High-strength environment-friendly marine furniture board based on super-flat core board and processing method of high-strength environment-friendly marine furniture board

Abstract

The invention relates to the technical field of artificial board manufacturing, in particular to a high-strength environment-friendly ocean board furniture board based on a super-flat core board and a processing method thereof.The high-strength environment-friendly ocean board furniture board is composed of five layers of composite structures, and the five layers of composite structures are sequentially laminated and combined from bottom to top and comprise a flame-retardant base layer, a high-density fiberboard with the density larger than or equal to 0.80 g / cm < 3 > and the oxygen index larger than or equal to 32%, and the thickness of the flame-retardant base layer is 0.5-1.5 mm; the formaldehyde adsorption functional layer is a composite felt layer comprising a glass fiber mesh and bamboo charcoal fibers, the bamboo charcoal fibers account for 30-50wt%, and the gram weight is 80-200g / m; the method has the beneficial effects that double-effect formaldehyde control is achieved, and formaldehyde release is remarkably reduced through the synergistic effect of bamboo charcoal fiber adsorption and nano catalytic decomposition; a formaldehyde-free adhesive system is adopted, so that a formaldehyde source is completely eradicated; the long-acting salt spray corrosion resistance is achieved, the fiber interface bonding force is improved through plasma activation, and the peel strength is obviously superior to that of a traditional plate after a salt spray test; low water absorption deformation: the densified structure greatly inhibits expansion caused by water permeation; and super-flat core layer control: magnetic suspension positioning and asymmetric gluing technology are combined for gradient hot pressing.

Description

Technical Field

[0001] The invention relates to the technical field of artificial board manufacturing, in particular to a high-strength environmentally friendly marine board furniture board based on an ultra-flat core board and a processing method thereof. Background Art

[0002] Traditional marine board furniture panels are prone to problems such as delamination, deformation, and excessive formaldehyde release in humid and high-salt environments.

[0003] The prior art has the following problems:

[0004] ① Insufficient base material performance: Ordinary high-density fiberboard has low flame retardancy, poor density uniformity, and is prone to delamination in salt spray environments;

[0005] ② Excessive formaldehyde release: The physical adsorption layer is easily saturated and lacks a long-term purification mechanism;

[0006] ③Poor structural stability: Low single board assembly precision leads to core warping and surface cracking after hot and cold cycles;

[0007] ④Weak interface bonding: The surface of the reinforcing fiber is inert and the adhesive penetration rate is low;

[0008] ⑤ Process limitations: Constant temperature hot pressing causes insufficient curing of the core layer and a high water absorption and expansion rate.

[0009] Therefore, we propose a high-strength environmentally friendly marine board furniture board based on ultra-flat core board and a processing method thereof to solve the above problems. Summary of the Invention

[0010] In view of the problems existing in the prior art, the present invention discloses a high-strength environmentally friendly marine board furniture board based on an ultra-flat core board and a processing method thereof. The technical solution adopted is that it consists of a five-layer composite structure, which is laminated and combined in sequence from bottom to top, namely:

[0011] Flame retardant base layer: high-density fiberboard with density ≥0.80g / cm³, oxygen index ≥32%, thickness 0.5-1.5mm;

[0012] Formaldehyde adsorption functional layer: a composite felt layer comprising glass fiber mesh and bamboo charcoal fiber, wherein the bamboo charcoal fiber accounts for 30-50wt% and has a gram weight of 80-200g / m²;

[0013] Ultra-flat core board layer: It is composed of 5-11 layers of eucalyptus veneers with a thickness of 1.2-2.0mm, which are crisscrossed and bonded with isocyanate adhesive. The core board thickness tolerance is ≤±0.10mm, and the warpage within 1m length is ≤0.5mm.

[0014] Interface reinforcement layer: basalt fiber mesh cloth treated with plasma surface treatment, surface energy ≥55mN / m, adhesive impregnation rate ≥90%;

[0015] Functional finishing layer: melamine impregnated paper loaded with nano inorganic particles, with a surface wear resistance of ≥6000 revolutions.

