WO2015106667A1 - 一种丛生竹集成型材的制造方法 - Google Patents

一种丛生竹集成型材的制造方法 Download PDF

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Publication number
WO2015106667A1
WO2015106667A1 PCT/CN2015/070559 CN2015070559W WO2015106667A1 WO 2015106667 A1 WO2015106667 A1 WO 2015106667A1 CN 2015070559 W CN2015070559 W CN 2015070559W WO 2015106667 A1 WO2015106667 A1 WO 2015106667A1
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Prior art keywords
bamboo
parts
temperature
water
manufacturing
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PCT/CN2015/070559
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English (en)
French (fr)
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项林
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深圳市康尔竹木业有限公司
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Publication of WO2015106667A1 publication Critical patent/WO2015106667A1/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
    • B27N3/08—Moulding or pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
    • B27K1/00—Damping wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
    • B27K5/00—Treating of wood not provided for in groups B27K1/00, B27K3/00
    • B27K5/007—Treating of wood not provided for in groups B27K1/00, B27K3/00 using pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
    • B27K5/00—Treating of wood not provided for in groups B27K1/00, B27K3/00
    • B27K5/0085—Thermal treatments, i.e. involving chemical modification of wood at temperatures well over 100°C
    • B27K5/009—Thermal treatments, i.e. involving chemical modification of wood at temperatures well over 100°C using a well-defined temperature schedule
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
    • B27K9/00—Chemical or physical treatment of reed, straw, or similar material
    • B27K9/002—Cane, bamboo

Definitions

  • the invention relates to a bamboo forming process, in particular to a method for manufacturing a bundled bamboo integrated profile.
  • bamboo is a high-altitude herb that has been produced for many years and is suitable for artificial planting with low cultivation costs. Because of its rapid growth and growth, short material production period, bamboo fiber has good toughness and strong pressure resistance. After bamboo is formed into forest, it can be harvested once and for all. And a large part of the bamboo shoots of the new born bamboo is a food. As long as it is suitable for bamboo to produce long environment areas, it can be planted.
  • the bamboo of Chenglin can cover the mountainous areas continuously, and the bamboos are always green in the four seasons, which not only protects the soil and water, but also beautifies the natural environment.
  • the finished bamboo material can be completed by modern technology processing technology; it has been used in the realm of “taking bamboo for wood”, “taking bamboo to win wood” and “taking bamboo for steel”. So how can we use all kinds of bamboo more effectively? It is a strategic issue with far-reaching social and economic significance.
  • bamboo nowadays, the comprehensive development and utilization of bamboo resources has reached the level of “taking bamboo for wood”, but nowadays it is only the bamboo in the “spread bamboo” bamboo species, and the branches are thick and thick, and the bamboo poles are thicker and resource. Better than The resources of bamboo (such as dragon bamboo) of bamboo have not been effectively exploited.
  • the global cluster of bamboo resources is ten times that of scattered bamboo. But why is bamboo really good to use?
  • the bamboo has not been used so far. The reason is that scattered bamboo (such as bamboo) and cluster bamboo (such as dragon bamboo) are the same as bamboo, but they are very different because of their long environment and long physical properties. Therefore, it is impossible to process the bamboo with the technical requirements of processing bamboo.
  • the technical problem to be solved by the present invention is to provide a method for manufacturing a bundled bamboo integrated profile to solve the problem that the existing preparation method cannot obtain a qualified bundled bamboo integrated profile.
  • Global bamboo is divided into two major categories, namely, cluster bamboo and loose bamboo.
  • the diameter is more than 8 cm, and the length is more than 6 meters.
  • bamboos in the scattered bamboo species and dragon bamboo in the cluster bamboo species are used because its bamboo quality meets the industrial processing requirements of “taking bamboo for wood”. It is completely different from the method of growing climate and breeding and growing of bamboo. Therefore, the growth period of these two types of bamboo species is also different, and the physical structure and fiber molecular structure content are also different. Based on the analysis below, it can be found that the processing methods of the two are absolutely not equal and theoretical.
  • Loose bamboo (the following bamboo is an example), and the bamboo is a high-rod herb.
  • the suitable growing areas are mainly distributed in the middle and lower reaches of the Yangtze River and some coastal areas in China.
  • the long-term climatic conditions of bamboo production should be abundant in four seasons, suitable for temperatures between -5° and +35°.
  • bamboo grows in large and small years.
  • bamboo shoots born in small years must be eradicated. It takes two years for bamboo to grow Hsinchu.
  • bamboo will experience a cold season of at least 4 months within one year and requires 6 years of mature harvesting.
  • Cong bamboo for example, dragon bamboo
  • Dragon bamboo should generate long master It should be distributed in the southern subtropical and some tropical regions, Yunnan and Hainan provinces of China and parts of Guangdong province. Southeast Asian countries are particularly rich in resources.
  • the cluster bamboos prefer to grow in relatively high temperatures during the day, with strong water mist at night and abundant water. Its fatal weakness is that it is very cold, and it cannot survive if the temperature is below -0°. Suitable temperatures range from +12° to +35°. Due to climatic reasons, unlike bamboo, there are large and small years, and every year, Hsinchu grows.
  • bamboo shoots for example, Longzhu
  • the bamboo yield per acre is at least 8 times that of bamboo.
