A method for preparing honeycomb bamboo board

Abstract

This invention discloses a method for preparing a honeycomb bamboo board, relating to the field of packaging material production technology. The honeycomb bamboo board comprises upper and lower face panels and a honeycomb core layer located between the upper and lower face panels, the honeycomb core layer being composed of honeycomb units. The preparation method includes the following steps: after applying adhesive to the upper and lower surfaces of the honeycomb core layer, the upper and lower face panels are respectively placed on the honeycomb core layer, and then cold-pressed; the edges of the cold-pressed honeycomb bamboo board are trimmed, and its surface is ground and polished. This invention provides a method for preparing a honeycomb bamboo board, the resulting honeycomb bamboo board possessing high strength, good cushioning performance, and environmentally friendly characteristics, thereby solving the problems of insufficient strength, cushioning performance, and environmental friendliness in existing packaging materials, and providing the packaging industry with a new, high-performance packaging material solution.

Description

Technical Field

[0001] This invention relates to the field of packaging material production technology, and in particular to a method for preparing honeycomb bamboo panels for packaging. Background Technology

[0002] In modern commerce and logistics, packaging materials play a crucial role. While traditional packaging paperboard, such as corrugated cardboard, is widely used, its limitations are becoming increasingly apparent as market demands for packaging performance rise. The strength of corrugated cardboard often falls short of providing sufficient protection for heavier, fragile products or those requiring high cushioning performance. Furthermore, corrugated cardboard is prone to moisture damage and deformation in humid environments, affecting its packaging performance and lifespan. Simultaneously, with increasing environmental awareness, consumers and businesses are placing higher demands on the environmental friendliness of packaging materials. Traditional packaging materials such as foam plastics, due to their difficulty in degradation and significant environmental pollution, are gradually being restricted and phased out. Therefore, developing a new type of packaging material that combines high strength, good cushioning performance, and environmental degradability has become an urgent need for the industry.

[0003] Bamboo is a natural, renewable resource with rapid growth and wide distribution. Bamboo possesses high strength and toughness, and its fibrous structure gives it considerable resistance to compression and bending. Applying bamboo to packaging not only fully utilizes its excellent properties but also reduces reliance on traditional resources like wood and plastics, aligning with the concept of sustainable development. Currently, the application of bamboo in packaging is not fully realized. While some bamboo packaging products exist, most simply utilize the original shape of bamboo or undergo preliminary processing, failing to meet the protective performance and standardization requirements of modern logistics and commodity packaging. Flattened bamboo slices, as a processed bamboo product, retain the natural texture and fibrous characteristics of bamboo, offering excellent appearance and physical properties. Inspired by honeycomb cardboard, if bamboo could be made into a similar honeycomb structure, combined with the inherent advantages of bamboo, it holds promise for developing a superior packaging material that overcomes the shortcomings of traditional packaging materials and meets the market's demand for high-performance packaging materials. Summary of the Invention

[0004] This invention provides a method for preparing honeycomb bamboo panels. The honeycomb bamboo panels prepared by this method have high strength, good cushioning performance and environmental protection characteristics, thereby solving the problems of insufficient strength, cushioning performance and environmental protection of existing packaging materials, and providing the packaging industry with a new type of high-performance packaging material solution.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] The honeycomb bamboo panel includes upper and lower panels and a honeycomb core layer located between the upper and lower panels, the honeycomb core layer being composed of honeycomb units;

[0007] Its preparation method includes the following steps:

[0008] A. After applying adhesive to the upper and lower surfaces of the honeycomb core layer, cover the upper and lower panels onto the honeycomb core layer respectively, and then cold press;

[0009] B. Trim the edges of the honeycomb bamboo board obtained after cold pressing, and grind and polish its surface.

[0010] A more specific technical solution than the above could be: the specific preparation method includes the following steps:

[0011] (1) After applying adhesive to the upper and lower surfaces of the honeycomb core layer, cover the upper and lower panels onto the honeycomb core layer respectively, and place them in a cold press and cold press for 1 to 2 hours under a pressure of 0.1 to 0.2 MPa. During the cold pressing process, ensure that the pressure is stable and the panels are placed correctly.

