WO2009127092A1 - 竹重组型材及其制造方法 - Google Patents

竹重组型材及其制造方法 Download PDF

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Publication number
WO2009127092A1
WO2009127092A1 PCT/CN2008/001596 CN2008001596W WO2009127092A1 WO 2009127092 A1 WO2009127092 A1 WO 2009127092A1 CN 2008001596 W CN2008001596 W CN 2008001596W WO 2009127092 A1 WO2009127092 A1 WO 2009127092A1
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WO
WIPO (PCT)
Prior art keywords
bamboo
reconstituted
raft
profile
dried
Prior art date
Application number
PCT/CN2008/001596
Other languages
English (en)
French (fr)
Inventor
张齐生
蒋身学
林海
徐旭峰
刘红征
许斌
何文
Original Assignee
杭州大庄地板有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
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Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=39960428&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2009127092(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by 杭州大庄地板有限公司 filed Critical 杭州大庄地板有限公司
Priority to EP20080800590 priority Critical patent/EP2269788B8/en
Priority to AU2008355033A priority patent/AU2008355033B2/en
Priority to ES08800590.5T priority patent/ES2527945T3/es
Priority to US12/934,868 priority patent/US8709578B2/en
Publication of WO2009127092A1 publication Critical patent/WO2009127092A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1056—Perforating lamina
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y10T156/1064—Partial cutting [e.g., grooving or incising]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24298—Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
    • Y10T428/24314—Slit or elongated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y10T428/31982—Wood or paper

Definitions

  • the present invention relates to a human modeling material and a method of manufacturing the same, and more particularly to a bamboo reconstituted material and a method of manufacturing the same. Background technique
  • bamboo reconstituted materials are usually a kind of structural material with high density and high strength, which is made by cutting, splitting, making or layering bamboo, longitudinally forming a blank, and hot pressing. It has been widely used in recent years.
  • the bamboo material needs to be processed into bamboo wire, so the processing is complicated and time-consuming and laborious.
  • the bamboo raft has high rigidity and the bamboo rafts are inevitably bridged with each other due to the large thickness and width of the bamboo rafts, so that the bamboo rafts cannot be fully contacted and softened during the pressing. Therefore, the product density is uneven and the surface is rough.
  • bamboo like wood
  • the unmodified bamboo reconstituted profiles for example, bamboo reconstituted furniture and laminate flooring
  • bamboo contains more nutrients than wood, is highly susceptible to decay by bacteria and molds outdoors, and has poor biological durability. Summary of the invention
  • the object of the present invention is to at least solve one of the above problems in the prior art.
  • an embodiment of the present invention provides a bamboo reconstituted profile which has the advantages of low water absorption, high dimensional stability, good bio-durability, and the like, and is particularly suitable for outdoor use.
  • the bamboo reconstituted profile according to the embodiment of the present invention is formed by pressing a dipped bamboo raft, wherein the bamboo raft is modified by heat treatment, and the bamboo rafts are respectively formed with a plurality of slits penetrating in the thickness direction thereof. a gap, and a length direction of the slit coincides with a fiber length direction of the bamboo pole.
  • the bamboo rafts are layered in a cross section of the bamboo reconstituted profile and are arranged in parallel along the length of the fiber.
  • the modification of the bamboo stalk includes at least a portion of hemicellulose pyrolysis in the bamboo raft.
  • the dry weight ratio of the dried bamboo stalk and the glue in the bamboo composite profile is 5 to 10:100.
  • the bamboo raft has a thickness of from 1.0 mm to 4.5 mm.
  • the glue is a water soluble resin.
  • the water-soluble resin is a phenol resin, a resorcinol-modified or a melamine-modified phenolic resin.
  • a method for producing a bamboo reconstituted product which is simple in process and capable of producing a bamboo reconstituted product having low water absorption, high dimensional stability, and good biological durability.
  • a method for manufacturing a bamboo reconstituted profile according to another aspect of the present invention includes the steps of: processing a bamboo material into a bamboo raft; and subjecting the bamboo raft to a seaming process to form a plurality of slits penetrating in the thickness direction on the bamboo raft, wherein The longitudinal direction of the gap is consistent with the fiber length direction of the bamboo pole; the bamboo raft after the seam treatment is heat-treated to modify the bamboo raft; the bamboo raft after heat treatment is dipped and dried; and after dipping and drying The bamboo raft is placed in a mold for cold pressing and then dried to cure or heat-cured to form a bamboo reconstituted profile.
  • the bamboo rafts are layered and loaded into the mold in parallel along the length of the fiber.
  • the hot press curing is carried out in a temperature range of from 120 ° C to 150 ° C and a pressure in the range of from 7 MPa to 9 MPa.
  • the cold pressing is carried out in a pressure range of 45 MPa to 70 MPa and the drying and solidification after cold pressing is carried out in a temperature range of 100 ° C to 140 ° C.
  • the heat treatment comprises: drying the bamboo raft to a thousand; pyrolyzing at least a portion of the hemicellulose dried to the dried bamboo stalk; and cooling the hemicellulose pyrolyzed bamboo raft.
  • the heat treatment further includes adjusting the moisture content of the cooled bamboo rafts with saturated steam.
  • Drying the bamboo stalks to dryness is carried out at a temperature ranging from 100 ° C to 130 ° C, so that at least a portion of the hemicellulose pyrolysis in the bamboo raft is carried out at a temperature ranging from 150 ° C to 220 ° C, and half
  • the bamboo crucible after the pyrolysis of the cellulose is cooled to below 90 °C.
  • a method for manufacturing a bamboo reconstituted profile comprising the steps of: processing a bamboo material into a bamboo raft; and subjecting the bamboo raft to a seaming process so as to form a plurality of thicknesses in the bamboo raft.
  • a slit wherein the longitudinal direction of the slit and the fiber length of the bamboo pole.
  • the heat treatment comprises: drying the bamboo raft to an absolute temperature in a temperature range of ioo ° c - i 3 (rc; at least a part of the dried bamboo shoots in a temperature range of 150 ° C - 220 ° C Cellulose pyrolysis; the bamboo puddle pyrolyzed by hemicellulose is cooled to below 90 ° C and the water content of the bamboo raft is adjusted by saturated steam.
  • the present invention has at least one of the following advantages:
  • the bamboo raft is formed with a slit penetrating in the thickness direction.
  • the bamboo raft can be broken into a plurality of small bamboo pieces by rolling with a tooth roll, but joined together, thereby increasing The surface area of the bamboo raft is increased, the amount of immersion is increased, the rigidity of the bamboo raft is reduced, the bamboo raft is not sufficiently contacted and softened during pressing, and the resulting uneven density and rough surface of the bamboo reconstituted profile are avoided.
  • the thickness of the bamboo raft can be very wide, for example, from 1.0 mm to 4.5 mm, so the selection of materials is extensive, and the processing of bamboo into bamboo is simple.
  • the bamboo raft is subjected to high temperature heat treatment to be modified. Specifically, by high-temperature heat treatment, most or almost all of the hemicellulose in the bamboo rafts will undergo pyrolysis-based degradation, but cellulose and lignin are hardly pyrolyzed, and the moisture content of the bamboo raft can also be adjusted. .
  • bamboo rafts After heat treatment at high temperature, bamboo rafts have permanent changes in their physical and mechanical properties due to changes in chemical composition. For example, the equilibrium moisture content is reduced by 30%-50%, and the dry shrinkage and swelling properties are significantly improved. The dimensional stability is improved due to heat treatment. Dry stress is generated, and water absorption is significantly reduced.
  • bamboo reconstituted profile Even if the bamboo reconstituted profile is applied to an outdoor environment, cracking and deformation are not likely to occur; biological durability is improved, and due to pyrolysis of hemicellulose, various decaying bacteria lose their nutrition.
