TW201600338A - 具氣孔及纖維之仿真木材及其製法 - Google Patents

具氣孔及纖維之仿真木材及其製法 Download PDF

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Publication number
TW201600338A
TW201600338A TW103121900A TW103121900A TW201600338A TW 201600338 A TW201600338 A TW 201600338A TW 103121900 A TW103121900 A TW 103121900A TW 103121900 A TW103121900 A TW 103121900A TW 201600338 A TW201600338 A TW 201600338A
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Taiwan
Prior art keywords
thermoplastic elastomer
sheets
wood
synthetic fibers
sheet
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TW103121900A
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English (en)
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TWI547377B (zh
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rui-sheng Shi
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Microcell Composite Company
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Publication date
Application filed by Microcell Composite Company filed Critical Microcell Composite Company
Priority to TW103121900A priority Critical patent/TWI547377B/zh
Priority to US14/490,316 priority patent/US10443193B2/en
Priority to CN201410524757.0A priority patent/CN105196567B/zh
Priority to PL15173624T priority patent/PL2960056T3/pl
Priority to EP15173624.6A priority patent/EP2960056B1/en
Publication of TW201600338A publication Critical patent/TW201600338A/zh
Priority to HK16104167.1A priority patent/HK1216167A1/zh
Application granted granted Critical
Publication of TWI547377B publication Critical patent/TWI547377B/zh
Priority to US15/834,273 priority patent/US10550523B2/en

