A solid wood veneer faced panel and a method of making the same

Abstract

The present application relates to the technical field of veneer faced panel, and particularly relates to a solid wood veneer faced panel and a preparation method thereof. The solid wood veneer faced panel comprises a base material layer and a wood veneer layer arranged on at least one side of the base material layer, a connecting body is arranged between the base material layer and the wood veneer layer, the connecting body is sequentially provided with a polyurethane adhesive layer, a first fiber layer, a first adhesive layer, a metal layer and a second adhesive layer along the direction from the base material layer to the wood veneer layer, the first fiber layer comprises a plurality of pores, and the pores are filled with a reinforcing glue connected with the polyurethane adhesive layer or / and the first adhesive layer. The present application provides a solid wood veneer faced panel, and a multilayer connecting body is used to replace a single adhesive layer in a traditional faced panel to improve the connecting effect between the base material layer and the wood veneer layer.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of veneer faced panels, in particular to a solid wood veneer faced panel and a preparation method thereof. BACKGROUND

[0002] With the progress of science and technology and economy, building decoration materials are moving from traditional composite boards to new environmentally-friendly decoration materials. The ultimate goal of new living environment should be to achieve harmony between man and nature, while improving people's quality of life and reducing the harm of materials to the human body and the environment. Existing decoration materials such as wood veneer paint boards have wood veneer, technical wood and other wood veneer materials as the veneer material, and have wood-based panels such as particle board and density board as the substrate layer. The veneer process uses white latex to cold press and then hot press. The veneer adhesive and the substrate of such boards have a large amount of formaldehyde release, and such carcinogenic substances will continue to be emitted for a long period of time. The preparation process of wood veneer paint boards is relatively complex. Before production, the substrate needs to be pretreated, the surface dust, glue printing and gap are treated clean with a scraper, but the wood veneer cannot be damaged and the surface wood veneer cannot be raised. Then sanding treatment is performed to ensure smooth surface. In the painting process, multiple polishing, putty filling, multiple primer and topcoat are required to achieve the surface effect, which is time-consuming and labor-intensive. In addition, the dust generated by polishing affects personal health and has the risk of dust electrostatic explosion.

[0003] To replace traditional wood-based panels, there are currently technologies that use PVC foam boards, bamboo-wood fiber boards and stone plastic boards as substrates. Organic boards such as PVC foam boards have no formaldehyde release, are light in weight, have good processability and can realize curved modeling, which are new integrated wall panel materials. For example, the patent document with publication number CN102953507A discloses a PVC composite wood veneer which includes a modified PVC layer, an adhesive layer, a double-layer vertical hot-pressed wood veneer layer and a topcoat layer from back to surface, and the modified PVC layer, the adhesive layer, the double-layer vertical hot-pressed wood veneer layer and the topcoat layer are integrally combined by interlayer compounding to form the whole composite wood veneer.

[0004] However, there are still some problems, such as poor permeability of PVC material and strong permeability of wood veneer surface glue, which makes it difficult to paste and combine the two materials. For example, the substrate materials of PVC foam boards or extruded bamboo-wood fiber hollow boards and stone plastic boards have poor heat resistance and stability, and are not pressure-resistant. The hot pressing process of traditional wood veneer white latex requires high temperature and high pressure for glue curing, which is prone to warping and deformation. SUMMARY

[0005] The present application solves the above problems and provides a solid wood veneer faced panel and a preparation method thereof.

[0006] The technical scheme for solving the problem of the present application is to provide a solid wood veneer facing panel, comprising a substrate layer and a wood veneer layer arranged on at least one side of the substrate layer, a connecting body arranged between the substrate layer and the wood veneer layer, and a polyurethane adhesive layer, a first fiber layer, a first adhesive layer, a metal layer and a second adhesive layer arranged in sequence along the direction from the substrate layer to the wood veneer layer; the first fiber layer comprises a plurality of pores filled with a reinforcing adhesive connected with the polyurethane adhesive layer or / and the first adhesive layer.