  • bamboo reconstituted profiles made of bamboo stalks modified by high-temperature heat treatment have improved durability, weather resistance, dimensional stability and safety, and are environmentally friendly and can be widely used in outdoor flooring, outdoor furniture, outdoor buildings. Park facilities and steam bath interior facilities.
  • the bamboo reconstituted profile of the embodiment of the present invention the bamboo rafts are arranged in a layerless manner on the cross section of the bamboo reconstituted profile, and the so-called "no gradation" means that the bamboo rafts are not arranged one by one, but are not arranged in layers. Therefore, there is no obvious interlayer boundary between the bamboo reconstituted profiles, and the texture of the bamboo reconstituted profiles is more uniform, avoiding the problem that the interlayer cracking is prone to occur.
  • the dry weight of the bamboo raft and the glue (excluding the dry weight of the water) can reach 5 to 10:100, so that the bamboo raft has good bonding property, and the density of the bamboo reconstituted profile is more uniform. .
  • the surface area of the bamboo raft is increased due to the addition of the quilting treatment, thereby increasing the amount of immersion and reducing the rigidity of the bamboo raft, which is easier. Pressing, the required pressure is reduced, the density of the prepared bamboo reconstituted profiles is more uniform, and the surface quality is good.
  • the bamboo stalk is subjected to high-temperature heat treatment, for example, the bamboo stalk is dried to dryness, and the dried bamboo stalk is gently pyrolyzed (that is, the bamboo stalk is large). Part or nearly all of the hemicellulose pyrolysis, while cellulose and lignin are hardly pyrolyzed), cooling the hemicellulose pyrolyzed bamboo raft and regulating the moisture content of the bamboo raft. Therefore, the prepared bamboo reconstituted profile has the advantages of biological durability, weather resistance, dimensional stability and safety, and is environmentally friendly and has a wide range of applications, and is particularly suitable for outdoor use.
  • the bamboo stalk may not be subjected to high temperature heat treatment before pressing, but after the bamboo stalk is pressed into a bamboo reconstituted profile, the prepared bamboo reconstituted profile is subjected to high temperature heat treatment. It is also possible to improve the durability, resistance, and dimensional stability of the bamboo reconstituted profile, and thus is particularly suitable for outdoor use.
  • Figure 1 is a schematic view of a bamboo raft for making a bamboo reconstituted profile
  • FIG. 2 is a schematic view of a rectangular bamboo reconstituted profile in accordance with an embodiment of the present invention.
  • Figure 3 is a cross-sectional view of a cleave reconstituted profile in accordance with an embodiment of the present invention
  • FIG. 4 is a cross-sectional view of a circular bamboo reconstituted profile in accordance with an embodiment of the present invention.
  • Figure 8 is a flow chart showing a method of manufacturing a heat-cured bamboo reconstituted profile according to another example of the present invention.
  • Figure 9 is a flow chart showing a method of manufacturing a bamboo reconstituted profile which is cold pressed and then dried to a gel cured according to an example of the present invention
  • Figure 10 is a flow chart showing a method of manufacturing a bamboo reconstituted profile in which a finished bamboo reconstituted profile is heat treated in accordance with an example of the present invention. detailed description
  • bamboo reconstituted profile 1 is pressed from the bamboo raft (also known as bamboo) 10 shown in Figure 1.
  • the bamboo raft 10 is processed from bamboo, for example, bamboo, and the bamboo raft 10 is formed with a plurality of slits 10a penetrating in the thickness direction thereof, and the slit 10a is along the longitudinal direction of the bamboo raft 10 (i.e., bamboo raft
  • the fiber length direction can be continuous or discontinuous.
  • the surface area of the bamboo raft 10 and the amount of immersion during dipping can be increased, the rigidity of the bamboo raft 10 can be reduced, the bamboo raft 10 can be prevented from being sufficiently contacted and softened during pressing, and the resulting product density unevenness can be avoided. , surface roughness defects.
  • the thickness of the bamboo raft 10 used can be in a wide range, for example, 1.0 mm - 4.5 mm.
  • the bamboo raft 10 which is made into the bamboo reconstituted profile 1 is subjected to high-temperature heat treatment to be modified. Specifically, the bamboo raft 10 is first dried at a temperature of, for example, about 100 ° C -13 (TC temperature conditions are dry to dry (the term is absolutely dry, not referring to the absolute moisture content of the bamboo raft, but the water content is very small, never Affecting the subsequent hemicellulose pyrolysis), and then pyrolyzing most or almost all of the hemicellulose in the bamboo raft at a temperature of, for example, about 150 ° C - 220 ° C, and finally cooling the hemicellulose pyrolyzed bamboo raft 10.
  • TC temperature conditions are dry to dry (the term is absolutely dry, not referring to the absolute moisture content of the bamboo raft, but the water content is very small, never Affecting the subsequent hemicellulose pyrolysis)
  • pyrolyzing most or almost all of the hemicellulose in the bamboo raft at a temperature
  • the water content of the bamboo raft 10 can be adjusted by using saturated steam after cooling to 90 °C. After high temperature heat treatment, most of the hemicellulose in the bamboo raft 10 produces pyrolysis-based degradation, while cellulose and lignin are hardly pyrolyzed, and the chemical composition of the bamboo raft 10 causes its physical and mechanical properties to be permanent.
  • the bamboo reconstituted profile 1 made of bamboo raft 10 has the advantages of low water absorption, high dimensional stability, and high biological durability.
  • the longitudinal direction of the slit 10a coincides with the longitudinal direction of the fiber of the bamboo raft 10 (i.e., the longitudinal direction of the bamboo reconstituted profile 1).
  • the slit is formed through the thickness direction of the raft 10 in the longitudinal direction thereof.
  • the bamboo rafts 10 are placed in the mold 2 (the lower mold 2a and the upper mold 2b) in a layerless manner and in parallel in the longitudinal direction, thereby producing the bamboo reconstituted profile 1
  • the bamboo rafts 10 are arranged in layers, that is, the bamboo rafts 10 are not arranged one by one, but are not arranged in layers, but the fibers are oriented in the same direction (ie, in the longitudinal direction, the bamboo raft 10 Parallel to each other, but the present invention is not limited thereto, whereby the bamboo rafts 10 are more easily contacted when the mold is closed, so that the texture of the bamboo reconstituted profile 1 is more uniform, reducing the possibility of cracking.
  • the bamboo rafts 10 of the bamboo reconstituted profile 1 are pressed together by dipping, and the glue may be a water-soluble resin such as a phenol resin, a resorcinol-modified or a melamine-modified phenolic resin.
  • the dry weight ratio of the bamboo raft 10 to the glue can be in the range of 5 to 10:100.
  • the bamboo raft 10 is formed with a gap, the amount of immersion is increased, and the bamboo raft 10 is modified by heat treatment, so that the density of the bamboo reconstituted profile is more uniform and the surface is smoother. It has good dimensional stability, is not easy to crack, deform and open, and is not easily attacked by decay bacteria and molds. It has improved biological durability and good environmental protection. It is especially suitable for drastic changes in temperature and humidity as well as ultraviolet radiation (on the surface of bamboo reconstituted profiles). Outdoor environment with UV protection coating). For example, it can be widely used in outdoor floors, outdoor furniture (tables, chairs, stools, etc.), outdoor buildings, park facilities, and steam bath interior facilities.
  • a method of manufacturing a bamboo reconstituted profile according to an embodiment of the present invention will be described below with reference to FIG. As shown in Fig. 6, the method for manufacturing a bamboo reconstituted profile of this embodiment comprises the following steps:
  • Step 101 The bamboo is processed into bamboo rafts having a thickness of 1.0-4.5 mm.
  • Step 102 Add a seam treatment to the bamboo pole.
  • the bamboo raft is passed through a sewing machine, and the bamboo raft is rolled by the tooth roller on the sewing machine to form a plurality of slits extending in the thickness direction along the longitudinal direction (fiber length direction) of the bamboo raft, and the slit is along the longitudinal direction of the bamboo raft.