[0012] (2) Trim the edges of the honeycomb bamboo board obtained after cold pressing, and control the dimensional error within ±0.8mm. Then grind and polish the surface, using 80 grit, 120 grit and 240 grit sandpaper in sequence.

[0013] Furthermore, the panel is a flattened bamboo slicing, and the preparation method of the flattened bamboo slicing includes the following steps:

[0014] (1) Select bamboo with an age of 3 to 5 years, a diameter at breast height of 10 cm, a wall thickness of 8 to 10 mm, and no obvious cracks or insect infestation, and process it into bamboo tubes 100 to 150 cm long;

[0015] (2) Soften the bamboo tubes at a temperature of 160-180℃ and a pressure of 1.0-1.5MPa for 5-8 minutes. After softening, the bamboo tubes are flattened, the green and yellow parts are removed, and flattened bamboo is obtained by using a flattening device.

[0016] (3) Apply glue to one side of the flat bamboo facing up, with an amount of glue of 150-200 g / m², and then press it under a pressure of 0.5-1.0 MPa for 1-2 hours to obtain flat bamboo laminate.

[0017] (4) Apply glue to the side of the flat bamboo plywood along its length, and then bond it under a pressure of 0.5-1.0 MPa for 1-2 hours to obtain a large-size flat bamboo plywood with a length of 200-500 cm and a width of 100-300 cm. Cut the large-size flat bamboo plywood into thin sheets with a thickness of 0.5-2.0 mm.

[0018] Furthermore, the honeycomb core layer is formed by rolling and splicing flattened bamboo slicing sheets into thin sheets, and the preparation method of the flattened bamboo slicing sheets into thin sheets includes the following steps:

[0019] (1) Select bamboo with an age of 3 to 5 years, a diameter at breast height of 10 cm, a wall thickness of 8 to 10 mm, and no obvious cracks or insect infestation, and process it into bamboo tubes 100 to 150 cm long;

[0020] (2) Soften the bamboo tubes at a temperature of 160-180℃ and a pressure of 1.0-1.5MPa for 5-8 minutes. After softening, the bamboo tubes are flattened, the green and yellow parts are removed, and flattened bamboo is obtained by using a flattening device.

[0021] (3) Use a slicing machine to slice individual flat bamboo into thin slices with a thickness of 0.3 to 0.5 mm;

[0022] (4) After the obtained thin sheet is finger-jointed, it is prepared into flat bamboo slicing thin sheet roll material by rolling machine. Then, according to the size of the target product, the flat bamboo slicing thin sheet roll material is cut into fixed widths of 5-10mm using cutting equipment.

[0023] Furthermore, the method for preparing the honeycomb core layer includes the following steps:

[0024] (1) Apply glue to one side of the flattened bamboo slices and rolls of a fixed width, with an glue application amount of 60-100 g / m. 2 A layer of release agent is applied to the surface of the mold, and then the bamboo slices are flattened and rolled around the mold. The rolling speed is controlled between 5 and 10 m / min to finally obtain the honeycomb unit.

[0025] (2) The prepared honeycomb units are spliced ​​together. During the splicing process, a special positioning fixture is used to ensure the neatness of the honeycomb units.

[0026] Furthermore, the cellular unit is a regular hexagonal cellular unit.

[0027] Furthermore, after the honeycomb units are manufactured, they are inspected using a combination of visual inspection system and manual touch inspection. After the honeycomb core layers are spliced, a sampling tensile test is used to test the bonding strength.

[0028] Furthermore, after the panel and the honeycomb core layer are laminated, the bonding strength is tested through a peel test.

[0029] Furthermore, during the post-processing sanding of the honeycomb bamboo panels, the surface of the panels is cleaned between each sanding step, and the sanding force and speed are controlled.

[0030] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0031] 1. High Strength and Excellent Cushioning Performance: The honeycomb structure combined with the strength advantages of bamboo gives the honeycomb bamboo board of this invention excellent compression resistance, impact resistance, and cushioning performance. Tests show that the compressive strength of the honeycomb bamboo board of this invention is more than 50% higher than that of traditional corrugated cardboard of the same thickness, effectively withstanding and dispersing external forces, protecting the contents of the packaged item from impact and compression. In simulated drop tests, the damage rate of products packaged with honeycomb bamboo boards is significantly reduced.

