A light-weight super-thick plate

Abstract

The application discloses a kind of light super-thick plate in the field of new material new technology, including plate body, the density of plate is 350-400Kg / m 3 , thickness is 35mm-50mm, plate production raw material selection is pure pine, by once pre-press forming technology, hot-pressing is formed into low-density and super-thick board;In order to solve the problem that the weight of super-thick plate is generally overweight, the purpose of the application is to improve the strength of the plate by thickening design, so as to prevent the deformation of the plate, and once pre-press forming technology is used to prepare low-density super-thick plate, so that the weight of the plate is reduced.

Description

Technical Field

[0001] This invention belongs to the field of new materials and new processes, specifically a lightweight ultra-thick plate. Background Technology

[0002] Originally, "board" referred to solid wood boards used by carpenters for making furniture or other household facilities. Currently, extra-thick furniture boards or door panels produced domestically are generally made of spliced ​​solid wood, thickened medium- and high-density fiberboard (MDF), or spliced ​​plywood. Among these, extra-thick boards made of spliced ​​solid wood have many advantages, such as durability, natural grain, environmental friendliness, and aesthetic appeal. However, these boards consume a lot of raw materials, have a long wood production cycle, and require high-level construction techniques, leading to increased costs. Furthermore, due to variations in wood batches and inadequate drying techniques during production, they are prone to cracking, warping, and insect infestation. Extra-thick boards made of thickened MDF or spliced ​​plywood avoid the problems of high raw material consumption and uneven or unstable wood composition. However, they suffer from poor moisture resistance, weak nail-holding power, poor resistance to deformation, poor structural stability, and generally excessive weight, causing inconvenience for after-sales service and daily use. Therefore, it is necessary to propose a lightweight extra-thick board. Summary of the Invention

[0003] To address the issue of excessive weight in ultra-thick plates, the present invention aims to improve the strength of the plates through thickening design, thereby preventing deformation, and to produce low-density ultra-thick plates using a one-time pre-compression molding technology, thus reducing the weight of the plates.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows: It includes a sheet material body, the density of which is 350-400 kg / m³. 3 The thickness is 35mm-50mm.

[0005] The principle of the basic solution is: by thickening the board material, the strength of the board material is improved, and the density of the board material is reduced during the manufacturing process through pre-compression molding, so that the weight of the board material is controlled while it is thickened.

[0006] Beneficial effects: 1. The thickened design of the board increases its strength and compressive strength, thereby preventing deformation of the board.

[0007] 2. By using pre-compression molding technology to reduce the density of the board during the preparation process, the weight of the board can be controlled while increasing its thickness. This solves the problem of excessive weight of finished products in furniture and door panel production, thus improving the user experience in daily life.

[0008] 3. The lightweight and high-strength properties of the board material are conducive to meeting the modern consumer concept of lightweight and simple luxury, thereby improving the market competitiveness of the board material and increasing the benefits for enterprises.

[0009] Furthermore, the raw material for the board is pure pine wood.

[0010] Beneficial effects: Using local pure pine wood as raw material, which is widely available, inexpensive, and has a short production cycle, helps reduce the cost and price of board production, allowing for large-scale production and use. After the pine wood is chipped and ground again, the resulting wood fibers are mixed with environmentally friendly adhesives. The mixed wood fibers reduce the usage rate of pine wood during hot pressing, thereby effectively reducing the amount of raw materials used and avoiding excessive deforestation, which is beneficial to the protection of the ecological environment.

[0011] Furthermore, the boards are hot-pressed into low-density and ultra-thick boards using a 46.5-meter continuous press through a one-time pre-pressing forming technology.

[0012] Beneficial effects: Due to the thickened design of the sheet material, the opening of ordinary press production lines is limited and cannot reach the set height. Therefore, it is necessary to use the latest generation of extended 46.5-meter continuous presses from abroad to meet the needs of producing thickened products. Furthermore, through the one-time pre-pressing technology of the continuous press, ultra-low density and ultra-thick sheet materials can be produced, thereby improving the strength of the sheet material while controlling its weight to avoid overloading.

[0013] Furthermore, the board material includes a base layer, a support frame, a thermal insulation layer, and a leveling layer, which are symmetrically distributed through the base layer.

