WO2007118389A1

WO2007118389A1 - A process for manufacturing a composite board

Info

Publication number: WO2007118389A1
Application number: PCT/CN2007/000222
Authority: WO
Inventors: Hongji Chen; Wenjie Shen; Zhaotang Xu
Original assignee: Hongji Chen; Wenjie Shen; Zhaotang Xu
Priority date: 2006-04-14
Filing date: 2007-01-19
Publication date: 2007-10-25
Also published as: CN1982771A

Abstract

A process for manufacturing a composite board comprises the following steps: recycling (or preparing) at lease one of thermoplastic polymer resin material (S1); heating the thermoplastic polymer resin material to form a thermoplastic polymer resin sheet (S2); heating and sticking the thermoplastic polymer resin sheet on at lease one surface of a wood veneer to form a unit plate (S3); and hot-pressing at least two unit plates to form a composite board (S4). Alternatively, the above thermoplastic polymer resin material is formed into a thermoplastic polymer resin sheet on the wood veneer by curing and thus directly assembled into the unit plate.

Description

Method for manufacturing composite board

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a composite sheet, and more particularly to recycling various thermoplastic polymer resin raw materials to be combined with a wood sheet to form a unit sheet, thereby increasing water repellency and manufacturing yield and manufacturing of the composite sheet. method. BACKGROUND OF THE INVENTION A commonly used composite board and manufacturing method, as shown in FIG. 1A to FIG. 1G, mainly includes the following steps: As shown in FIG. 1A, a log 90 is cut into a fixed length; as shown in FIG. 1B, the log 90 is cut. Forming a wood sheet 91; as shown in FIG. 1C, the wood sheet 91 is cut into a fixed length and width dimension and dried; as shown in FIG. 1D, the wood sheet 91 is brushed with a formaldehyde resin glue 92, the formaldehyde resin glue 92 is viscous at normal temperature; as shown in FIG. 1E, a plurality of pieces of the wood sheet 91 are positioned to be initially bonded to a pre-assembly 93; as shown in FIG. 1F, the pre-assembly 93 is fed into a molding die. Thermal compression is performed in 94; as shown in Fig. 1G, the molding die 94 is opened to take out a composite sheet 95. Finally, the composite sheet 95 is subjected to preliminary inspection, cutting, inspection, packaging and transportation of the product. In general, the above-mentioned conventional composite sheet manufacturing method has the following disadvantages, for example, the wood sheet 91 is bonded to the composite sheet 95 by the adhesive bonding of the formaldehyde resin paste 92. However, after the finished product of the composite sheet 95, a small amount of formaldehyde gas is continuously released, which may not only cause harm to the human body, but also fail to meet increasingly strict environmental standards. Furthermore, the formaldehyde resin 92 in the composite sheet 95 is not waterproof, so that in the case of a wet or watery environment, degumming occurs, resulting in loose structure and relatively low service life.

In addition, as shown in FIG. 1D, when the wood foil 91 is coated with a formaldehyde resin paste 92, the formaldehyde resin adhesive 92 is usually coated to a thickness that is too thin to fill the fiber pores of the wood foil 91, and is susceptible to brushing. The problem of unevenness easily affects the quality of the subsequent hot press. At the same time, since the formaldehyde resin glue 92 has great viscosity at normal temperature, when the wood chips 91 are stacked and positioned, if the wood chips 91 are displaced but contacted, they are easily adhered to each other, resulting in a pile. The inconvenience of positioning. In addition, in the inspection of the product, if the composite sheet 95 is found to be poorly glued, since the wood sheets 91 are tightly glued and cannot be re-stacked, the composite sheet 95 must be completely scrapped, so that the raw materials are relatively wasted and the yield is lowered. , and also caused environmental problems in the disposal of scrap materials. For the above reasons, it is necessary to further improve the manufacturing method of the above-mentioned conventional composite board. ' SUMMARY OF THE INVENTION The main object of the present invention is to provide a method for manufacturing a composite board, which utilizes various thermoplastic polymer resin raw materials to be pre-combined with a wood sheet into a unit plate for subsequent manufacture of the composite sheet, so that the present invention has a reduced raw material. The cost of the effect.