[0032] 2. Environmental Protection and Sustainable Development Characteristics: Bamboo is a renewable resource, reducing environmental pollution. Honeycomb bamboo panels are biodegradable after disposal, aligning with the environmental development trend of modern packaging materials. This helps companies enhance their environmental image and meet consumers' demand for green packaging.

[0033] 3. Excellent moisture-proof performance: Compared with traditional honeycomb paperboard, the honeycomb bamboo board of this invention has better moisture-proof performance due to the inherent characteristics of bamboo. The fiber structure of bamboo is relatively dense, and its water absorption is weaker than that of paper, which can resist the effects of humid environments to a certain extent.

[0034] 4. Aesthetics and Applicability: Flattened bamboo slicing retains the natural, beautiful texture of bamboo, enhancing the packaging's grade and visual appeal. It is suitable for various products with high aesthetic requirements, such as high-end electronics and gifts. Furthermore, it can be customized to fit different product packaging sizes and shapes, demonstrating strong adaptability. Attached Figure Description

[0035] Figure 1 Large-sized flat bamboo plywood for panel slicing.

[0036] Figure 2 Diagram showing the process of finger-jointing bamboo slices to flatten them.

[0037] Figure 3 This is a diagram illustrating the process of rolling up a cellular cell.

[0038] Figure 4 This is a top view of the honeycomb core layer.

[0039] Figure 5 This is a schematic diagram of the composite structure of the face panel and the honeycomb core layer of a honeycomb bamboo panel.

[0040] Among them, number 1 - flattened bamboo, 2 - flattened bamboo slices, 3 - regular hexagonal mold, 4 - flattened bamboo slices rolls, 5 - honeycomb unit, 6 - honeycomb core layer, and 7 - panel. Detailed Implementation

[0041] The invention will be further described in detail below with reference to examples;

[0042] A method for preparing a honeycomb bamboo board includes the following steps:

[0043] 1. Material preparation and processing, and preparation of flattened bamboo

[0044] (1) Purchase bamboo with an age of 3-5 years, a diameter at breast height of 10 cm, and a wall thickness of 8-10 mm. The surface of the bamboo should be free of obvious cracks, insect infestation, or other defects. After the purchased bamboo is transported to the processing workshop, it is processed into bamboo tubes of a certain length using professional cutting equipment, generally between 100 and 150 cm. During the cutting process, it is necessary to ensure that both ends of the bamboo tube are flat and the length error is controlled within ±1 cm.

[0045] (2) Place the processed bamboo tubes into a high-temperature, high-pressure softening device. The softening temperature is 160–180℃, the softening pressure is 1.0–1.5 MPa, and the softening time is 5–8 minutes. During the softening process, the temperature change should be monitored in real time to ensure that the temperature fluctuates within the set range. At the same time, observe the softening state of the bamboo tubes. When the surface color of the bamboo tubes slightly darkens and the texture softens but still maintains a certain degree of shape integrity, it indicates that the softening effect has been achieved. Send the softened bamboo tubes into a flattening device for flattening, removing the green and yellow parts.

[0046] (3) The flattened bamboo is sent to a plate dryer for drying to prevent the flattened bamboo from shrinking. The moisture content of the dried bamboo is 9-11%.

[0047] (4) The flatness of the bamboo after it is flattened should be tested, and the flatness error should be controlled within ±0.5mm.

[0048] 2. Preparation of bamboo slicing thin sheets after flattening the panel

[0049] (1) Applying adhesive to the bamboo green surface and laminating (first bonding)

[0050] Select qualified flattened bamboo and clean its surface to remove impurities, dust, and other factors that may affect the bonding quality. Place the flattened bamboo with the green side facing up on the gluing worktable and apply the adhesive evenly using precise gluing equipment. The amount of adhesive applied is controlled according to the surface characteristics of the flattened bamboo, generally 150-200 g / m². 2 During the adhesive application process, ensure that the adhesive covers the entire bamboo surface to avoid missed areas or uneven adhesive thickness.