  • Congsheng bamboo (Dragon bamboo as an example)
  • Physiological characteristics Longzhu new bamboo shoots were born in the growing season, one was completed from mid-June to the end of July of the year, because this season is the beginning of the rainy season in the southern subtropical region, the water is more abundant .
  • the buds of the young bamboo shoots of Longzhu have plenty of water, and Hsinchu grows very fast.
  • the dragon bamboo is attached to the root of the mother bamboo body. It is 10 to 30 cm below the land and some are even lighter. After the roots of the mother bamboo, they gradually grow into a bamboo. Close to the mother bamboo and continue to develop outward. A mother bamboo will grow 2-3 Hsinchu grown into a single product.
  • bamboo is a bamboo whip in the mother bamboo root, bamboo whip is connected with the mother bamboo, about 30 to 50 cm below the land, some even deeper and outward, each bamboo whip bamboo
  • the new shoots will break through and grow into a material.
  • the loose bamboo is extended by the bamboo whip at the root of the mother bamboo, it forms a separate material in the mountains. It relies on the physiological characteristics of the bamboo whip to extend out of the mother's body, so that it does not depend on the mother bamboo body to grow independently.
  • the long geographical environment and long climatic conditions of bamboo production differ greatly from that of dragon bamboo.
  • the growth and maturity of bamboo has to go through six spring, summer, autumn and winter, and the fiber density is relatively high.
  • the density of bamboo in 6 years can reach 0.7 to 0.8.g/cm 3 .
  • Due to climatic conditions the length of bamboo poles of bamboo varies from 8 to 9 m from the root to the bamboo shoots.
  • the available bamboo that can be processed into bamboo sheets is only 6 to 7 m at most.
  • the bamboo's physiological characteristics and geographical and climatic conditions are limited. Its bamboo rafts are also very thin. According to the bamboo with a diameter of 12cm and a length of 9m, the average wall thickness of the bamboo rafts will not exceed 1.2cm.
  • Nanzhu also has a long period of development, it has to go through six years, winter to fight against blizzard, summer and autumn to resist wind and other factors, in order to adapt to the ability to survive bamboo is not thick, the branches are not high and the roots to the bamboo shoots
  • the size of the cone is more than 3 to 4 cm.
  • the bamboo and bamboo joints are densely spaced, and the bamboo parts protruding from the bamboo body are relatively flat.
  • the original bamboo fiber is hard and fine, and the bamboo fiber has toughness. Due to the physical and structural characteristics of bamboo, it has been used directly by people for daily necessities and building materials for thousands of years.
  • the thick diameter of the bamboo branches is generally about 12 ⁇ 15cm, and some diameters can reach more than 20cm.
  • the height of the branches of the bamboo can reach more than 18 meters, and some can reach 20 meters.
  • the distance between the bamboo and the bamboo is very wide, which is twice that of the bamboo, and the bamboo poles pass from the root to the middle.
  • the size of the parts is well-proportioned. Only 10 meters or more can be tapered.
  • the bamboo raft of the cluster bamboo has an average thickness of about 2 cm from the root at least 8 meters upwards, and its bamboo raft wall thickness is at least 3 to 5 cm within 4 meters of the root.
  • the bamboo fiber Due to the long-term formation of the bamboo, the long-speed and long-term water is sufficient, so the bamboo fiber is thicker and the density is not high, about 0.5-0.6g/cm 3 .
  • the bamboo fiber has good softness, and the bamboo is better than the bamboo. Resistance to strongness In the case of the same diameter, the bamboo is at least 35% weaker than the bamboo. The water content of the bamboo bamboo is also 25% higher than that of the bamboo. From the comparison of the above figures, it can be concluded that the two bamboos of the same diameter have a single weight of at least double the weight of the bamboo.
  • the clusters of bamboo and bamboo produce long geographical and climatic conditions.
  • the molecular organization of cluster bamboo differs greatly from that of bamboo.
  • the moisture content of bamboo shoots is about 25% higher than that of bamboo.
  • the bamboo sugar content of the bamboo shoots is about 0.8% higher than that of the bamboo.
  • the bamboo and bamboo contained in the bamboo shoots are about 0.3% to 0.5% higher than the bamboo.
  • the density of bamboo bamboo fiber is about 0.3g/cm3 lower than that of bamboo.
  • the bamboo essence of the bamboo is about 0.5% higher than that of the bamboo.
  • the alkali content of the bamboo bamboo is about 0.3-0.5% lower than that of the bamboo.
  • the bamboo fiber of the cluster is about 25% larger than the bamboo.
  • the present invention solves the aforementioned technical problems by the following methods:
  • a method for manufacturing a clustered bamboo integrated profile comprising the steps of:
  • the water used for cooking contains 5% to 10% by mass of hydrogen peroxide and 0.5% to 1% of sodium hydroxide, and the cooking temperature is 100 ° C ⁇ 120 ° C, cooking time of not less than 4 hours;
  • step S2 the wet bamboo filaments which are cooked at a high temperature in step S1 are carbonized in a carbonization furnace, the carbonization temperature is 130 ° C to 150 ° C, the carbonization time is 4-6 hours, and the pressure during carbonization is 3-4 MPa;
  • the second dried bamboo wire is loaded into a mold for high-pressure molding, and the pressure of high-pressure molding is not less than 1.2 tons/cm 2 ;
  • the high-pressure molded profile is subjected to heat curing and setting without releasing the mold to maintain the pressure, and the heat curing setting time is 10 hours or more, and the heat curing setting temperature is 80-150 ° C.