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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/06—Vegetable or imitation parchment; Glassine paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1214—Anchoring by foaming into a preformed part, e.g. by penetrating through holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1266—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being completely encapsulated, e.g. for packaging purposes or as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/129—Enhancing adhesion to the preformed part using an interlayer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3415—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3442—Mixing, kneading or conveying the foamable material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5636—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching with the addition of heat
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/562—Winding and joining, e.g. winding spirally spirally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/564—Winding and joining, e.g. winding spirally for making non-tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/26—Layered products comprising a layer of synthetic resin characterised by the use of special additives using curing agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B32B37/185—Laminating sheets, panels or inserts between two discrete plastic layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/22—Agents rendering paper porous, absorbent or bulky
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Laminated Bodies (AREA)

Abstract

本發明係一種具氣孔及纖維之仿真木材及其製法，係將呈同向排列在一平面上之複數條合成纖維浸入一樹脂，令該樹脂沾附在各該合成纖維之表面及相鄰之該等合成纖維間的縫隙；再將該等合成纖維放置在二薄片之間，令三者貼合成一體，各該薄片係由熱塑性彈性體、發泡劑及架橋劑均勻混合製成之一呈平板狀的片體；嗣，對該等薄片的外側表面執行熱壓處理，使該等薄片中之該發泡劑能在受熱後，進行微發泡，而在該等薄片中形成密緻之封閉氣孔，且令該等薄片鄰近內側表面之材料，因本身發泡及其所承受之周遭發泡作用力，而分別朝該等合成纖維之方向發生膨脹變形，且分別穿過該等合成纖維間的縫隙，而彼此糾結在一起。如此，完成發泡後之該等薄片的內側表面及該等合成纖維間即能分別以不規則之接觸面，藉該樹脂之黏結力，令彼此相互緊密且牢固地結合成一體，形成該板狀仿真木材，且使該板狀仿真木材不僅能模擬出真實木材之木質特性及紋理，尚具備較真實木材更佳之可塑性及更高之纖維強度。

Description

具氣孔及纖維之仿真木材及其製法
