Multifunctional superplane composite plate preparation process, product and application

Abstract

The present application relates to the field of patent IPC classification B27M1, and more particularly to a multifunctional super-flat composite panel preparation process, product and application. The preparation process steps at least include the following steps: (1) the coating step of the adhesive layer on the upper and lower surfaces of the substrate; (2) the coating step of the wood fiber layer on the surface of the adhesive layer; (3) the hot pressing, flat pressing and laminating of the composite board after coating; (4) sanding and polishing the surface of the formed panel to obtain the product. The composite panel prepared by the present application has good surface flatness and density, good waterproofness, crack resistance and edge collapse prevention effect, and different substrates and wood fiber materials can be replaced according to different needs to achieve different performances. It is suitable for popularization in the field of artificial panels and has broad development prospects.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of patent IPC classification B27M1, and in particular to a multifunctional super-flat composite panel preparation process, product and application. BACKGROUND

[0002] With the progress of society and economic development, the acceleration of urbanization, the construction and decoration industry has also entered a period of rapid development, and artificial board as an important raw material for decoration and furniture industry, with the improvement of people's requirements for furniture and decoration industry, in recent years, has also gradually entered the public's view. Artificial board, as the name implies, is a board prepared by using wood or wood waste through the assistance of chemical adhesives through pressing process. It mainly includes particle board, density board, plywood, fine woodworking board and veneer.

[0003] However, although there are many types of artificial boards on the market, various boards have more or less certain use defects in actual production and life application, and the unevenness of the surface of the wood board, the water resistance and the cracking phenomenon are the use pain points of many wood boards.

[0004] The prior art (CN202010624653.2) provides a veneer treatment process and treatment equipment for density board, which adjusts the surface state of the density board by adjusting the moisture content of the surface of the density board, heating, coating and other treatment processes, and then performs veneer work; however, the above-mentioned surface treatment process has little effect on the improvement of the flatness, cracking resistance and other properties of the wood board surface, and cannot be applied to all types of boards, and cannot effectively solve the problems of unevenness, water resistance and cracking phenomenon of the wood board, thereby causing inconvenience for further processing of the wood board surface.

[0005] Therefore, there is an urgent need for a composite panel with excellent surface flatness, cracking resistance, water resistance and edge collapse prevention, and a preparation process, to improve the use quality of artificial boards and reduce the difficulty of processing the surface of the board. SUMMARY

[0006] In order to solve the above problems, the first aspect of the present application provides a multifunctional super-flat composite panel preparation process, which comprises at least the following steps: (1) coating of the adhesive layer on the upper and lower surfaces of the substrate; (2) coating of the wood fiber layer on the surface of the adhesive layer; (3) hot pressing, flat pressing and laminating of the composite board after coating; (4) sanding and polishing the surface of the formed panel.

[0007] As a preferred solution, a multifunctional super-planar composite board preparation process includes at least the following steps: (1) Coating the adhesive layer on the upper and lower surfaces of the substrate: the substrate is sawn to the required size, and the surface is sanded. Then, the adhesive layer is coated on the upper and lower surfaces of the sanded substrate; (2) Coating the wood fiber layer on the surface of the adhesive layer: after the adhesive layer is coated, wood fiber layer material is coated on the surface of the adhesive layer; (3) Hot pressing, flat pressing, and lamination of the coated composite board: the substrate coated with wood fiber layer material is hot-pressed, flat-pressed, and laminated to form a wood fiber layer on the surface of the substrate, thus obtaining the composite board; (4) Sanding and polishing the surface of the formed board to obtain the composite board.

[0008] In this application, the preparation process of the wood fiber layer on the substrate surface effectively improves the surface flatness and smoothness of the composite board, providing an excellent environment for subsequent surface processing and decoration. The applicant believes that the surface wood fiber layer in this application can effectively fill and encompass micro-cracks and uneven surfaces on the substrate, thereby integrating the substrate surface into a consistent and highly flat board surface. This avoids surface unevenness and low crack resistance caused by the presence of micro-cracks and protruding surfaces. Furthermore, the synergistic effect of wood powder fibers and adhesive reduces the stress on the board surface, providing excellent mitigation and resulting in better surface mechanical strength.