  • the present invention performs high-temperature cooking through step S1, and adds an appropriate amount of hydrogen peroxide and sodium hydroxide thereto, thereby capable of sterilizing, softening, and balancing bamboo.
  • the high temperature and high pressure carbonization of the wet bamboo can be carried out in step S2, and the excess protein, starch and sugar in the bamboo can be analyzed by the moisture in the wet bamboo;
  • the process adopts a pressure of 1.2 tons/cm 2 and a heat curing setting time of more than 10 hours.
  • the heat curing setting is divided into 3-4 stages according to time, and the temperature of each stage is sequentially increased, and each stage is maintained for 2-4 hours.
  • the cooking temperature in the step S1 is 110 °C.
  • the component of the glue used for the dipping in the step S3 comprises a resin glue comprising: formaldehyde, phenol, anhydrous sodium sulfate, urea, oleic acid, rosin powder and water, further comprising propylene glycol, and a liquid base or a tablet. Alkali.
  • the individual components of the resin glue include, by mass,:
  • Liquid base or tablet base 8-14 Liquid base or tablet base 8-14.
  • the liquid base is any one or a mixture of two or more kinds of ammonium hydroxide, sodium hydroxide, potassium hydroxide or barium hydroxide having a water content of less than 1% by mass;
  • the plate base is ammonium hydroxide and hydrogen Any one or a mixture of two or more of sodium oxide, potassium hydroxide, and barium hydroxide.
  • the resin glue is a resin glue prepared according to the following method:
  • the pH of the reaction product is adjusted to 7 to 8 by adding an appropriate amount of water, liquid alkali or caustic soda, and then the temperature is lowered to 65 to 70 ° C;
  • the pH of the reaction product is adjusted to 7 to 9 by adding an appropriate amount of water, liquid alkali or caustic soda, and then the temperature is lowered to 55 to 65 ° C, and then 10 to 25 parts of urea is added to the reaction product, and the mixture is uniformly stirred.
  • the glue is obtained by mixing the resin glue and water in a mass ratio of 1: (0.7-0.9).
  • the rubber compound is combined with the characteristics of the bamboo structure, and anhydrous sodium sulfate, oleic acid, propylene glycol, rosin powder and the like are added to the resin glue, and the anhydrous phenolic resin is added to the modified phenolic resin gel to cure at a high temperature. It can quickly remove excess moisture in the integrated bamboo. During the high-temperature molding process, oleic acid oxidation can increase the hardening degree of the profile. At the same time, the addition of rosin powder increases the viscose strength of the phenolic resin, and the bonding ability of the bundled bamboo and bamboo fibers is greatly enhanced.
  • the integrated bamboo integrated profiles are not easy to crack, have high weather resistance, low immersion and peeling rate, tight adhesion and water absorption, and small Peng coefficient is not easy to mold.
  • the propylene glycol combined with anhydrous sodium sulphate and other components can promote the rapid dispersion of the liquid glue absorbed by the bamboo sheet under the high temperature reaction and solidification, so that the liquid glue component is balanced to penetrate into each part of each bamboo piece, thereby achieving the integrated
  • the inner and outer gluing strength of the bamboo profiles are consistent.
  • a method for manufacturing a clustered bamboo integrated profile comprising the steps of:
  • the bamboo shoots of the bamboo shoots are cut into bamboo, bamboo branches, bamboo strips, and yellow sheets are obtained to obtain bundles of bamboo and bamboo, and then the integrated profiles are prepared according to the following steps:
  • the water used for cooking contains 5% to 10% by mass of hydrogen peroxide and 0.5% to 1% of sodium hydroxide, and the cooking temperature is The temperature is from 100 ° C to 120 ° C, the optimum temperature is 110 ° C, and the cooking time is not less than 4 hours.
  • step S2 the wet bamboo wire which is cooked at a high temperature in step S1 is carbonized in a carbonization furnace, the carbonization temperature is 130 ° C to 150 ° C, the carbonization time is 4-6 hours, and the pressure at the time of carbonization is 3-4 MPa.
  • the carbonization pressure is less than 3 MPa, and the protein, starch, and sugar in the bamboo cannot be fully analyzed; the protein, starch, and sugar can not be analyzed without using wet bamboo.
  • the carbonized bamboo fiber is firstly dried, and then the bamboo fiber after the first drying is dipped, and the second drying is performed after dipping. Drying and then dipping helps the glue to fully immerse into the interior of the bamboo.
  • the second dried bamboo wire is put into a mold for high-pressure molding, and the pressure of high-pressure molding is not less than 1.2 tons / square centimeter. In this step, if the pressure is less than 1.2 ton / cm 2 , the final formed bamboo material is easy to loose and expand and deform, and the density is low.
  • the high-pressure molded profile is subjected to heat curing and setting without releasing the mold to maintain the pressure, and the heat curing setting time is 10 hours or more, and the heat curing setting temperature is 80-150 °C.
  • This step is preferably carried out in stages, and the whole process is divided into 3-4 stages according to time, and the temperature of each stage is sequentially increased, and the maintenance time of each stage is 2-4 hours. For example, it is thermally cured at 80 ° C for 2 hours, then heated to 100 ° C for 3 hours, then heated to 130 ° C for 3 hours, and finally heated to 150 ° C for 2 hours.
