A flame-retardant and antioxidant bamboo-wood composite board

Abstract

This invention relates to the field of bamboo-wood-plastic composite board technology, and discloses a flame-retardant and oxidation-resistant bamboo-wood-plastic composite board. The invention includes upper and lower wood-look composite surface layers and an injection-molded adhesive layer connecting the two layers. The wood-look composite surface layer comprises a bamboo-wood-plastic composite surface layer and a flame-retardant adhesive injection layer. The thickness of the bamboo-wood-plastic composite surface layer is at least three times the thickness of the flame-retardant adhesive injection layer. The bamboo-wood-plastic composite surface layer is composed of PVC and solid wood fibers. This invention achieves excellent flame-retardant properties by adding flame-retardant masterbatch, which is hot-melt mixed into the PVC component of the bamboo-wood-plastic composite surface layer, thereby completely encapsulating the solid wood fibers.

Description

Technical Field

[0001] This invention relates to the field of bamboo-wood-plastic composite board technology, and in particular to a flame-retardant and oxidation-resistant bamboo-wood-plastic composite board. Background Technology

[0002] Currently, there are many applications for wood-based panels. The mainstream types on the market are solid wood panels and multi-layer plywood. Solid wood panels are expensive, not environmentally friendly, heavy, require maintenance, and are prone to warping and bulging when exposed to moisture. Multi-layer plywood is cheaper, but its mechanical strength is affected by the process and material selection, resulting in inconsistent quality. Furthermore, the formaldehyde volatilization of plywood poses a significant safety hazard, and it is prone to cracking under high temperatures. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a flame-retardant and antioxidant bamboo-wood-plastic composite board in order to overcome the problems mentioned above.

[0004] The technical problem solved by this invention is achieved through the following technical solution:

[0005] The material employs a multi-layer structure and is heat-melted injection molding material, which is then laminated in multiple layers using a catalytic method. This includes upper and lower wood-look composite surface layers and an injection molding adhesive layer that connects the upper and lower wood-look composite surface layers.

[0006] The wood-look composite surface layer comprises a bamboo-wood-plastic composite surface layer and a flame-retardant adhesive injection molding layer. The thickness of the bamboo-wood-plastic composite surface layer is at least three times the thickness of the flame-retardant adhesive injection molding layer. The bamboo-wood-plastic composite surface layer is composed of PVC and solid wood fibers. The PVC granules are melted by an injection molding machine and injected into a customized mold. A material addition module is provided at the end of the extrusion port of the injection molding machine to add solid wood fibers into the PVC melt so that they are combined into one. The mass fraction ratio of PVC to solid wood fibers in the bamboo-wood-plastic composite surface layer is 1-3:7-9. When the user needs a higher degree of wood-look imitation, the mass fraction ratio of PVC to solid wood fibers can be 2:9. When the user needs better comprehensive mechanical properties, comprehensive toughness, and surface strength, the mass fraction ratio of PVC to solid wood fibers can be 3:7.

[0007] In addition, to increase flame retardancy, flame retardant masterbatch is added to the bamboo-wood-plastic composite surface layer and is hot-melted and mixed into the PVC component of the bamboo-wood-plastic composite surface layer. Good flame retardant performance is achieved by completely wrapping the solid wood fibers.

[0008] The injection-molded adhesive layer is a core board, mainly used for support on non-contact surfaces. The injection-molded adhesive layer is formed by hot-melting PVC particles and mixing them with porous bamboo particles, then curing them in a mold. Blind holes are provided on the surface of the porous bamboo particles. These blind holes help to quickly improve the integrity and mechanical properties of the injection-molded adhesive layer. The top and bottom surfaces of the injection-molded adhesive layer also have pure PVC layers with the same thickness as the flame-retardant adhesive injection layer.