[0016] As a preferred technical solution of the present invention, the coating amount of the isocyanate adhesive of the ultra-flat core board layer is asymmetrically distributed - the coating amount on the upper surface is 120-140g / m², the coating amount on the lower surface is 105-125g / m², and the coating amount difference is ≥10g / m².

[0017] As a preferred technical solution of the present invention, the plasma surface treatment adopts an inert gas atmosphere, a processing power of 300-500W, and a processing time of 40-90 seconds, so that the hydroxyl density on the fiber surface is increased to 8.2-12.5 / nm².

[0018] As a preferred technical solution of the present invention, the particle size distribution of the bamboo charcoal fiber in the formaldehyde adsorption functional layer is: D50: 15-25 μm, specific surface area: 400-600 m² / g, and iodine adsorption value: 800-1100 mg / g.

[0019] As a preferred technical solution of the present invention, the nano inorganic particles are mesoporous silica-coated zinc oxide (ZnO@mSiO2), with a particle size of 50-100nm, a loading amount of 3-8wt%, and a formaldehyde catalytic decomposition efficiency of ≥92% (28℃ / RH65%).

[0020] As a preferred technical solution of the present invention, a method for processing a high-strength environmentally friendly marine board furniture board based on an ultra-flat core board comprises the following steps:

[0021] (a) Core panel prefabrication

[0022] ① Sand the eucalyptus veneer dried to a moisture content of 6-10% on both sides to a fixed thickness with a thickness tolerance of ≤±0.05mm;

[0023] ②Use a differential glue coating machine for asymmetric glue coating (the amount of glue on the upper surface is greater than the amount of glue on the lower surface);

[0024] ③Complete single plate orthogonal assembly on the magnetic suspension positioning platform with a positioning accuracy of ±0.15mm;

[0025] ④Three-stage gradient hot pressing:

[0026] Stage 1: 85-95°C / 0.8-1.2 MPa × 2-4 min

[0027] Stage 2: 105-115°C / 1.3-1.8 MPa × 3-6 min

[0028] Stage 3: 95-105°C / 0.7-1.0 MPa × 1-3 min;

[0029] (b) Enhancement layer activation

[0030] Basalt fiber mesh is processed in an argon plasma reactor with a power density of 0.8-1.5W / cm²;

[0031] (c) Composite lamination

[0032] ① Assemble the blanks in the following order: flame retardant base layer → formaldehyde adsorption functional layer → ultra-flat core board layer → interface reinforcement layer → functional finishing layer;

[0033] ②Cold isostatic pressing: pressure 20-30MPa / 20-30℃ × 8-15min;

[0034] (d) Post-curing treatment

[0035] Step-by-step humidity regulation and health preservation:

[0036] Phase 1: 28±2℃ / 70±5%RH × 12-24h

[0037] Phase 2: 23±2℃ / 50±5%RH × 36-48h.

[0038] As a preferred technical solution of the present invention, the temperature change rate of the gradient hot pressing in step (a) is:

[0039] ① Stage 1 → Stage 2: Heating rate 3-5℃ / min;

[0040] ②Phase 2→Phase 3: Cooling rate 2-4℃ / min.

[0041] As a preferred technical solution of the present invention, the fiber mesh cloth after plasma treatment in step (b) needs to be impregnated with MDI glue within 15 minutes, and the impregnation viscosity is controlled to be 350-550 mPa·s (25°C).