  • the component of the glue used for the dipping in the step S3 comprises a resin glue
  • the resin glue preferably comprises: formaldehyde, phenol, anhydrous sodium sulfate, urea, oleic acid, rosin powder and water, and also includes propylene glycol, and liquid alkali or Tablet base.
  • Each component includes, by mass, 70-110 parts of formaldehyde, 40-60 parts of phenol, 10-35 parts of anhydrous sodium sulfate, 10-25 parts of urea, 3-8 parts of oleic acid, 1-3 parts of rosin powder, water. 35-60 parts, 1-5 parts of propylene glycol, liquid base or tablet base 8-14.
  • the liquid base is any one or a mixture of two or more kinds of ammonium hydroxide, sodium hydroxide, potassium hydroxide or barium hydroxide having a water content of less than 1% by mass;
  • the tablet base is ammonium hydroxide, Any one or a mixture of two or more of sodium hydroxide, potassium hydroxide, and barium hydroxide.
  • the aforementioned resin glue is prepared by the following method:
  • the pH of the reaction product is adjusted to 7 to 8 by adding an appropriate amount of water, liquid alkali or caustic soda, and then the temperature is lowered to 65 to 70 ° C;
  • the pH of the reaction product is adjusted to 7 to 9 by adding an appropriate amount of water, liquid alkali or caustic soda, and then the temperature is lowered to 55 to 65 ° C, and then 10 to 25 parts of urea is added to the reaction product, and the mixture is uniformly stirred.
  • the temperature is raised to 55-70 ° C, and then added -8 parts of oleic acid, 3-6 parts of liquid alkali, 20 ⁇ 35 parts of water, stirred evenly, heated to 85 ⁇ 99 ° C and kept 60 ⁇ 100min;
  • the glue used in the step S3 is prepared by mixing the resin glue prepared by the above method with water in a mass ratio of 1:0.7-0.9, and the ratio of the preferred resin glue to water is 1:0.85 by mass.
  • the resin glue prepared by the above method is a transparent liquid, has stable performance, strong bonding property, good weather resistance, low immersion peeling rate and fast curing speed.
  • the resin glue is used in the integrated bamboo integrated profile, and the strength of the glued bamboo profile can be fully Achieve the strength requirements of the structural material.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)