本發明係關於一種仿真木材，尤指一種利用熱塑性彈性體發泡製成，且具有氣孔及纖維之仿真木材，以期該仿真木材不僅具備真實木材之物理特性(具備無毒性、環保收回之再使用性、優良之著色性及耐候性等)及木質紋理，尚具備較真實木材更佳之可塑性及更高之纖維強度。
按，在眾多自然資源中，森林資源實乃地球資源中極為重要之一資產，森林資源除孕育了豐富多樣的動植物生態外，亦提供人類所需之各種資材，且與人類生活息息相關，因此，如何增進木材利用率、回收率及再利用率等，即成為世界各國亟欲突破之一重要議題，以期能減少天然資源的無謂浪費，並有效減少殘料處理時所需之人力與物力。有鑒於此，近年來，對於以木材殘削或碎片製備高分子塑膠生物複合材料(woodplastic composite，以下簡稱WPC)之研究，越來越受到世界各國重視，其原因係WPC除能有效利用木質纖維殘料製備複合材外，WPC較真實木材具備更良好的尺寸安定性及抵抗病蟲之能力，因此，無須特別維護，其使用年限即能高達25~30年之久。目前，WPC的應用範疇主要以交通運輸工具與非結構及半結構建築等用材為主，以美國為例，已有超過30家WPC戶外鋪板製造廠，且WPC所製備之戶外鋪板約達到25%之市場佔有率，由此顯示，未來WPC之利用及應用將更顯寬廣及普遍。
一般言，複合材料係利用兩種或兩種以上不同性質的原材料，以不同的加工法，結合在一起，以擷取各該原材料之特性與優點，發揮協同作用(synergistic effect)，製成性能優異並能滿足需求的一種新材料。在眾多複合材料中，尤以纖維強化(fiber reinforced)之複合材料的性能較佳，應用也較廣。若複合材料所使用之一原材料為木質材料時，則稱為木質複 合材料(wood-based composites)，其製造方式主要是利用不同尺寸大小之木質殘削或碎片，與膠合劑混合，並於高溫高壓下，膠合成板材。傳統木質複合材料大多利用甲醛系膠合劑，使用時，常有游離甲醛等問題，若將該類木質複合材料浸泡於水中，常會使板材發生膨脹潰散之問題。因此，為解決此一問題，近年來，專家學者乃將木質材料混合塑膠原料，製造出木材塑膠複合材料(WPC)，以減少甲醛釋出，並改善材料尺寸安定性等問題。除此之外，由於WPC結合了木材和塑膠兩種原材料的特性，所以能相互改善兩種原材料之各自缺點，如：塑膠比重大、抗靜電性差及彈性不佳等缺點，但在加入木質原材料後，則能降低材料比重、提高材料抗靜電性及彈性；相對地，對於木質原材料而言，在加入塑膠原材料後，則能改善木材本身的尺寸安定性、抗蟲性、耐腐性及耐候性等特性。此外，當添加木質纖維比例增加時，材料之結構強度或彈性係數(modulus of elasticity，MOE)亦會隨之增加。
查，傳統WPC複合材的製備方式主要是將木粉或製漿纖維與典型的熱塑性塑膠，如；聚乙烯(Polyethylene)、聚丙烯(Polypropylene)、聚氯乙烯(Polyvinyl chloride)或聚苯乙烯(Polystyrene)等混合，並在高溫下製成木材纖維(或木粉)塑膠複合材。目前，約70%的WPC是以聚乙烯作為塑膠基質，少部分則係以聚丙烯及聚氯乙烯作為塑膠基質。此外，為增進熱塑性塑膠製品之強度與韌性，同時，尚能降低生產成本，往往會在膠體中添加纖維及填料，以作為增強劑，早期大部分塑膠工業(約93%)所使用的纖維多半為合成纖維，近年來，則多利用回收再生之木材纖維，此外，在1970年代石油危機衝擊期間，更直接助長了業界使用生質物(Biomass)之纖維。
綜上所述，WPC複合材料即是利用木質纖維取代傳統塑膠中之無機纖維材料或填料，其與熱塑性塑膠混合製造成複合材料時，不僅能有效改善木質材料之物理特性與力學性質，尚能改善其加工性。因此，近年來，WPC在使用上已大量取代傳統的金屬、塑膠與實木材料，並常被應用至舖板、柵欄、外壁板、窗框及屋頂材料等製品上。然而，以木質纖維(或木粉)作為塑膠中之增強劑或填料，仍存在許多問題，其中，最大的問題係在膠體與木質纖維間常因表面極性的不同，阻礙二者間之化學鍵結， 不僅如此，木質纖維在膠體中，尚會因纖維與纖維間氫鍵而造成低分散性(Poor dispersion)之問題。