  • It can be continuous or discontinuous, which increases the surface area and the amount of dipping during dipping, and reduces the rigidity of the bamboo raft. Lamination.
  • the sewing machine can use any existing suitable sewing machine.
  • Step 103 The quilted bamboo raft is subjected to a high temperature heat treatment under anaerobic conditions to modify the bamboo raft.
  • the bamboo raft air-drying or wet mash
  • the bamboo raft is stacked and sent to a high-temperature heat treatment kiln with a good sealing and heat preservation performance or a high-temperature heat treatment tank with a heating device, and the kiln or the tank is filled with steam as a shielding gas.
  • the heat source for heating the bamboo raft and the shielding gas may be a hot oil provided by a hot oil furnace, or may be a high temperature furnace gas or an electric heating tube. According to durability and color requirements.
  • the pressure in the high temperature heat treatment kiln or tank is about 0.1-0.6 MPa.
  • the bamboo rafts undergo the following treatment stages in a high temperature heat treatment kiln or tank: Dry the bamboo rafts to dryness (temperature control is about 100 ° C - 130 ° C), making most of the bamboo stalks or Almost all hemicellulose pyrolysis (temperature control is about 15 (TC-22 (rC), cooling hemicellulose pyrolyzed bamboo rafts (below 90 ° C) and using saturated steam to regulate the moisture content of bamboo rafts after cooling .
  • the main purpose of the high temperature heat treatment of the bamboo raft is to degrade the bamboo stalk main, and the cellulose and lignin are hardly pyrolyzed, thereby improving the dry shrinkage and swelling property of the bamboo reconstituted profile, and the size. Improved stability, significantly reduced water absorption, improved biodurability, and corrosion protection.
  • Step 104 Dipping and drying the bamboo raft after high temperature heat treatment, for example, immersing the bamboo raft in the glue for 5-20 minutes, then lifting the glue pool, dripping off the excess glue, and aging in the air. Or send to the drying kiln at low temperature (for example, the temperature is not higher than 80 ° C) to dry to a moisture content of not more than 20%.
  • the adhesive is, for example, a phenolic resin, a resorcinol-modified phenolic resin or other similarly water-soluble resin adhesive, and the adhesive is diluted to a solid content of 15% to 30%.
  • Step 105 The dipped and dried bamboo rafts are weighed according to the required density and then placed in the lower mold 2a in parallel in the longitudinal direction, and the bamboo rafts are placed in the lower mold 2a in a layerless and parallel manner.
  • the bamboo rafts can also be The layer is placed in the lower mold 2a, the lower mold 2a is fed into the press to which the upper mold 2b is fixed, and then the bamboo crucible in the mold 2 is pressed by hot pressing or cold pressing. If hot pressing is employed, the temperature control is about 120.
  • pressure F is controlled to be about 7-9 MPa; if cold pressing is used, the pressure is controlled to be about 45-70 MPa, when the bamboo raft is pressed to the specified size, the pressure is maintained and the press is unloaded together with the mold 2 After being sent to the drying room, it is dried at a temperature of about 100-140 ° C until the adhesive is solidified, thereby preparing a bamboo reconstituted profile.
  • the bamboo reconstituted profiles can be stacked by heat stacking or at room temperature, for example, the reconstituted bamboo reconstituted profiles are arranged neatly, covered with heavy objects, stacked 48 Subsequent processing is carried out for more than an hour.
  • the bamboo reconstituted profiles solidified in the drying room after cold pressing are stacked at room temperature for more than 10 days.
  • it is also possible to carry out other treatments on the finished bamboo reconstituted profile for example by applying an anti-UV coating to the surface.
  • the quilted bamboo raft can be dipped and dried without heat treatment, and then the dipped and dried bamboo stalk is subjected to hot press curing or cold pressing to synthesize the bamboo reconstituted structure. Finally, the prepared bamboo reconstituted profile is heat-treated to modify the bamboo rafts constituting the bamboo reconstituted profile, and the method according to this embodiment has the same effect as the method described with reference to FIG.
  • Fig. 7 is a flow chart showing a method of manufacturing a heat-cured bamboo reconstituted profile according to an example of the present invention.
  • the method for manufacturing a bamboo reconstituted profile shown in Figure 7 comprises the following steps:
  • Step 201 The bamboo is made into a bamboo pole.
  • Step 202 Add a seam treatment to the bamboo pole. Specifically, the air-dried or wet bamboo raft having a thickness of 3.5 mm and a width of 25 mm is passed through a sewing machine, and the bamboo raft is pierced and crushed by a toothed roller that is meshed up and down by a sewing machine to form a plurality of bamboo rafts in the longitudinal direction. Continuous and/or discontinuous slits are penetrated in the thickness direction, thereby realizing the softness of the bamboo raft and increasing the amount of glue contained in the dipping.
  • Step 203 performing high-temperature heat treatment on the bamboo raft, specifically, arranging the bamboo raft into small bundles, layering and stacking, feeding the high-temperature heat treatment kiln with hot oil as heating medium and steam as protection medium; then closing the kiln door, fast Warming up and introducing steam into the kiln; when the temperature reaches about 100 ° C, the temperature is raised, the bamboo raft is dried to dryness (step 203a); then the temperature is raised to about 180 ° C and kept for 3 hours, so that the bamboo The hydrazine is modified, for example, most or almost all of the hemicellulose of the bamboo raft is pyrolyzed, and the cellulose and lignin are hardly pyrolyzed, and then the temperature is lowered, and the inlet and exhaust of the high temperature heat treatment kiln are maintained in the early stage of cooling.
  • the port is closed, and the inlet port and the exhaust port are opened at the late stage of cooling to accelerate the cooling rate (step
  • the temperature in the high temperature heat treatment kiln is in the range of about 150 ° C - 180 ° C
  • the hemicellulose of the bamboo raft can be pyrolyzed, but the pyrolysis speed is different, in this example, the temperature It was rapidly raised to 180 ° C for 3 hours and then cooled, so the hemicellulose of the bamboo raft was pyrolyzed mainly at about 180 ° C.
  • step 203c When the temperature in the high temperature heat treatment kiln falls below 90 ° C, the inlet port and the exhaust port are closed, and then saturated steam is introduced into the high temperature heat treatment kiln for 3 hours to adjust the moisture content of the bamboo raft (step 203c); Open the inlet and outlet ports and the kiln door. When the temperature in the high temperature heat treatment kiln drops below 50 °C, remove the bamboo raft.
  • Step 204 Dipping and drying the heat-treated bamboo stalk, specifically, diluting the phenol resin glue to a solid content of 24%, immersing the bamboo raft in the glue for 10 minutes, and immersing the amount of 7% (resin is absolutely The ratio of the dry weight to the dry weight of the bamboo stalks, after dipping, the bamboo stalks are dried to a moisture content of 15% under low temperature conditions (for example, a temperature lower than 70 ° C).
  • Step 205 The dipped and dried bamboo rafts are loaded into the mold 2 and hot pressed. Specifically, the amount of bamboo stalks is calculated according to the density of 1.0 g/cm 3 , and the bamboo rafts are arranged in the longitudinal direction, and the thickness direction is not divided.
  • the layer is placed in the lower mold 2a of the rectangular mold, and then fed into the hot press having the upper mold 2b, and the mold 2 (the upper mold 2b and the lower mold 2a) is closed, and when the pressure rises to about 4.0 MPa, the pressurization is stopped.
  • Turn on the high-frequency generator power supply, and the high-frequency electromagnetic wave heats the bamboo raft in the mold 2.
  • the steam in the mold is discharged, and the prepared rectangular bamboo reconstituted material is taken out.
  • Length X width X thickness 2500 x 600 x 200 mm
  • the prepared bamboo reconstituted profile can be thermally stacked as described above.