Abstract

一种丛生竹集成型材的制造方法，包括以下步骤：S1、将刨青、去黄的丛生竹竹丝浸于水中进行高温蒸煮，水中含有质量百分比为5%～10%的双氧水和0.5%～1%的氢氧化钠，温度为100℃～120℃，时间不少于4小时；S2、将湿竹丝置于炭化炉中进行碳化，碳化温度为130℃～150℃，碳化时间4-6小时，碳化时的压力为3-4MPa；S3、第一次烘干，浸胶，浸胶后进行第二次烘干；S4、高压成型，高压成型的压力不小于1.2吨/平方厘米；S5、保持所述压力的条件下进行热固化定型，热固化定型时间10小时以上，热固化定型温度为80-150℃。该制造方法能够制备符合结构型材要求的丛生竹集成型材。

Description

一种丛生竹集成型材的制造方法 技术领域
本发明涉及竹材成型工艺，尤其是涉及一种丛生竹集成型材的制造方法。
背景技术
随着人类的进步和社会的快速发展，人们对居住和生活条件要求越来越高，对生活居住用品也越来越精良。尤其当今世界各类日常生活高科技产品的迅猛发展，促进了人类社会生活多元化。快速提高了人们的物质文明和生活水平。所以人们对木材的需求量越来越大。尤其发展中国家为满足国内需求发展，大批量进口木材，反之欠发达国家为了生存大量出口木材而无序采伐，造成了全球森林资源严重破坏。有些木材材种已经匮绝。大量采伐破坏森林资源，已经对全球生态平衡造成了严重失衡，威胁到人类的生存环境造成了恶劣气候变化。为了保持生态平衡，绿色低碳生活。全球很多有竹材资源的国家，对竹资源的利用也已经提到议事日程上来。尤其我国对竹材的综合利用已经起得了很好的效果。人们对“以竹代木”的概念越来越认同。对“以竹代木”的各类产品也越来越青睐。这对保护森林资源、低碳环保生活无疑是一个良好的开端。“以竹代木”、“以竹胜木”、“以竹代钢”是社会发展的必然趋势，是人类进步的必然产物。是保护地球绿色低碳生活的可续性保障。
竹材是多年常生速生成材的高杆草本植物，适合人工种植，栽培成本低。因其繁殖生长速度快，成材周期短，竹纤维韧性好，抗压能力强，竹子成林后可以轮复采伐一劳永逸。而且很大部分竹子当年新出生的竹笋是食用佳肴。只要能适合竹子生成长环境地区多可以种植。成林的竹子可以复盖山地连绵不断，竹子四季常青排山如海，既保护了水土流失又美化了自然环境。成品竹材经现代科技手段加工技术完成能；“以竹代木”、“以竹胜木”、“以竹代钢”的境界而有过之。所以怎样更有效的综合利用各种竹子？是一项有着深远社会和经济意义的战略课题。
现在对竹材资源综合开发利用已经到了“以竹代木”的水平，但现在普遍开发利用的仅仅是“散生竹”竹种里面的楠竹，而枝粗杆高，竹襄更厚，资源优于 楠竹的丛生竹(例如龙竹)资源尚无被有效的开发利用。据国际竹藤组织对全球竹资源调查统计查明，全球丛生竹资源是散生竹的儿十倍。但为什么楠竹已经很好的在利用？而丛生竹却到至今尚未能很好利用？其原因在于：散生竹(例如楠竹)与丛生竹(例如龙竹)虽同属竹类但因它们生成长环境和生成长的物理特性区别很大。所以用加工楠竹的技术要求来加工丛生竹是无法做到的。
发明内容
本发明所要解决的技术问题是，提供一种丛生竹集成型材的制造方法，以解决现有制备方法无法获得合格的丛生竹集成型材的问题。
人们往往把丛生竹和楠竹两种竹类混合为完全相同的竹种，认为楠竹专利的公知常识同样适合用在丛生竹的加工工艺上。但经验证，楠竹的集成型材加工方法应用于丛生竹而制备的型材，具有容易变形开裂、膨胀、霉变等缺陷。为了获得丛生竹的资源利用方法，本发明人对丛生竹与楠竹在诸多方面的差异进行研究、分析、对比，并在此基础上作出本发明，为便于理解，下文对与本发明相关的分析结果进行介绍，但这些内容并非均为现有公知的技术知识，而经发明人研究获得的，因而，在没有在先公开证据的情况下，不应作为现有技术评价本发明的创造性。
全球竹子分为两大类即丛生竹和散生竹。两大类竹种中直径大于8厘米，长度在6米以上的就有散生竹竹种里面的楠竹和丛生竹种中的龙竹等。现在利用的只有楠竹因为它的竹子质量符合“以竹代木”的工业化加工要求。因和楠竹生长气候环境和繁殖生成长方法完全不同。所以这两类竹种的生长期也不同，物理结构和纤维分子组织含量也不同。基于下述分析则可发现两者的加工工艺方法绝对不能同等而理论。
(一)气候地理条件和生成长规律的区别
(1)散生竹(以下楠竹为例)，楠竹属高杆草本植物。宜生长地区主要是分布在我国的长江中下游和一些沿海地区。楠竹生成长气候条件要四季分明雨量充沛，适宜温度-5°～+35°之间。楠竹生长有大小年之分，小年出生的竹笋多必须要铲除，楠竹需要两年才可以培育一次新竹成材。楠竹一年之内要经历至少4个月的寒冷季节，需6年成熟采伐。
(2)“丛生竹”(以龙竹为例)也同样是高杆草本植物。龙竹宜生成长主 要分布在南亚热带和有些热带地区，我国的云南省和海南省及广东省部分地区。东南亚各国资源尤为丰富。丛生竹喜好生长在白天气温相对较高，晚上水雾气较强，水分充沛地区。它致命的弱点就是很怕寒冷，气温在-0°以下就无法生存。适宜温度在+12°～+35°之间。因气候原因不象楠竹有大小年之分，每年有新竹长成。因没有寒冬，加上南亚热带有充足的水分，丛生竹只需4年，比楠竹成熟采伐期整整缩短二年。丛生竹(龙竹为例)枝粗杆高竹襄厚，每年每亩的产竹量至少是楠竹的8倍以上.