[0009] After two wood-look composite surface layers and one injection-molded adhesive layer are prepared, molded, and cured, they are hot-pressed together using multiple bamboo grafting clips. First, the upper and lower ends of the injection-molded adhesive layer and the flame-retardant adhesive injection layer are brought to a semi-melted state under high temperature and pressure using equipment. Then, I-shaped bamboo grafting clips are placed between the two and flattened using a hot press, so that the bamboo grafting clips are grafted and cured within the overlapping layer of the flame-retardant adhesive injection layer. After cooling, the excess overflow at the edges is cut off to complete the product. Compared with solid wood boards, this board has similar structural strength and mechanical properties, but at a much lower cost. It is also lightweight and easy to install, has excellent flame retardant properties, is not prone to warping or moisture damage, and has good surface oxidation resistance. In addition, the multi-layer grafting structure design and porous bamboo particles effectively reduce resonance, resulting in good sound insulation.

[0010] For outdoor applications, bamboo fiber powder can be added to the bamboo-wood-plastic composite surface layer. The mass percentage of the bamboo fiber powder shall not exceed 15% of the total mass. Within this range, the higher the mass percentage of the bamboo fiber powder, the better its surface hardness and anti-slip performance, but its noise reduction and surface toughness will be reduced.

[0011] For better economic efficiency, the lower wood-look composite surface layer can be replaced with a board made of PVC and bamboo fiber particles that have been heat-fused and cured. The bamboo fiber particles have a particle size between three and eight millimeters. This can further reduce costs while maintaining essentially the same performance, except that its compressive strength decreases slightly in high humidity environments. However, the board's strength can be increased by cold-rolling hexagonal countersunk holes at intervals on the lower end of the board made of PVC and bamboo fiber particles that have been heat-fused and cured. This increases the local structural density and thus the board's strength, although it will reduce the sound insulation performance. Nevertheless, its sound insulation performance is still higher than that of traditional solid wood boards or plywood. Furthermore, this board is formed by high-pressure heat fusion using a catalytic method, which avoids the use of glue and is more environmentally friendly and safer than plywood, as it contains no formaldehyde.

[0012] The advantages and positive effects of the present invention are: flame retardant masterbatch is added to the bamboo-wood-plastic composite surface layer and is hot-melted and mixed in the PVC component of the bamboo-wood-plastic composite surface layer, thereby achieving good flame retardant performance by completely wrapping the solid wood fibers.

[0013] Compared to solid wood boards, this board has similar structural strength and mechanical properties, but at a much lower cost. It is also lightweight and easy to install, with excellent flame retardant properties. It is not prone to warping or bulging due to moisture, and has good surface oxidation resistance. Furthermore, the multi-layer grafting structure design and porous bamboo particles effectively reduce resonance and provide good sound insulation.

[0014] Furthermore, this board is formed by high-pressure hot-melt molding using a catalytic method, which avoids the use of glue. Compared with glued plywood, it is more environmentally friendly and safe, and contains no formaldehyde. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0016] Figure 1 This is a schematic diagram of the cross-sectional structure of the present invention. Detailed Implementation

[0017] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention. The embodiments of the invention are further described in detail below with reference to the accompanying drawings:

[0018] like Figure 1 As shown, the present invention provides a flame-retardant and oxidation-resistant bamboo-wood-plastic composite board.

[0019] The multi-layer structure is adopted and the injection molding material is hot melted and then pressed into multiple layers by a catalyst method. This includes the wood-like composite surface layer 19 located on the upper and lower layers and the injection molding adhesive layer 13 connecting the upper and lower wood-like composite surface layers 19.

