CN112172279A - 一种3d型耐磨软质保温墙板及其制作工艺 - Google Patents

一种3d型耐磨软质保温墙板及其制作工艺 Download PDF

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CN112172279A
CN112172279A CN202011040450.5A CN202011040450A CN112172279A CN 112172279 A CN112172279 A CN 112172279A CN 202011040450 A CN202011040450 A CN 202011040450A CN 112172279 A CN112172279 A CN 112172279A
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艾华
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Anhui Yinuo Wood Plastic Sheet Technology Co ltd
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Abstract

本发明公开了一种3D型耐磨软质保温墙板及其制作工艺，属于板材加工技术领域。本发明通过在软质基板组分中添加秸秆段作为胶液的缓释载体；所述缓释载体在软质基板的辊压成型过程中，以及将耐磨层、3D视觉效果层、软质基板、布纤层和保温层依次叠放并压合成板过程中缓释出胶液。由于秸秆段的中空结构对胶液有良好的暂存功能，可以在后续的辊压成型以及叠放压合过程中缓慢释放胶液，从而达到3D视觉效果层、软质基板、布纤层在复合过程中无需浸胶、刷胶，而且，布纤层是纱线和芳纶纤维混合织成，充分利用布纤层的吸附式附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果。解决了现有技术中复合木墙板容易产生开胶和变形现象的不足以及耐冲击性、耐磨性、保温及视觉效果欠佳的问题。

Description

一种3D型耐磨软质保温墙板及其制作工艺
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3D型耐磨软质保温墙板及其制作工艺。
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。
在体育场馆内，对墙体的要求较高，比如为了避免撞伤，会经常使用软质墙板，而现有的软质墙板在受到频繁的人体碰撞以及球体等体育器材的击打后，抗冲击性和耐磨性较差，墙体表面经常有撞痕、刮痕等，从而需要经常的维护。
随着生活水平的提高，人们对板材的要求越来越高，除了关注板材的质量之外，对板材的外观视觉效果也越来越关注。现有的板材的外观普遍是二维的木纹纹理，视觉效果单一乏味，消费者更倾向于接受更有视觉冲击力、更追求艺术美感、木材纹理清晰有致的立体板材。
经检索，美国专利US2014/0109507A1，ENGINEERED WATERPROOFFLOORING ANDWALL COVERING PLANKS(工程防水墙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；(3)墙板保温和视觉效果欠佳。
发明内容
1、要解决的问题
针对现有技术中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、保温和视觉效果欠佳的问题，本发明提供一种3D型耐磨软质保温墙板及其制作工艺，充分利用秸秆段对胶液的暂存作用，起到胶液缓释的技术效果，从而在后续的辊压和压机压制过程中将胶液释放，在无需3D视觉效果层、软质基板、布纤层复合前浸胶或刷胶的前提下将三者辊压复合，避免开胶和变形，而且，结合软软质基板的缓冲效果，提高了耐冲击性，并和耐磨层缓冲式协同作用下，提高了整个板材的耐磨性，还通过软质基板与3D视觉效果层的协同作用，提高了缓冲、保温以及视觉能力的三重技术效果。
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3D型耐磨软质保温墙板的制作工艺，在软质基板组分中添加秸秆段作为胶液的缓释载体；所述缓释载体在软质基板的辊压成型过程中，以及将耐磨层、3D视觉效果层、软质基板、布纤层和保温层依次叠放并压合成板过程中缓释出胶液。由于秸秆段的中空结构对胶液有良好的暂存功能，可以在后续的辊压成型以及叠放压合过程中缓慢释放胶液，从而达到3D视觉效果层、软质基板、布纤层在复合过程中无需浸胶、刷胶，而且，布纤层是纱线和芳纶纤维混合织成，充分利用布纤层的吸附式附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果。