[0009] Furthermore, the use of waste materials such as wood flour and sawdust in the wood fiber layer helps reduce the cost of manufacturing boards and reduces waste emissions and transportation, greatly improving the sustainability and environmental friendliness of board production.

[0010] A second aspect of the present invention provides the above-mentioned multifunctional super-planar composite board, wherein the composite board structure includes a middle substrate 1, an adhesive layer 3 located on the upper and / or lower surface of the middle substrate, and a wood fiber layer 2 located on the surface of the adhesive layer.

[0011] As a preferred embodiment, the substrate is any one of particleboard, plywood, PVC board, OSB board, LVTT board, multi-layer vertical plywood, MDF, blockboard, decorative panel, finger-jointed board, poplar, and Malacca plywood.

[0012] As a preferred embodiment, the substrate is made of any one of the following: eucalyptus, poplar, paulownia, mixed wood, eucalyptus, okoume, mahogany, teak, walnut, catalpa, ash, elm, maple, birch, beech, camphor, pine, and fir.

[0013] In the actual use of the composite board prepared in this application, the material of the substrate can be adjusted or replaced as needed according to methods well known to those skilled in the art. For example, when preparing fire-resistant boards, flame-retardant boards, formaldehyde-free boards, waterproof boards, etc., the material of the substrate can be replaced with the corresponding fire-resistant wood, flame-retardant wood, formaldehyde-free wood, and waterproof wood.

[0014] As a preferred embodiment, the thickness of the adhesive layer is 0.05 to 0.5 mm.

[0015] As a preferred embodiment, the thickness of the adhesive layer is 0.1 to 0.3 mm.

[0016] As a preferred embodiment, the thickness of the single-layer wood fiber layer is 0.15 to 30 mm; the number of wood fiber layers is 1 to 10.

[0017] As a preferred embodiment, the thickness of the single-layer wood fiber layer is 0.5 to 10 mm; the number of wood fiber layers is 1 to 5.

[0018] As a preferred embodiment, the thickness of the single-layer wood fiber layer is 0.8 to 8 mm; the number of wood fiber layers is 1 to 3.

[0019] As a preferred embodiment, the raw material of the wood fiber layer, by weight, includes the following components: 40-100 parts wood fiber powder, 10-50 parts adhesive, and 0-20 parts additives.

[0020] As a preferred embodiment, the raw material of the wood fiber layer, by weight, includes the following components: 60-80 parts wood fiber powder, 20-25 parts adhesive, and 10-20 parts additives.

[0021] As a preferred embodiment, the wood fiber powder is at least one of wood shavings, wood chips, wood flour, sawdust, wood chips, and wood fiber; the material of the wood fiber powder is any one of eucalyptus, poplar, paulownia, mixed wood, lauan, okoume, mahogany, teak, walnut, catalpa, ash, elm, maple, birch, beech, camphor, pine, and fir.

[0022] As a preferred embodiment, the average particle size of the wood fiber powder is 800-1500 mesh.

[0023] In the actual use of the composite board prepared in this application, the material of the wood fiber powder can be adjusted and replaced as needed according to methods well known to those skilled in the art. For example, when preparing fire-resistant boards, flame-retardant boards, formaldehyde-free boards, waterproof boards, etc., the material of the wood fiber powder can be replaced with the corresponding fire-resistant wood, flame-retardant wood, formaldehyde-free wood, and waterproof wood.

[0024] As a preferred solution, the adhesive is any one of aldehyde-based adhesive or non-aldehyde-based adhesive.

[0025] As a preferred solution, the raw material for the bonding layer is consistent with the adhesive in the wood fiber layer.

[0026] As a preferred solution, the auxiliary agent is a functional filler; the functional filler is at least one of carbon material, modified carbon material, metal oxide, modified metal oxide, metal hydroxide, metal salt, diatomite, bentonite, and elemental metal.