[0007] As a preferred embodiment of the present application, a transparent protective layer is further arranged on the wood veneer layer.

[0008] As a preferred embodiment of the present application, a second fiber layer is further arranged between the metal layer and the wood veneer layer.

[0009] As a preferred embodiment of the present application, the first fiber layer comprises at least two sub-layers, each of which is provided with the pores, and the pore diameters of adjacent two sub-layers are different.

[0010] As a preferred embodiment of the present application, the wood veneer layer comprises a plurality of wood veneer strips, and a strip gap is arranged between adjacent two wood veneer strips for exposing the metal layer.

[0011] As a preferred embodiment of the present application, a metal strip is arranged in the strip gap, and the metal strip is connected with the metal layer.

[0012] As a preferred embodiment of the present application, the substrate layer is provided with a plurality of grooves, and the first fiber layer comprises an insertion part inserted into the grooves.

[0013] As a preferred embodiment of the present application, the substrate layer is selected from one of a PVC plate, a bamboo-wood fiber plate and a stone-plastic plate.

[0014] As a preferred embodiment of the present application, the first fiber layer is selected from one of a fiber paper and a non-woven fabric.

[0015] As a preferred embodiment of the present application, the metal layer is selected from one of an aluminum foil, a copper foil and a tin foil.

[0016] As a preferred embodiment of the present application, the thickness of the wood veneer layer is 0.25-0.6 mm.

[0017] The present application also aims to provide a preparation method of a solid wood veneer facing panel, comprising the following steps:

[0018] S1. gluing the wood veneer layer, the second adhesive layer, the metal layer, the first adhesive layer and the first fiber layer to obtain a veneer;

[0019] S2. after the substrate layer is inspected, dusted, preheated and coated with a polyurethane adhesive, the veneer is covered on the surface of the substrate layer, and then is pressed by a rubber roller and stacked for aging for 18-30 h;

[0020] S3. The cut-out is trimmed to remove the irregular side edge excess veneer.

[0021] Advantages of the present application:

[0022] 1. The present application provides a solid wood veneer panel, which replaces the single adhesive layer in the traditional veneer panel with a multi-layer structure to improve the connection effect between the substrate layer and the wood veneer layer: in the connecting body, first, a polyurethane adhesive layer is arranged on the substrate layer, the polyurethane adhesive contains a very strong and chemically active isocyanate group and an urethane group, which can react with active hydrogen to form excellent chemical bonding force, suitable for bonding of PVC and other substrate layers, and can be cured at low temperature to avoid the problem of deformation of the substrate layer caused by high temperature. Secondly, a metal layer is arranged between the substrate layer and the wood veneer layer, the metal layer has poor permeability, so the polyurethane adhesive between the substrate layer and the metal layer will not penetrate in a single direction, ensuring the connection balance between the substrate layer and the metal layer. Then a first fiber layer is inserted between the substrate layer and the metal layer, the first fiber layer has a porous structure, which can relieve the problem of cracking or wrinkling caused by the mismatch of the thermal expansion coefficient between PVC and metal; and the first fiber layer has high roughness, pores for adhesive penetration, and is not easy to peel off from the adhesive layer, which will not affect the connection effect between the substrate layer and the metal layer.

[0023] And in the metal layer and the wood veneer layer, the surface energy of the metal is high, so the connection between the metal layer itself and the wood veneer layer is good; in addition, the metal layer can also impart flame retardant properties to the wood veneer layer by virtue of its non-combustibility, and the metal layer also plays a role in structural reinforcement, overcoming the defects of the wood veneer material such as fragility, easy breakage and cracking.

[0024] 2. In an optional embodiment, the wood veneer layer includes a strip gap for the metal layer to be exposed, which is used as a flame-retardant strip, so that after the wood veneer layer is partially burned, the burning area can be prevented from further expanding through the strip gap, thereby having more excellent flame retardancy. On this basis, a metal strip is further arranged in the strip gap to avoid the problem of dust accumulation and difficulty in cleaning.