进一步的制作工艺，具体步骤为：
S1、原料加工：将农村秸秆截断为秸秆段；
S2、混料：将秸秆段、胶液、添加剂和其它组分混匀；
S3、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；
S4、挤出：将半流体转入挤出机挤出呈条状体；挤出过程中，部分胶液会少量缓释，方便物料的挤出；
S5、一次辊压：将条状体直接接入压辊单元辊压成片状的软质基板；辊压过程中，胶液第一次缓释，缓释过程中，和其它组分二次混合，方便胶液在物料中的均匀分布；
S6、二次辊压：压辊单元将布纤层辊压在软质基板的表面，辊压过程中，胶液第二次缓释，缓释过程中，渗出胶液至成软质基板表面，布纤层是纱线和芳纶纤维混合织成；二次辊压过程中，渗出的胶液将布纤层和软质基板粘合，胶液在胶合布纤层布纤层的同时，还渗透至布纤层布纤层表面，成为软质辊压成型渗胶板；
S7、叠放：将耐磨层、3D视觉效果层、软质辊压成型渗胶板、保温层依次叠放；叠放过程中，无需浸胶和刷胶；
S8、压合：叠放后置入压机进行压制复合；压合过程中，第三次缓释，渗出的胶液将耐磨层、3D视觉效果层胶合在软质辊压成型渗胶板的上表面，将保温层胶合在软质辊压成型渗胶板的下表面，布纤层在提高软质基板和保温层之间摩擦力的同时，还具有普通板材的防潮防水性能；又将两者牢固粘合，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，还节约了工序，提高了生产效率，提高了耐冲击性，软质基板和耐磨层缓冲式协同作用下，提高了耐磨层的耐磨性。
S9、装饰：在保温层的外表面喷涂涂层，制作成3D型耐磨软质保温墙板。
进一步的制作工艺，步骤S2中先将秸秆段和胶液均匀混合后，再按顺序混入添加剂和其它组分混匀。段状的秸秆和胶液先行混合，这样，可以让胶液先行暂存于秸秆段12的空芯结构中，尤其是小麦的秸秆，其空心体积更大，胶液因粘性而附着在空芯结构内，胶液暂存量可更多。
进一步的制作工艺，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，在板材中还起到一定的植物钢筋的作用，让板材组分的结合更加牢固；所述秸秆段和胶液在软质基板组分中重量比分别为10～20％和8～12％；所述软质基板组分中还包括绿粉，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，占重量比10～20％。
进一步的制作工艺，压辊单元中的压辊为热压辊；所述压机为热压机，可让胶液保持一定高温而提高其流动性，提高缓释效果，并尽可能的避免粘辊。
进一步的制作工艺，压机和压辊温度在130～150℃，胶液在该温度范围内流动性较好；所述压机压力在100～130bar，压合的时间为10～20min。
进一步的制作工艺，压辊单元中的压辊之间的间距可调，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3D型耐磨软质保温墙板及其制作工艺，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，而软质基板的缓冲能力，室内触感相对较好，任意物体碰到墙体时，不容易产生彼此的伤害；而且，3D视觉效果层和耐磨层附着在软质基板内侧，提高观赏效果的同时，提高了耐磨性，进而提高了使用寿命；
(2)本发明的3D型耐磨软质保温墙板及其制作工艺，充分利用秸秆段对胶液的暂存作用，起到胶液缓释的技术效果，从而在后续的辊压和压机压制过程中将胶液释放，在无需3D视觉效果层、软质基板、布纤层复合前浸胶的前提下将三者辊压复合，避免开胶和变形，而且，结合软软质基板的缓冲效果，提高了耐冲击性，并和耐磨层缓冲式协同作用下，提高了整个板材的耐磨性；
(3)本发明的3D型耐磨软质保温墙板及其制作工艺，充分利用广大农村闲置而不能充分利用的秸秆资源，降低了生产成本，并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，尤其是小麦杆，更容易吸收胶液，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，还进一步降低了板材的生产成本；
(4)本发明的3D型耐磨软质保温墙板及其制作工艺，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；