[0027] As a preferred solution, the carbon material is at least one of carbon black, graphene, graphene oxide, redox graphene, graphite, carbon fiber, carbon nanotube, and nano-carbon powder.

[0028] As a preferred solution, the modified carbon material is a corresponding modification of the carbon material.

[0029] As a preferred solution, the metal oxide is at least one of aluminum oxide, zinc oxide, magnesium oxide, calcium oxide, iron oxide, titanium dioxide, antimony dioxide, and molybdenum oxide.

[0030] As a preferred solution, the modified metal oxide is a corresponding modification of the carbon material.

[0031] As a more preferred solution, the functional filler is modified zinc oxide.

[0032] As a more preferred solution, the preparation method of the modified zinc oxide comprises the following steps: (1) dissolve succinic anhydride in DMF solution, add a certain amount of silane coupling agent, heat and stir at a water bath temperature of 40-60℃ for 3-4 hours; (2) then add the DMF solution containing zinc oxide into the reaction solution dropwise, continue to stir for 4-5 hours to obtain pretreated zinc oxide particles; (3) mix and add the pretreated zinc oxide particles with 2-methyl imidazole and zinc nitrate, ultrasonic polymerization for 2-6 hours under a water bath ultrasonic device of 600-800W, wash and dry the obtained product to obtain modified zinc oxide particles.

[0033] As a preferred solution, the average fineness of the functional filler is 5-500nm.

[0034] As a preferred solution, the average fineness of the functional filler is 20-300nm.

[0035] As a preferred solution, the average fineness of the functional filler is 120-200nm.

[0036] In the present application, by adjusting the average fineness of the functional filler of modified zinc oxide, the anti-cracking strength and surface flatness of the composite panel surface are effectively improved. The present applicant speculates that when the average fineness of the modified zinc oxide is 120-200 nm, the addition of zinc oxide can not only effectively fill the connection pores between the wood fibers and the adhesive in the wood fiber layer, but also effectively connect the adhesive resin through the active groups on the surface of the zinc oxide, thereby improving the surface density and preventing liquid from penetrating in cooperation with the high layer density of the wood fiber layer. On the other hand, the modified zinc oxide at the nanoscale can form micro-pores in the wood fiber layer. When external force or internal stress acts, the pores can absorb the crazing caused by external force. When the effect of external force and internal stress reaches the cracking limit of the wood fiber layer, the active group connection effect can effectively reconvert the cracks into a crazing state, thereby improving the cracking limit strength of the wood fiber layer.

[0037] As a preferred scheme, the mass ratio of the pretreated zinc oxide particles to 2-methyl imidazole and zinc nitrate is 2:10-15:4-6.

[0038] As a preferred scheme, the ultrasonic polymerization time is 4.5-5.5 hours.

[0039] In the present application, by controlling the compounding of the raw materials for preparing the modified zinc oxide and the reaction time, the waterproof performance and chemical resistance of the composite panel surface are effectively improved. Although the use of zinc oxide in the present application can effectively improve the surface density and surface strength of the panel, the equivalent active hydrophilic groups on the zinc oxide can easily allow water vapor to enter when added to the wood fiber layer, thereby reducing the waterproof performance of the panel. However, the present applicant found that when the mass ratio of the pretreated zinc oxide particles to 2-methyl imidazole and zinc nitrate is 2:10-15:4-6 during the preparation of the composite modified zinc oxide, and the ultrasonic polymerization time is 4.5-5.5 hours, the morphology of the composite material will change greatly from the initial zinc oxide spheres to a framework structure mainly composed of metal and carbon chains. The framework structure can effectively reduce the surface energy of the composite particles, thereby effectively avoiding the water vapor absorption phenomenon. In addition, the framework material can form a good PN junction structure with zinc oxide, promoting the aggregation of electrons and electron holes on the surface and inside of the composite particles, and reducing the electron migration rate of the raw materials in the wood fiber layer.