[0042] Beneficial effects of the present invention:

[0043] 1. Double-effect formaldehyde control: bamboo charcoal fiber adsorption and nano-catalytic decomposition work synergistically to significantly reduce formaldehyde release; formaldehyde-free adhesive system: completely eliminate the source of formaldehyde;

[0044] 2. Long-term resistance to salt spray corrosion: Plasma activation improves the fiber interface bonding strength, and the peel strength after salt spray test is significantly better than that of traditional boards; Low water absorption and deformation: The densified structure greatly inhibits expansion caused by water penetration;

[0045] 3. Ultra-flat core layer control: Magnetic levitation positioning and asymmetric gluing technology combined with gradient hot pressing achieve extremely low warpage; homogeneous core layer structure: density distribution uniformity reaches the industry-leading level;

[0046] 4. Improved three-dimensional mechanics: The gradient hot pressing process optimizes the resin curing network, and the static bending strength, elastic modulus and internal bonding strength are simultaneously enhanced; high-level flame retardancy: The oxygen index of the base layer is improved, and the vertical combustion level is greatly improved;

[0047] 5. Process controllability: Plasma treatment-impregnation process aging control ensures interfacial activity; stress release design: step-by-step humidity control eliminates internal stress, and the qualified rate of finished products is extremely high. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0049] Figure 1 Schematic diagram of the structure of the five-layer composite structure of the present invention.

[0050] In the figure: 1 functional finishing layer, 2 interface reinforcement layer, 3 ultra-flat core board layer, 4 formaldehyde adsorption functional layer, 5 flame retardant base layer. DETAILED DESCRIPTION

[0051] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0052] like Figure 1 As shown, the present invention discloses a high-strength environmentally friendly marine board furniture board based on an ultra-flat core board and a processing method thereof. The technical solution adopted is that it consists of a five-layer composite structure, and the five-layer composite structure is laminated and combined in sequence from bottom to top, namely:

[0053] Flame retardant base layer 5: high-density fiberboard with a density of ≥0.80g / cm³ and an oxygen index of ≥32%, and a thickness of 0.5-1.5mm;

[0054] Formaldehyde adsorption functional layer 4: a composite felt layer comprising glass fiber mesh and bamboo charcoal fiber, wherein the bamboo charcoal fiber accounts for 30-50wt% and has a gram weight of 80-200g / m²;

[0055] Ultra-flat core board layer 3: It is composed of 5-11 layers of eucalyptus veneers with a thickness of 1.2-2.0mm, which are crisscrossed and bonded with isocyanate adhesive. The core board thickness tolerance is ≤±0.10mm, and the warpage within 1m length is ≤0.5mm;

[0056] Interface reinforcement layer 2: basalt fiber mesh cloth treated with plasma, surface energy ≥55mN / m, adhesive impregnation rate ≥90%;

[0057] Functional finishing layer 1: melamine impregnated paper loaded with nano-inorganic particles, with a surface wear resistance of ≥6000 revolutions.

[0058] As a preferred technical solution of the present invention, the coating amount of the isocyanate adhesive of the ultra-flat core board layer 3 is asymmetrically distributed - the coating amount on the upper surface is 120-140g / m², the coating amount on the lower surface is 105-125g / m², and the coating amount difference is ≥10g / m².

[0059] As a preferred technical solution of the present invention, the plasma surface treatment adopts an inert gas atmosphere, a processing power of 300-500W, and a processing time of 40-90 seconds, so that the hydroxyl density on the fiber surface is increased to 8.2-12.5 / nm².

[0060] As a preferred technical solution of the present invention, the particle size distribution of the bamboo charcoal fiber in the formaldehyde adsorption functional layer 4 is: D50: 15-25 μm, specific surface area: 400-600 m² / g, and iodine adsorption value: 800-1100 mg / g.

[0061] As a preferred technical solution of the present invention, the nano inorganic particles are mesoporous silica-coated zinc oxide (ZnO@mSiO2), with a particle size of 50-100nm, a loading amount of 3-8wt%, and a formaldehyde catalytic decomposition efficiency of ≥92% (28℃ / RH65%).