(5)本发明的3D型耐磨软质保温墙板及其制作工艺，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3D型耐磨软质保温墙板及其制作工艺，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3D型耐磨软质保温墙板及其制作工艺，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；
附图说明
图1为本发明制得的3D型耐磨软质保温墙板使用状态结构示意图。
图中：1、软质基板；2、布纤层；3、保温层；4、3D视觉效果层；5、涂层；7、耐磨层；12、秸秆段。
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
本实施例的3D型耐磨软质保温墙板的制作工艺，通过在软质基板1组分中添加秸秆段12作为胶液的缓释载体；所述缓释载体在软质基板1的辊压成型过程中，以及将耐磨层7、3D视觉效果层4、软质基板1、布纤层2和保温层3依次叠放并压合成板过程中缓释出胶液。由于秸秆段12的中空结构对胶液有良好的暂存功能，可以在后续的辊压成型以及叠放压合过程中缓慢释放胶液，从而达到3D视觉效果层4、软质基板1、布纤层2在复合过程中无需浸胶、刷胶，而且，布纤层2是纱线和芳纶纤维混合织成，充分利用布纤层2的吸附式附着能力，进而达到抗开胶变形和提高缓冲能力的双重技术效果。还通过软质基板1与3D视觉效果层4、保温层3的协同作用，提高了缓冲、保温以及视觉能力的三重技术效果；其具体的步骤为：
S1、原料加工：将农村秸秆截断为秸秆段12；
S2、混料：将秸秆段12、胶液、添加剂和其它组分混匀；添加剂包括丙烯酰氨(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。其它组分包括钙粉、绿粉、聚氯乙烯、回料和树脂粉等，占比为软质基板60％的重量比，秸秆段12和胶液在软质基板1组分中重量比分别为10～20％和8～12％，优选分别为20％和10％；其它为各种添加剂；回料是指制板过程中的下脚料，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，占软质基板1的组分重量比10～20％，优选为15％；
S3、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；
S4、挤出：将半流体转入挤出机挤出呈条状体；挤出过程中，部分胶液会少量缓释，方便物料的挤出；
S5、一次辊压：将条状体直接接入压辊单元辊压成片状的软质基板1；辊压过程中，胶液第一次缓释，缓释过程中，和其它组分二次混合，方便胶液在物料中的均匀分布；
S6、二次辊压：压辊单元将布纤层2辊压在软质基板1的表面，辊压过程中，胶液第二次缓释，缓释过程中，渗出胶液至成软质基板表面，布纤层是纱线和芳纶纤维混合织成；二次辊压过程中，渗出的胶液将布纤层2和软质基板粘合，胶液在胶合布纤层布纤层2的同时，还渗透至布纤层布纤层2表面，成为软质辊压成型渗胶板；
S7、叠放：将耐磨层7、3D视觉效果层4、软质辊压成型渗胶板、保温层3依次叠放；叠放过程中，无需浸胶和刷胶；耐磨层7为AL2O3耐磨层，具有超强耐磨、高弹性、超强抗冲击、防火阻燃、防水防潮、吸音防噪、花纹逼真等优点；保温层3为为岩棉板、聚苯板、酚醛板或挤塑板，其中的聚苯板或酚醛板效果最好，能够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；
S8、压合：叠放后置入压机进行压制复合；压合过程中，第三次缓释，渗出的胶液将耐磨层7、3D视觉效果层4胶合在软质辊压成型渗胶板的上表面，将保温层3胶合在软质辊压成型渗胶板的下表面，布纤层2在提高软质基板和保温层3之间水平摩擦力的同时，还具有普通板材的防潮防水性能；又将两者在垂直方向上牢固粘合，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，还节约了工序，提高了生产效率，提高了耐冲击性，软质基板和耐磨层7缓冲式协同作用下，提高了耐磨层的耐磨性。
S9、装饰：在保温层3的外表面喷涂涂层5，制作成如图1所示的3D型耐磨软质保温墙板。
本实施例制得的3D型耐磨软质保温墙板，软质基板1可以不使用任何的木材成分，本实施例的3D型耐磨软质保温墙板，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，任意物体，包括人体、体育用品等碰到墙体时，不容易产生彼此的伤害；经检测，各层间拉伸粘结强度≥0.25MPa；耐冲击性≥12J；检测标准JG/T287-2013。