[0040] As a preferred scheme, the density of the wood fiber layer is 300-1200 kg / m 3 .

[0041] As a preferred scheme, the density of the wood fiber layer is 600-1000 kg / m 3 .

[0042] As a preferred scheme, the thickness of the composite panel is 5-50mm; the length of the composite panel is 0.5-10m.

[0043] As a preferred scheme, the width of the composite panel is 0.3-4m.

[0044] The third aspect of the present application provides an application of the above-mentioned preparation process of the multifunctional ultra-flat composite panel, including the application of the preparation process in the preparation process of all artificial panels.

[0045] Beneficial effects:

[0046] 1. The composite panel prepared by the preparation process in the present application has excellent surface flatness, strength and waterproof performance, and the process steps are simple and easy to operate, which can be applied to various types of panels, solving the technical problems faced by the panel industry for a long time. The setting of the surface wood fiber layer can effectively protect the surface of the panel and reduce the damage of wood during use. The surface of the prepared panel should have excellent flatness, and the panel surface can be attached to any form of other products, including printing and other beautifying and functional products, with excellent surface processing properties.

[0047] 2. The composite panel prepared by the preparation process in the present application can replace the base plate type, base plate material and surface wood fiber layer raw material of the composite panel according to different needs. When preparing fireproof and flame-retardant panels, formaldehyde-free panels and waterproof panels, the raw materials can be replaced accordingly, so that the composite panel has good surface strength, flatness, and good flame-retardant, waterproof, formaldehyde-free and anti-edge collapse effect, with broad application prospects.

[0048] 3. The composite panel prepared in the present application can effectively improve the surface waterproof performance and chemical resistance of the composite panel by adding specific functional particle additives in the wood fiber layer, such as modified zinc oxide, further improving the use quality of the composite panel. BRIEF DESCRIPTION OF DRAWINGS

[0049] Figure 1 The figure is a schematic diagram of the layer structure of the composite panel prepared in Example 1 of the present application.

[0050] In the figure: 1-base plate, 2-wood fiber layer, 3-bonding layer. DETAILED DESCRIPTION

[0051] Example 1

[0052] The first aspect of the embodiment 1 provides a multifunctional superplane composite panel preparation process, which comprises the following steps: (1) a bonding layer coating step on the upper and lower surfaces of the substrate: the substrate is sawn into the required size, and the surface is sanded, and then the bonding layer is coated on the upper and lower surfaces of the sanded substrate; (2) a wood fiber layer coating step on the surface of the bonding layer: after the bonding layer coating is completed, the wood fiber layer material is coated on the surface of the bonding layer; (3) a hot pressing, flat pressing and laminating step of the composite panel after coating: the substrate coated with the wood fiber layer material is subjected to the hot pressing, flat pressing and laminating step to form the wood fiber layer on the surface of the substrate, and the composite panel is obtained; and (4) the surface of the formed panel is sanded and polished, and the composite panel is obtained.

[0053] The multifunctional superplane composite panel structure comprises a middle layer substrate, a bonding layer on the upper and lower surfaces of the middle layer substrate, and a single-layer wood fiber layer on the surface of the bonding layer; the thickness of the wood fiber layer is 0.8 mm; the density of the wood fiber layer is 850 kg / m 3 ; the thickness of the bonding layer is 0.2 mm.

[0054] The substrate is a multi-layer board, and the material of the multi-layer board is eucalyptus.

[0055] The thickness of the composite panel is 18 mm; the length of the composite panel is 2.44 m; and the width of the composite panel is 1.22 m.

[0056] The raw material of the wood fiber layer comprises the following components by weight: 65 parts of wood fiber powder, 25 parts of adhesive, and 18 parts of additive.

[0057] The wood fiber powder is wood powder, and the material is eucalyptus.

[0058] The adhesive is a non-aldehyde adhesive, and the non-aldehyde adhesive is an EPI non-aldehyde adhesive product sold by Shengji Environmental Protection Engineering Co., Ltd. in Dongying; the raw material used for the bonding layer is consistent with the adhesive in the wood fiber layer.