A secondary object of the present invention is to provide a method for producing a composite sheet in which the thermoplastic polymer resin sheet on the unit body is insoluble in water, so that the present invention has an effect of increasing the water repellency and moisture resistance of the composite sheet. Another object of the present invention is to provide a method for producing a composite sheet in which the thermoplastic polymer resin sheet on the unit body is free of formaldehyde, so that the present invention has an effect of increasing the safety of the product of the composite sheet. A further object of the present invention is to provide a method for manufacturing a composite sheet, wherein the thermoplastic polymer resin sheet on the unit sheet is formed into a fiber embedded in the fiber of the wood sheet, so that the invention has the structural strength and convenient transportation of the composite sheet. efficacy. Another object of the present invention is to provide a method for producing a composite sheet, wherein the thermoplastic polymer resin sheet on the unit sheet is not viscous at normal temperature, so that the present invention has the effect of increasing the stack positioning accuracy of the composite sheet. A method of manufacturing a composite sheet according to a preferred embodiment of the present invention, comprising the steps of: recovering (or preparing) at least one thermoplastic polymer resin raw material; heat treating the thermoplastic polymer resin material into a thermoplastic polymer resin sheet; and the thermoplastic polymer resin The sheet is heat-applied to at least one surface of a wood sheet to be combined into a unit plate body; and at least two unit plate bodies are thermocompression-bonded to form a composite sheet. A method of manufacturing a composite sheet according to another preferred embodiment of the present invention, comprising the steps of: recovering (or preparing) at least one thermoplastic polymer resin raw material; and heating and coating the thermoplastic polymer resin material on at least one surface of a wood sheet, The thermoplastic polymer resin material forms a thermoplastic polymer resin sheet and is combined with the wood sheet into a unit plate body; and at least two unit plate bodies are thermocompression bonded to form a composite sheet. By recycling various thermoplastic polymer resin raw materials, pre-formed into a thermoplastic polymer resin sheet, and then combined with a wood sheet to form a unit plate; or, the thermoplastic polymer resin material is selected to be directly cured on a wood sheet to form a thermoplastic polymer resin. The sheets are then directly combined into a unit plate. The thermoplastic polymer resin sheet is insoluble in water, does not contain formaldehyde, does not have viscosity at normal temperature, and can increase the structural strength of the unit plate body, making it suitable for long-distance transportation, and can select the number of stack layers according to requirements for subsequent Thermal compression process. Therefore, the present invention can reduce the raw material cost and increase the water repellency, product safety, transportation convenience, stack positioning accuracy, and manufacturing yield of the composite sheet. ' BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A to FIG. 1G are schematic diagrams showing the flow of a method for manufacturing a conventional composite sheet. Figure Id: A partial enlarged view of a common wood foil brushed with formaldehyde resin. Fig. 2 is a flow block diagram showing a method of manufacturing a composite sheet according to a first embodiment of the present invention. 3A to 3H are schematic views showing the flow of a method of manufacturing a composite board according to a first embodiment of the present invention. Fig. 3e is a partially enlarged view of a heat-press bonded thermoplastic polymer resin sheet of the wood chip of the first embodiment of the present invention.

Fig. 4 is a schematic view showing another process of the unit plate body of the first embodiment of the present invention. Figure 5 is a block diagram showing the flow of a method of manufacturing a composite sheet according to a second embodiment of the present invention. Fig. 6 is a flow chart showing a method of manufacturing a composite board according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION The above and other objects, features and advantages of the present invention will become more <RTIgt; As shown in Fig. 2, the manufacturing method of the composite sheet according to the first embodiment of the present invention comprises the steps of: a recycled resin step S1, a resin flaking step S2, a unit plate step S3, and a thermal pressing step S4. The recycled resin step S1 may or may not be performed, which is: recycling (or preparation) of at least one thermoplastic polymer resin raw material. The resin flaking step S2 is: heat-treating the thermoplastic polymer resin material into a thermoplastic polymer resin sheet. The unit plate step S3 is: heating and coating the thermoplastic polymer resin sheet on at least one surface of a wood sheet to form a unit plate body. The thermocompression bonding step S4 is: thermocompression bonding at least two of the unit plates to form a composite sheet.