  • Fig. 8 is a flow chart showing a method of manufacturing a heat-cured bamboo reconstituted profile according to another example of the present invention.
  • the method for manufacturing the bamboo reconstituted profile shown in Fig. 8 comprises the following steps:
  • Steps 301 and 302 are the same as steps 201 and 202 in Example 1, respectively, and their detailed descriptions are omitted.
  • Step 303 performing high-temperature heat treatment on the quilted bamboo raft, specifically, tying the air-dried bamboo raft into small bundles, layering and stacking, pushing into a pressure tank having an electric heating device, closing the tank door, and introducing saturation Steam, simultaneously turn on the electric heating tube in the pressure tank, the pressure in the tank is kept at 0.4MPa, and the temperature is slowly increased from 100 °C to 130 °C, so that the bamboo raft is dried to dryness (step 303a); 200 ° C and heat for 3 hours (step 303b), so that most or almost all of the hemicellulose in the bamboo raft is pyrolyzed mainly at 200 ° C, and cellulose and lignin are hardly pyrolyzed, and then the pressure inside the tank and Steam, saturated steam, for rapid cooling. Then, the temperature is naturally lowered to 90 ° C
  • Steps 304 and 305 are the same as steps 204 and 205 in Example 1, and their detailed descriptions are omitted.
  • Example 3
  • the manufacturing method of the bamboo reconstituted profile according to Example 3 of the present invention is different from the manufacturing method of the bamboo reconstituted profile according to Example 1, in that the cross-sectional shape of the mold is T-shaped, and the other steps are the same as those described in Example 1, and The physical and mechanical properties of the bamboo reconstituted profile are also the same as the examples and will not be discussed in detail here.
  • Example 4
  • the method for producing a bamboo reconstituted profile according to Example 4 of the present invention is different from the method for producing a bamboo reconstituted profile according to Example 1, in that the cross-sectional shape of the mold 2 is circular, and in the step of molding and hot pressing, Density 1.05g/cm 3 Calculate the amount of bamboo rafts, weigh, the bamboo rafts are arranged in the same direction, the thickness direction is not divided into layers, placed in the semicircular lower mold 2a, and fed into the semi-circular upper mold 2b.
  • the maximum pressure is 7.5MPa
  • steam is heated to the hot press, and the temperature starts when the temperature rises to 130 °C, such as the diameter of the design profile. 50 mm, the maximum pressure is maintained for 10 minutes and then the pressure is reduced to 4.5 MPa for 15 minutes, then cold water is passed through the cooling water.
  • the temperature gauge on the pipe shows 50 ° C, the pressure is completely relieved and the profile is discharged.
  • Example 4 The other steps of Example 4 were the same as those of Example 1, and the physical and mechanical properties of the bamboo reconstituted profile were also the same as those of the bamboo reconstituted profile of Example 1, and will not be described in detail herein.
  • Example 5
  • Figure 9 is a flow diagram of a method of making a bamboo reconstituted profile using cold press gluing and then drying, in accordance with an example of the present invention.
  • the manufacturing method of the bamboo reconstituted profile shown in Fig. 9 includes the following steps:
  • Steps 401 and 402 are the same as steps 201 and 202 in Example 1, respectively, and their detailed descriptions are omitted.
  • Step 403 Perform high temperature heat treatment on the quilted bamboo raft, wherein step 403a is the same as step 203a in the example 1, in step 403b, the temperature is heated to 160 ° C for 3 hours, and then the temperature is lowered; step 403c and example 1 Step 203c is the same.
  • Step 404 The same as step 204 in Example 1.
  • Step 405 The dipped and dried bamboo rafts are placed in a rectangular mold 2 for cold pressing. Specifically, the bamboo rafts are calculated according to a density of 1.05 g/cm 3 , and are weighed and arranged in the longitudinal direction, and the thickness direction is not hierarchical and parallel.
  • the ground is loaded into the rectangular lower mold 2a, and then fed into the cold press having the upper mold 2b, and the upper mold 2b and the lower mold 2a are press-closed in sections, until the applied pressure rises to about 68 PMa, and then the pressure is released, and the mold is pushed out. 2.
  • Step 406 The mold 2 is sent to the drying room together with the compacted bamboo crucible for a glue curing or infrared curing line, and maintained at a temperature of about 100-130 ° C until the adhesive is completely cured.
  • Length X width X thickness 1900 X 104 X 160 mm
  • Figure 10 is a flow chart showing a method of manufacturing a bamboo reconstituted profile using heat treatment of a finished bamboo reconstituted profile according to the present example.
  • the method for manufacturing a bamboo reconstituted profile shown in Fig. 10 comprises the following steps: Step 501: processing bamboo into bamboo raft
  • Step 502 Adding a seam to the bamboo pole.
  • Step 504 Dipping and drying the quilted bamboo raft.
  • Step 505 The dipped and dried unheated bamboo rafts are placed in a mold to produce a rectangular bamboo reconstituted profile by hot press curing at a temperature of about 130 ° C and a pressure of 8 MPa.
  • Step 503 Perform high temperature heat treatment on the produced bamboo reconstituted profile.
  • the bamboo reconstituted profiles are stacked and sent to a high-temperature heat treatment kiln with hot oil as a heating shield and steam as a protective medium; the kiln door is closed, the temperature is rapidly increased, and saturated steam is introduced into the kiln; the temperature reaches 100 ° C.
  • step 503a the temperature is increased, so that the bamboo stalk is dried to almost dry (step 503a); then the temperature is raised to 160 ° C and kept for 4 hours so that the large bamboo reconstituted material in the bamboo stalk and its manufacturing method Cfi change 2) Or almost all of the hemicellulose is pyrolyzed mainly at 200 ° C, and then begins to cool down (step 503b ), the inlet and outlet ports of the high temperature heat treatment kiln are kept closed in the early stage of cooling, and the inlet and outlet ports are accelerated at the later stage to accelerate the cooling rate.
  • step 503c When the temperature in the high temperature heat treatment kiln falls below 90 °C, close the steam inlet and the steam outlet, and pass saturated steam for 3 hours to adjust the moisture content of the bamboo raft (step 503c); finally open the steam inlet and The steam exhaust port and the kiln door are taken out from the high temperature heat treatment kiln when the temperature in the high temperature heat treatment kiln falls below 50 °C.
  • the bamboo reconstituted profile manufacturing method of Example 6 before the bamboo reconstituted profile is made, the bamboo raft is not subjected to high-temperature heat treatment, but the prepared bamboo reconstituted profile is heat-treated, and the method shown in Example 6 and Examples 1-5 are shown. The method has the same effect.

