High-strength light artificial board based on polyester material and manufacturing process of high-strength light artificial board

Abstract

The invention provides a high-strength light artificial board based on a polyester material and a manufacturing process of the high-strength light artificial board, and aims to solve the problems of insufficient strength, mildewing and high cost in the prior art. The artificial board is of a multi-layer stacked structure and is composed of a first polyester-based core layer, a foaming strength promoting layer, a second polyester-based core layer, a bonding layer and a heat insulation layer. Through the embedded foaming technology and the static pressure curing technology, the foaming strength promoting layer is embedded into the core layer to form an embedded structure, the strength and uniformity of the board are greatly improved, and expansion bubble residues are effectively avoided; moreover, according to the method, special-shaped holes do not need to be machined, only straight holes need to be machined, high machining efficiency and low manufacturing cost are achieved, mechanical clamping can be provided besides material bonding, and the bonding strength and reliability of the plate are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of polyester layered materials (B32B27 / 36), and in particular to a high-strength and lightweight artificial board based on polyester materials and a manufacturing process thereof. Background Art

[0002] Artificial board is a kind of board made by processing logs into veneers, shavings, and fibers of different specifications and sizes, and gluing (pressing) them together with adhesives or other fastening materials. Artificial board can make up for the defects of natural wood, not only greatly improving the utilization rate of wood, but also helping to expand the scope of application; and artificial board has a large width, a flat surface, and a uniform texture. It can be machined (chemically) into a variety of shapes according to needs, and the processing performance is significantly improved. Artificial board can be divided into five categories according to product characteristics and production processes: plywood (code BP), particleboard (code PB), fiberboard (code MDF), integrated wood (code GLUE), and blockboard (code BLK).

[0003] Polyester material is a polymer compound with an ester group in the main chain. It can be a natural polyester material or obtained through chemical synthesis. Artificial synthetic polyester is one of the commonly used polymers in industry. Polyethylene terephthalate (PET) is a commonly used synthetic polyester in industry, widely used in the fields of fiber, packaging film, plastic main panel, etc. In addition to PET, other types of polyester are used in hot melt adhesives, films, plastic parts resins or engineering resins for new closed blow molding products, etc.

[0004] Artificial boards made of polyester materials can be used to replace traditional wooden boards. Through artificial synthesis, the different characteristics of the material can be adjusted to obtain the required performance. Especially when the technology is mature and the cost is low, polyester artificial boards can be used for interior decoration, non-load-bearing wall construction and other purposes. Polyester artificial boards have a discontinuous structure. Compared with natural wooden boards, their compression strength and fracture strength in all directions are more uniform and stable, making them suitable for high-intensity use.

[0005] The production process of high-strength lightweight boards based on polyester materials generally includes steps such as mixing, extrusion, hot pressing and cutting. Due to its dense structure and high requirements for product uniformity, it will encounter various technical bottlenecks. Especially in the process of internal foaming, in order to reduce the overall density and reduce its weight, a foaming agent will be added to expand the polyester material to form a foaming structure. This internal foaming process will lead to the appearance of a large number of tiny bubbles, and most of them are open structures, which will not only reduce the strength of the board, but also cause mold to grow inside due to the capillary effect formed by moisture absorption, causing it to age rapidly.

[0006] However, with the large-scale production of polyester artificial boards, the following technical problems will arise in the production process:

[0007] 1. The cost of polyester artificial board is relatively high, so foaming agent needs to be added during the production process to expand it to produce a porous structure, so as to reduce the use of raw materials and reduce the overall density. The expansion process is difficult to control, and uneven expansion will occur, resulting in a sharp drop in the internal mechanical strength.

[0008] 2. Adding a variety of solution-like matrix materials inside the polyester artificial board requires heating and pressurization after mixing and expansion to complete the curing process. However, due to the influence of uneven heat, the degree of curing will be inconsistent, forming a hardened layer and a softened area, which greatly reduces the overall strength of the artificial board.

[0009] 3. If the board is exposed to moisture during the curing and use process, the uncured parts will absorb moisture, and the moisture will fill the entire interior of the board through capillary phenomena inside and outside, causing mold to grow inside and causing the internal structure to rot rapidly. Summary of the invention

[0010] In order to overcome the problems existing in the prior art, the purpose of the present invention is to provide a high-strength and lightweight artificial board based on polyester material and a manufacturing process thereof. Through a multi-layer stacking structure and an innovative manufacturing process, the comprehensive strength of the high-strength and lightweight artificial board based on polyester material is improved, mildew is avoided, and the cost is lower.