进一步的，步骤S1中可以先将秸秆段12和胶液混合后，再按顺序混入添加剂和其它组分混匀。段状的秸秆和胶液先行混合，这样，可以让胶液先行暂存于秸秆段12的空芯结构中，尤其是小麦的秸秆，其空心体积更大，胶液因粘性而附着在空芯结构内，胶液暂存量可更多，这样，后期的辊压成型以及压机压制中，胶液缓释效果更好。经检测，各层间拉伸粘结强度≥0.3MPa；耐冲击性≥15J；《GB/T 18102-2007浸渍纸层压木质地板》。
再进一步的，压辊单元中的压辊为热压辊；所述压机为热压机，可让胶液保持一定高温而提高其流动性，提高缓释效果，并尽可能的避免粘辊。压机和压辊温度在130～150℃，胶液在该温度范围内流动性较好；所述压机压力在100～130bar，压合的时间为10～20min，根据板材各层间厚度进行相应的调整。经检测，制得的3D型耐磨软质保温墙板，各层间拉伸粘结强度≥0.35MPa；耐冲击性≥18J；《GB/T 18102-2007浸渍纸层压木质地板》。
再进一步的，秸秆段12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，在板材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。压辊单元中的压辊之间的间距可调，根据成品板的厚度需求进行适应性的调整。经检测，制得的3D型耐磨软质保温墙板，包括由内及外层叠分布的耐磨层7、3D视觉效果层4、软质基板1、布纤层2、保温层3和装饰层5；各层间拉伸粘结强度≥0.4MPa；耐冲击性≥20J，《GB/T 18102-2007浸渍纸层压木质地板》。
再进一步的，3D视觉效果层4可以选择足球、篮球、排球、羽毛球等体育元素的3D立体视觉，提高观赏效果。而且，也可以将AL2O3喷涂在3D视觉效果层表面作为耐磨层7，这样，两层状结构可以合二为一，喷涂时注意透明效果即可，避免影响3D视觉效果。
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 (8)

1.一种3D型耐磨软质保温墙板的制作工艺，其特征在于，在软质基板(1)组分中添加秸秆段)作为胶液的缓释载体；所述缓释载体在软质基板(1)的辊压成型过程中，以及将耐磨层(7)、3D视觉效果层(4)、软质基板(1)、布纤层(2)和保温层(3)依次叠放并压合成板过程中缓释出胶液。
2.根据权利要求1所述的3D型耐磨软质保温墙板的制作工艺，其特征在于：具体步骤为：
S1、原料加工：将农村秸秆截断为秸秆段(12)；
S2、混料：将秸秆段(12)、胶液、添加剂和其它组分混匀；
S3、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；
S4、挤出：将半流体转入挤出机挤出呈条状体；
S5、一次辊压：将条状体直接接入压辊单元辊压成片状的软质基板(1)；
S6、二次辊压：压辊单元将布纤层(2)辊压在软质基板(1)的表面，成为软质辊压成型渗胶板；
S7、叠放：将耐磨层(7)、3D视觉效果层(4)、软质辊压成型渗胶板和保温层(3)依次叠放；
S8、压合：叠放后置入压机进行压制复合；
S9、装饰：在保温层(3)的外表面喷涂涂层(5)，制作成3D型耐磨软质保温墙板。
3.根据权利要求2所述的3D型耐磨软质保温墙板的制作工艺，其特征在于：步骤S2中先将秸秆段(12)和胶液均匀混合后，再按顺序混入添加剂和其它组分混匀。
4.根据权利要求2所述的3D型耐磨软质保温墙板的制作工艺，其特征在于：所述压辊单元中的压辊为热压辊；所述压机为热压机。
5.根据权利要求4所述的3D型耐磨软质保温墙板的制作工艺，其特征在于：所述压机和压辊温度在130～150℃；所述压机压力在100～130bar，压合的时间为10～20min。
6.根据权利要求5所述的3D型耐磨软质保温墙板的制作工艺，其特征在于：所述压辊单元中的压辊之间的间距可调。
7.根据权利要求2至6任一所述的3D型耐磨软质保温墙板的制作工艺，其特征在于：所述秸秆段(12)为2～4mm段状颗粒；所述秸秆段(12)和胶液在软质基板(1)组分中重量比分别为10～20％和8～12％；所述软质基板(1)组分中还包括绿粉，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，占重量比10～20％。
8.一种根据权利要求2至7任一所述的制作工艺制得的3D型耐磨软质保温墙板，其特征在于：包括由内及外层叠分布的耐磨层(7)、3D视觉效果层(4)、软质基板(1)、布纤层(2)、保温层(3)和装饰层(5)。
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