As shown in Fig. 2, Fig. 3A and Fig. 3B, the recycled resin step S1 of the method for producing a composite board according to the first embodiment of the present invention is: recovering (or preparing) at least one thermoplastic polymer resin raw material 10. In more detail, the present invention is preferably obtained from the recovered thermoplastic polymeric resin raw material 10, but may also be obtained from a new thermoplastic polymeric resin raw material (not shown). The recovery source of the thermoplastic polymer resin raw material 10 is at least one selected from the group consisting of a film-form recovery raw material and a non-membrane-shaped recovered raw material. For example, the film-shaped recovered raw material may be selected from a crop masking film, a greenhouse shading film, an industrial packaging film, or various plastic bags. The non-membrane-recovery raw material may be selected from packaging textile belts, plastic pipe fittings, or various household/industrial plastic products. The recovered thermoplastic polymer resin raw material 10 is preferably selected from thermoplastic polymer resins which are solid at room temperature and are non-tacky, such as poly Ethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), acrylonitrile/butadiene/styrene copolymer (ABS) or polycarbonate (PC) ), etc., which does not contain formaldehyde, and can only melt and become viscous after heating to the melting point. The recovered film-like recovered raw material is preferably formed into plastic granules which are convenient for subsequent processes through steps of washing, dehydrating, drying, heating and melting, and granulation. The recovered non-membrane-recovery raw material is preferably formed into plastic granules which are convenient for subsequent processes through steps of pulverization, washing, dehydration, drying, heat melting and granulation. Further, when a new thermoplastic polymer resin raw material is used, it is preferably selected from the group consisting of plastic pellets. '

As shown in FIG. 2, FIG. 3B and FIG. 3C, the resin flaking step S2 of the method for producing a composite sheet according to the first embodiment of the present invention is to heat-treat the thermoplastic polymer resin material 10 into a thermoplastic polymer resin sheet 11. More specifically, the thermoplastic polymer resin raw material 10 is solid at room temperature and has no stickiness. Therefore, the thermoplastic polymer resin sheet 11 is formed by heating or melting by a high frequency or the like, and then by a suitable method such as rolling. The thermoplastic polymer resin sheet 11 can be selectively cut into a suitable length and width dimension, or alternatively formed into a long strip wound on a supply wheel 100. As shown in FIG. 2, FIG. 3D, FIG. 3E and FIG. 3F, the unit plate body step S3 of the method for manufacturing a composite board according to the first embodiment of the present invention is: heating and laminating the thermoplastic polymer resin sheet 11 to a wood sheet 20. At least one surface is combined to form a unit plate body 30. In more detail, the present invention prefabricates the wood chip 20 by prefabricating the logs sequentially through steps of cutting, rolling, drying, and cutting (as shown in FIG. 1A). The wood sheet 20 is cut to a suitable length and width dimension. If the wood chip 20 does not meet the size standard, the two adjacent wood chips 20 are first bonded by the molten thermoplastic polymer resin material 10 by a splicing method, and then the edges are trimmed to meet the length and width dimension standards. After the prefabrication of the wood chip 20, the thermoplastic polymer resin sheet 11 and the wood sheet 20 are first conveyed to a stack and positioned in a molding die 300, and then heated by means of high frequency or the like for hot pressing bonding of the thermoplastic polymer resin. The sheet 11 and the wood sheet 20 further constitute the unit plate body 30. As shown in Fig. 3e, during the thermocompression bonding, the thermoplastic polymer resin sheet 11 is partially melted and infiltrated into the wood fibers of the wood sheet 20, thereby forming a plurality of plastic nails 111 which add the thermoplastic polymer resin sheet 11 The bonding strength of the wood chips 20 prevents the thermoplastic polymer resin sheet 11 from coming off the wood chips 20. On the other hand, as shown in FIG. 4, the thermoplastic polymer resin sheet 11 and the wood sheet 20 may be selected in addition to the unit sheet body 30, and may be selected after the unit board body 30 is formed. Make a cut. That is, the thermoplastic polymer resin sheet 11 can be selectively formed into a long winding on a supply wheel 100, and the wood sheet 20 can also be selectively formed into a long winding on the other supply wheel 200, The two can be transported to a hot pressing roller 301 through a plurality of rollers and the like (not labeled) to perform hot pressing bonding such as rolling, and finally cut into the unit plate 30, and properly stored for supply. Subsequent use or shipping. As shown in FIG. 2, FIG. 3G and FIG. 3H, the thermal compression bonding step S4 of the method for manufacturing a composite board according to the first embodiment of the present invention is: thermocompression bonding at least two of the unit board bodies 30 to form a composite sheet 40. More specifically, first, an appropriate number of the unit plate bodies 30 are stacked and fed into a molding die 400 for thermal compression by means of high frequency or the like. After the thermocompression is completed, the molding die 400 is opened, and the composite sheet 40 can be taken out. During the thermocompression bonding, the thermoplastic polymer resin sheet 11 of each of the unit plate bodies 30 is partially melted and infiltrated into the wood fibers of the wood chips 20 adjacent to the unit plate body 30, thereby forming a plurality of plastic nails 111 (for example). Figure 3e)) to increase the bonding strength of each of the adjacent unit plate bodies 30. Finally, the composite sheet 40 is subjected to preliminary inspection, cutting, inspection, packaging and transportation of the product.