[0011] In order to achieve the purpose of the present invention, the following technical solutions are used:

[0012] It comprises at least one first polyester-based core layer 1, at least one foaming and strengthening layer 2, at least one second polyester-based core layer 3, an adhesive layer 4 and a heat-insulating layer 5 stacked in sequence from the inside to the outside, wherein one layer of the foaming and strengthening layer is between one layer of the first polyester-based core layer 1 and one layer of the second polyester-based core layer 3;

[0013] The foaming and strengthening layer 2 is made of foaming and strengthening material;

[0014] The first polyester-based core layer 1 is provided with a plurality of first embedding holes on the side wall adjacent to the foaming and strengthening layer 2; the second polyester-based core layer 3 is provided with a plurality of second embedding holes on the side wall adjacent to the foaming and strengthening layer 2;

[0015] The foaming and strengthening layer 2 is at least partially embedded in the first embedding hole to form a first embedding portion, and is at least partially embedded in the second embedding hole to form a second embedding portion;

[0016] The first engaging portion has at least one first tenon portion; the second engaging portion has at least one second tenon portion; the first tenon portion and the second tenon portion are formed by the foaming and strengthening material foaming and squeezing the side walls of the first embedding hole and the second embedding hole, or the foaming and strengthening material foaming is squeezed and deformed by the side walls of the first embedding hole and the second embedding hole.

[0017] Preferably, the foaming and strengthening material is polyvinyl butyral.

[0018] Preferably, the first polyester-based core layer 1 and the second polyester-based core layer 3 are made of polyester material; and the bonding insulation layer 4 is made of long carbon chain polyester.

[0019] Preferably, the foaming material is closed-cell isocyanate.

[0020] Preferably, the adhesive layer 4 and the heat insulation layer 5 are bonded at a mass ratio of 1:4-1:5.

[0021] Preferably, the adhesive layer 4 is made of substituted diisocyanate (MDI), 1,3-dihydroxyaminomethylcyclohexane as a self-catalytic chain extender and furfural as a catalyst for cross-linking and curing, and the substituent of the substituted diisocyanate is hydroxyl or tert-hydroxyl; the mass fraction of the substituent of the substituted diisocyanate is between 5-10%.

[0022] Preferably, the carbon chain number of the long carbon chain polyester is between 12-18.

[0023] Preferably, the long carbon chain polyester is made of 1,13-tetradecanediol substituted diol; wherein the disubstituted group in the diol used as the material for the shrinkage reaction is 1,13-tetradecanediol or 12-hydroxyoctadecanoic acid.

[0024] The manufacturing process of the high-strength lightweight artificial board based on polyester material according to any one of the above technical solutions comprises the following process steps:

[0025] S1. Making polyester core layer:

[0026] Processing polyvinyl butyral into a plate, drilling straight holes on the side wall to make a first embedding hole and / or a second embedding hole, and obtaining a first polyester-based core layer and a second polyester-based core layer;

[0027] S2. Foam material injection:

[0028] The first polyester-based core layer and the second polyester-based core layer are sequentially placed in a static pressure mold, and closed-cell isocyanate is used as a foaming material and injected between the first polyester-based core layer and the second polyester-based core layer to obtain a laminated board;

[0029] S3, static pressure curing:

[0030] Place the static pressure mold in a static pressure curing chamber and cure it in a closed environment at a static pressure of 0.8-1.0MPa for 4-6 hours. The temperature in the static pressure curing chamber is controlled at 45-60℃.

[0031] S4, take out and cut:

[0032] Take out the pressurized and cured sheet and cut it according to the designed size;

[0033] S5. Hot pressing:

[0034] A hot press is used to hot-press the cut stacked plates. Under the action of hot pressing, the foaming reinforcement material foams and squeezes the side walls of the first embedding hole and the second embedding hole, or the foaming reinforcement material is squeezed and deformed by the side walls of the first embedding hole and the second embedding hole to form the first tenon portion and the second tenon portion.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] 1. The present invention adopts an embedded foaming process to embed the core layer of polyester material into the foaming layer of epoxy curing resin, thereby solving the uneven expansion process of polyester material. At the same time, the overall strength of epoxy resin is higher, and its overall structure can be artificially controlled, which can effectively solve the problem of structural strength of the board. At the same time, it is carried out under an ultra-long static pressure environment, so that the bubbles inside are squeezed out or broken, and effectively eliminated, thereby avoiding the residual expansion bubbles inside. Under high-intensity curing, the ultra-high pressure environment can replace the temperature to promote the curing of the foaming material, and the overall environment in the static pressure cabin is more uniform, which can effectively promote the hardening of the foaming material.