為了解決膠體與纖維相容性(Compatibility)的問題，耦合劑(Coupling agent)或膠合促進劑(Adhesion promoting agent)，如：Maleated polyethylene(MAPE)、Maleic anhydridegrafted polypropylene(MAgPP)及Oxidized LDPE等的使用，雖能克服此一問題，但是，對於纖維間低分散性之問題，則尚必需藉由添加分散劑(Dispersing agent)，如：硬脂酸(Stearic acid)、石蠟(Paraffin wax)或礦物油等始能獲得改善，除此之外，業者尚會利用接枝(Grafting)方式，將低分子聚合物(如：1-Phenylthene、4-Methyl-2-oxy-3-oxopent-4-ene等)與木質纖維形成共聚合體，以解決纖維極性及分散性之問題。此外，近年來，尚有業者利用化學改質(Chemical modification)方式，來改善WPC複合材之界面性質。一般言，透過化學改質雖能降低WPC複合材之表面極性，進而提高木質材料與膠體之相容性，但化學改質又必須使用到許多化學藥劑，其中，最基本之化學改質法係使用具有單官能基之改質藥劑；此外，亦有使用具雙官能基，甚至，多官能基之藥劑者，在眾多的化學改質方法中，較受業界重視亦較實用者，為利用醋酸酐(Acetic anhydride)與木材羥基反應的方法，即所謂的乙醯化反應(Acetylation)，但以醋酸酐進行乙醯化反應時，若在無溶劑且未添加催化劑的環境下，則需要較長之反應時間，方可獲得較佳之重量增加率(weight percent gain，簡稱WPG)或取代度(degree of substitution)，故，以醋酸酐進行乙醯化反應時，多會使用二甲基甲醯胺(dimethyl formamide，簡稱DMF)、二甲亞楓(dimethyl sulfoxide，簡稱DMSO)或吡啶(pyridine)等溶劑，以提高與醋酸酐混合之反應效率，使其在較短的反應時間內，達到較佳的乙醯化效果。然而，添加溶劑除必然會增加成本及增加此類溶劑帶來之毒性等缺點外，反應時間仍需數小時，方可達較佳之乙醯化效果。
近年來，在環保意識日益高漲之氛圍下，前述WPC複合材或其它塑膠複合材仍因存在前述諸多結構性缺點及毒性問題，而始終無法被普及使用或應用至人們之日常生活需求中。據此，如何開發出一種仿真木材，以使仿真木材本身不僅具有高彈性及高強度，具備無毒性、環保收 回之再使用性、優良之著色性及耐候性等諸多優點之外，尚能模擬出真實木材之木質特性及紋理，且具備較真實木材更佳之可塑性及更高之纖維強度，即成為世界各國業者長久以來亟思解決之一重要課題。
本發明之一目的，係提供一種具氣孔及纖維之仿真木材及其製法，係將呈同向排列在一平面上之複數條合成纖維(如：玻璃纖維或碳纖維)浸入一樹脂，令該樹脂沾附在各該合成纖維之表面及相鄰之該等合成纖維間的縫隙；再將該等合成纖維放置在二薄片之間，令三者貼合成一體，各該薄片係由熱塑性彈性體(Thermoplastic Elastomer，簡稱TPE)、發泡劑及架橋劑等成份原料，均勻混合製成之一呈平板狀的片體；嗣，對該等薄片的外側表面執行熱壓處理，使該等薄片中之該發泡劑能在受熱後，進行微發泡，進而在該等薄片中形成密緻之封閉氣孔，且令該等薄片鄰近內側表面之材料，因本身發泡及其所承受之周遭發泡作用力，而分別朝該等合成纖維之方向發生膨脹變形，且分別穿過該等合成纖維間的縫隙，而彼此糾結在一起。如此，完成發泡後之該等薄片的內側表面及該等合成纖維間即能分別以不規則之接觸面，藉該樹脂之黏結力，令彼此相互緊密且牢固地結合成一體，形成一板狀仿真木材。在本發明中，由於該等薄片本身不僅具有橡膠的高彈性及高強度，且具備無毒性、環保收回之再使用性、優良之著色性及耐候性等諸多優點，故在完成著色處理及發泡處理，且在其中形成密緻之封閉氣孔後，即能在該等薄片中模擬出真實木材之木質特性及紋理，另，由於該等合成纖維係以不規則之接觸面，緊密且牢固地結合在完成發泡後之該等薄片的內側表面間，因此，所製成之板狀仿真木材尚具備較真實板狀木材更佳之可塑性及更高之纖維強度。
本發明之另一目的，係在完成該板狀仿真木材後，尚能對該板狀仿真木材執行一捲繞加工處理，使其成為一柱狀仿真木材，該捲繞加工處理係先對該板狀仿真木材進行加熱，俟該等薄片及其外側表面被加熱至軟化，且接近熱熔狀態後，再以該等合成纖維作為軸線，對該板狀仿真木材進行緊密地捲繞，使其內層薄片之內側表面能因捲繞，而逐一貼附至其外層薄片的外側表面，且彼此熔接成一體。如此，在完成該捲繞加工處 理及冷卻後，即能形成該柱狀仿真木材，此時，由於該等合成纖維係沿該柱狀仿真木材的軸向，呈等間距或螺旋狀地分佈在其徑向間，使得該柱狀仿真木材尚能具備遠較真實柱狀木材更高之纖維強度，並能輕易被塑形成不同斷面形狀之柱狀體。