[0025] 3. In an optional embodiment, the substrate layer includes a groove for the first fiber layer to be inserted, further improving the connection effect between the substrate layer and the first fiber layer.

[0026] 4. The present application provides a preparation method of a solid wood veneer panel, which cooperates with a polyurethane adhesive to realize cold pressing and compounding between the substrate layer and the veneer at room temperature by rolling and stacking and curing, avoiding the influence of high temperature on the substrate layer. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a structural schematic diagram of an embodiment 1 of a solid wood veneer panel;

[0028] Figure 2This is a structural schematic diagram of embodiments 2 and 3 of a solid wood veneer panel;

[0029] Figure 3 This is a structural schematic diagram of embodiments 4, 5, and 6 of a solid wood veneer panel;

[0030] In the figure: substrate layer 1, polyurethane adhesive layer 21, first fiber layer 22, layer 221, insertion part 222, metal layer 23, metal strip 231, second fiber layer 24, wood veneer layer 3, wood veneer strip 31. Detailed Implementation

[0031] The following are specific embodiments of the present invention, and the technical solution of the present invention will be further described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0032] Example 1

[0033] A type of solid wood veneer panel, such as Figure 1 As shown, the material first includes a substrate layer 1, which forms the main body of the board. The substrate layer 1 is generally relatively thick to provide high strength to the board. The substrate layer 1 can be solid or hollow. In some embodiments, when the substrate layer 1 is hollow, several support plates are generally placed inside its cavity to increase its strength. To reduce formaldehyde release, in this embodiment, the substrate layer 1 is made of PVC board, which is generally obtained by heating and melting PVC and then extruding it.

[0034] The PVC substrate layer 1 includes a front and a back side. The front side serves as the decorative surface, and a wood veneer layer 3 is usually bonded to the front side to give the board a wood panel appearance. The wood veneer layer 3 can be a single large piece of wood veneer or it can be made up of several strips of wood veneer spliced ​​together. The thickness of the wood veneer is generally around 0.25-0.6mm.

[0035] To improve the connection between the PVC substrate layer 1 and the wood veneer layer 3, this application provides a connector between the substrate layer 1 and the wood veneer layer 3, such as... Figure 1 As shown, the connector is provided with a polyurethane adhesive layer 21, a first fiber layer 22, a first adhesive layer, a metal layer 23 and a second adhesive layer in sequence along the direction from the substrate layer 1 to the upper veneer layer 3.

[0036] The metal layer 23 refers to a thin metal sheet stretched from metal, which can be any one of aluminum foil, copper foil, or tin foil, or a composite of any two or three of them, such as a composite foil of aluminum foil and copper foil bonded together with an adhesive. In this embodiment, a single aluminum foil is used. The poor permeability of the metal allows the adhesive between the PVC substrate layer 1 and the metal layer 23 to flow and permeate in both directions more evenly and evenly under the pressure of subsequent pressing, avoiding the problem of insufficient adhesion between the adhesive and the structure in the other direction due to the adhesive permeating in only one direction.

[0037] On this basis, the substrate layer 1 and the metal layer 23 are further provided with a first fiber layer 22, which is a mesh structure woven by fibers, and is mainly characterized by a large number of micro-pores. On the one hand, the pores can alleviate the mismatching of the thermal expansion degrees of the PVC substrate layer 1 and the metal layer 23 when the board is heated. On the other hand, when the two surfaces of the first fiber layer 22 are respectively in contact with the adhesive, the adhesive will inevitably flow into the pores of the first fiber layer 22 before solidification. After the adhesive solidifies, the adhesive in the pores solidifies to form reinforced glue and connects with the adhesive layers on both surfaces of the first fiber layer 22. Through the reinforced glue, the contact area between the adhesive layer and the first fiber layer 22 is greatly increased, and the anti-peeling performance between the adhesive layer and the first fiber layer 22 is improved. The first fiber layer 21 can be any one of fiber paper and non-woven fabric, or a superimposed body of fiber paper and non-woven fabric. The fiber paper can be plant fiber paper or synthetic fiber paper. The non-woven fabric is a fiber web structure made of polyester fibers by needle punching process. In this embodiment, polyurethane non-woven fabric is used as the first fiber layer 22.