[0037] 2. The present invention uses a multi-level destructuring form to stack the foam material and the core material in succession, so that it can achieve uniform lightweight and improve the overall mechanical strength. By using long carbon chain polyester to form the middle partition, the multi-layer structure is internalized and bonded. At the same time, the long carbon chain polyester can achieve effective heat insulation and prevention, so that the inner foam layer will not be affected by heat and reduce strength. At the same time, the multi-level long carbon chain polyester can effectively block the internal capillary phenomenon that causes mildew, which can fundamentally prevent the decay caused by mold and ensure the service life of the lightweight artificial board. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a schematic diagram of the method flow of the present invention;

[0039] Figure 2 It is a schematic diagram of the structure of the artificial board of the present invention;

[0040] Figure 3It is a schematic diagram of the local structure of the artificial board of the present invention before hot pressing;

[0041] Figure 4 It is a schematic diagram of the local structure of the artificial board of the present invention after hot pressing.

[0042] Markings in the figure:

[0043] 1. The first polyester-based core layer; 2. The foaming and strengthening layer; 3. The second polyester-based core layer; 4. The bonding layer; 5. The heat-insulating layer. DETAILED DESCRIPTION

[0044] The following is a detailed description of the preparation method of the present invention in conjunction with the accompanying drawings:

[0045] Example 1

[0046] High-strength and lightweight wood-based panels based on polyester materials, see Figure 2-Figure 4 , including at least one first polyester-based core layer 1, at least one foaming reinforcement layer 2, at least one second polyester-based core layer 3, an adhesive layer 4 and a heat-insulating layer 5 stacked in sequence from the inside to the outside, wherein one layer of the foaming reinforcement layer is between one layer of the first polyester-based core layer 1 and one layer of the second polyester-based core layer 3.

[0047] The first polyester-based core layer 1 is provided with a plurality of first embedding holes on the side wall adjacent to the foaming reinforcement layer 2; the second polyester-based core layer 3 is provided with a plurality of second embedding holes on the side wall adjacent to the foaming reinforcement layer 2; at least one first polyester-based core layer 1 and at least one second polyester-based core layer 3 are sheets made of polyester material.

[0048] The adhesive layer 4 is a polyurethane layer; the adhesive heat-insulating layer 5 is made of long carbon chain polyester; the carbon chain number of the long carbon chain polyester is between 12-18.

[0049] Example 2

[0050] According to the high-strength and lightweight artificial board based on polyester material of Example 1, see Figure 1 , based on the manufacturing process of the high-strength lightweight artificial board based on polyester material described in the above technical solution, the following is obtained:

[0051] S1. Making polyester core layer:

[0052] Processing polyvinyl butyral into a plate, drilling straight holes on the side wall to make a first embedding hole and / or a second embedding hole, and obtaining a first polyester-based core layer and a second polyester-based core layer;

[0053] S2. Foam material injection:

[0054] The first polyester-based core layer and the second polyester-based core layer are sequentially placed in a static pressure mold, and closed-cell isocyanate is used as a foaming material and injected between the first polyester-based core layer and the second polyester-based core layer to obtain a laminated board;

[0055] S3, static pressure curing:

[0056] Place the static pressure mold in a static pressure curing chamber and cure it in a closed environment at a static pressure of 0.8-1.0MPa for 4-6 hours. The temperature in the static pressure curing chamber is controlled at 45-60℃.

[0057] S4, take out and cut:

[0058] Take out the pressurized and cured sheet and cut it according to the designed size;

[0059] S5. Hot pressing:

[0060] A hot press is used to heat-press the cut stacked plates. Under the action of hot pressing, the foamed reinforcement material foams and squeezes the side walls of the first embedded hole and the second embedded hole, or the foamed reinforcement material is squeezed and deformed by the side walls of the first embedded hole and the second embedded hole to form the first latch portion and the second latch portion. Specifically, when the stacked plate is subjected to longitudinal heat pressure, the first polyester-based core layer, the foamed reinforcement layer, and the second polyester-based core layer will expand laterally due to the Poisson's ratio. Since the Poisson's ratios of the polyester-based core layer and the foamed reinforcement layer are different, they will squeeze each other. At this time, the side walls of the first embedded hole and the second embedded hole, which were originally straight holes, will bend and deform into a drum shape (mushroom head) or a waisted shape. In this way, the first latch portion and the second latch portion that provide mechanical engagement can be formed. This method does not require the processing of special-shaped holes, but only requires the processing of straight holes. It has high processing efficiency and low manufacturing cost, and can provide mechanical engagement in addition to material bonding, thereby improving the bonding strength and reliability of the board.