(二)繁殖生理特性区别
(1)丛生竹(龙竹为例)生理特性：龙竹新笋出土生长期，一股是在当年公历的6月中旬到7月底完成，因这个季节是南亚热带地区雨季开始，水分更加充沛。龙竹初生幼笋芽有充沛水分，新竹成长非常迅猛。龙竹是紧帖依附在母竹体根部周边，在土地下10～30厘米有些甚至更浅，依符母竹竹根部发育后渐步成长自成一竹。紧靠母竹四周不断向外发展。一根母竹当年一股多会长出2-3根新竹成长成材。
(2)散生竹的生理特性：楠竹是母竹根部长有一条竹鞭，竹鞭连着母竹，大约在土地下30～50厘米有些甚至更深向外延伸，每根竹鞭的竹节上多长有新笋芽，楠竹在农历3月开始只要有符合新笋芽生成长的条件，新笋芽就会破土而出成长成材。因散生竹是靠母竹根部的竹鞭向周边延伸，形成了散生在山野上独立成材。它靠竹鞭离开母体向外延伸的生理特性，造就它不依符母竹体独立成长成材。
(三)物理结构和分子组织的区别(以楠竹和龙竹为例)
(1)楠竹生成长地理环境和生成长气候条件与龙竹差异很大，楠竹它的成长成熟期要经历六个春夏秋冬，纤维密度就比较高，6年成材竹的密度大约能够达到0.7～0.8.g/cm3。因气候条件的限制楠竹的竹杆长度：从根部到竹梢一股多在8～9m以下，真正可以加工成竹板材用的可用原竹最多也只是在6～7m。楠竹的生理特性和地理气候条件限制原因，它的竹襄也很薄，按直径12cm，长度9m的楠竹，它的竹襄平均壁厚也不会超过1.2cm。所以楠竹可利用材料就相当的有限。楠竹也因它的生成长期长，要经历六个年头，冬天要抗暴雪，夏秋季要抗风等等因素，为了适应生存能力楠竹的经不粗，枝杆不高而且根部到竹梢大小锥形 3～4cm以上就很明显。为抗风雪楠竹竹节与竹节间距较密，竹身突出的竹节较平低。原竹纤维硬细、竹纤维有韧性。因楠竹的物理组织结构特性，千百年来一直被人们直接用来制作成生活用品和建筑材料。
(2)龙竹的生成长地理环境气候条件和楠竹也同样有很大的区别。龙竹首先它的生成长气温平均多在+20°左右。不像楠竹到了冬季就进入休眠状态不再成熟。而是一年四季都在成长成熟，不受强风和雪压而且在南亚热带地区雨量也极为丰富。所以成长的特别快，成熟年龄也相应比楠竹缩短二年。丛生竹的物理组织结构和楠竹就有着很大的区别：
1.丛生竹枝粗直径一股普遍可达12～15cm左右有些直径可达20厘米以上。
2.丛生竹”枝杆高度可达18米以上，有的可达20儿米。竹节与竹节间距很开，足足是楠竹的两倍，而且竹杆通身从根部到中上部位大小匀称。10儿米以上才能分别出锥形。
3.丛生竹的竹襄从根部向上至少8米之内平均厚度多在2cm左右，根部4米之内它的竹襄壁厚至少有3～5cm。
4.丛生竹因生成长期短，生成长速度快水分充足，所以的竹纤维较粗，密度不高，大约0.5～0.6g/cm3，竹纤维柔软性较好，丛生竹与楠竹比，抗强性在同等直径的情况下丛生竹至少要弱于楠竹35％。丛生竹原竹的含水量也较楠竹高25％。从以上数字对比照可以得出：同等直径的两个竹种，丛生竹的单支重量至少是楠竹重量的一倍以上。
(四)分子组织机构的对照
丛生竹和楠竹的生成长地理和气候条件的因素，丛生竹的分子组织机构与“楠竹”区别很大：
1.丛生竹原竹含水率高约超出楠竹25％之多。
2.丛生竹原竹含糖量高出楠竹约0.8％左右。
3.丛生竹原竹含蛋白质及淀粉约高出楠竹0.3～0.5％不等。
4.丛生竹原竹纤维密度约低于楠竹0.3g/cm3左右。
5.丛生竹原竹含梅酸约高于楠竹0.5％之间。
6.丛生竹原竹含碱约低于楠竹0.3-0.5％之间。
7.丛生竹竹纤维粗约超出楠竹25％左右。
以上“丛生竹”和“楠竹”的分子组织对照可以表明，两种材料分子组织有明显的差别。所以用加工“楠竹”的方法来完成“丛生竹”集成和加工制造，是无法达到产品合格标准的。也正因为“丛生竹”物理组织结构和分子组织特性原因，千百年来一直未被人们直接用来制作成生活用品和建筑材料。“丛生竹”使用“楠竹”的胶水更无法达到集成质标。
在结合上述研究和大量实验的前提下，本发明通过下述方法解决前述技术问题：
一种丛生竹集成型材的制造方法，包括以下步骤：
S1、将刨青、去黄的丛生竹竹丝浸于水中进行高温蒸煮，用于蒸煮的水中含有质量百分比为5％～10％的双氧水和0.5％～1％的氢氧化钠，蒸煮温度为100℃～120℃，蒸煮时间不少于4小时；
S2、将经步骤S1高温蒸煮的湿竹丝置于炭化炉中进行碳化，碳化温度为130℃～150℃，碳化时间4-6小时，碳化时的压力为3-4MPa；
S3、将碳化后的竹丝进行第一次烘干，然后将第一次烘干后的竹丝浸胶，浸胶后进行第二次烘干；
S4、将第二次烘干的竹丝装入模具中进行高压成型，高压成型的压力不小于1.2吨/平方厘米；
S5、将高压成型的型材在不脱模以保持所述压力的条件下进行热固化定型，热固化定型时间10小时以上，热固化定型温度为80-150℃。
与现有技术相比，本发明在通过步骤S1进行高温蒸煮，并在其中添加适量的双氧水和氢氧化钠，一方面能够起到很好的杀菌、软化竹节、平衡竹材的作用，另一方面能够脱出竹材中的蛋白质、淀粉、糖分等；而步骤S2中采用对湿竹进行高温、高压碳化，能够通过湿竹中的水分使得竹材中多余的蛋白质、淀粉、糖分析出；而在高压成型过程中采用1.2吨/平方厘米的压力，10小时以上的热固化定型时间，最终与其他步骤一同保证了最后的型材能够达到现有楠竹型材同等的质量指标，具有高密度，且不易容易变形开裂、膨胀、霉变的有益效果。