As shown in Fig. 5 and Fig. 6, a method of manufacturing a composite board according to a second embodiment of the present invention. Compared with the first embodiment, the second embodiment comprises the steps of a resin recovery step S1, a resin flaking and a unit plate step S2+S3 and a thermal compression step S4, thereby further simplifying the process. The recycled resin step S1 may or may not be performed, which is: recycling (or preparation) of at least one thermoplastic polymer resin raw material 10. After the resin material 10 is heated and melted, it is uniformly applied to at least one surface of a wood sheet 20 by using the hot press roller 301. The thermoplastic polymer resin material 10 forms a thermoplastic polymer resin sheet 11, and the thermoplastic polymer resin sheet is at this time. 11 is combined with the wood sheet 20 to form a unit plate body 30 during curing, and the glue nail 111 is formed (as shown in Fig. 3e). The thermal compression step S4 is: thermocompression bonding at least two of the unit plates 30 to form a composite sheet 40 (as shown in Figures 3G and 3H). During the coating and forming of the unit plate body 30, the thermoplastic polymer resin sheet 11 is also partially melted and infiltrated into the wood fibers of the wood sheet 20 of the other unit plate body 30, thereby forming a plurality of plastic nails 111 to increase The bonding strength of each of the adjacent unit plate bodies 30 (as shown in Fig. 3e). In addition, other process conditions of the second embodiment follow the process conditions of the first embodiment. As described above, the manufacturing method of the conventional composite board of FIG. 1A to FIG. 1G uses the formaldehyde resin glue 92 to bond the wood sheet 91, but formaldehyde is a harmful substance, cannot be waterproof, and is sticky at normal temperature, which is disadvantageous to the stack. Positioning, in addition, may also be disadvantageous in brushing unevenness. The present invention of Fig. 2 recovers various thermoplastic polymer resin raw materials 10, which are preliminarily prepared into the plastic polymer resin sheet 11, and then combined with the wood sheet 20 to become the unit board. Alternatively, the thermoplastic polymer resin material 10 is selected to be directly cured on the wood sheet 20 to form the thermoplastic polymer resin sheet 11 which is insoluble in water, contains no formaldehyde, is viscous at normal temperature, and can be increased by the nail 111. The structural strength of the unit plate body 30 is suitable for long-distance transportation before the post-stage processing, and the number of stack layers of the unit plate body 30 can be selected according to requirements for subsequent hot pressing. Therefore, the present invention can reduce the raw material cost and increase the water repellency, product safety, transportation convenience, stack positioning accuracy, and manufacturing yield of the composite sheet 40.

Claims

Rights request

A method of manufacturing a composite panel, comprising the steps of:

Heating at least one thermoplastic polymer resin material into a thermoplastic polymer resin sheet; heating and coating the thermoplastic polymer resin sheet on at least one surface of a wood sheet to form a unit plate; and thermocompression bonding at least two units The plate body is formed to form a composite sheet.

The method of producing a composite sheet according to claim 1, wherein at least one of the thermoplastic polymer resin raw materials is recovered for producing the thermoplastic polymer resin sheet.

The method of producing a composite sheet according to claim 2, wherein the source of the thermoplastic polymer resin is recovered from at least one of a film-like recovery material or a non-membrane-type recovery material.