[0038] The substrate layer 1 and the first fiber layer 22 are connected by a polyurethane adhesive layer 21, which is a structure formed after the polyurethane adhesive solidifies. Before the polyurethane adhesive solidifies, the polyurethane adhesive fluid will flow into the pores of the first fiber layer 22. The polyurethane adhesive contains strong polar isocyanate groups and urethane groups, which can react with active hydrogen to form excellent chemical bonding force. The polyurethane adhesive can use single-component polyurethane adhesive, such as PUR hot melt adhesive, or double-component polyurethane adhesive.

[0039] The first fiber layer 22 and the metal layer 23 are connected by a first adhesive layer. The first adhesive layer can be a structure formed after any adhesive solidifies. Similarly, before the adhesive solidifies, the adhesive fluid will flow into the pores of the first fiber layer 22. In this embodiment, the first adhesive layer uses polyurethane adhesive.

[0040] The metal layer 23 and the wood veneer layer 3 are connected by a second adhesive layer. The second adhesive layer can be a structure formed after any adhesive solidifies. In this embodiment, the second adhesive layer uses polyurethane adhesive.

[0041] In addition, in order to improve the service life of the wood veneer layer 3, a transparent protective layer 4 is usually added on the wood veneer layer 3 to reduce the wear of the wood veneer layer 3 without affecting the decorative effect of the wood veneer layer 3. Transparent paint can be used.

[0042] The above completes the veneer facing of the front surface of the PVC substrate layer 1. The back surface of the PVC substrate layer 1 can be untreated or can be attached with the veneer layer 3 to improve the integrity of the board. The back surface of the substrate layer 1 and the veneer layer 3 can be directly connected by polyurethane adhesive or can be connected by the connecting body. In this embodiment, the back surface of the substrate layer 1 and the veneer layer 3 are connected by polyurethane adhesive.

[0043] The solid wood veneer decorative panel is prepared by the following steps:

[0044] S1. The solid wood veneer strip is spliced according to the requirements of the grain direction and is glued and combined with the aluminum foil to form a whole large wood veneer. The finished product has a width specification of 1220 mm and a length specification according to requirements. In this embodiment, the length specification is 1800 mm, and the wood veneer thickness is 0.25-0.6 mm. Then a non-woven fabric is combined on the aluminum foil bottom layer by adhesive, and finally a transparent paint is coated on the surface of the whole wood veneer to obtain the veneer.

[0045] S2. The substrate layer 1 is inspected, dusted, preheated, and sent to the facing machine to coat the interface agent on the front and back surfaces. First, polyurethane adhesive is coated on the back surface of the substrate layer 1, and ordinary technical wood veneer is attached to the back surface of the substrate layer 1. Rubber roller is pressed and stacked for 24 hours to complete the attachment of the back technical wood veneer. Then, polyurethane adhesive is coated on the front surface of the substrate layer 1, and the veneer is attached to the surface of the substrate layer 1. Rubber roller is pressed and stacked for 24 hours to complete the front solid wood veneer attachment.

[0046] S3. The irregular excess decoration on the side edge is cut off.

[0047] Example 2

[0048] This embodiment is basically the same as example 1, and the difference is only that:

[0049] As shown in Figure 2 , a second fiber layer 24 is further arranged between the metal layer 23 and the wood veneer layer 3, so that the second adhesive layer between the original metal layer 23 and the wood veneer layer 3 includes a first sub-layer between the second fiber layer 24 and the metal layer 23, a second sub-layer between the second fiber layer 24 and the wood veneer layer 3, and a glue filled in the pores of the second fiber layer 24, and the glue is connected with the two sub-layers respectively. The second fiber layer 24 is made of polyurethane non-woven fabric, and the first sub-layer, the second sub-layer and the glue are formed by curing polyurethane adhesive.