[0014] Beneficial effects: The board consists of a base layer, with several support frames bonded to the top and bottom. Insulation layers are installed at both the top and bottom of the base layer, and these insulation layers are bonded to adjacent support frames and the base layer. A leveling layer is bonded to the side of the insulation layer away from the support frames, and a moisture-proof layer is applied to the outside of the leveling layer. The support frame design provides support to the board, enhancing its resistance to deformation, increasing structural stability, and making it more durable. Furthermore, the addition of the insulation layer improves the board's moisture resistance and reduces its heat transfer coefficient, which is beneficial for improving the energy-saving and thermal insulation performance of the building. The insulation layer also provides some sound insulation and fire resistance, enhancing the functionality of the board and bringing convenience to daily use. While maintaining the board's density, its weight is reduced. The leveling layer improves the smoothness of the board's outer surface, allowing for direct veneer decoration and increasing the choice of board materials.

[0015] Furthermore, both the base layer and the leveling layer are made of wood fiber, which is steamed and ground using a hot mill at a temperature of 160℃-190℃.

[0016] Beneficial effects: Using locally sourced pine wood as raw material, the wood is chipped and then processed using a new generation of hot milling machines with appropriate steaming and grinding processes to obtain high-strength wood fibers of a set size. High-temperature and high-pressure treatment of these high-strength wood fibers improves the nail-holding ability of the board, resulting in a board without joints or cracks, with good overall uniformity and enhanced internal bonding strength. During the steaming process, the wood expands due to humidification, causing residual compression deformation that offsets the original residual tensile deformation. After treatment, excess moisture evaporates and shrinks along with the inner wood layers, thus preventing residual deformation and cracking, thereby extending the board's lifespan. Furthermore, because pine wood has a high resin content, which can cause discoloration, reduced adhesive properties, decreased paint adhesion, and surface contamination, the dried pine wood is heat-treated at 160℃-190℃ to degrease it, preventing discoloration and reduced adhesive properties.

[0017] Furthermore, the particle size of the wood fibers in the base layer is larger than that in the leveling layer.

[0018] Beneficial effects: By using wood fibers with small particle size to hot-press into the surface layer of the board, the protruding parts of the support frame are filled in. The width of the filling layer is set, and pressure is applied to it, making the surface of the board smooth and delicate, and easier to coat.

[0019] Furthermore, the interior of the board is formed in one step by hot pressing using environmentally friendly resin adhesive.

[0020] Beneficial effects: While ensuring the performance of the board, the use of environmentally friendly adhesive formulas, such as resin adhesives, improves the bonding strength of the board after hot pressing with wood fibers and ensures the interlacing strength of the wood fibers. The use of environmentally friendly adhesives also helps to reduce the formaldehyde content in the board, thus reducing its harm to the human body. At the same time, the low formaldehyde characteristics of the board meet the modern people's environmental and health consumption concept, thereby improving the market competitiveness of the board and increasing the benefits for enterprises.

[0021] Furthermore, the wood fibers in the base layer are laid out in an oriented manner, and the arrangement direction of the wood fibers is changed sequentially according to the set number of layers.

[0022] Beneficial effects: The wood fibers in the base layer are arranged in a crisscross pattern, which reorganizes the wood grain structure, thereby reducing the impact of internal stress on processing, improving the workability and moisture resistance of the board, and increasing the bonding between the fibers through the crisscrossing, thus strengthening the board's compressive strength and nail-holding power.

[0023] Furthermore, the insulation layer is made of aerogel felt.

[0024] Beneficial effects: Aerogel felt has a thermal insulation effect 2-5 times that of traditional thermal insulation materials, and with the same thermal insulation effect, its thickness is only a fraction of that of traditional materials. It has low heat loss after insulation, and its lightweight and softness allows it to be used in various environments and reduces the overall weight of the board. Aerogel felt is relatively hydrophobic, which can effectively prevent moisture from entering the board, thereby improving the board's waterproofness. In addition, the unique three-dimensional network structure of aerogel avoids the phenomenon of sintering deformation and settlement that occurs in other thermal insulation materials during long-term high-temperature use, which significantly reduces the thermal insulation effect. This improves the service life and fire resistance of the board, making the board more reliable.

[0025] Furthermore, a waterproofing agent is sprayed onto the wood fibers during the laying process, and the fibers are then subjected to pressure treatment together with the waterproofing agent.

[0026] Beneficial effects: When a waterproofing agent is sprayed onto the wood fibers during the installation process, it forms a moisture-proof layer on the surface. By applying pressure through a one-sided pre-pressing process, the waterproofing agent forms a moisture-proof layer on the outside of the board while penetrating into the board due to the pressure, thus achieving a durable crack-resistant effect and extending the service life of the board. Attached Figure Description

[0027] Figure 1 This is a front cross-sectional view of an embodiment of the present invention.

[0028] Figure 2 This is a schematic diagram of the production process according to an embodiment of the present invention.