本發明之又一目的，係該薄片中各成份原料之重量百分比分別為10~80%之熱塑性彈性體、0.01~2.0%之架橋劑及0.1~15.0%之發泡劑，該熱塑性彈性體之種類與比例係用以製備出不同硬度或密度等性質之仿真木材。
本發明之又另一目的，係該熱塑性彈性體包括至少兩種不同特性之熱塑性彈性體(即，一第一熱塑性彈性體及一第二熱塑性彈性體)，其中，該第一熱塑性彈性體係選用自苯乙烯-丁二烯嵌段共聚物(SBS)、苯乙烯-異戊二烯嵌段共聚物(SIS)、苯乙烯類嵌段共聚物(styrenic block copolymers，SBC)或前述化合物任一混合物之高分子化合物群組，以作為該薄片中軟段結構的基材，其重量百分比為10~80%；該第二熱塑性彈性體材料係選用自聚苯乙烯(Polystyrene，PS)、丙烯腈-苯乙烯共聚物(Acrylonitrile-styrene copolymer，AS)、丙烯腈-丁二烯丙烯-苯乙烯共聚物(Acrylonitrile-butadiene-styrene，ABS)、高抗衝聚苯乙烯(High impact polystyrene，HIPS)或前述化合物任一混合物之高分子化合物群組，以作為該薄片中硬段結構的基材，其重量百分比為10~80%。如此，即能視實際需要，藉增減該第一熱塑性彈性體或第二熱塑性彈性體之重量百分比，調整各該薄片之軟硬段結構的材料特性，以模擬出各種真實木材之不同軟硬木質特性。
本發明之又另一目的，係各該薄片之製備程序是將該等成份原料以100℃以上之溫度，加熱至軟化並接近熱熔狀態，混合成一熱熔原料後，再以110~130℃之溫度，對該熱熔原料進行捏合，以使其中各成份原料均勻混合，嗣，利用一出片機，對該熱熔原料進行滾壓出片，而形成一呈平板狀且厚度介於0.5~1.0公釐(mm)的片體。
本發明之又另一目的，係在對該等薄片的外側表面執行熱壓處理時，其熱壓溫度為160℃至180℃間，熱壓壓力則為250Kg/cm2至300 Kg/cm2間。
為便 貴審查委員能對本發明之目的、製程、構造特徵及其功效，做更進一步之認識與瞭解，茲舉實施例配合圖式，詳細說明如下：
〔習知〕
無
〔本發明〕
10‧‧‧板狀仿真木材
11、12‧‧‧薄片
13‧‧‧合成纖維
131‧‧‧縫隙
14‧‧‧樹脂
20‧‧‧柱狀仿真木材
B‧‧‧封閉氣孔
第1圖係本發明之仿真木材之結構分解示意圖；第2圖係本發明之仿真木材之製程示意圖；第3圖係本發明之板狀仿真木材成形前之局部剖面示意圖；第4圖係本發明之板狀仿真木材成形後之局部剖面示意圖；第5圖係本發明之柱狀仿真木材之成品示意圖；及第6圖係本發明之柱狀仿真木材之製程示意圖。
按，市售之熱塑性彈性體(Thermoplastic Elastomers，以下簡稱TPE)是一種具有橡膠之高彈性及高強度等特性之高分子化合物，不僅具有熱塑性塑膠的加工性能，又具有硫化橡膠的物理性能，可謂是塑膠和橡膠優點的優勢組合，且具有良好的抗紫外線、耐候性及耐高溫之材料特性，適於長期使用於戶外，因此，目前熱塑性彈性體之應用已逐漸佔據原本屬於硫化橡膠之應用領域。此外，由於在熱塑性彈性體之製造過程中，大多不需要硫化或硫化時間很短，故不僅能有效節約能源，且所產生之廢料(逸出毛邊、擠出廢膠)及最終出現之廢品，亦均能直接被回收再利用，甚至，使用過的熱塑性彈性體之舊品亦能在簡單再生處理後，被回收利用，故，簡而言之，熱塑性彈性體尚具有能減少環境污染及擴大資源再生之優異特性。
查，市售之諸多熱塑性彈性體材料中，苯乙烯類之熱塑性彈性體的性能最接近丁苯橡膠(styrene-butadiene rubber，簡稱SBR)，為一種丁二烯或異戊二烯與苯乙烯嵌段型的共聚物(based on styrene block copolymers)，以下簡稱為TPS。目前，世界TPS的產量約占全部TPE一半左右，由於其材料特性穩度、無毒性，且具備能百分之百回收及價格相對低廉之優點，故，不僅已被廣泛使用於制鞋業，取代了大部分橡膠，在膠 布、膠板等工業橡膠製品中的用途也不斷擴大，現今，更以防水卷材進一步推廣到建築物屋頂、地鐵、隧道、溝槽等的防水、防潮上面，因此，發明人經長期研究後，乃思及利用苯乙烯類熱塑性彈性體之前述諸多優異特性，製作本發明之一種具氣孔及纖維之仿真木材，使得能在取材容易且成本低廉之前提下，製作出仿真木材，且使該仿真木材不僅本身具有高彈性及高強度，具備無毒性、環保收回之再使用性、優良之著色性及耐候性等諸多優點之外，尚能模擬出真實木材之木質特性及紋理，且具備較真實木材更佳之可塑性及更高之纖維強度。
