Formaldehyde-free adhesive film carbon fiber reinforced wood composite board

Abstract

The utility model relates to a formaldehyde-free adhesive film carbon fiber reinforced wood composite board which comprises a middle base material layer, a first grafting modified polyethylene resin film layer, a fiber cloth layer, a second grafting modified polyethylene resin film layer and a surface veneer layer, wherein the first grafting modified polyethylene resin film layer, the fiber cloth layer, the second grafting modified polyethylene resin film layer and the surface veneer layer are sequentially arranged on the upper side and the lower side of the middle base material layer. The formaldehyde-free adhesive film carbon fiber reinforced wood composite board is low in manufacturing cost, environmentally friendly and capable of greatly widening the application field of bamboo wood and fast-growing wood, and therefore the contradiction between supply and demand of wood is relieved.

Description

Technical Field

[0001] This utility model belongs to the technical field of bamboo and wood-based composite materials, and relates to a formaldehyde-free carbon fiber reinforced wood composite board that can be used in indoor load-bearing environments without formaldehyde release. Background Technology

[0002] Currently, due to global efforts to protect the environment and forest resources, high-quality timber is extremely scarce. However, with increasing emphasis and preference for wood-based materials, the demand for wood-based composite materials has been continuously increasing in recent years. Optimizing the utilization of plantation timber to produce low-cost, high-performance wood products is an important research and development direction. Carbon fiber, due to its advantages such as high strength, good fatigue resistance, low coefficient of thermal expansion, good corrosion resistance, and low fiber density, is widely used as a reinforcing material. However, traditional phenolic adhesives contain formaldehyde and free phenol, while epoxy resin adhesives release large amounts of volatile organic compounds during use, both of which pollute the environment.

[0003] Currently, a Chinese patent, CN101824205A, entitled "Integrated Molded Article, Formaldehyde-Free Film Carbon Fiber Reinforced Wood Composite Board and Housing for Electrical and Electronic Equipment," has been found. The integrated molded article is formed by connecting a component (I) containing a formaldehyde-free film carbon fiber reinforced wood composite board and other components (II). The formaldehyde-free film carbon fiber reinforced wood composite board is formed from (a) continuous reinforcing fibers, (b) a matrix resin with thermosetting resin as the main component, and (c) a flame retardant. The characteristic feature is that the flame retardancy of component (I) based on UL-94, measured on a test piece of substantial thickness, is V-1 or V-0. The formaldehyde-free film carbon fiber reinforced wood composite board of this patent is not suitable for indoor flooring or decorative panels.

[0004] The search also yielded a Chinese patent, "Formaldehyde-Free Carbon Fiber Reinforced Wood Composite Board and Steel Plate Combination Structure for Reinforcing Concrete Beams," publication number CN106337567B. This patent comprises multiple formaldehyde-free carbon fiber reinforced wood composite boards and multiple steel plates. Based on the stress characteristics of the concrete beam to be reinforced, the formaldehyde-free carbon fiber reinforced wood composite boards are discontinuously adhered to the bottom of the beam, with adjacent boards spaced at appropriate intervals. Two spaced boards are then fixedly connected by a steel plate. This invention utilizes external bonding high-strength... While the formaldehyde-free carbon fiber reinforced wood composite board is relatively brittle, it improves the stiffness and load-bearing capacity of concrete beams. The use of steel plates with good ductility enhances the deformation capacity of the concrete beam near the mid-span, preventing continuous brittle failure of the concrete beam reinforced with the formaldehyde-free carbon fiber reinforced wood composite board. Furthermore, it helps reduce stress on the mid-span concrete and the formaldehyde-free carbon fiber reinforced wood composite board, delaying the peeling failure of the formaldehyde-free carbon fiber reinforced wood composite board, improving the utilization rate of fiber-reinforced composite materials, and increasing the load-bearing capacity of the concrete beam. This patent is not applicable to indoor flooring or decorative panels. Summary of the Invention

[0005] In view of the above-mentioned shortcomings of the prior art, the purpose of this utility model is to provide a formaldehyde-free carbon fiber reinforced wood composite board. This formaldehyde-free carbon fiber reinforced wood composite board has low production cost and is environmentally friendly, which can greatly broaden the application fields of bamboo and fast-growing wood, thereby alleviating the contradiction between wood supply and demand.