[0050] The solid wood veneer decorative panel is prepared by the following steps:

[0051] S1. Impregnate two polyurethane nonwoven fabrics in polyurethane adhesive for later use; lay aluminum foil flat, and then stack a polyurethane nonwoven fabric impregnated with polyurethane adhesive and wood veneer on it in sequence, and press and cure; then turn the resulting pressed body over and lay it flat, and stack another polyurethane nonwoven fabric impregnated with polyurethane adhesive on it, and press and cure; to obtain the veneer.

[0052] Steps S2 and S3 are the same as in Example 1.

[0053] Example 3

[0054] This embodiment is basically the same as Embodiment 1, except that:

[0055] like Figure 2 As shown, the first fiber layer 22 includes two layers 221. The layer 221 closest to the substrate layer 1 and the polyurethane adhesive layer 21 has a density of 1 g / cm³. 3 The fiber paper has small pores; the layer 221 near the metal layer 23 has a density of 0.5 g / cm³. 3 The fiber paper has relatively large pores; the two layers 221 are also connected by polyurethane adhesive.

[0056] This type of solid wood veneer panel is produced through the following steps:

[0057] S1. A substance with a density of 0.5 g / cm³ 3 The fiber paper is impregnated in polyurethane adhesive for later use; after gluing wood veneer to one side of the aluminum foil, it is turned over and laid flat, and layers of polyurethane adhesive-impregnated paper with a density of 0.5 g / cm³ are then stacked on top. 3 The fiber paper has a dry density of 1 g / cm³. 3 The fiber paper is pressed and cured to obtain the veneer.

[0058] Steps S2 and S3 are the same as in Example 1.

[0059] Example 4

[0060] This embodiment is basically the same as Embodiment 1, except that:

[0061] like Figure 3 As shown, the veneer layer 3 includes several veneer strips 31, and there are gaps between two adjacent veneer strips 31 that allow the metal layer 23 to be exposed.

[0062] This type of solid wood veneer panel is produced through the following steps:

[0063] S1. First, lay the metal layer 23 flat, coat the back of the wood veneer strips 31 with adhesive, then place the wood veneer strips 31 on the metal layer 23 in turn, control the gap between the two adjacent wood veneer strips 31, and finally press and bond. Then lay the obtained press-bonded body upside down, coat it with adhesive, cover it with non-woven fabric, press and bond, and obtain the veneer.

[0064] Steps S2 and S3 are the same as in Example 1.

[0065] Example 5

[0066] This example is basically the same as Example 4, except that:

[0067] Considering that only the gap is provided, the gap width is not easy to control, and the gap is easy to enter dust when the board is used, therefore, in this example, the gap is filled with metal strips 231, and the metal strips 231 are connected with the metal layer 23.

[0068] This solid wood veneer panel is prepared by the following steps:

[0069] S1. Prepare the metal layer 23: obtain a metal sheet with a plurality of metal strips 231 thereon by extrusion or other means. Lay the metal sheet flat, coat the surface of the metal sheet and the two side surfaces of the metal strips 231 with adhesive respectively, and the adhesive preferably uses fire-retardant adhesive. Then insert the wood veneer strips 31 between the two adjacent metal strips 231, and finally press and bond. If necessary, the adhesive can be extruded between the metal strips 231 and the wood veneer strips 31 to fill the gap therebetween; the excess adhesive can be removed by a blade after curing. Then lay the obtained press-bonded body upside down, coat it with adhesive, cover it with non-woven fabric, press and bond, and obtain the veneer.

[0070] Steps S2 and S3 are the same as in Example 1.

[0071] Example 6

[0072] This example is basically the same as Example 1, except that:

[0073] As shown in Figure 3 , the substrate layer 1 is provided with a plurality of grooves 11, and the first fiber layer 22 includes an insertion part 222 inserted into the groove 11.