本發明係提供一種具氣孔及纖維之仿真木材，其製法主要係利用苯乙烯類之熱塑性彈性體，進行發泡，以模擬出真實木材之木質特性及紋理，並利用合成纖維，模擬出較真實木材更佳之可塑性及更高之纖維強度。在本發明中，請參閱第1圖所示，該板狀仿真木材10至少係由二薄片11、12及複數條合成纖維13(如：玻璃纖維或碳纖維)組合而成，各該薄片11、12包括一熱塑性彈性體、一發泡劑及一架橋劑等成份原料，各該薄片11、12之製備程序係將該等成份原料以100℃以上之溫度，加熱至軟化並接近熱熔狀態，且混合成一熱熔原料後，再以110~130℃之溫度，對該熱熔原料進行捏合，以使其中之各成份原料均勻混合，嗣，利用一出片機，對該熱熔原料進行滾壓出片，而形成一呈平板狀且厚度介於0.5~1.0公釐(mm)的片體。
在本發明之一較佳實施例中，為了能依實際需要，模擬出各種真實木材之不同軟硬木質特性，該熱塑性彈性體包括至少兩種不同特性之熱塑性彈性體(即，一第一熱塑性彈性體及一第二熱塑性彈性體)，其中，該第一熱塑性彈性體係選用自苯乙烯-丁二烯嵌段共聚物(SBS)、苯乙烯-異戊二烯嵌段共聚物(SIS)、苯乙烯類嵌段共聚物(styrenic block copolymers，SBC)或前述化合物任一混合物之高分子化合物群組，以作為該薄片中軟段結構的基材，其重量百分比為10~80%；該第二熱塑性彈性體材料係選用自聚苯乙烯(Polystyrene，PS)、丙烯腈-苯乙烯共聚物(Acrylonitrile-styrene copolymer，AS)、丙烯腈-丁二烯丙烯-苯乙烯共聚物(Acrylonitrile-butadiene-styrene，ABS)、高抗衝聚苯乙烯(High impact polystyrene，HIPS) 或前述化合物任一混合物之高分子化合物群組，以作為該薄片中硬段結構的基材，其重量百分比為10~80%。如此，即能視實際需要，藉增減該第一熱塑性彈性體或第二熱塑性彈性體之重量百分比，調整各該薄片11、12之軟硬段結構的材料特性，以模擬出各種真實木材之不同軟硬木質特性。
在本發明中，該發泡劑係選自偶氮類化學發泡劑或小蘇打粉等物理性發泡劑，其重量百分比為0.1~15.0%；該架橋劑係選自二異丙苯基過氧化物(dicumyl peroxide)、2,5-過氧三級丁基-2,5-二甲基己烷〈2,5-(tert-butylperoxide)-2,5-dimethylhexane〉或硫黃，其重量百分比則為0.01~2.0%。本發明在製作該板狀仿真木材10時，請參閱第2圖所示，其製法包括下列步驟：(201)將呈同向排列在一平面上之複數條合成纖維13(如：玻璃纖維或碳纖維)浸入一樹脂14，令該樹脂14沾附在各該合成纖維13之表面及相鄰之該等合成纖維13間的縫隙131；(202)請參閱第3圖所示，再將該等合成纖維13放置在該二薄片11、12之間，令三者貼合成一體；(203)嗣，藉一熱壓機，對該等薄片11、12及其外側表面執行熱壓處理，其中，該熱壓處理之加熱溫度及加熱壓力係依該等薄片11、12的材質及厚度進行設定，該加熱溫度能被調整至介於160℃至180℃之間，該加熱壓力則能被調整至介於250至300公斤/每平方公分(Kg/cm2)，使得該等薄片11、12中發泡劑能在受熱後，進行微發泡，進而在該等薄片11、12中形成密緻之封閉氣孔B，且令該等薄片11、12鄰近內側表面之材料，能因本身發泡及其所承受之周遭發泡作用力，而分別朝該等合成纖維13之方向發生膨脹變形，且分別穿過該等合成纖維13間的縫隙，而如第4圖所示，彼此糾結在一起；及(204)對該等薄片11、12進行冷卻。
如此，復請參閱第4圖所示，完成發泡後之該等薄片11、12的內側表面及該等合成纖維13間，即能分別以不規則之接觸面，藉該樹脂14之黏結力，令彼此相互緊密且牢固地結合成一體，形成一板狀仿真木材10，且使該板狀仿真木材10不僅能模擬出真實木材之木質特性及紋理， 尚具備較真實木材更佳之可塑性及更高之纖維強度。