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Description

竹重组型材及其制造方法
技术领域
本发明涉及一种人造型材及其制造方法， 尤其是涉及一种竹重组型材 及其制造方法。 背景技术
竹重组材通常是将竹材截断、 剖分、 制丝或分层制篾、 纵向组坯、 热 压制成的一种密度大、 强度高的结构用材， 近年来得到了广泛的应用。
对于用竹材加工成竹丝、 然后制成型材的技术， 需要将竹材加工成竹 丝， 因此加工复杂， 费时费力。
对于将竹材加工成竹篾制成型材的技术， 由于竹篾厚度和宽度尺寸较 大， 竹篾刚度高， 组坯时竹篾不可避免相互搭桥， 致使压合时竹篾不能充 分接触和软化， 所以产品密度不均， 表面粗糙。
无论利用竹丝还是竹篾制成型材， 竹材及其制成的型材都没有经过处 理而改性。 众所周知， 竹材与木材一样， 属于多孔生物质材料， 自身具有 干缩湿胀的特点， 当温度和相对湿度发生变化时， 竹重组型材的尺寸也会 产生相应的变化。 尤其是， 当将竹重组型材用于温度和湿度剧烈变化以及 紫外线照射的室外环境下时， 未经改性处理的竹重组型材（例如竹重组材 家具和重组材地板） 的尺寸稳定性很差， 在短期内就会发生开裂、 变形、 开胶等缺陷。 另一方面， 竹材比木材含有更多的营养物质， 在室外极易受 腐朽菌和霉菌侵蚀， 生物耐久性也很差。 发明内容
本发明的目的旨在至少解决现有技术中的上述问题之一。
为此，根据本发明的第一方面，本发明的实施例提出一种竹重组型材， 该竹重组型材具有吸水率低、 尺寸稳定性高、 生物耐久性好等优点， 特别 适用于室外场合。
根据本发明实施例的竹重组型材由浸胶的竹篾压制而成， 其中竹篾经 过热处理而发生改性、 所述竹篾分别形成有在其厚度方向上贯穿的多条缝 隙， 且所述缝隙的长度方向与所述竹篾的纤维长度方向一致。
根据本发明实施例的竹重组型材还具有如下附加技术特征：
在竹重组型材的横截面上所述竹篾无层次且沿纤维长度方向平行地 排列。 所述竹篾的改性包括竹篾中的至少一部分半纤维素热解。 所述竹重 组型材中绝干竹篾与胶的干重量比为 5 ~ 10: 100。
所述竹篾的厚度为 1.0毫米- 4.5毫米。 所述胶为水溶性树脂。 水溶 性树脂为酚醛树脂、 间苯二酚改性或三聚氰胺改性酚酪树脂。
根据本发明的另一方面， 提出一种竹重组型材的制造方法， 其工序简 单、 能够制造出吸水率低、 尺寸稳定性高、 生物耐久性好的竹重组型材。
根据本发明另一方面的竹重组型材的制造方法包括以下步骤：将竹材 加工成竹篾； 对竹篾进行加缝处理， 以便在竹篾上形成在厚度方向上贯穿 的多条缝隙， 其中所述缝隙的纵向方向与竹篾的纤维长度方向一致； 对加 缝处理后的竹篾进行热处理以便竹篾发生改性； 对热处理后的竹篾进行浸 胶和干燥； 和将浸胶和干燥后的竹篾装入模具内进行冷压而后烘干至胶固 化或进行热压固化， 从而制成竹重组型材。
根据本发明实施例的竹重组型材的制造方法还具有如下附加技术特 征：
所述竹篾无层次且沿纤维长度方向平行地装入模具内。所述热压固化 在 120°C-150°C的温度范围内和 7MPa-9MPa的压力范围内进行。
所述冷压在 45MPa - 70MPa的压力范围内进行且冷压后烘干固化在 100°C - 140 °C的温度范围内进行。
所述热处理包括： 将竹篾干燥至绝千； 使干燥至绝干的竹篾中的至少 一部分半纤维素热解 ； 和冷却半纤维素热解后的竹篾。 所述热处理进一 步包括利用饱和蒸汽调节冷却后竹篾的含水率。
将竹篾干燥至绝干在 100°C-130°C的温度范围内进行， 使竹篾中的至 少一部分半纤维素热解在 150°C - 220°C的温度范围内进行，且将半纤维素 热解热后的竹篾冷却至 90 °C以下。
根据本发明的再一方面，提出一种竹重组型材的制造方法， 包括以下 步骤： 将竹材加工成竹篾； 对竹篾进行加缝处理， 以便在竹篾上形成在厚 度方向上贯穿的多条缝隙， 其中所述缝隙的纵向方向与竹篾的纤维长度方 向一致； 对加缝处理后的竹篾进行浸胶和干燥； 将浸胶和干燥后的竹篾无 层次且沿纤维长度方向平行地装入模具内进行冷压而后烘干至胶固化或 进行热压固化， 从而制成竹重组型材； 和对制成的竹重组型材进行热处理 从而使组成竹重组型材的竹篾改性。
所述热处理包括： 在 ioo°c-i3(rc的温度范围内将竹篾干燥至绝干； 在 150°C - 220°C的温度范围内对干燥至绝干的竹篾中的至少一部分半纤 维素热解；将半纤维素热解后的竹篾冷却到 90°C以下并利用饱和蒸汽调节 竹篾的含水率。
与现有技术相比， 本发明至少具有下列优点之一：
根据本发明实施例的竹重组型材， 竹篾形成有在厚度方向上贯穿的缝 隙， 例如竹篾可以通过齿辊碾压而破裂成多个小的竹片但又连接成一体， 由此增加了竹篾浸胶时的表面积， 增加了浸胶量， 降低了竹篾的刚度， 避 免了压合时竹篾不能充分接触和软化以及由此导致的竹重组型材密度不 均、 表面粗糙的问题。 此外， 由于竹篾形成有缝隙， 竹篾的厚度范围可以 非常宽， 例如可以为 1.0毫米- 4.5毫米， 因此选材广泛， 将竹材加工成竹 篾简单。
根据本发明实施例的竹重组型材， 竹篾经过高温热处理从而发生改 性。 具体而言， 通过高温热处理， 竹篾中的大部分或几乎全部半纤维素会 产生以热解为主的降解， 但纤维素和木素几乎不热解， 并且还可以调节竹 篾的含水率。 竹篾经过高温热处理后， 由于化学成分的变化导致其物理力 学性质发生永久性改变， 例如， 平衡含水率降低 30%-50%， 明显改善干缩 湿胀性能； 尺寸稳定性提高， 由于热处理不产生干燥应力， 且吸水性显著 降低， 即使竹重组型材应用于室外环境， 也不容易产生开裂和变形； 生物 耐久性提高，由于热解了半纤维素，各种腐朽菌失去赖以生存的营养物质， 从而达到防腐的目的； 尽管竹重组型材的静曲强度下降 10%-30%, 强度仍 然 4艮高， 密度不小于 1.0g/cm3; 热处理过程中没有添加任何化学物质， 室 外使用时竹重组型材也不会污染土壤和水质， 环保性好。
换言之， 利用经过高温热处理而改性的竹篾制成的竹重组型材， 生物 耐久性、 耐候性、 尺寸稳定性及安全性提高， 并且环保， 可广泛地应用于 室外地板， 室外家具、 室外建筑、 公园设施以及蒸汽浴室内部设施等。 根据本发明实施例的竹重组型材， 在竹重组型材的横截面上， 竹篾无 层次地排列， 所谓 "无层次" 是指竹篾不是一层一层地排列， 而是不分层 地排列， 因此竹重组型材没有明显的层间分界， 竹重组型材的质地更加均 匀， 避免了容易发生层间处裂开的问题。
根据本发明实施例的竹重组型材， 竹篾与胶的干重量（不包括水份的 干重量）比可以达到 5 ~ 10: 100, 从而竹篾的结合性好， 竹重组型材的密 度更加均匀。
根据本发明实施例的竹重组型材的制造方法， 由于增加了对竹篾进行 加缝处理， 因此竹篾浸胶时的表面积增大， 增加了浸胶量， 降低了竹篾的 刚度， 更加容易压合， 所需压力降低，制成的竹重组型材的密度更加均匀， 表面质量好。