[0051] The coated bamboo is stacked in the thickness direction according to the designed number of layers. During stacking, each layer of bamboo must be aligned to avoid misalignment. The stacked bamboo is then placed in a laminator, with the pressure controlled between 0.5 and 1.0 MPa, and maintained for 1 to 2 hours to allow the adhesive to fully cure, resulting in a bamboo laminate. After lamination, the bamboo laminate is preliminarily inspected, including checking for surface flatness and delamination. Laminates that do not meet quality requirements are promptly rejected.

[0052] (2) Flatten the bamboo laminate and glue the sides together (second gluing)

[0053] Apply adhesive evenly to the sides along the length of the prepared, flattened bamboo laminate, typically at a rate of 150–200 g / m². 2 The bamboo plywood is then fed into a lateral press for side bonding. The pressure applied by the press is controlled at 0.5–1.0 MPa and maintained for 1–2 hours to allow the adhesive to fully cure, resulting in large-sized flat bamboo plywood. The dimensions are determined according to actual product requirements, generally between 200–500 cm in length and 100–300 cm in width. The final flat bamboo plywood undergoes comprehensive quality inspection, including thickness measurement and flatness checks, to ensure it meets the requirements for subsequent panel processing.

[0054] (3) Large-size flat bamboo plywood slicing

[0055] Large-sized, flattened bamboo plywood sheets are fixed onto a precision slicing machine. Slicing parameters are adjusted according to the designed panel sheet thickness to obtain panel sheets with a final thickness of 0.5–2.0 mm. During the slicing process, the uniformity of the sheet thickness must be ensured, with a thickness error controlled within ±0.1 mm. The sliced ​​panel sheets must be stored properly to avoid scratches, contamination, or other damage.

[0056] 3. Preparation of honeycomb core layer flattened bamboo slices and rolls

[0057] (1) Fix a single flat bamboo on the worktable of a high-precision slicing machine. Adjust the height and cutting angle of the slicing blade according to the designed sheet thickness, and control the slicing speed to 2-5 m / min. Finally, obtain flat bamboo sheets with a thickness of 0.3-0.5 mm. The flat bamboo sheets obtained by slicing need to be sorted to remove damaged or defective products.

[0058] (2) The flattened bamboo sheets obtained from slicing are then finger-jointed on a finger-jointing machine. Before finger-jointing, the ends of the sheets must be finely processed to ensure a good fit. During the finger-jointing process, environmentally friendly adhesives are used. The adhesive should be applied evenly, and the amount of adhesive applied depends on the finger-jointing area and the properties of the adhesive, generally 100-200 g / m². 2The finger-jointed sheets are cured in an environment with a temperature of 20-25℃ and a relative humidity of 50-60%. During the curing process, external factors must be prevented from interfering with the adhesive curing to ensure the strength of the finger joints. The finger-jointed sheets require quality inspection, checking the strength of the finger joints and the overall flatness. The strength should meet the requirements of subsequent processing. The finger-jointed sheets are then prepared into flattened bamboo slicing sheets using a rolling machine. These sheets are then cut to a fixed width, typically 5-10mm, using high-precision cutting equipment according to the dimensions of the target product. This fixed-width cutting of the flattened bamboo slicing sheets meets the length and width requirements for subsequent honeycomb core layer fabrication.

[0059] 4. Preparation of the honeycomb core layer

[0060] (1) Fabrication of cellular units

[0061] Apply adhesive to one side of the flattened bamboo slices / rolls of a fixed width, with an adhesive application rate of 60–100 g / m. 2 A release agent is applied to the surface of a specially made hexagonal mold. Then, thin sheets of bamboo are flattened and rolled around the mold at a speed controlled between 5 and 10 m / min to obtain the honeycomb cells. After rolling, the mold is removed, and the honeycomb cells are preliminarily inspected to check if the shape is hexagonal, the wall thickness is uniform, and the bonding is firm. This can be done using a combination of visual inspection and manual touch inspection. Defective honeycomb cells should be discarded promptly.