[0006] The present invention relates to a formaldehyde-free carbon fiber reinforced wood composite board, characterized in that it comprises an intermediate substrate layer and a first grafted modified polyethylene resin film layer, a fiber cloth layer, a second grafted modified polyethylene resin film layer, and a surface veneer layer, all disposed sequentially on the upper and lower sides of the intermediate substrate layer, wherein the fiber cloth layer is carbon fiber cloth.

[0007] Preferably, the intermediate substrate layer is a wood-based material or a bamboo-based material, and the moisture content of the intermediate substrate layer is 8-12%.

[0008] Preferably, the wood-based material is 9mm thick plywood, and the bamboo-based material is 28mm thick container flooring.

[0009] Preferably, the specifications of the aforementioned carbon fiber cloth are 3k160g-3k300g.

[0010] Preferably, the thickness of the first grafted modified polyethylene resin film layer and the second grafted modified polyethylene resin film layer is 0.04 mm.

[0011] Preferably, the surface veneer layer is a 1.4mm thick wood veneer.

[0012] The manufacturing process of this utility model for formaldehyde-free carbon fiber reinforced wood composite board.

[0013] Step (1). Raw material preparation

[0014] (1.1) Wood-based materials: 9mm plywood, 30cm×30cm in size, dried to a moisture content of 8%-12%;

[0015] (1.2) Reinforcing material: Select carbon fiber cloth with specifications of 3k160g-3k300g;

[0016] (1.3) Adhesive material: Grafted modified polyethylene resin film is used, with a single layer film thickness of 0.04 mm;

[0017] (1.4) Wood veneer: 1.4mm thick wood veneer;

[0018] Step (2). Assembly

[0019] Carbon fiber cloth is laid on the bamboo or wood base material as the intermediate substrate layer, and the outermost layer is wood veneer. Grafted modified polyethylene resin film is used as an adhesive between the intermediate substrate layer and the carbon fiber cloth, and between the carbon fiber cloth and the wood veneer.

[0020] Step (3). Pressure plate

[0021] One-time hot pressing can be used, or a combination of hot pressing followed by cold pressing can be used:

[0022] (3.1) The one-time hot pressing process is as follows: hot pressing temperature 140-160℃, hot pressing pressure 0.8-1.2MPa, hot pressing time: 250-420s;

[0023] (3.2) The hot-pressing followed by cold-pressing process is as follows: hot pressing temperature 140-160℃, hot pressing pressure 0.8-1.2MPa, hot pressing time: 250-420s; cold pressing pressure 1.0-2.0MPa, cold pressing time: 30s-300s;

[0024] Step (4). Trimming and Inspection

[0025] After pressing, the molded board is placed in a constant temperature and humidity environment for 48 hours before edge trimming. After inspection, carbon fiber reinforced wood matrix composite products are obtained.

[0026] This application uses grafted modified polyethylene resin film to replace traditional adhesives in the composite board. It has the advantages of no organic solvents and no formaldehyde release. It is used as an adhesive between carbon fiber cloth and bamboo and wood-based materials to prepare high-strength bamboo and wood-based composite board. This makes the composite board low in production cost and environmentally friendly, which will greatly broaden the application fields of bamboo and fast-growing wood, thereby alleviating the contradiction between wood supply and demand.

[0027] This application utilizes grafted modified polyethylene resin and carbon fiber reinforcement to give bamboo and wood-based products excellent peel resistance and immersion peel strength, with no delamination, cracking, delamination, or peeling between layers, and no defects such as blistering, wrinkling, discoloration, or mold on the surface. This improves the performance of the product compared to substrates without surface reinforcement. Compared to phenolic or epoxy resin adhesives, using formaldehyde-free film-like polyethylene resin as an adhesive results in a more uniform adhesive after hot melting, and the final product is formaldehyde-free. Attached Figure Description

[0028] Figure 1 This is a cross-sectional structural diagram of the present invention. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0030] The following detailed description, with reference to the accompanying drawings, describes some embodiments of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0031] The formaldehyde-free carbon fiber reinforced wood composite board of this utility model includes an intermediate substrate layer 1 and a first grafted modified polyethylene resin film layer 2, a fiber cloth layer 3, a second grafted modified polyethylene resin film layer 4, and a surface veneer layer 5, which are sequentially disposed on the upper and lower sides of the intermediate substrate layer.

[0032] The intermediate substrate layer can be made of wood or bamboo, with a moisture content of 8-12%. The wood-based material can be 9mm thick plywood, and the bamboo-based material can be 28mm thick container flooring. Plywood is a mature product available on the market, with various specifications, commonly 2440×1220 or 1830×915 mm in size. Container flooring is also available on the market. Plywood and container flooring are used for load-bearing, and this application provides relevant examples, but is not limited to these two. Other materials such as bamboo, wood, particleboard, and fiberboard can also be used.