根据本发明实施例的竹重组型材的制造方法，由于对竹篾进行了高温 热处理， 例如将竹篾干燥至绝干， 使干燥至绝干的竹篾温和热解（即， 竹 篾中的大部分或几乎全部半纤维素热解， 而纤维素和木素几乎不热解）， 冷却半纤维素热解后的竹篾并且调节竹篾的含水率。 因此， 制成的竹重组 型材生物耐久性、 耐候性、 尺寸稳定性及安全提高， 并且环保， 适用范围 广， 特别适于室外场合。
根据本发明实施例的竹重组型材的制造方法， 在压合之前也可以不对 竹篾进行高温热处理， 而是在将竹篾压合成竹重组型材之后， 对制成的竹 重组型材进行高温热处理，同样能够使得竹重组型材生物耐久性、耐^ ί'吴性、 尺寸稳定性提高， 由此特别适用于室外场合。
本发明附加的方面和优点将在下面的描述中部分给出， 部分将从下面 的描述中变得明显， 或通过本发明的实践了解到。 附图说明
图 1是用于制造竹重组型材的竹篾的示意图；
图 2是根据本发明实施例的矩形竹重组型材的示意图；
图 3是根据本发明实施例的 Τ形竹重组型材的横截面视图；
图 4是根据本发明实施例的圆形竹重组型材的横截面视图；
图 5是将竹篾无层次地放置到模具内进行压合的示意图； 图 6是根据本发明实施例的竹重组型材的制造方法的流程图； 图 7是根据本发明一个示例的采用热压固化的竹重组型材的制造方法 的流程图；
图 8是根据本发明另一示例的采用热压固化的竹重组型材的制造方法 的流程图；
图 9是根据本发明示例的采用冷压然后烘干至胶固化的竹重组型材的 制造方法的流程图； 和
图 10是根据本发明示例的其中对制成的竹重组型材进行热处理的竹 重组型材的制造方法的流程图。 具体实施方式
' 下面详细描述本发明的实施例， 所述实施例的示例在附图中示出， 其 功能的元件。 下面通过参考附图描述的实施例是示例性的， 仅用于解释本 发明， 而不能解释为对本发明的限制。
下面参考图 1-5描述根据本发明实施例的竹重组型材 1。竹重组型材 1 由图 1所示的竹篾（也可以称为竹片） 10压制而成。 如图 1所示， 竹篾 10由竹材， 例如毛竹， 加工而成， 竹篾 10形成有在其厚度方向上贯穿的 多条缝隙 10a, 缝隙 10a沿竹篾 10的纵向方向 （即竹篾的纤维长度方向） 可以连续， 也可以不连续。 通过形成缝隙 10a， 能够增加竹篾 10的表面积 和浸胶时的浸胶量， 降低竹篾 10的刚度， 避免了压合时竹篾 10不能充分 接触和软化以及由此导致的产品密度不均、 表面粗糙的缺陷。
根据本发明的实施例， 由于在竹篾 10上形成有缝隙 10a， 因此使用的 竹篾 10的厚度可以在很宽的范围内， 例如 1.0毫米 - 4.5毫米。
另外， 制成竹重组型材 1 的竹篾 10经过高温热处理从而发生改性。 具体而言， 竹篾 10首先在例如大约 100°C-13(TC温度条件干燥至绝干（术 语绝干， 并非是指竹篾中绝对不含水份， 而是含水量非常小， 从而不影响 后续的半纤维素热解）， 然后在例如大约 150°C - 220°C温度条件下竹篾中 的大部分或几乎全部半纤维素热解， 最后冷却半纤维素热解后的竹篾 10, 在冷却到 90°C以后可以利用饱和蒸汽调节竹篾 10的含水率。 经过高温热处理， 竹篾 10 中的大部分半纤维素产生以热解为主的降 解， 而纤维素和木素几乎不热解， 竹篾 10的化学成分的变化导致其物理 力学性质发生永久性改变， 因此竹篾 10制成的竹重组型材 1具有吸水率 低、 尺寸稳定性高、 生物耐久性高等优点。
缝隙 10a的长度方向与竹篾 10的纤维长度方向 （即， 竹重组型材 1 的纵向方向）一致， 换言之， 缝隙是沿着竹篾 10的纵向方向贯穿其厚度 方向形成。
根据本发明进一步的实施例， 如图 5所示， 竹篾 10无层次且沿纵向 方向平行地放入模具 2 (下模 2a和上模 2b ) 内， 由此在制成的竹重组型 材 1的横截面内， 竹篾 10不分层次地排列， 即， 竹蔑 10不是一层一层地 排列， 而是不分层地排列， 但是纤维长度方向一致（即在纵向方向上， 竹 篾 10相互平行， 但本发明并不限于此）， 由此在闭合模具时， 竹篾 10之 间更容易接触，从而竹重组型材 1的质地更加均匀，降低了开裂的可能性。
竹重组型材 1 的竹篾 10是通过浸胶后压合在一起的， 胶可以为水溶 性树脂， 例如酚 树脂、 间苯二酚改性或三聚氰胺改性酚酪树脂。 在制成 的竹重组型材 1中，竹篾 10与胶的干重量比可以在 5 ~ 10: 100的范围内。
因此，根据本发明实施例的竹重组型材 1 ,其中的竹篾 10形成有缝隙， 增加了浸胶量， 竹篾 10 又经过热处理而改性， 因此竹重组型材密度更加 均匀， 表面更加光滑， 并且尺寸稳定性好， 不易开裂、 变形和开胶， 而且 不容易受腐朽菌和霉菌侵蚀， 生物耐久性提高， 环保性好， 特别适用于温 度和湿度剧烈变化以及紫外线照射（在竹重组型材的表面涂有防紫外线涂 层） 的室外环境。 例如， 可广泛地应用于室外地板， 室外家具（桌、 椅、 凳等）、 室外建筑、 公园设施以及蒸汽浴室内部设施等。
下面参考图 6描述根据本发明实施例的竹重组型材的制造方法。 如图 6所示， 此实施例的竹重组型材的制造方法包括以下步骤：
步骤 101 : 将毛竹加工成厚度 1.0-4.5毫米的竹篾。
步骤 102: 对竹篾进行加缝处理。 具体地， 使竹篾通过加缝机， 利用 加缝机上的齿辊碾压竹篾， 从而沿竹篾的纵向 （纤维长度方向）形成多条 沿厚度方向贯穿的缝隙， 缝隙沿竹篾的纵向可以是连续的， 也可以是不连 续的， 从而增加了浸胶时的表面积和浸胶量， 又可降低竹篾的刚度， 便于 压合。 加缝机可以使用任何现有合适的加缝机。
步骤 103: 对加缝处理后的竹篾在无氧条件下进行高温热处理以便使 竹篾改性。 具体地， 将竹篾 (气干篾或湿篾)堆垛后送入密封及保温性能好 的高温热处理窑或具有加热装置的压力高温热处理罐内， 处理窑或罐内充 满作为保护气体的蒸汽或氮气， 加热竹篾和保护气体的热源可以是由热油 炉提供的热油，也可以是高温炉气体或电加热管。根据耐久性和颜色要求。 压力高温热处理窑或罐内的压力为大约 0.1-0.6MPa。
更具体而言， 竹篾在高温热处理窑或罐内经历以下几个处理阶段： 将 竹篾干燥至绝干（温度控制为大约 100°C-130°C )、使竹篾中的大部分或几 乎全部半纤维素热解（温度控制为大约 15(TC-22(rC )、 冷却半纤维素热解 后的竹篾（90°C以下）且在冷却后利用饱和蒸汽调节竹篾的含水率。
需要说明的是， 在本发明中， 对竹篾的高温热处理主要目的是使竹篾 主的降解， 而纤维素和木素几乎不热解， 从而改善竹重组型材的干缩湿胀 性能， 尺寸稳定性提高， 吸水性显著降低， 生物耐久性提高， 并且防腐。
步骤 104: 对高温热处理后的竹篾进行浸胶和干燥， 例如将竹篾浸入 胶液内， 保持 5-20分钟， 然后吊出胶池， 滴去多余的胶液， 置于空气中陈 化或送入干燥窑低温（例如温度不高于 80°C )干燥至含水率不大于 20%。 胶例如为酚醛树脂、 间苯二酚改性酚醛树脂或其它性能相似的水溶性树脂 的胶粘剂， 胶粘剂稀释至固含量 15%-30%。