[0062] As a preferred technical solution of the present invention, a method for processing a high-strength environmentally friendly marine board furniture board based on an ultra-flat core board comprises the following steps:

[0063] (a) Core panel prefabrication

[0064] ① Sand the eucalyptus veneer dried to a moisture content of 6-10% on both sides to a fixed thickness with a thickness tolerance of ≤±0.05mm;

[0065] ②Use a differential glue coating machine for asymmetric glue coating (the amount of glue on the upper surface is greater than the amount of glue on the lower surface);

[0066] ③Complete single plate orthogonal assembly on the magnetic suspension positioning platform with a positioning accuracy of ±0.15mm;

[0067] ④Three-stage gradient hot pressing:

[0068] Stage 1: 85-95°C / 0.8-1.2 MPa × 2-4 min

[0069] Stage 2: 105-115°C / 1.3-1.8 MPa × 3-6 min

[0070] Stage 3: 95-105°C / 0.7-1.0 MPa × 1-3 min;

[0071] (b) Enhancement layer activation

[0072] Basalt fiber mesh is processed in an argon plasma reactor with a power density of 0.8-1.5W / cm²;

[0073] (c) Composite lamination

[0074] ① Assemble the blanks in the following order: flame retardant base layer 5 → formaldehyde adsorption functional layer 4 → ultra-flat core board layer 3 → interface reinforcement layer 2 → functional finishing layer 1;

[0075] ②Cold isostatic pressing: pressure 20-30MPa / 20-30℃ × 8-15min;

[0076] (d) Post-curing treatment

[0077] Step-by-step humidity regulation and health preservation:

[0078] Phase 1: 28±2℃ / 70±5%RH × 12-24h

[0079] Phase 2: 23±2℃ / 50±5%RH × 36-48h.

[0080] As a preferred technical solution of the present invention, the temperature change rate of the gradient hot pressing in step (a) is:

[0081] ① Stage 1 → Stage 2: Heating rate 3-5℃ / min;

[0082] ②Phase 2→Phase 3: Cooling rate 2-4℃ / min.

[0083] As a preferred technical solution of the present invention, the fiber mesh cloth after plasma treatment in step (b) needs to be impregnated with MDI glue within 15 minutes, and the impregnation viscosity is controlled to be 350-550 mPa·s (25°C).

[0084] Table 1: Core performance comparison test (third-party testing: SGS-CTI)

[0085] Test items The present invention High-end marine boards on the market Improvement Test standards Formaldehyde emission 0.008mg / m³ 0.118mg / m³ 93.2%↓ GB / T 39600-2021 Salt spray 1000h peel strength 1.85MPa 0.72MPa 157%↑ ASTM D429 24h water absorption expansion rate 4.1% 15.3% 73.2%↓ GB / T 17657-2013 Vertical combustion level Level B1 Level B2 Security upgrades GB 8624-2012 Core density uniformity CV value ≤ 2.1% CV value ≥8.7% 75.9%↑ ISO 9427

[0086] Table 2: Effect of gradient pressing process on core board properties

[0087] Hot pressing process Static bending strength (MPa) Elastic modulus (GPa) Internal bonding strength (MPa) Traditional constant temperature pressing 38.2 4.5 0.85 Gradient compression of the present invention 52.7 6.8 1.42 Performance improvements 37.96%↑ 51.11%↑ 67.06%↑

[0088] Components not described in detail herein are prior art.

[0089] Although the specific embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by ordinary technicians in this field, various changes can be made without departing from the purpose of the present invention. Modifications or deformations that do not involve creative work are still within the scope of protection of the present invention.

Claims

1. A high-strength environmentally friendly marine board furniture board based on an ultra-flat core board, characterized in that: It consists of five layers of composite structure, which are laminated and combined in sequence from bottom to top, namely: Flame retardant base layer (5): high-density fiberboard with a density of ≥0.80 g / cm³ and an oxygen index of ≥32%, and a thickness of 0.5-1.5 mm; Formaldehyde adsorption functional layer (4): a composite felt layer comprising a glass fiber mesh and bamboo charcoal fiber, wherein the bamboo charcoal fiber accounts for 30-50wt% and has a gram weight of 80-200g / m²; Ultra-flat core board layer (3): It is composed of 5-11 layers of eucalyptus veneers with a thickness of 1.2-2.0 mm, which are crisscrossed and assembled. The veneers are bonded by isocyanate adhesive. The core board thickness tolerance is ≤±0.10 mm, and the warpage within 1 m length is ≤0.5 mm. Interface reinforcement layer (2): basalt fiber mesh cloth treated with plasma, surface energy ≥55mN / m, adhesive impregnation rate ≥90%; Functional finishing layer (1): melamine impregnated paper loaded with nano inorganic particles, with a surface wear resistance of ≥6000 revolutions.