[0029] Figure 3 for Figure 1 Schematic diagram of raw material processing. Detailed Implementation

[0030] The following detailed description illustrates the specific implementation method:

[0031] The reference numerals in the accompanying drawings of the instruction manual include: base layer 1, support frame 2, insulation layer 3, leveling layer 4, and moisture-proof layer 5.

[0032] Example 1, basically as shown in the attached document. Figure 1-3The diagram illustrates a lightweight, ultra-thick board material, comprising a board body with a density of 350-400 kg / m³ and a thickness of 35-50 mm. The thickened design enhances the board's strength and compressive resistance, preventing deformation. Pre-compression molding technology reduces the board's density during manufacturing, allowing for weight control while maintaining its thickness. This addresses the issue of excessive weight in furniture and door panel production, improving the user experience. The board's lightweight yet high-strength properties are beneficial for... In line with modern people's consumption concepts of lightness, simplicity, and luxury, this enhances the market competitiveness of the board material and increases the company's profits. The raw material for the board material is pure pine wood, using local pure pine wood as the raw material. Its wide availability, low price, and short production cycle help reduce the cost and price of board production, allowing for large-scale production and use. After the pine wood is chipped and ground again, the resulting wood fibers are mixed with environmentally friendly adhesives. The mixed wood fibers reduce the usage rate of pine wood during hot pressing, thereby effectively reducing the amount of raw materials used and avoiding excessive deforestation, which is beneficial to the protection of the ecological environment.

[0033] The boards are internally bonded using environmentally friendly resin adhesives through a single hot-press molding process. This ensures board performance while utilizing environmentally friendly adhesive formulations, such as resin adhesives, to enhance the bonding strength of the boards after hot-pressing with wood fibers, ensuring the interweaving strength of the wood fibers. The use of environmentally friendly adhesives also helps reduce formaldehyde content in the boards, minimizing harm to human health. The low-formaldehyde characteristic of the boards aligns with modern consumers' environmentally conscious and health-conscious consumption concepts, thereby enhancing the boards' market competitiveness and increasing enterprise profits. The boards are produced using a 46.5-meter continuous press with a single pre-pressing technology, hot-pressing them into low-density and ultra-thick sheets. Due to the thickened design of the boards, ordinary press production lines have limited openings and cannot reach the set height. Therefore, the latest generation of extended 46.5-meter continuous presses from abroad are used to meet the production needs of thicker products. The single pre-pressing technology of the continuous press produces ultra-low-density and ultra-thick sheets, thus improving the strength of the boards while controlling their weight to avoid excessive weight.

[0034] The board material comprises a base layer 1, support frames 2, insulation layers 3, and leveling layers 4. The support frames 2, insulation layers 3, and leveling layers 4 are symmetrically distributed through the base layer 1. Several support frames 2 are bonded to the top and bottom of the base layer 1. Insulation layers 3 are also provided at both the top and bottom of the base layer 1, and each insulation layer 3 is bonded to an adjacent support frame 2 and the base layer 1. Leveling layers 4 are bonded to the side of each insulation layer 3 away from the support frames 2. A moisture-proof layer 5 is coated on the outer side of each leveling layer 4. The design of the support frames 2 provides support for the board material, enhancing its resistance to moisture. The enhanced structural stability and improved heat insulation layer 3 make the board more durable. The addition of the insulation layer 3 improves the moisture resistance of the board and reduces the heat transfer coefficient, which helps improve the energy-saving and heat-insulating performance of the house. The insulation layer 3 also has certain sound insulation and fire resistance, which improves the functionality of the board and brings convenience to daily use. While maintaining the density of the board, the weight of the board is reduced. The leveling layer 4 improves the smoothness of the outer surface of the board, which can be directly veneered and decorated, making the board more versatile.

[0035] Both the base layer 1 and the leveling layer 4 are made of wood fiber. The wood fiber is steamed and ground using a hot mill at a temperature of 160℃-190℃. Pine wood is sourced locally as raw material, which is chipped and then processed using a new generation of hot mills with appropriate steaming and grinding processes to obtain high-strength wood fiber of a set size. By subjecting the high-strength wood fiber to high temperature and pressure, the nail-holding ability of the board is improved, and the board is free of joints, cracks, and has good overall uniformity. The internal bonding strength is also improved. During the steaming of the pine wood, the wood expands due to humidification, resulting in residual compression deformation, which offsets the original residual expansion deformation. After treatment, the excess moisture is evaporated and shrinks along with the inner wood layer, thus avoiding residual deformation in the board, preventing cracking, and improving the service life of the board.

