全可以在不偏离本项发明技术思想的范围内，进行多样的变更以及修改。本项发明的技术性范围并不局限于说明书上的内容，必须要根据权利要求范围来确定其技术性范围。

Claims (8)

1.一种高抗冲型A级不燃高压装饰板，其特征在于：自上而下依次包括装饰层、缓冲层、无机板材、缓冲层、装饰层；
所述装饰层由装饰纤维纸浸渍在改性三聚氰胺甲醛树脂中形成，所述装饰纤维纸的上胶量为75-140wt.％，挥发份为6-8wt.％；
所述改性三聚氰胺甲醛树脂按照以下步骤制备：
将甲醛与三聚氰胺按摩尔比1.1-1.7:1投料，以水为溶剂，将溶液pH调节至9.0-9.5，加入增塑剂，搅拌均匀，将反应溶液升温至114±2℃，反应10-15min，直至反应溶液变得澄清，然后降温至102±2℃，当反应溶液的水倍数为1.0-1.2时，立即将反应溶液温度降至50-60℃，然后加入水性聚氨酯，持续搅拌至反应溶液降温至常温，即得到固含量为35-55％的改性三聚氰胺甲醛树脂。
2.根据权利要求1所述的一种高抗冲型A级不燃高压装饰板，其特征在于：
所述增塑剂的添加量为反应溶液总质量的1-50％；
所述水性聚氨酯的添加量为反应溶液总质量的1-50％。
3.根据权利要求2所述的一种高抗冲型A级不燃高压装饰板，其特征在于：
所述水性聚氨酯为聚酯型水性聚氨酯、聚醚型水性聚氨酯、聚碳型水性聚氨酯中的一种或几种；
所述增塑剂为己内酰胺、双氰胺、硫脲、二甘醇、1,4-丁二醇中一种或几种。
4.根据权利要求1所述的一种高抗冲型A级不燃高压装饰板，其特征在于：所述缓冲层是由抗冲击纤维浸渍在酚醛树脂中形成，抗冲击纤维的上胶量为35-65wt.％，挥发份为6-8wt.％。
5.根据权利要求 4所述的一种高抗冲型A级不燃高压装饰板，其特征在于：所述抗冲击纤维为牛皮纸、碳纤纸、无纺布中的一种或几种。
6.根据权利要求1所述的一种高抗冲型A级不燃高压装饰板，其特征在于：所述无机板材是通过涂布的方式在无机不燃板材双面涂覆丙烯酸树脂胶黏剂形成，胶黏剂的涂布量为10-100g/m2。
7.根据权利要求6所述的一种高抗冲型A级不燃高压装饰板，其特征在于：所述无机不燃板材为硅酸钙板、玻镁板、硅酸铝棉板、无石棉纤维水泥板中的一种或几种。
8.根据权利要求1所述的一种高抗冲型A级不燃高压装饰板，其特征在于，按照以下步骤制备：
所述高抗冲型A级不燃高压装饰板按由上往下的顺序将装饰层、缓冲层、无机板材、缓冲层、装饰层进行排叠后进入多层高压压机进行压制成型，单位压力6.5-10MPa，板芯温度到达135℃降温成型，即得到高抗冲型A级不燃高压装饰板。
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