[0033] The fiber cloth layer is made of carbon fiber cloth, and the specifications of the carbon fiber cloth are 3k160g-3k300g.

[0034] The thickness of the first grafted modified polyethylene resin film layer and the second grafted modified polyethylene resin film layer is 0.04 mm.

[0035] The first grafted modified polyethylene resin film layer and the second grafted modified polyethylene resin film layer can be the formaldehyde-free film-like wood adhesive of the invention titled "A formaldehyde-free film-like wood adhesive and its preparation and use method" in patent number "201310443412.8".

[0036] The aforementioned surface veneer layer can be a 1.4mm thick wood veneer.

[0037] Example 1

[0038] 1. Raw material preparation

[0039] 1.1 Wood-based material: 9mm plywood, 30cm×30cm in size, dried to a moisture content of 10%;

[0040] 1.2 Reinforcing material: 3k300g carbon fiber cloth was selected;

[0041] 1.3 Adhesive material: Graft-modified polyethylene resin film, single-layer film thickness 0.04mm;

[0042] 1.4 Surface wood veneer: 1.4mm thick wood veneer.

[0043] 2. Billet assembly

[0044] Carbon fiber cloth is laid on both sides of the plywood substrate, and the outermost layer is wood veneer. Modified polyethylene resin film is used as an adhesive between the units.

[0045] 3. Pressure plate

[0046] It adopts a one-time hot pressing method.

[0047] The one-time hot pressing process is as follows: hot pressing temperature 140℃, hot pressing pressure 0.8MPa, hot pressing time: 250s;

[0048] 4. Trimming and Inspection

[0049] After pressing, the formed board is placed in a constant temperature and humidity environment for 48 hours before edge trimming. After inspection, carbon fiber reinforced wood matrix composite board is obtained.

[0050] Example 2

[0051] 1. Raw material preparation

[0052] 1.1 Wood-based materials: 9mm plywood, 30cm×30cm in size, dried to a moisture content of 10%;

[0053] 1.2 Reinforcing material: 3k300g carbon fiber cloth was selected;

[0054] 1.3 Adhesive material: Grafted modified polyethylene resin film, single layer film thickness 0.04mm.

[0055] 1.4 Surface wood veneer: 1.4mm thick wood veneer.

[0056] 2. Billet assembly

[0057] Carbon fiber cloth is laid on both sides of the plywood substrate, and the outermost layer is wood veneer. Modified polyethylene resin film is used as an adhesive between the units.

[0058] 3. Pressure plate

[0059] The product of this utility model adopts a hot-pressing followed by cold-pressing method.

[0060] The process is as follows: hot pressing temperature 160℃, hot pressing pressure 1.0MPa, hot pressing time: 330s; cold pressing pressure 1.5MPa, cold pressing time: 60s.

[0061] 4. Trimming and Inspection

[0062] After pressing, the formed board is placed in a constant temperature and humidity environment for 48 hours before edge trimming. After inspection, carbon fiber reinforced wood matrix composite board is obtained.

[0063] Comparison Standard: The physical and mechanical properties of the product are listed in Table 1, compared with the mechanical properties of the substrate without surface reinforcement.

[0064] Compare implementation cases 1 and 2.

[0065]

[0066] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model are permitted.

Claims

1. A formaldehyde-free glue-film carbon fiber reinforced wood composite panel, characterized by: The intermediate substrate layer is a wood-based material or a bamboo-based material, and the water content of the intermediate substrate layer is 8-12%.

2. The formaldehyde-free glue-film carbon fiber reinforced wood composite panel according to claim 1, characterized in that: The wood-based material is a 9mm-thick plywood, and the bamboo-based material is a 28mm-thick container bottom plate.

3. The formaldehyde-free glue film carbon fiber reinforced wood composite panel according to claim 2, characterized in that: The carbon fiber cloth has a specification of 3k160g-3k300g.

4. The formaldehyde-free glue-film carbon fiber reinforced wood composite panel according to claim 1, characterized in that: The first and second graft-modified polyethylene resin film layers have a thickness of 0.04mm.

5. The formaldehyde-free glue-film carbon fiber reinforced wood composite panel according to claim 1, characterized in that: The surface veneer layer is a 1.4mm-thick wood veneer.

6. The formaldehyde-free glue-film carbon fiber reinforced wood composite panel according to claim 1, characterized in that: ​

Images