在本發明之另一較佳實施例中，在完成該板狀仿真木材10後，尚能對該板狀仿真木材10執行一捲繞加工處理，使其成為第5圖所示之一柱狀仿真木材20，該捲繞加工處理包括下列步驟，請參閱第6圖所示：(601)先對該板狀仿真木材10進行加熱；(602)俟該等薄片11、12被加熱至軟化，且其外側表面接近熱熔狀態後，再以該等合成纖維13作為軸線，對該板狀仿真木材10進行緊密地捲繞，使其內層薄片11之內側表面能因捲繞，而逐一貼附至其外層薄片12的外側表面，且彼此熔接成一體；(603)對該內層薄片11及外層薄片12進行冷卻後，即形成該柱狀仿真木材20。
如此，在完成該捲繞加工處理及冷卻後，由於，該等合成纖維13係沿該柱狀仿真木材20的軸向，呈等間距或螺旋狀地分佈在其徑向間，且其內層薄片11之內側表面係與其外層薄片12的外側表面緊密地熔接成一體，使得該柱狀仿真木材20尚能具備遠較真實柱狀木材更高之纖維強度，並能輕易被塑形成不同斷面形狀之柱狀體。
在本發明之其它實施例中，尚能依實際需要，在各該薄片11、12之製備程序中，藉添加發泡助劑、色料或防火劑，來強化及提升利用該等薄片11、12組合製成之仿真木材10、20之各項功效及性能；其中，該發泡助劑之重量百分比為0.1~10.0%；該色料係用以調整該仿真木材10、20之木質顏色及紋理；該防火劑則係用以強化該仿真木材10、20之防火能力。
據上所述，透過本發明所製成之該仿真木材10、20，其木質顏色不僅能被調製成與真實木材十分接近，其橫斷面尚具有宛如年輪般之規則紋理，此外，經由發明對其進行各式物理性質測試後尚發現，該仿真木材10、20之硬度及材質與柚木十分接近，但其質量卻較柚木輕，且較柚木能承受更大之重量，此外，無論就該仿真木材10、20分別與一般真實木材或其它木材塑膠複合材料(WPC)進行各式物理性質測試及比較後尚發現，本發明之該仿真木材10、20具有更佳之不吸水性質，非常適合應用於 一般露天使用之公園座椅或圍欄、家具或家飾、玩具或積木、園藝造景或木工藝品、文具、各種模型等產品之製作，且長期使用於露天高溫或潮濕之環境中，亦遠較一般之其它真實木材或其它木材塑膠複合材料(WPC)，具備更佳之使用壽命及強度，此外，由於本發明之該仿真木材10、20係以前述高分子材料作為主要之基材，且在整個製造過成中，完全未添加其他具毒性之溶劑或化學材料，因此，當該仿真木材10、20不堪使用而被廢棄後，將如同一般高分子材料般，僅需簡單處理，即能完全回收再利用，故不僅能有效避免廢棄物之處理不易及堆積空間之無謂浪費，且能輕易達成節能減碳及保護環境資源之最終目的。
按，以上所述，僅係本發明之較佳實施例，惟，本發明所主張之權利範圍，並不侷限於此，按凡熟悉該項技藝人士，依據本發明所揭露之技術內容，可輕易思及之等效變化，均應屬不脫離本發明之保護範疇。
10‧‧‧板狀仿真木材
11、12‧‧‧薄片
13‧‧‧合成纖維
14‧‧‧樹脂
B‧‧‧封閉氣孔

Claims (18)

  1. 一種具氣孔及纖維之仿真木材之製法，包括下列步驟：將呈同向排列在一平面上之複數條合成纖維浸入一樹脂，令該樹脂沾附在各該合成纖維之表面及相鄰之該等合成纖維間的縫隙；將該等合成纖維放置在二薄片之間，令三者貼合成一體，各該薄片係由熱塑性彈性體、發泡劑及架橋劑等成份原料均勻混合製成之一呈平板狀的片體；嗣，對該等薄片的外側表面執行熱壓處理，使該等薄片中之該發泡劑能在受熱後，進行微發泡，而在該等薄片中形成密緻之封閉氣孔，且令該等薄片鄰近內側表面之材料，因本身發泡及其所承受之周遭發泡作用力，分別朝該等合成纖維之方向發生膨脹變形，且分別穿過該等合成纖維間的縫隙，而彼此糾結在一起；及對該等薄片進行冷卻，即形成一板狀仿真木材，其中，完成發泡後之該等薄片的內側表面及該等合成纖維間，係分別以不規則之接觸面，藉該樹脂之黏結力，令彼此相互緊密且牢固地結合成一體。
  2. 如申請專利範圍第1項所述之製法，其中，在製成該板狀仿真木材後，尚包括一捲繞加工處理，該捲繞加工處理包括下列步驟：對該板狀仿真木材進行加熱； 俟該等薄片被加熱至軟化，且其外側表面接近熱熔狀態後，再以該等合成纖維作為軸線，對該板狀仿真木材進行緊密地捲繞，使其內層薄片之內側表面能捲繞貼附至其外層薄片的外側表面，且彼此熔接成一體；及對該內層薄片及外層薄片進行冷卻，即形成一柱狀仿真木材。
  3. 如申請專利範圍第1或2項所述之製法，該等成份原料係以攝氏100度以上之溫度，加熱至軟化，且接近熱熔狀態，混合成一熱熔原料後，再以攝氏110~130度之溫度，對該熱熔原料進行捏合，以使其中之各該成份原料均勻混合，嗣，利用一出片機，對該熱熔原料進行滾壓出片，而形成該薄片。