[0020] The wood-look composite surface layer 19 includes a bamboo-wood-plastic composite surface layer 10 and a flame-retardant adhesive injection molding layer 11. The thickness of the bamboo-wood-plastic composite surface layer 10 is at least three times the thickness of the flame-retardant adhesive injection molding layer 11. The bamboo-wood-plastic composite surface layer 10 is composed of PVC granules and solid wood fibers 17. The PVC granules are injected into a customized mold after being melted by an injection molding machine. A material addition module is provided at the end of the extrusion port of the injection molding machine to add solid wood fibers 17 into the PVC melt so that they are combined into one. The mass fraction ratio of PVC to solid wood fibers 17 in the bamboo-wood-plastic composite surface layer 10 is 1-3:7-9. When the user needs a higher degree of wood-look imitation, the mass fraction ratio of PVC to solid wood fibers 17 can be 2:9. When the user needs better comprehensive mechanical properties, comprehensive toughness and surface strength, the mass fraction ratio of PVC to solid wood fibers 17 can be 3:7.

[0021] In addition, to increase flame retardancy, flame retardant masterbatch is added to the bamboo-wood-plastic composite surface layer 10 and is hot-melted mixed in the PVC component of the bamboo-wood-plastic composite surface layer 10. Good flame retardant performance is achieved by completely wrapping the solid wood fiber 17.

[0022] The injection-molded adhesive layer 13 is a core board, mainly used for support on non-contact surfaces. The injection-molded adhesive layer 13 is formed by hot-melting PVC particles and mixing them with porous bamboo particles 14, and then curing them in a mold. Blind holes are provided on the surface of the porous bamboo particles 14. The blind holes on the surface of the porous bamboo particles 14 help to quickly improve the integrity and mechanical properties of the injection-molded adhesive layer 13 in terms of compression and bending resistance. The upper and lower surfaces of the injection-molded adhesive layer 13 also have pure PVC layers with the same thickness as the flame-retardant adhesive injection layer 11.

[0023] After two wood-look composite surface layers 19 and one injection-molded adhesive layer 13 are prepared and cured, they are hot-pressed together using multiple bamboo grafting buckles 12. First, the upper and lower ends of the injection-molded adhesive layer 13 and the flame-retardant adhesive injection layer 11 are brought to a semi-melted state under high temperature and pressure using equipment. Then, the I-shaped bamboo grafting buckles 12 are placed between the two and flattened using a hot press, so that the bamboo grafting buckles 12 are grafted and cured in the overlapping layer of the flame-retardant adhesive injection layer 11. After cooling, the excess overflow at the edges is cut off to form the final product. Compared with solid wood boards, this board has similar structural strength and mechanical properties, and is much cheaper. In addition, it is lightweight and easy to lay. It also has good flame retardant properties, is not easy to warp or bulge due to moisture, and has good surface oxidation resistance. Furthermore, the multi-layer grafting structure design and the porous bamboo particles 14 can effectively reduce resonance and have a good sound insulation effect.

[0024] For outdoor applications, bamboo fiber powder 18 can be added to the bamboo-wood-plastic composite surface layer 10. The mass percentage of bamboo fiber powder 18 shall not exceed 15% of the total mass. Within this range, the higher the mass percentage of bamboo fiber powder 18, the better its surface hardness and anti-slip performance, but its noise reduction and surface toughness will be reduced.

[0025] For better economic efficiency, the lower wood-look composite surface layer 19 can be replaced with a board made of PVC and bamboo fiber particles 15 that have been heat-fused and cured. The particle size of the bamboo fiber particles 15 is between three and eight millimeters. This can further reduce costs while maintaining essentially the same performance. The only slight decrease in its compressive strength is under high humidity conditions. However, the strength of the board can be improved by cold-rolling hexagonal countersunk holes at intervals on the lower end of the board made of PVC and bamboo fiber particles 15 that have been heat-fused and cured. This increases the local structural density and thus the strength of the board. However, this will reduce the sound insulation performance, but it is still better than traditional solid wood boards or plywood. Furthermore, this board is formed by high-pressure hot-melt molding using a catalytic method, which avoids the use of glue and is more environmentally friendly and safer than plywood, as it contains no formaldehyde.