[0061] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A high-strength and lightweight artificial board based on polyester material, characterized in that: The invention comprises at least one first polyester-based core layer (1), at least one foaming and strengthening layer (2), at least one second polyester-based core layer (3), an adhesive layer (4) and a heat-insulating layer (5) stacked in sequence from the inside to the outside, wherein one layer of the foaming and strengthening layer is located between one layer of the first polyester-based core layer (1) and one layer of the second polyester-based core layer (3); The foaming and strengthening layer (2) is composed of a foaming and strengthening material; A plurality of first embedding holes are provided on the side wall of the first polyester-based core layer (1) adjacent to the foaming and strengthening layer (2); a plurality of second embedding holes are provided on the side wall of the second polyester-based core layer (3) adjacent to the foaming and strengthening layer (2); The foaming and strengthening layer (2) is at least partially embedded in the first embedding hole to form a first embedding portion, and is at least partially embedded in the second embedding hole to form a second embedding portion; The first engaging portion has at least one first tenon portion; the second engaging portion has at least one second tenon portion; the first tenon portion and the second tenon portion are formed by the foaming and strengthening material foaming and squeezing the side walls of the first embedding hole and the second embedding hole, or the foaming and strengthening material foaming is squeezed and deformed by the side walls of the first embedding hole and the second embedding hole.

2. The high-strength and lightweight artificial board based on polyester material as claimed in claim 1, characterized in that: The foaming and strengthening material is polyvinyl butyral.

3. The high-strength and lightweight artificial board based on polyester material as claimed in claim 2, characterized in that: The first polyester-based core layer (1) and the second polyester-based core layer (3) are made of polyester material; The bonding heat-insulating layer (4) is made of long carbon chain polyester.

4. The high-strength and lightweight artificial board based on polyester material as claimed in claim 3, characterized in that: The foaming material is closed-cell isocyanate.

5. The high-strength and lightweight artificial board based on polyester material as claimed in claim 1, characterized in that: The bonding layer (4) and the heat insulation layer (5) are bonded to each other at a mass ratio of 1:4-1:

5.

6. The high-strength and lightweight artificial board based on polyester material as claimed in claim 5, characterized in that: The adhesive layer (4) is made of substituted diisocyanate (MDI), 1,3-dihydroxyaminomethylcyclohexane as a self-catalytic chain extender and furfural as a catalyst for cross-linking and curing, the substituent of the substituted diisocyanate is hydroxyl or tertiary hydroxyl; the mass fraction of the substituent of the substituted diisocyanate is between 5-10%.

7. The high-strength and lightweight artificial board based on polyester material as claimed in claim 1, characterized in that: The carbon chain number of the long carbon chain polyester is between 12 and 18.

8. The high-strength and lightweight artificial board based on polyester material as claimed in claim 7, characterized in that: The long carbon chain polyester is prepared by using 1,13-tetradecanediol to replace diol; wherein the di-substituent in the diol used as a material for the shrinkage reaction is 1,13-tetradecanediol or 12-hydroxyoctadecanoic acid.

9. The manufacturing process of the high-strength lightweight artificial board based on polyester material according to any one of claims 1 to 8, characterized in that: The process steps include: S1. Making polyester core layer: Processing polyvinyl butyral into a plate, drilling straight holes on the side walls to make first embedding holes and / or second embedding holes, and obtaining a first polyester-based core layer (1) and a second polyester-based core layer (3); S2. Foam material injection: The first polyester-based core layer (1) and the second polyester-based core layer (3) are sequentially placed in a static pressure mold, and closed-cell isocyanate is used as a foaming material and injected between the first polyester-based core layer (1) and the second polyester-based core layer (3) to obtain a laminated board; S3, static pressure curing: Place the static pressure mold in a static pressure curing chamber and cure it in a closed environment at a static pressure of 0.8-1.0MPa for 4-6 hours. The temperature in the static pressure curing chamber is controlled at 45-60℃. S4. Take out and cut: Take out the pressurized and cured sheet and cut it according to the designed size; S5. Hot pressing: A hot press is used to hot-press the cut stacked plates. Under the action of hot pressing, the foaming reinforcement material foams and squeezes the side walls of the first embedding hole and the second embedding hole, or the foaming reinforcement material is squeezed and deformed by the side walls of the first embedding hole and the second embedding hole to form the first tenon portion and the second tenon portion.

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