优选地：
所述步骤S5中，热固化定型按照时间先后分成3-4个阶段，各个阶段的温度依次提高，每个阶段维持2-4个小时。
所述步骤S1中的蒸煮温度为110℃。
所述步骤S3中浸胶所用胶水的组分包括树脂胶，所述树脂胶包括：甲醛、苯酚、无水硫酸钠、尿素、油酸、松香粉和水，还包括丙二醇，以及液碱或片碱。
优选地：
所述树脂胶的各个组分按照质量计包括：
甲醛 70-110份
苯酚 40-60份
无水硫酸钠 10-35份
尿素 10-25份
油酸 3-8份
松香粉 1-3份
水 35-60份
丙二醇 1-5份
液碱或片碱 8-14。
所述液碱为含水量低于1质量％的氢氧化铵、氢氧化钠、氢氧化钾、氢氧化钡中的任意一种或两种以上的混合物；所述片碱为氢氧化铵、氢氧化钠、氢氧化钾、氢氧化钡中的任意一种或两种以上的混合物。
更进一步地：
所述树脂胶为按照下述方法制备的树脂胶：
S11、取甲醛50～70份、苯酚40～60份、丙二醇1～5份、液碱或片碱5～8份、水15～25份加入反应釜内搅拌均匀后通过添加适量水、液碱或片碱调节混合物的PH值为7～8，然后升温至65～85℃，然后保温反应70～100min，保温时温度也控制在65～85℃范围内；
S21、保温70～100min后，通过添加适量水、液碱或片碱调节反应产物的PH值为7～8，然后降温到65～70℃；
S31、温度降到65～70℃后，往反应产物里加入甲醛20～40份，无水硫酸钠10～35份，搅拌均匀后升温至80～85℃，保温反应80～100min；
S41、反应完成后，通过添加适量水、液碱或片碱调节反应产物的PH值为7～9后降温至55～65℃，然后往反应产物中添加尿素10～25份，搅拌均匀后将温 度升至55-70℃，再往里面添加油酸3～8份、液碱3～6份、水20～35份，搅拌均匀后升温至85～99℃并保温60～100min；
S51、保温60～100min后降温到45～50℃，再添加1～3份的松香粉后搅拌30min以上，搅拌完成后降温到45℃以下即得到丛生竹集成型材用树脂胶。
所述胶水为所述树脂胶与水按照质量比例1∶(0.7-0.9)混合而成。
前述优选方案的胶料结合丛生竹结构特点，在树脂胶中添加了无水硫酸钠、油酸、丙二醇、松香粉等物质，该改性酚醛树脂胶内加入无水硫酸钠在高温反应固化时能快速去除集成竹材内多余的水分，高温成型的过程中油酸氧化能增加型材的硬化度，同时由于添加了松香粉增加了酚醛树脂胶的粘胶强度，对丛生竹竹纤维胶合能力大大增强，所制造的丛生竹集成型材不易开裂变形、耐候性高、浸渍剥离率低、粘合严密不易吸水、彭涨系数小而不易霉变。而丙二醇配合无水硫酸钠及其他组分，能促使被竹片吸收的液胶在高温反应固化下快速分散，使液胶成份平衡的浸透到每根竹片的各个部位，从而达到所集成的丛生竹型材内外胶合强度一致。
具体实施方式
下面结合优选的实施方式对本发明作进一步说明。
一种丛生竹集成型材的制造方法，包括以下步骤：
首先将丛生竹原竹进行定尺锯竹、破竹分条、竹条刨青去黄分层压丝获得丛生竹竹丝，然后按照下述步骤制备集成型材：
S1、将刨青、去黄的丛生竹竹丝浸于水中进行高温蒸煮，用于蒸煮的水中含有质量百分比为5％～10％的双氧水和0.5％～1％的氢氧化钠，蒸煮温度为100℃～120℃，最佳温度为110℃，蒸煮时间不少于4小时。
S2、将经步骤S1高温蒸煮的湿竹丝置于炭化炉中进行碳化，碳化温度为130℃～150℃，碳化时间4-6小时，碳化时的压力为3-4MPa。本步骤中：碳化压力低于3MPa无法使得竹中的蛋白质、淀粉、糖分等充分析出；不采用湿竹也同样无法充分析出蛋白质、淀粉、糖分。
S3、将碳化后的竹丝进行第一次烘干，然后将第一次烘干后的竹丝浸胶，浸胶后进行第二次烘干。先烘干再浸胶有助于胶水充分浸入竹材内部。
S4、将第二次烘干的竹丝装入模具中进行高压成型，高压成型的压力不小于 1.2吨/平方厘米。本步骤中，如果压力小于1.2吨/平方厘米，最终成型的竹材容易松散和膨胀变形，而且密度偏低。
S5、将高压成型的型材在不脱模保持所述压力的条件下进行热固化定型，热固化定型时间10小时以上，热固化定型温度为80-150℃。本步骤优选采用分阶段进行，按照时间先后将整个过程分为3-4个阶段，各个阶段的温度依次提高，每个阶段的维持时间为2-4小时。例如：先80℃热固化2小时，然后升温至100℃热固化3小时，再升温至130℃热固化3小时，最后升温至150℃热固化2小时。
所述步骤S3中浸胶所用胶水的组分包括树脂胶，所述树脂胶优选包括：甲醛、苯酚、无水硫酸钠、尿素、油酸、松香粉和水，还包括丙二醇，以及液碱或片碱。各个组分按照质量计包括：甲醛70-110份，苯酚40-60份，无水硫酸钠10-35份，尿素10-25份，油酸3-8份，松香粉1-3份，水35-60份，丙二醇1-5份，液碱或片碱8-14。其中所述液碱为含水量低于1质量％的氢氧化铵、氢氧化钠、氢氧化钾、氢氧化钡中的任意一种或两种以上的混合物；所述片碱为氢氧化铵、氢氧化钠、氢氧化钾、氢氧化钡中的任意一种或两种以上的混合物。
在更优的实施例中，前述树脂胶是采用下述方法制备的：
S11、取甲醛50～70份、苯酚40～60份、丙二醇1～5份、液碱或片碱5～8份、水15～25份加入反应釜内搅拌均匀后通过添加适量水、液碱或片碱调节混合物的PH值为7～8，然后升温至65～85℃，然后保温反应70～100min，保温时温度也控制在65～85℃范围内；