[0036] Furthermore, due to the high resin content of pine wood, which can cause discoloration of the board, reduced adhesive properties, decreased paint adhesion, and surface contamination, dried pine wood is heat-treated at 160℃-190℃ to degrease it and prevent discoloration and reduced adhesive properties. The wood fiber particle size of the base layer 1 is larger than that of the leveling layer 4. The smaller wood fiber particle size is used to hot-press the surface layer of the board to level the protruding parts of the support frame 2. The width of the leveling layer 4 is set, and pressure is applied to it to make the board surface smooth and delicate, making it easier to apply a coating.

[0037] The specific implementation process is as follows: Pine wood is sourced locally as raw material, chipped by a chipper, and then sent to a wood chip silo for temporary storage. The wood chips are then processed into wood fibers by a grinder and stored in a timber warehouse along with purchased timber. The wood fibers are then sent to a rotary dryer for drying. After drying, the wood fibers are screened by a oscillating screen. Qualified core and surface dry wood are sent to timber silos for temporary storage, while excessively large wood fibers are crushed or polished before being sorted by the oscillating screen. The sorted wood is then washed and steamed, undergoing high-temperature conditioning to remove pine resin. After this, resin adhesives and wax are applied to allow the wood to bond. Using the latest generation of extended 46.5-meter continuous presses, the glued wood fibers are transported to a paving machine. The paving machine lays out a base layer 1 of a certain thickness. After the base layer 1 is pressed, the bonding between the wood fibers is strengthened, thereby increasing the compressive strength of the board. Several support frames 2 are evenly placed on the top and bottom of the base layer 1, and a heat insulation layer 3 is laid flat on the support frames 2. The top of the heat insulation layer 3 is evenly covered with glued wood fibers. The use of finer wood fibers makes the surface of the board smoother and easier to finish. After the paving is completed, the whole board becomes a flat, continuous, and thick porous board blank. Then, the board blank is formed by a pre-pressing machine through a one-time pre-pressing molding technology, resulting in a bonded board blank with a certain strength and water resistance. The board blank is then sent to the loading machine by the board blank conveyor and the pusher. The loading machine sends the board blank together into the hot press and presses it to a thickness of 35-50mm and a density of 350-400Kg / m³. 3 The rough-edged boards are processed by a hot press. The hot-pressed rough-edged boards are pushed from the loading machine to the unloading machine. The base boards in the unloading machine are then sent to the cooling flipping machine via the unloading conveyor and the infeed roller conveyor. After cooling, the rough-edged boards are sent to the board warehouse for intermediate storage. Then, they are transported to the 12-sanding production line by the outfeed roller conveyor, the centering conveyor, and the roller conveyor to make the surface smoother and more even, ensuring the surface processing performance. They are then sent to the longitudinal and transverse edge sawing machine to be sawn into extra-thick boards of the set size. Finally, they are transported to the hydraulic lifting platform for stacking and then transported by forklift to the extra-thick board warehouse for inspection and grading.

[0038] Example 2

[0039] The difference from the above embodiments lies in that the wood fibers of the base layer 1 are laid out in a directional manner. The arrangement direction of the wood fibers is changed sequentially according to the set number of layers, resulting in a crisscrossing arrangement of the wood fibers in the base layer 1. This reorganizes the wood grain structure, thereby reducing the impact of internal stress on processing and improving the workability and moisture resistance of the board. Furthermore, the crisscrossing of the wood fibers increases the bonding between them, thus strengthening the board's compressive strength and nail-holding power. The insulation layer 3 is made of aerogel felt. Aerogel felt has a thermal insulation effect 2-5 times that of traditional insulation materials, and with the same thermal insulation effect, its thickness is only a fraction of that of traditional materials. It results in minimal heat loss after insulation, and its lightweight and soft nature allows it to be used in various environments while reducing the overall weight of the board. The felt is relatively hydrophobic, effectively preventing moisture from penetrating the board's interior, thus improving its waterproofness. It also boasts fire resistance ranging from B1 to A grades. Furthermore, the unique three-dimensional network structure of aerogel avoids the significant decrease in insulation performance caused by sintering deformation and settling that occurs with other insulation materials during long-term high-temperature use, thereby improving the board's lifespan and fire resistance, resulting in greater reliability. During installation, the wood fibers are sprayed with a waterproofing agent, which is then pressurized together with the agent. The waterproofing agent is sprayed onto the wood fibers during installation, forming a moisture-proof layer 5 on their surface. Through a one-sided pre-pressing process, the waterproofing agent forms a moisture-proof layer 5 on the outside of the board while simultaneously penetrating into the board due to pressure, achieving a durable crack-resistant effect and extending the board's lifespan.