[0062] (2) splicing of honeycomb core layers

[0063] The fabricated honeycomb cells are assembled on a splicing workbench according to a predetermined arrangement. During the splicing process, specialized positioning fixtures are used to ensure the neatness of the honeycomb cells. The adhesive used for splicing must be compatible with the adhesive used during the fabrication of the honeycomb cells to ensure good bonding. After applying the adhesive, adjacent honeycomb cells should be quickly spliced ​​together and secured using a special fixing device to prevent displacement of the honeycomb cells before the adhesive cures. After curing for 30–60 minutes, the fixing device is removed, and a comprehensive inspection of the honeycomb core layer is conducted, including the arrangement of the honeycomb cells and the bonding strength between them. A sampling tensile test can be used to test the bonding strength, which should meet the design requirements.

[0064] 5. Panel and honeycomb core layer composite

[0065] Apply adhesive evenly to both the upper and lower surfaces of the prepared honeycomb core layer. Strictly control the amount of adhesive used during application to avoid excessive seepage. After adhesive application, flatten bamboo slices are laid flat on the honeycomb core layer as panels. The composite board is then placed in a cold press for pressure treatment. The cold pressing pressure is 0.1–0.2 MPa, and the cold pressing time is 1–2 hours. Maintain stable pressure during cold pressing and pay attention to the placement of the boards to avoid external interference. After cold pressing, inspect the boards for quality, checking the adhesion between the panels and the honeycomb core layer. This can be done through peel tests to ensure the bonding strength meets requirements.

[0066] 6. Post-processing of honeycomb bamboo panels

[0067] The surface of the board is sanded using a multi-pass sanding process. First, 80-grit sandpaper is used for initial sanding, maintaining a consistent sanding direction to remove surface unevenness and impurities. Then, 120-grit and 240-grit sandpaper are used for further sanding. The board surface should be cleaned between each sanding pass to prevent sandpaper clogging. During sanding, the sanding pressure and speed must be controlled to avoid over-sanding, which can lead to uneven board thickness or surface damage. The sanding effect is assessed through a combination of visual and tactile inspection until the board surface is smooth, flat, and free of burrs and unevenness.

[0068] Furthermore, if it is necessary to print logos, patterns, or other information on the surface of honeycomb panels, environmentally friendly inks and advanced printing equipment should be prioritized. Before printing, the ink's adhesion, water resistance, and abrasion resistance should be tested to ensure compliance with packaging printing standards. The printing equipment must be able to precisely control the ink application rate and the clarity of the printed pattern. During the printing process, the printing quality should be monitored in real time, and the integrity, clarity, and color accuracy of the printed pattern should be checked using a visual inspection system. Panels with substandard printing quality should be reprinted or treated. Simultaneously, attention should be paid to the drying process after printing. Appropriate drying methods (such as natural drying or hot air drying) should be selected based on the characteristics of the ink to ensure that the ink is fully dried and firmly adheres to the surface of the honeycomb bamboo panel.

[0069] If the honeycomb bamboo panel is used as packaging material for a specific product and the customer has specific requirements, it can be integrated with the product packaging design for customized packaging. For example, for packaging some high-end electronic products, the honeycomb bamboo panel can be made into a specially shaped liner, allowing the product to be directly embedded in the packaging, improving both convenience and aesthetics. In this case, attention must be paid to the compatibility between the honeycomb bamboo panel and the product, as well as the cushioning design, to ensure the stability and safety of the product within the packaging.