步骤 105: 将浸胶和干燥后的竹篾根据所需密度称重后沿纵向平行地 放入下模 2a内， 竹篾无层次且平行地放入下模 2a内， 当然， 竹篾也可以 分层放入下模 2a内， 将下模 2a送入固定有上模 2b的压机， 然后利用热 压或冷压压合模具 2内的竹篾， 如果采用热压， 温度控制为大约 120-150 °C，压力 F控制为大约 7-9MPa;如果采用冷压，压力控制为大约 45-70MPa， 当竹篾被压至规定的尺寸后， 保持压力并且连同模具 2—起卸出压机后送 入烘房， 在温度大约 100-140°C条件下烘干至胶粘剂固化， 由此制成竹重 组型材。
为了舞放竹重组型材的内应力， 可以热堆放或常温堆放制成的竹重组 型材， 例如将热压固化的竹重组型材排列整齐， 上面覆以重物， 堆放 48 小时以上再进行后续加工。冷压后烘房固化的竹重组型材在常温下堆放 10 天以上。 当然， 还可以对制成的竹重组型材进行其他处理， 例如在表面涂 上防紫外线涂层。
根据本发明的一个实施例， 加缝处理后的竹篾可以进行浸胶和干燥， 而不进行热处理， 然后将浸胶和干燥后的竹篾通过热压固化或冷压胶合成 竹重组型材， 最后对制成的竹重组型材进行热处理， 从而使组成竹重组型 材的竹篾发生改性，根据此实施例的方法与参考图 6描述的方法具有同样 的效果。
下面参考图 7-10描述根据本发明实施例的竹重组型材的制造方法的 示例。
示例 1
图 7是根据本发明示例的采用热压固化的竹重组型材的制造方法的流 程图。 图 7所示的竹重组型材的制造方法包括以下步骤：
步骤 201 : 将毛竹制成竹篾。
步骤 202: 对竹篾进行加缝处理。 具体地， 使厚度 3.5毫米、 宽度 25 毫米的气干或湿竹篾通过加缝机， 利用加缝机上下啮合的齿辊对竹篾进行 穿刺、碾压，使竹篾沿纵向方向形成多条沿厚度方向贯穿连续和 /或不连续 的缝隙， 从而实现竹篾变软、 增加浸胶时含胶量的目的。
步骤 203: 对竹篾进行高温热处理， 具体地， 将竹篾扎成小捆， 分层 堆垛， 送入以热油为加热介质、 蒸汽为保护介质的高温热处理窑； 然后关 闭窑门， 快速升温并向窑内通入蒸汽； 当温度达到大约 100°C以后放^ ·曼升 温速度， 使竹篾干燥至绝干 （步骤 203a ); 然后升温至大约 180°C并且保 温 3小时， 从而竹篾发生改性， 例如竹篾的大部分或几乎全部半纤维素发 生热解， 且纤维素和木素几乎不热解， 而后开始降温， 降温前期保持高温 热处理窑的进汽体口和排汽口关闭， 降温后期开启进汽体口和排汽口加快 降温速度 (步骤 203b )。
需要说明的是， 当高温热处理窑内的温度在大约 150°C-180°C的范围 内时， 竹篾的半纤维素都能发生热解， 但热解速度不同， 在此示例中， 温 度快速升到 180°C并保持 3小时， 然后降温， 因此竹篾的半纤维素主要在 大约 180°C热解。 当高温热处理窑内的温度降至 90°C以下时关闭进汽体口和排汽口，接 着向高温热处理窑内通入饱和蒸汽并保持 3小时以便调节竹篾含水率（步 骤 203c ); 最后开启进汽体口和排汽口及窑门， 当高温热处理窑内的温度 温降至 50°C以下时取出竹篾。
步骤 204: 对热处理后的竹篾进行浸胶及干燥， 具体地， 将酚 树脂 胶稀释至固含量 24%，将竹篾浸入胶液内并保持 10分钟，浸胶量为 7% (树 脂绝干重量与竹篾绝干重量之比）， 浸胶后竹篾在低温条件下 （例如低于 70°C的温度）干燥至含水率 15%。
步骤 205: 将浸胶和干燥后的竹篾装入模具 2并热压， 具体而言， 按 照密度 1.0g/cm3计算竹篾量、 称重， 将竹篾沿纵向排列， 厚度方向不分层 次， 置于矩形模具的下模 2a内， 然后送入具有上模 2b的热压机， 将模具 2 (上模 2b和下模 2a ) 闭合， 压力升至大约 4.0MPa时， 停止加压， 接通 高频发生器电源， 高频电磁波加热模具 2内的竹篾， 当温度升至大约 130 °C后， 再次加压， 直至压力升至大约 8.0MPa，保压 15分钟后分阶段降压、 排出模具内的蒸汽， 取出制成的矩形竹重组型材。
竹重组型材的尺寸及物理力学性能如下：
长 X宽 X厚： 2500 x 600 x 200毫米
密度： 1.0-l.lg/cm3
吸水厚度膨胀率： 1.5% (置于 25°C水中浸泡 24小时后测量的结果)， < 2.5% (置于 25 °C水中浸泡 48小时后测量的结果）
静曲强度（MOR ) > lOOMPa
抗弯弹性模量（ MOE ) > 1 OOOOMPa.,
当然， 如上所述， 为了消除竹重组型材的内应力， 制成的竹重组型材 可以进行如上所述的热堆放。 示例 2
图 8示出了 居本发明另一示例的采用热压固化的竹重组型材的制造 方法的流程图。 图 8所示竹重组型材的制造方法包括以下步骤：
步骤 301和 302分别与示例 1中的步骤 201和 202相同， 它们的详细 描述省略。 步骤 303: 对加缝处理后的竹篾进行高温热处理， 具体地， 将气干竹 篾扎成小捆， 分层堆垛， 推入具有电加热装置的压力罐， 关闭罐门， 通入 饱和蒸汽， 同时接通压力罐内电加热管， 罐内压力保持为 0.4MPa, 温度 从 100°C緩慢升至 130°C， 以便将竹篾烘干至绝干（步骤 303a ); 然后快速 升温至 200°C并保温 3小时 （步骤 303b )， 以便竹篾中的大部分或几乎全 部半纤维素主要在 200°C热解， 且纤维素和木素几乎不热解， 接着排除罐 内压力和蒸汽， 通入饱和蒸汽， 达到快速降温的目的。 然后自然降温至 90 °C并保持 3小时以便调节竹篾含水率 （步骤 303c ), 然后打开罐门， 完成 竹篾高温热处理。
步骤 304和 305与示例 1中的步骤 204和 205相同， 它们的详细描述 省略。 示例 3
根据本发明示例 3所述的竹重组型材的制造方法与根据示例 1所述的 竹重组型材的制造方法区别在于模具的横截面形状为 T形，其他步骤与示 例 1所述的步骤相同， 且竹重组型材的物理力学性能也与示例相同， 这里 不再详细赞述。 示例 4
根据本发明示例 4所述的竹重组型材的制造方法与根据示例 1所述的 竹重组型材的制造方法区别在于模具 2的横截面形状为圆形， 以及在装模 和热压步骤中， 按照密度 1.05g/cm3计算竹篾量、 称重， 竹篾沿同一方向 排列， 厚度方向不分层次， 置于半圓形的下模 2a 内， 送入具有半圆形的 上模 2b的热压机 ,在温度为大约 60-70 °C时闭合模具 2，最高压力为 7.5MPa， 同时向热压机通入蒸汽升温， 当温度升至 130°C时开始计时， 如设计型材 的直径为 50毫米， 最高压力保持 10分钟后开始减低压力至 4.5MPa, 保 持 15分钟， 然后通入冷水降温， 当管道上温度表显示为 50°C时完全卸压、 卸出型材。
示例 4的其他步骤与示例 1的步骤相同， 竹重组型材的物理力学性能 也与示例 1中的竹重组型材相同， 这里不再详细赘述。 示例 5
图 9是根据本发明示例的采用冷压胶合然后烘干的竹重组型材的制造 方法的流程图。 图 9所示竹重组型材的制造方法包括以下步骤：
步骤 401和 402分别与示例 1中的步骤 201和 202相同， 它们的详细 描述省略。