[0040] The specific implementation process is as follows: When laying the base layer 1, the laying direction of the wood fibers is changed sequentially according to the set number of layers, so that the base layer 1 forms a crisscross structure with a certain thickness. After hot pressing, the wood texture structure of the base layer 1 is reorganized, thereby increasing the compressive strength of the board. The material of the insulation layer 3 is aerogel felt, which has the advantages of softness, water repellency, fire resistance, low density and green environmental protection, improving the functionality of the board and giving it certain waterproof, fireproof and sound insulation functions, improving the daily use experience and the durability of the board. After the wood fibers are laid and formed, a waterproofing agent is sprayed on it to form a moisture-proof layer 5 on its surface. Then, the waterproofing agent is penetrated into the interior of the board through hot pressing, thereby increasing the moisture resistance of the board, preventing water penetration into the board, and slowing down the evaporation intensity of the board surface, making the board less prone to cracking and deformation.

[0041] A waterproofing agent is sprayed onto the wood fiber and shavings during the laying process, allowing it to penetrate into the board through a hot press, increasing the board's moisture resistance and reducing its susceptibility to cracking and deterioration. The insulation layer 3 is made of aerogel felt, which possesses advantages such as softness, water repellency, fire resistance, low density, and environmental friendliness, enhancing the board's functionality. This provides the board with waterproofing, fireproofing, and sound insulation, improving the user experience and durability. Furthermore, a waterproof coating is applied to the surface of the extra-thick board after hot pressing, further preventing water penetration and slowing down surface evaporation, thus making the board less prone to cracking and ensuring its lifespan.

[0042] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0043] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics of the solutions are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A lightweight, ultra-thick sheet material, characterized in that: The density of the plate body is 350-400 Kg / m 3 , and the thickness is 35mm-50mm. The board consists of a base layer, a support frame, a thermal insulation layer, a leveling layer, and a moisture-proof layer, which are symmetrically distributed through the base layer. Furthermore, both the base layer and the leveling layer are made of wood fiber, which is steamed and ground using a hot mill at a temperature of 160℃-190℃. The preparation steps for the board are as follows: Pine wood is obtained as raw material, and after being chipped by a chipper, it is sent to a wood chip silo for temporary storage. The wood chips are then sent to a grinder to be processed into wood fibers, which are then stored in a wood warehouse along with purchased timber. The wood fibers are then sent to a rotary dryer for drying. The dried wood fibers are screened by a oscillating screen. Qualified core and surface dry wood are sent to wood silos for temporary storage, while excessively large wood fibers are crushed or polished before being sent back to the oscillating screen for sorting. The sorted wood is then washed and steamed to remove pine resin through high-temperature conditioning. After this process, resin adhesives and wax are applied, using 46... A 0.5-meter continuous press transports the glued wood fibers to the laying machine, which lays a base layer of a certain thickness. Several support frames are evenly placed on top and bottom of the base layer, and an insulation layer is laid flat on the support frames. The glued wood fibers are then evenly laid on top of the insulation layer, resulting in a flat, continuous, and thick porous board. This board is then pre-pressed using a one-time pre-pressing technology to create a bonded board with a certain strength and water resistance. The board is then conveyed by a board conveyor and a pusher into a board loading machine, which together feeds the board into a hot press to press it to a thickness of 35-50mm and a density of 350-400 kg / m³. 3 The rough-edged boards are processed by pushing the already hot-pressed rough-edged boards from the loading machine's pad to the unloading machine. The base boards in the unloading machine are then sent to the cooling flipping machine via the unloading conveyor and the infeed roller conveyor. The rough-edged boards remain in the cooling flipping machine and are then sent to the board warehouse for intermediate storage. They are then transported to the 12-sanding production line by the outfeed roller conveyor, the centering conveyor, and the roller conveyor for sanding. They are then sent to the longitudinal and transverse edge sawing machine to be sawn into extra-thick boards of the set size. Finally, they are transported to the hydraulic lifting platform for stacking and then transported by forklift to the extra-thick board warehouse to await inspection and grading. The base layer of wood fibers is laid out in a directional manner. The arrangement direction of the wood fibers is changed sequentially according to the set number of layers, and the wood fibers of the base layer are arranged in a crisscross pattern to reorganize the wood texture structure. The insulation layer is made of aerogel felt. When the wood fibers are laid out, a waterproofing agent is sprayed on them and they are pressurized together with the waterproofing agent. The waterproofing agent is sprayed on the wood fibers during the laying process to make the surface of the waterproofing agent adhere to form a moisture-proof layer. The wood fibers are then pressurized using a one-sided pre-compression molding technology.

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