[0074] This solid wood veneer panel is prepared by the following steps:

[0075] S1. The solid wood veneer strips are spliced according to the requirements of the grain direction, and are glued and combined with the aluminum foil to form a whole wood veneer. Transparent paint is applied on the surface of the whole wood veneer to obtain the veneer.

[0076] S2. The substrate layer 1 with the groove 11 structure is obtained by extrusion through a mold, and the substrate layer 1 is inspected, dusted, preheated, and coated with an interface agent on the surface of the substrate layer 1, the groove wall, and the groove bottom.

[0077] The side of the substrate layer 1 with the groove 11 is taken as the front side, and the flat side is taken as the back side. First, glue is applied to the back side of the substrate layer 1, and a common technical veneer is attached to the back side of the substrate layer 1, and the rubber roller is pressed to complete the attachment of the back technical veneer after 24 hours of stacking and aging.

[0078] A pressing mold is prepared, which includes a flat main body and a plurality of insertion blocks arranged on the main body. When the pressing mold is pressed against the front side of the substrate layer 1, the insertion blocks can be inserted into the groove 11. The surface of the main body of the pressing mold and the side surface of the insertion blocks are each provided with a lubricating layer, such as a wax layer. Non-woven fabric is covered on the pressing mold so that the non-woven fabric is attached to the surface of the main body of the pressing mold and the side surface of the insertion blocks, and the ends of the non-woven fabric are fixed to the ends of the pressing mold, respectively.

[0079] The polyurethane adhesive is applied to the front side of the substrate layer 1, the groove wall, and the groove bottom, and then the entire structure of the non-woven fabric and the pressing mold is covered on the substrate layer 1. The pressing mold is pressed with a rubber roller, and after 24 hours of stacking and aging, the non-woven fabric is fixed to the pressing mold, and the pressing mold is slowly removed.

[0080] The adhesive is applied to the surface of the non-woven fabric on the substrate layer 1, and the adhesive is self-leveling so that the recessed part in the insertion part 222 of the non-woven fabric is filled; then the veneer is covered, the rubber roller is pressed, and the stacking and aging is completed for 24 hours to complete the front real wood veneer attachment.

[0081] S3. The irregular excess finish on the side is cut off.

[0082] The specific embodiments described herein are merely illustrative of the spirit of the present application. Those skilled in the art of the present application can make various modifications or supplements to the described specific embodiments or replace them with similar ways, without departing from the spirit of the present application or exceeding the scope defined by the appended claims.

Claims

1. A solid wood veneer faced panel, characterized by: The wood veneer layer (3) is provided with a transparent protective layer (4).

2. A solid wood veneer panel according to claim 1, characterized in that: The metal layer (23) and the wood veneer layer (3) are further provided with a second fiber layer (24).

3. A solid wood veneer panel according to claim 1, characterized in that: The wood veneer layer (3) comprises a plurality of wood veneer strips (31), and a strip gap is provided between two adjacent wood veneer strips (31) for exposing the metal layer (23).

4. A solid wood veneer panel according to claim 1, characterized in that: The strip gap is provided with a metal strip (231), and the metal strip (231) is connected with the metal layer (23).

5. A solid wood veneer panel according to claim 4, wherein: The substrate layer (1) is provided with a plurality of grooves (11), and the first fiber layer (22) comprises an insertion part (222) inserted into the grooves (11).

6. A solid wood veneer panel according to claim 1, wherein: The first fiber layer (22) is selected from one of fiber paper and non-woven fabric.

7. A solid wood veneer panel according to claim 1, wherein: The following steps are included:

8. A method of manufacturing a solid wood veneered panel according to any one of claims 1 to 7, characterized in that: S1. The wood veneer layer (3), the second adhesive layer, the metal layer (23), the first adhesive layer and the first fiber layer (22) are glued to obtain a veneer; S2. After the substrate layer (1) is inspected, dusted, preheated and coated with polyurethane adhesive, the veneer is covered on the surface of the substrate layer (1), and then it is pressed with a rubber roller and stacked for 18-30 hours for aging; S3. The side irregular excess finish is removed. ​

Images