步骤 403: 对加缝处理后的竹篾进行高温热处理， 其中步骤 403a与示 例 1中的步骤 203a相同， 在步骤 403b， 温度加热到 160°C并保持 3小时， 然后降温； 步骤 403c与示例 1中的步骤 203c相同。
步骤 404: 与示例 1中的步骤 204相同。
步骤 405: 将浸胶和干燥后的竹篾装入矩形模具 2内冷压， 具体地， 按照密度 1.05g/cm3计算竹篾量， 称重后沿纵向排列， 厚度方向不分层次 且平行地装入矩形下模 2a内， 然后送入具有上模 2b的冷压机， 分段加压 闭合上模 2b和下模 2a， 直至施加的压力上升至大约 68PMa， 然后卸压， 将推出模具 2。
步骤 406: 将模具 2连同压实的竹篾一起送入烘房进行胶固化或红外 线固化生产线， 在大约 100-130°C温度的条件保持至胶粘剂完全固化。
竹重组型材的尺寸及物理力学性能如下：
长 X宽 X厚： 1900 X 104 X 160毫米
密度： 1.0-1. lg/cm3
吸水厚度膨胀率： 1.5% (置于 25 °C水中浸泡 24小时后测量的结果)， < 2.5% (置于 25 °C水中浸泡 48小时后测量的结果）
静曲强度（MOR ) > lOOMPa
抗弯弹性模量（ MOE ) > 10000MPa„ 示例 6
图 10是根据本示例的采用对制成的竹重组型材进行热处理的竹重组 型材制造方法的流程图。 图 10所示竹重组型材的制造方法包括以下步骤： 步骤 501 : 将毛竹加工成竹篾
步骤 502: 对竹篾进行加缝处理。 步骤 504: 对加缝处理后的竹篾进行浸胶和干燥。
步骤 505: 将经过浸胶和干燥的未经热处理的竹篾装入模具内在温度 大约 130°C、压力为 8MPa的条件下通过热压固化生产出矩形竹重组型材。
步骤 503: 对生产出的竹重组型材进行高温热处理。 具体地， 将竹重 组型材堆垛，送入以热油为加热介盾、蒸汽为保护介质的高温热处理窑内； 关闭窑门， 快速升温并向窑内通入饱和蒸汽； 温度达到 100°C以后放 'f曼升 温速度， 使竹篾干燥至几乎绝干（步骤 503a ); 然后升温至 160°C并保温 4 小时以便竹篾中的大部竹重组型材及其制造方法 Cfi 改 2 )分或几乎全部半 纤维素主要在 200°C热解， 然后开始降温 （步骤 503b ), 降温前期保持高 温热处理窑的进汽口和排汽口关闭，后期开启进汽口和排汽口加快降温速 度； 当高温热处理窑内的温降至低于 90°C时关闭进汽口和排汽口，通入饱 和蒸汽并保持 3小时以便调节竹篾含水率 （步骤 503c ); 最后开启进汽口 和排汽口和窑门，当高温热处理窑内的温度温降至低于 50°C后从高温热处 理窑内取出竹重组型材。
根据示例 6的竹重组型材制造方法， 在制成竹重组型材之前， 竹篾不 进行高温热处理， 而是对制成的竹重组型材进行热处理， 示例 6所示的方 法与示例 1-5所示的方法具有同样的效果。
尽管已经示出和描述了本发明的实施例， 对于本领域的普通技术人员 而言， 可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例 进行多种变化、 修改、 替换和变型， 本发明的范围由所附权利要求及其等 同限定。

Claims

权利要求书
1、 一种竹重组型材， 其特征在于， 所述竹重组型材由浸胶的竹篾压 制而成， 其中所述竹篾经过热处理而发生改性、 所述竹篾分别形成有在其 厚度方向上贯穿的多条缝隙， 且缝隙的长度方向与竹篾的纤维长度方向一 致。
2、 根据权利要求 1所述的竹重组型材， 其特征在于， 在竹重组型材 的横截面上所述竹篾无层次且沿纤维长度方向平行地排列。
3、 根据权利要求 1所述的竹重组型材， 其特征在于， 所述竹篾的改 性包括竹篾中的至少一部分半纤维素热解。
4、 根据权利要求 1所述的竹重组型材， 其特征在于， 所述竹重组型 材中竹篾与胶的干重量比为 5 ~ 10: 100。
5、 根据权利要求 1所述的竹重组型材， 其特征在于， 所述竹篾的厚 度为 1.0毫米- 4.5毫米。
6、 根据权利要求 1所述的竹重组型材， 其特征在于， 所述胶为水溶 性树脂。
7、 根据权利要求 1所述的竹重组型材， 其特征在于， 所述水溶性树 脂为酚醛树脂、 间苯二酚改性或三聚氰胺改性酚醛树脂。
8、 一种竹重组型材的制造方法， 其特征在于， 包括以下步骤： 将竹材加工成竹篾；
对竹篾进行加缝处理，以便在竹篾上形成在厚度方向上贯穿的多条缝 隙， 其中所述缝隙的纵向方向与竹篾的纤维长度方向一致；
对加缝处理后的竹篾进行热处理以便竹篾发生改性；
对热处理后的竹篾进行浸胶和干燥； 和
将浸胶和干燥后的竹篾装入模具内进行冷压而后烘干至胶固化或进 行热压固化， 从而制成竹重组型材。
9、 根据权利要求 8所述的竹重组型材的制造方法， 其特征在于， 所 述竹篾无层次且沿纤维长度方向平行地装入模具内。
10、根据权利要求 8所述的竹重组型材的制造方法， 其特征在于， 所 述热压固化在 120°C-15(TC的温度范围内和 7MPa-9MPa的压力范围内进 行。
11、根据权利要求 8所述的竹重组型材的制造方法， 其特征在于， 所 述冷压在 45MPa - 70MPa的压力范围内进行且冷压后烘干固化在 100°C - 140 °C的温度范围内进行。
12、根据权利要求 9所述的竹重组型材的制造方法， 其特征在于， 所 述热处理包括：
将竹篾干燥至绝干；
使干燥至绝干的竹篾中的至少一部分半纤维素热解 ； 和
冷却半纤维素热解后的竹篾。
13、 根据权利要求 13所述的竹重组型材的制造方法， 其特征在于， 所述热处理进一步包括： 利用饱和蒸汽调节冷却后的竹篾的含水率。
14、 根据权利要求 12所述的竹重组型材的制造方法， 其特征在于， 将竹篾干燥至绝干在 100°C-13(TC的温度范围内进行， 使竹篾中的至少一 部分半纤维素热解在 150°C - 220°C的温度范围内进行，且将半纤维素热解 热后的竹篾冷却至 90 °C以下。
15、 一种竹重组型材的制造方法， 其特征在于， 包括以下步骤： 将竹材加工成竹篾；
对竹篾进行加缝处理，以便在竹篾上形成在厚度方向上贯穿的多条缝 隙， 其中所述缝隙的纵向方向与竹篾的纤维长度方向一致；
对加缝处理后的竹篾进行浸胶和干燥；
将浸胶和干燥后的竹篾无层次且沿纤维长度方向平行地装入模具内 进行冷压而后烘干至胶固化或进行热压固化， 从而制成竹重组型材； 和 对制成的竹重组型材进行热处理从而使组成竹重组型材的竹篾改性。
16、 根据权利要求 15所述的竹重组型材的制造方法， 其特征在于， 所述热处理包括：
在 100°C-130°C的温度范围内将竹篾干燥至绝干；
在 15(TC - 220°C的温度范围内对干燥至绝干的竹篾中的至少一部分 半纤维素热解；
将半纤维素热解后的竹篾冷却到 90°C以下并利用饱和蒸汽调节竹篾 的含水率。
PCT/CN2008/001596 2008-04-18 2008-09-09 竹重组型材及其制造方法 WO2009127092A1 (zh)

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