[0070] It should be noted that the above embodiments are used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing a honeycomb bamboo board, characterized in that: The honeycomb bamboo board includes upper and lower panels and a honeycomb core layer located between the upper and lower panels, wherein the honeycomb core layer is composed of honeycomb units. The honeycomb core layer is formed by rolling and splicing flattened bamboo slicing sheets into thin sheets. The preparation method of the flattened bamboo slicing sheets includes the following steps: (1) Select bamboo with an age of 3 to 5 years, a diameter at breast height of 10 cm, a wall thickness of 8 to 10 mm, and no obvious cracks or insect infestation, and process it into bamboo tubes 100 to 150 cm long; (2) Soften the bamboo tubes at a temperature of 160-180℃ and a pressure of 1.0-1.5MPa for 5-8 minutes. After softening, the bamboo tubes are flattened, the green and yellow parts are removed, and flattened bamboo is obtained by using a flattening device. (3) Use a slicing machine to slice individual flat bamboo into thin slices with a thickness of 0.3 to 0.5 mm; (4) After the obtained thin sheet is finger-jointed, it is prepared into flat bamboo slicing thin sheet roll material by rolling machine. Then, according to the size of the target product, the flat bamboo slicing thin sheet roll material is cut to a fixed width of 5-10mm using cutting equipment. The method for preparing the honeycomb core layer includes the following steps: (1) Apply glue to one side of the flattened bamboo slices and rolls of a fixed width, with an glue application amount of 60-100 g / m. 2 A layer of release agent is applied to the surface of the mold, and then the bamboo slices are flattened and rolled around the mold. The rolling speed is controlled between 5 and 10 m / min to finally obtain the honeycomb unit. (2) The prepared honeycomb units are spliced ​​together. During the splicing process, a special positioning fixture is used to ensure the neatness of the honeycomb units. The method for preparing the honeycomb bamboo board includes the following steps: A. After applying adhesive to the upper and lower surfaces of the honeycomb core layer, cover the upper and lower panels onto the honeycomb core layer respectively, and then cold press; B. Trim the edges of the honeycomb bamboo board obtained after cold pressing, and grind and polish its surface.

2. The method for preparing a honeycomb bamboo board according to claim 1, characterized in that... The specific preparation method includes the following steps: (1) After applying adhesive to the upper and lower surfaces of the honeycomb core layer, cover the upper and lower panels onto the honeycomb core layer respectively, and place them in a cold press and cold press for 1 to 2 hours under a pressure of 0.1 to 0.2 MPa. During the cold pressing process, ensure that the pressure is stable and the panels are placed correctly. (2) Trim the edges of the honeycomb bamboo board obtained after cold pressing, and control the size error within ±0.8mm. Then grind and polish the surface, using 80 grit, 120 grit and 240 grit sandpaper in sequence.

3. A method for preparing a honeycomb bamboo board according to claim 1 or 2, characterized in that: The panel is a flattened bamboo slicing, and the preparation method of the flattened bamboo slicing includes the following steps: (1) Select bamboo with an age of 3 to 5 years, a diameter at breast height of 10 cm, a wall thickness of 8 to 10 mm, and no obvious cracks or insect infestation, and process it into bamboo tubes 100 to 150 cm long; (2) Soften the bamboo tubes at a temperature of 160-180℃ and a pressure of 1.0-1.5MPa for 5-8 minutes. After softening, the bamboo tubes are flattened, the green and yellow parts are removed, and flattened bamboo is obtained by using a flattening device. (3) Apply glue to one side of the flat bamboo facing up, with an amount of glue of 150-200 g / m², and then press it under a pressure of 0.5-1.0 MPa for 1-2 hours to obtain flat bamboo laminate. (4) Apply glue to the side of the flat bamboo plywood along its length, and then glue it under a pressure of 0.5-1.0 MPa for 1-2 hours to obtain a large-size flat bamboo plywood with a length of 200-500 cm and a width of 100-300 cm. Cut the large-size flat bamboo plywood into thin sheets with a thickness of 0.5-2.0 mm.

4. The method for preparing a honeycomb bamboo board according to claim 3, characterized in that: The cellular unit is a regular hexagonal cellular unit.

5. The method for preparing a honeycomb bamboo board according to claim 4, characterized in that: After the honeycomb unit is fabricated, it is inspected using a combination of visual inspection system and manual touch inspection. After the honeycomb core layer is spliced, a sampling tensile test is used to test the bonding strength.

6. The method for preparing a honeycomb bamboo board according to claim 5, characterized in that: After the panel and the honeycomb core layer are laminated, the bonding strength is tested by peel test.

7. The method for preparing a honeycomb bamboo board according to claim 6, characterized in that: During the sanding process of honeycomb bamboo panels, the surface of the panels is cleaned between each sanding step, and the sanding force and speed are controlled.

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