[0059] The average particle size of the wood powder is 1000 mesh.

[0060] The auxiliary agent is modified zinc oxide; the average particle size of the modified zinc oxide is 150 nm; the preparation method of the modified zinc oxide comprises the following steps (in terms of weight parts): (1) 10 parts of succinic anhydride are dissolved in 50 parts of DMF solution, and 6.5 parts of (3-aminopropyl) triethoxysilane is added, and heated and stirred at a water bath temperature of 50℃ for 3.5 hours; (2) then 50 parts of DMF solution containing 2 parts of zinc oxide is added dropwise into the reaction solution, and the pretreated zinc oxide particles are obtained after continuous stirring reaction for 4.5 hours; (3) 2 parts of the pretreated zinc oxide particles are mixed with 12 parts of 2-methyl imidazole and 5 parts of zinc nitrate and added, and ultrasonic polymerization is carried out under an 800W water bath ultrasonic device for 5 hours, and the obtained product is washed and dried to obtain modified zinc oxide particles.

[0061] Example 2

[0062] The specific implementation of the embodiment is the same as that of Embodiment 1, except that the forming of the plate in step (2) adopts a flat pressing step.

[0063] The raw material of the wood fiber layer comprises the following components in terms of weight parts: wood fiber powder 65 parts, adhesive 20 parts, and auxiliary agent 18 parts.

[0064] The multifunctional ultra-flat composite plate structure comprises a middle layer substrate, and two wood fiber layers located on the upper surface and the lower surface of the middle layer substrate; the thickness of the single wood fiber layer is 1 mm; the density of the wood fiber layer is 1000 kg / m 3 .

[0065] The substrate is an LVTT standing plate; the material of the LVTT standing plate is poplar.

[0066] The wood fiber powder is a shaving, and the material is poplar.

[0067] The thickness of the composite plate is 20 mm; the length of the composite plate is 3.05 m; and the width of the composite plate is 1.22 m.

[0068] Example 3

[0069] The specific implementation of the embodiment is the same as that of Embodiment 1, except that the forming of the plate in step (3) adopts a laminating step.

[0070] In the preparation process of the modified zinc oxide, 2 parts of pretreated zinc oxide particles are mixed with 10 parts of 2-methyl imidazole and 6 parts of zinc nitrate and added, and the ultrasonic reaction time is 4.5 hours, and the average particle size of the modified zinc oxide is 180 nm.

[0071] Example 4

[0072] The specific implementation of the present example is the same as that of Example 1, except that the adhesive is a urea-formaldehyde adhesive, which is a urea-formaldehyde adhesive product sold by Shengji Environmental Protection Engineering Co., Ltd. of Dongying City.

[0073] Comparative Example 1

[0074] The specific implementation of the present example is the same as that of Example 1, except that in the preparation of the modified zinc oxide, 2 parts of pretreated zinc oxide particles are mixed and added with 5 parts of 2-methylimidazole and 6 parts of zinc nitrate, and the ultrasonic reaction time is 4.5 hours, and the average particle size of the modified zinc oxide is 80 nm.

[0075] Comparative Example 2

[0076] The specific implementation of the present example is the same as that of Example 1, except that in the preparation of the modified zinc oxide, 2 parts of pretreated zinc oxide particles are mixed and added with 22 parts of 2-methylimidazole and 12 parts of zinc nitrate, and the ultrasonic reaction time is 6 hours, and the average particle size of the modified zinc oxide is 480 nm.

[0077] Performance evaluation

[0078] 1. Surface flatness test: A flatness tester is used to test the flatness of the boards prepared in all examples and comparative examples, 10 samples are tested for each example and comparative example, and the average value of the measured values is recorded in Table 1.

[0079] 2. Bending strength test: A universal material testing machine for boards is used to test the bending strength of the boards prepared in all examples and comparative examples, 10 samples are tested for each example and comparative example, and the average value of the measured values is recorded in Table 1.