[0026] It should be emphasized that the embodiments described in this invention are illustrative rather than limiting. Therefore, this invention is not limited to the embodiments described in the specific implementation. Any other implementation methods derived by those skilled in the art based on the technical solutions of this invention also fall within the scope of protection of this invention.

Claims

1. A flame-retardant and antioxidant bamboo-wood-plastic composite board, characterized in that: This includes the wood-look composite surface layer (19) located on the upper and lower layers and the injection-molded adhesive layer (13) that connects the upper and lower wood-look composite surface layers (19). The wood-look composite surface layer (19) includes a bamboo-wood-plastic composite surface layer (10) and a flame-retardant adhesive injection molding layer (11), wherein the thickness of the bamboo-wood-plastic composite surface layer (10) is at least three times the thickness of the flame-retardant adhesive injection molding layer (11). The bamboo-wood-plastic composite surface layer (10) is composed of PVC particles and solid wood fibers (17). The PVC particles are injected into a customized mold after being melted by an injection molding machine. A material addition module is provided at the end of the extrusion port of the injection molding machine to add solid wood fibers (17) into the PVC melt so that they are combined into one. The mass fraction ratio of PVC to solid wood fibers (17) in the bamboo-wood-plastic composite surface layer (10) is 1-3:7-9. Flame retardant masterbatch is also added to the bamboo-wood-plastic composite surface layer (10) and is melted and mixed in the PVC component of the bamboo-wood-plastic composite surface layer (10) to completely encapsulate the solid wood fibers (17). The injection molding adhesive layer (13) is a core board. The injection molding adhesive layer (13) is made by melting PVC particles and mixing them with porous bamboo particles (14) in the mold. The process involves curing and molding, wherein blind holes are provided on the surface of the porous bamboo particles (14), and the upper and lower surfaces of the injection molding adhesive layer (13) are also provided with pure PVC layers of the same thickness as the flame-retardant adhesive injection molding layer (11). After the two imitation wood composite surface layers (19) and one injection molding adhesive layer (13) are prepared, molded, and cured, they are hot-pressed together by multiple bamboo grafting buckles (12). First, the upper and lower end faces of the injection molding adhesive layer (13) and the flame-retardant adhesive injection molding layer (11) are in a semi-melted state under high temperature and high pressure by the equipment. Then, the I-shaped bamboo grafting buckle (12) is placed between the two, and then flattened by the hot press, so that the bamboo grafting buckle (12) is grafted and cured in the overlapping layer of the flame-retardant adhesive injection molding layer (11). After cooling, the excess overflowing part at the edge is cut off to form the product.

2. The flame-retardant and antioxidant bamboo-wood composite board according to claim 1, characterized in that: The mass fraction ratio of PVC to the solid wood fiber (17) is 2:

9.

3. The flame-retardant and antioxidant bamboo-wood composite board according to claim 1, characterized in that: The mass fraction ratio of PVC to the solid wood fiber (17) is 3:

7.

4. The flame-retardant and antioxidant bamboo-wood composite board according to claim 1, characterized in that: Bamboo fiber powder (18) is added to the bamboo-wood-plastic composite surface layer (10), and the mass percentage of the bamboo fiber powder (18) does not exceed 15 percent of the total mass.

5. The flame-retardant and antioxidant bamboo-wood composite board according to claim 4, characterized in that: Bamboo fiber powder (18) is added to the bamboo-wood-plastic composite surface layer (10), and the mass percentage of the bamboo fiber powder (18) does not exceed nine percent of the total mass.

6. The flame-retardant and antioxidant bamboo-wood composite board according to claim 5, characterized in that: Replace the lower wood-look composite surface layer (19) with a board made of PVC and bamboo fiber particles (15) that has been heat-melted and cured.

7. The flame-retardant and antioxidant bamboo-wood composite board according to claim 6, characterized in that: The particle size of the bamboo fiber particles (15) is between three and eight millimeters.

Images