  4. 如申請專利範圍第3項所述之製法，該薄片之厚度係介於0.5~1.0公釐間。
  5. 如申請專利範圍第4項所述之製法，該熱塑性彈性體係苯乙烯類之熱塑性彈性體。
  6. 如申請專利範圍第5項所述之製法，該熱塑性彈性體包括至少一第一熱塑性彈性體及一第二熱塑性彈性體，該第一熱塑性彈性體及第二熱塑性彈性體係兩種不同特性之熱塑性彈性體，其中，該第一熱塑性彈性體係用以作為該薄片中軟段結構的基材，該第二熱塑性彈性體係用以作為該薄片中硬段結構的基材。
  7. 如申請專利範圍第6項所述之製法，該第一熱塑性彈性體係苯乙烯-丁二烯嵌段共聚物、苯乙烯-異戊二烯嵌段共聚物、苯乙烯類嵌段共聚物或前述化合物任一混合物之高分子化合物群組，其重量百分比為10~80%；該第二熱塑性彈性體材料係聚苯乙烯、丙烯腈-苯乙烯共聚物、丙烯腈-丁二烯丙烯-苯乙烯共聚物、高抗衝聚苯乙烯或前述化合物任一混合物之高分子化合物群組，其重量百分比為10~80%。
  8. 如申請專利範圍第7項所述之製法，該發泡劑係偶氮類化學發泡劑或小蘇打粉等物理性發泡劑，其重量百分比為0.1~15.0%；該架橋劑係二異丙苯基過氧化物、2,5-過氧三級丁基-2,5-二甲基己烷或硫黃，其重量百分比則為0.01~2.0%。
  9. 如申請專利範圍第8項所述之製法，該合成纖維係玻璃纖維或碳纖維。
  10. 如申請專利範圍第9項所述之製法，該熱壓處理之熱壓溫度為攝氏160至180度間，其熱壓壓力則為250至300公斤/每平方公分。
  11. 一種具氣孔及纖維之仿真木材，包括：複數條合成纖維，該等合成纖維係呈同向排列在一平面；樹脂，該樹脂係沾附在該等合成纖維之表面及相鄰之該等合成纖維間之縫隙內；及 二薄片，各該薄片係由熱塑性彈性體、發泡劑及架橋劑等成份原料均勻混合製成之一片體，且分別貼附在該等合成纖維之兩相對側，該等薄片在被執行一熱壓處理後，其中之該發泡劑能因受熱，進行微發泡，而在該等薄片中形成密緻之封閉氣孔，該等薄片鄰近內側表面之材料，能因本身發泡及其所承受之周遭發泡作用力，分別朝該等合成纖維之方向發生膨脹變形，且分別穿過該等合成纖維間的縫隙，而彼此糾結在一起，令該等薄片的內側表面及該等合成纖維間，能分別以不規則之接觸面，藉該樹脂之黏結力，彼此緊密且牢固地結合成一體，而形成該仿真木材。
  12. 如申請專利範圍第11項所述之仿真木材，該等薄片係以該等合成纖維作為軸線而捲繞，其內層薄片之內側表面係捲繞貼附至其外層薄片的外側表面，且彼此熔接成一體而形成該仿真木材。
  13. 如申請專利範圍第11或12項所述之仿真木材，該薄片之厚度係介於0.5~1.0公釐間。
  14. 如申請專利範圍第13項所述之仿真木材，該熱塑性彈性體係苯乙烯類之熱塑性彈性體。
  15. 如申請專利範圍第14項所述之仿真木材，該熱塑性彈性體包括至少一第一熱塑性彈性體及一第二熱塑性彈性體，該第一熱塑性彈性體及第二熱塑性彈性體係兩種不同特性之熱塑性彈性體，其中，該第一熱塑性彈性體係作為 該薄片中軟段結構的基材，該第二熱塑性彈性體係作為該薄片中硬段結構的基材。
  16. 如申請專利範圍第15項所述之仿真木材，該第一熱塑性彈性體係苯乙烯-丁二烯嵌段共聚物、苯乙烯-異戊二烯嵌段共聚物、苯乙烯類嵌段共聚物或前述化合物任一混合物之高分子化合物群組，其重量百分比為10~80%；該第二熱塑性彈性體材料係聚苯乙烯、丙烯腈-苯乙烯共聚物、丙烯腈-丁二烯丙烯-苯乙烯共聚物、高抗衝聚苯乙烯或前述化合物任一混合物之高分子化合物群組，其重量百分比為10~80%。
  17. 如申請專利範圍第16項所述之仿真木材，該發泡劑係偶氮類化學發泡劑或小蘇打粉等物理性發泡劑，其重量百分比為0.1~15.0%；該架橋劑係二異丙苯基過氧化物、2,5-過氧三級丁基-2,5-二甲基己烷或硫黃，其重量百分比為0.01~2.0%。
  18. 如申請專利範圍第17項所述之仿真木材，該合成纖維係玻璃纖維或碳纖維。
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CN201410524757.0A CN105196567B (zh) 2014-06-25 2014-09-30 具气孔及纤维的仿真木材及其制法
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