[0080] 3. Water resistance test: samples are taken from the boards prepared in all examples and comparative examples, and the water contact angle of the surface of the board material is tested by a seat drop method instrument, the water drop amount is 2 microliters each time, the contact angle between the surface of the board and water is calculated, 5 samples are tested for each example and comparative example, and the average value of the measured values is recorded in Table 1.

[0081] Table 1

[0082]

[0083]

[0084] It can be known from Examples 1-3, Comparative Examples 1-2 and Table 1 that the multifunctional super-flat composite plate preparation process, product and application provided by the application have good surface flatness and compactness, good waterproofness, anti-cracking performance and anti-edge collapse effect, and different base plates and wood fiber materials can be replaced according to different needs to achieve different performances, are suitable for popularization in the field of artificial plates, and have broad development prospects. The Example 1 has the best performance index under the factors of the best preparation raw material ratio and preparation process.

Claims

1. A process for the preparation of a multi-functional superplane composite panel, characterized by: The steps include at least the following steps: (1) coating the adhesive layer on the upper and lower surfaces of the substrate; (2) coating the wood fiber layer on the surface of the adhesive layer; (3) hot pressing the composite board after coating; (4) sanding and polishing the surface of the formed board to obtain the final product. The raw materials for the wood fiber layer, by weight, include the following components: 40-100 parts wood fiber powder, 10-50 parts adhesive, and 18-20 parts additives. The additive is a functional filler with an average fineness of 5~500nm; the functional filler is modified zinc oxide. The preparation method of modified zinc oxide includes the following steps: (1) Dissolve 10 parts of succinic anhydride in 50 parts of DMF solution by weight, and add 6.5 parts of (3-aminopropyl)triethoxysilane. Heat and stir at 50°C in a water bath for 3.5 hours to obtain a reaction solution; (2) Add 50 parts of DMF solution containing 2 parts of zinc oxide to the reaction solution by weight, and stir continuously for 4.5 hours to obtain pretreated zinc oxide particles; (3) Mix 2 parts of pretreated zinc oxide particles with 12 parts of 2-methylimidazole and 5 parts of zinc nitrate by weight and add them. Ultrasonically polymerize in an 800W water bath ultrasonic device for 5 hours. Wash and dry the obtained product to obtain modified zinc oxide particles; The mass ratio of the pretreated zinc oxide particles to 2-methylimidazole and zinc nitrate is 2:10~15:4~6.

2. The multifunctional superplane composite panel obtained by the preparation process according to claim 1, characterized in that: The composite board structure includes a middle substrate, an adhesive layer located on the upper and / or lower surface of the middle substrate, and a wood fiber layer located on the surface of the adhesive layer.

3. The multi-functional super-flat composite panel according to claim 2, wherein: The substrate is any one of particleboard, plywood, PVC board, OSB board, LVTT board, multi-layer vertical board, MDF, blockboard, decorative panel, finger-jointed board, poplar, and Malacca board.

4. The multi-functional super-flat composite panel according to any one of claims 2-3, characterized in that: The thickness of a single wood fiber layer is 0.15~30mm; the number of wood fiber layers is 1~10.

5. The multi-functional super-flat composite panel according to claim 4, wherein: The wood fiber powder is at least one of wood shavings, wood chips, wood flour, sawdust, and wood chips; the material of the wood fiber powder is any one of eucalyptus, poplar, paulownia, mixed wood, eucalyptus, okoume, mahogany, teak, walnut, catalpa, ash, elm, maple, birch, beech, camphor, pine, and fir.

6. The multi-functional super-flat composite panel according to claim 5, wherein: The adhesive is either an aldehyde-based adhesive or a non-aldehyde-based adhesive.

7. The multi-functional super-flat composite panel according to any one of claims 2 to 3, characterized in that: The density of the wood fiber layer is 300-1200 kg / m 3 .

8. The multi-functional super-flat composite panel according to any one of claims 2 to 3, characterized in that: The composite board has a thickness of 5-50 mm; a length of 0.5-10 m; and a width of 0.3-4 m.

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