A method of producing a composite sheet according to claim 1, wherein the thermoplastic polymer resin material is selected from the group consisting of thermoplastic polymer resins which are solid at room temperature and are non-tacky.

The method for producing a composite board according to claim 4, wherein the thermoplastic polymer resin material is selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, acrylonitrile/butadiene. At least one of a / styrene copolymer and a polycarbonate.

The method for manufacturing a composite board according to claim 1, wherein: before the wood sheet and the thermoplastic polymer resin sheet are combined into the unit board, if the wood sheet does not meet the size standard, each of the pieces is firstly formed by a jigsaw method. Two adjacent wood chips are bonded by using the molten thermoplastic polymer resin material.

The method of producing a composite sheet according to claim 1, wherein the heating is performed by one of a high-frequency method and a rolling method to thermally bond the thermoplastic polymer resin sheet and the wood sheet.

The method of manufacturing a composite sheet according to claim 1, wherein the thermoplastic polymer resin sheet is partially melted and infiltrated into the wood fiber of the wood sheet during hot pressing, thereby forming a plurality of plastic nails to increase the unit. The bonding strength of the board.

The method of producing a composite sheet according to claim 1, wherein the thermoplastic polymer resin sheet and the wood sheet are first cut and then combined into the unit sheet.

The method of producing a composite sheet according to claim 1, wherein the thermoplastic polymer resin sheet and the wood sheet are cut after forming the unit sheet.

A method of manufacturing a composite sheet according to claim 1, wherein: heating is performed by a high-frequency method to thermally bond at least two of the unit plates.

12. The method of manufacturing a composite sheet according to claim 1, wherein: the thermoplastic polymer resin sheet of each of the unit sheets is partially melted and infiltrated into the wood of another wood sheet adjacent to the unit sheet during hot pressing. Within the fiber, a plurality of glue nails are formed to increase the bonding strength of the composite plate body.

13. A method of producing a composite sheet, comprising the steps of: heating at least one thermoplastic polymer resin material onto at least one surface of a wood sheet, the thermoplastic polymer resin material forming a thermoplastic polymer resin sheet, and Forming a unit plate with the wood sheet; and thermocompression bonding at least two unit plates to form a composite sheet.

A method of producing a composite sheet according to claim 13, wherein at least one thermoplastic polymer resin material is recovered for coating on the wood sheet to form the thermoplastic polymer resin sheet.

The method of producing a composite sheet according to claim 14, wherein the source of the thermoplastic polymer resin material is at least one selected from the group consisting of a film-formed raw material and a non-membrane-like recovered material.

The method of producing a composite board according to claim 13, wherein the thermoplastic polymer resin material is selected from the group consisting of thermoplastic polymer resins which are solid at room temperature and are non-tacky.

The method for producing a composite board according to claim 16, wherein the thermoplastic polymer resin material is selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, acrylonitrile/butyl At least one of an ene/styrene copolymer and a polycarbonate.

The method of manufacturing a composite board according to claim 13, wherein: before the wood sheet and the thermoplastic polymer resin sheet are combined into the unit board, if the wood sheet does not meet the size standard, the board is first used. Each of the two adjacent wood flakes is bonded by using the molten thermoplastic polymer resin material.

The composite sheet and the manufacturing method according to claim 13, wherein the thermoplastic polymer resin sheet is partially melted and infiltrated into the wood fibers of the wood sheet during coating, thereby forming a plurality of plastic nails to increase the The bonding strength of the unit plate body.

20. A composite panel and method of manufacture according to claim 13 wherein the wood foil is advanced for cutting and then combined into the unit panel.

The composite sheet and method of manufacturing according to claim 13, wherein the wood sheet is cut after the unit sheet is formed.

22. The composite sheet and method of manufacture according to claim 13, wherein: heating is performed by a high-frequency method to thermally bond at least two of the unit plates.

The composite sheet and the manufacturing method according to claim 13, wherein: the thermoplastic polymer resin sheet of each of the unit sheets is partially melted and infiltrated into the wood of another wood sheet adjacent to the unit sheet during hot pressing. Within the fiber, a plurality of glue nails are formed to increase the bonding strength of the composite plate body.