2. The high-strength environmentally friendly marine board furniture board based on the ultra-flat core board according to claim 1 is characterized in that: The coating amount of the isocyanate adhesive of the ultra-flat core board layer (3) is asymmetrically distributed—the coating amount on the upper surface is 120-140 g / m², and the coating amount on the lower surface is 105-125 g / m², and the coating amount difference is ≥10 g / m².

3. The high-strength environmentally friendly marine board furniture board based on the ultra-flat core board according to claim 1 is characterized in that: The plasma surface treatment adopts an inert gas atmosphere, a processing power of 300-500W, and a processing time of 40-90 seconds, so that the hydroxyl density of the fiber surface is increased to 8.2-12.5 / nm².

4. The high-strength environmentally friendly marine board furniture board based on the ultra-flat core board according to claim 1, characterized in that: The particle size distribution of the bamboo charcoal fibers in the formaldehyde adsorption functional layer (4) is: D50: 15-25 μm, specific surface area: 400-600 m² / g, and iodine adsorption value: 800-1100 mg / g.

5. The high-strength environmentally friendly marine board furniture board based on the ultra-flat core board according to claim 1, characterized in that: The nano inorganic particles are mesoporous silica-coated zinc oxide (ZnO@mSiO2), with a particle size of 50-100 nm and a loading amount of 3-8 wt %. The formaldehyde catalytic decomposition efficiency thereof is ≥92% (28°C / RH65%).

6. The method for processing high-strength environmentally friendly marine furniture board based on ultra-flat core board according to any one of claims 1 to 5, characterized in that: The following steps are involved: (a) Core panel prefabrication ① Sand the eucalyptus veneer dried to a moisture content of 6-10% on both sides to a fixed thickness with a thickness tolerance of ≤±0.05mm; ②Use a differential glue coating machine for asymmetric glue coating (the amount of glue on the upper surface is greater than the amount of glue on the lower surface); ③Complete single plate orthogonal assembly on the magnetic suspension positioning platform with a positioning accuracy of ±0.15mm; ④Three-stage gradient hot pressing: Stage 1: 85-95°C / 0.8-1.2 MPa × 2-4 min Stage 2: 105-115°C / 1.3-1.8 MPa × 3-6 min Stage 3: 95-105°C / 0.7-1.0 MPa × 1-3 min; (b) Enhancement layer activation Basalt fiber mesh is processed in an argon plasma reactor with a power density of 0.8-1.5W / cm²; (c) Composite lamination ① Assemble the blanks in the following order: flame retardant base layer (5) → formaldehyde adsorption functional layer (4) → ultra-flat core board layer (3) → interface reinforcement layer (2) → functional finishing layer (1); ②Cold isostatic pressing: pressure 20-30MPa / 20-30℃ × 8-15min; (d) Post-curing treatment Step-by-step humidity regulation and health preservation: Phase 1: 28±2℃ / 70±5%RH × 12-24h Phase 2: 23±2℃ / 50±5%RH × 36-48h.

7. The processing method according to claim 6, characterized in that: The temperature change rate of the gradient hot pressing in step (a) is: ① Stage 1 → Stage 2: Heating rate 3-5℃ / min; ②Phase 2→Phase 3: Cooling rate 2-4℃ / min.

8. The processing method according to claim 6, characterized in that: The fiber mesh cloth after plasma treatment in step (b) needs to be impregnated with MDI glue within 15 minutes, and the impregnation viscosity is controlled to be 350-550 mPa·s (25°C).

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