S21、保温70～100min后，通过添加适量水、液碱或片碱调节反应产物的PH值为7～8，然后降温到65～70℃；
S31、温度降到65～70℃后，往反应产物里加入甲醛20～40份，无水硫酸钠10～35份，搅拌均匀后升温至80～85℃，保温反应80～100min；
S41、反应完成后，通过添加适量水、液碱或片碱调节反应产物的PH值为7～9后降温至55～65℃，然后往反应产物中添加尿素10～25份，搅拌均匀后将温度升至55-70℃，再往里面添加油酸3～8份、液碱3～6份、水20～35份，搅拌均匀后升温至85～99℃并保温60～100min；
S51、保温60～100min后降温到45～50℃，再添加1～3份的松香粉后搅拌 30min以上，搅拌完成后降温到45℃以下即得到丛生竹集成型材用树脂胶。
优选实施例中，步骤S3中所用的胶水为前述方法制备的树脂胶与水按照质量比1∶0.7-0.9混合而成，优选的树脂胶与水配比比例为质量比1∶0.85。
采用前述方法制备的树脂胶为透明液体，性能稳定，胶合性能强，耐候性好，浸渍剥离率很低，固化速度快，该树脂胶用于丛生竹集成型材中，胶合的竹型材强度完全能达到结构材的强度要求。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明，不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的技术人员来说，在不脱离本发明构思的前提下，还可以做出若干等同替代或明显变型，而且性能或用途相同，都应当视为属于本发明的保护范围。

Claims (8)

  1. 一种丛生竹集成型材的制造方法，其特征在于，包括以下步骤：
    S1、将刨青、去黄的丛生竹竹丝浸于水中进行高温蒸煮，用于蒸煮的水中含有质量百分比为5％～10％的双氧水和0.5％～1％的氢氧化钠，蒸煮温度为100℃～120℃，蒸煮时间不少于4小时；
    S2、将经步骤S1高温蒸煮的湿竹丝置于炭化炉中进行碳化，碳化温度为130℃～150℃，碳化时间4-6小时，碳化时的压力为3-4MPa；
    S3、将碳化后的竹丝进行第一次烘干，然后将第一次烘干后的竹丝浸胶，浸胶后进行第二次烘干；
    S4、将第二次烘干的竹丝装入模具中进行高压成型，高压成型的压力不小于1.2吨/平方厘米；
    S5、将高压成型的型材在不脱模以保持所述压力的条件下进行热固化定型，热固化定型时间10小时以上，热固化定型温度为80-150℃。
  2. 根据权利要求1所述的制造方法，其特征在于：所述步骤S5中，热固化定型按照时间先后分成3-4个阶段，各个阶段的温度依次提高，每个阶段维持2-4个小时。
  3. 根据权利要求1所述的制造方法，其特征在于：所述步骤S1中的蒸煮温度为110℃。
  4. 根据权利要求1所述的制造方法，其特征在于：所述步骤S3中浸胶所用胶水的组分包括树脂胶，所述树脂胶的组分包括：甲醛、苯酚、无水硫酸钠、尿素、油酸、松香粉和水，还包括丙二醇，以及液碱或片碱。
  5. 根据权利要求4所述的制造方法，其特征在于：所述树脂胶的各个组分按照质量计包括：
    甲醛 70-110份
    苯酚 40-60份
    无水硫酸钠 10-35份
    尿素 10-25份
    油酸 3-8份
    松香粉 1-3份
    水 35-60份
    丙二醇 1-5份
    液碱或片碱 8-14。
  6. 根据权利要求4或5所述的制造方法，其特征在于：所述液碱为含水量低于1质量％的氢氧化铵、氢氧化钠、氢氧化钾、氢氧化钡中的任意一种或两种以上的混合物；所述片碱为氢氧化铵、氢氧化钠、氢氧化钾、氢氧化钡中的任意一种或两种以上的混合物。
  7. 根据权利要求6所述的制造方法，其特征在于：所述树脂胶为按照下述方法制备的树脂胶：
    S11、取甲醛50～70份、苯酚40～60份、丙二醇1～5份、液碱或片碱5～8份、水15～25份加入反应釜内搅拌均匀后通过添加适量水、液碱或片碱调节混合物的PH值为7～8，然后升温至65～85℃，然后保温反应70～100min，保温时温度也控制在65～85℃范围内；
    S21、保温70～100min后，通过添加适量水、液碱或片碱调节反应产物的PH值为7～8，然后降温到65～70℃；
    S31、温度降到65～70℃后，往反应产物里加入甲醛20～40份，无水硫酸钠10～35份，搅拌均匀后升温至80～85℃，保温反应80～100min；
    S41、反应完成后，通过添加适量水、液碱或片碱调节反应产物的PH值为7～9后降温至55～65℃，然后往反应产物中添加尿素10～25份，搅拌均匀后将温度升至55-70℃，再往里面添加油酸3～8份、液碱3～6份、水20～35份，搅拌均匀后升温至85～99℃并保温60～100min；
    S51、保温60～100min后降温到45～50℃，再添加1～3份的松香粉后搅拌30min以上，搅拌完成后降温到45℃以下即得到丛生竹集成型材用树脂胶。
  8. 根据权利要求7所述的制造方法，其特征在于：所述胶水为所述树脂胶与水按照质量比例1∶(0.7-0.9)混合而成。
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