A method of obtaining a decorative composite material

 

(57) Abstract:

The essence of the invention: in the manufacture of a composite material of urea-formaldehyde resin (UFR) is injected into the mass before the introduction of the coagulant used FSC from time gelatinization 140 - 260 in the form of a dispersion, which is a product suspension polycondensation of urea and formaldehyde in the presence of a protective colloid is a copolymer of butyl acrylate, butyl methacrylate and methacrylic acid at a mass ratio 1 : (0,41 - 0,45) : (0,15 - 0,19) and the ratio of urea and protective colloid 1 : (0,05 - 0,12). table 1.

The invention relates to the pulp and paper industry, namely the production technology of ornamental cellulose composite material (SMC), primarily securities for decorative laminate (DBSP). This method can also be used to obtain digital maps for cladding wood-fibre and chipboard plastics and plates.

Traditionally decorative SMC is obtained by impregnation of highly filled paper base with a solution of melamine-formaldehyde or melamine-urea-formaldehyde resin, which amount in the received CCM - impregnated Boo cellulose composite material, comprising preparing paper pulp by mixing powdered cellulose and filler injection of coagulant and flocculant, ebb paper web and the introduction of urea-formaldehyde resin by impregnation of the paper web to its solution [2].

This process of making the material difficult. Urea-formaldehyde resin, a binder is introduced into the SMC by impregnation, which requires the use of an impregnating equipment, and consequently, the cost of its operation, i.e., large capital investments, material costs, a large power consumption, heat, steam, costs of labor service personnel.

Impregnated paper in dried form content of the resin is not less than 50 wt. % , has a very high fragility, which inevitably leads to the destruction of the edges or individual sheets during loading, unloading and on-stage set of packages, which leads to a further appreciation of the final material.

The technical result of the invention is to simplify the process while maintaining the quality of the plastic.

The result is achieved that the method of obtaining decorative cellulose composite material, mainly for outdoor is spencie cellulose, filler, coagulant and flocculant, ebb paper web and the introduction of urea-formaldehyde resin in an amount of not less than 50% by weight cellulosic composite material according to the invention, urea-formaldehyde resin is injected at the stage of preparation of paper pulp before the introduction of the coagulant, while urea-formaldehyde resin with time gelatinization 140-260 to use in the form of a dispersion, which is a product suspension polycondensation of urea and formaldehyde in the presence of a protective colloid is a copolymer of butyl acrylate, butyl methacrylate and methacrylic acid at a ratio 1: (0,41-0,45): (0,15-0,19) and the ratio of urea and protective colloid 1: (0,05-0,12).

Introduction dispersion of urea-formaldehyde resin (UFR) in pulp and then adding the coagulant and flocculant allows to obtain in a single phase, bypassing the stage of impregnation, SMC, filled with the dispersion of the binder in an amount equivalent to input into the base paper by means of impregnation. When pressing the variance FSC melts and spreads over the whole volume of the decorative layer, mixing in boundary layers with phenol-formaldehyde resin of the inner layers DBSP and showing her wilst decorative layers can improve the interlayer adhesion due to migration to the surface of the connecting part of the inner layers.

Increasing the number of protective colloid for the limits indicated in the claims, without impacting on the colloidal properties of the dispersion CFS, leads to a slight increase of water absorption of plastics boiling, since the excess copolymer affects the fluidity of the molten resin and the uniformity of its distribution in dry - pressed material. The decrease in the amount of copolymer leads to the formation of larger particles dispersion CFS, which detect when storing the tendency to aggregation and result in degradation of physical and mechanical properties and deterioration of decorative plastic properties.

The presence of the binder - dispersion FSC - copolymer containing methacrylic acid, leads, due to the presence of this monomer, to a significant increase in the sensitivity of the particles to the action of the coagulant and their ability to precipitate when recharging as on the surface of cellulose fibers and on the surface of the particles of mineral filler, and in the interfibrillar space is almost free particles dispersion FSC. The change in the ratio of monomer in the protective colloid in the direction of decreasing the number m is I was partially allocates a resin phase, dispersion crumpled and the quality is poor to obtain uniformly filled with cellulose composite material for decorative layers of plastic. The increase in the number of methacrylic acid higher than specified in the claims ratio, has no effect on the colloidal properties of the dispersed CFS, however, somewhat deteriorates the fluidity of the binder when pressing plastic, which negatively affects the absorption of plastics by boiling, and also affects the quality decorative plastic surface. The change in the amount of the other monomer is butyl methacrylate - beyond specified in the claims, has a negative effect on the protective properties of the copolymer as the copolymer modified with a hydrophilic-lipophilic balance is having less affinity for micelles of urea-formaldehyde resin.

When using the dispersed product, at the time of gelatinization at 150aboutWith a smaller 140, there is the effect of negapressure plastic, because it is deeper than the required technological characteristics of pressing, stitching in the nuclei of CFS, the fluidity of the resin is reduced, resulting in a resistant plastic PR is no gelatinization, more 260 C, the conversion of the reactants is insufficient, the introduction of such precompensate FSC in the water while getting decorative SMC leads to loss of binding and, consequently, increased its consumption, as well as a deterioration of the physico-mechanical characteristics of plastic because education is not enough gulosity matrix utverzhdenii FSC.

P R I m e R 1. Prepare a 2% suspension of pulp - a mixture of bleached sulphate softwood and hardwood pulp with a beating degree of the 23aboutIt was taken in 1: 1 ratio. In the pulp suspension is injected filler is a mixture of titanium dioxide and carbon white modified, as well as the dye for securities color "ivory" VAT Golden yellow QCD, so that the ratio of the bleached pulp: titanium dioxide: white carbon black modified:dye is 35,96:8,0:6,0:0,04. Then in weight enter the variance of the CFS, which is obtained previously by suspension polycondensation of urea and formaldehyde at a pH of 7.5 to 12.0 in the presence of a protective colloid added when the mixture temperature 30aboutC. the polycondensation Reaction is carried out at a temperature of 80-100aboutWhen the ratio of urea and formaldehyde of 1: (0.5 to 2.0). As a protective colloid and 1: (0,41-0,45):(0,15-0,19); the ratio of urea and protective colloid is 1: (0,04-0,14). Get the variance FSC white with time gelatinization 130-280 with 150aboutC. After the introduction of mass dispersion was injected coagulant aluminum to achieve the pH of the mass of 4.3-4.7 and cast centrifugal weight 165 g/m2with a preliminary introduction to the mass of flocculant polyacrylamide in the amount of 0.25% of absolutely dry fiber.

P R I m m e R 2 (prototype). Cooked pulp from the pulp, filler and dye, as in example 1. Enter the coagulant to achieve a pH of 4.2 and directly before forming the paper introducing the flocculant is a polyacrylamide - in the amount of 0.25% of absolutely dry fiber. Cast paper web is dried and subjected to impregnation with a solution of urea-formaldehyde resin content binder 50 wt.% when the weight of base paper 165 g/m2.

Samples of SMC processed into plastic. Pressed sample TBSP thickness of 1.5 mm at a temperature of 145aboutC and at a pressure of 10 MPa. To do this, enter the package blank sheet of paper - the basic layers of unbleached sulfate pulp, containing 40 wt.% phenol-formaldehyde binder, after which the layer SMC for decorative layers.

As can be seen from the data given in the table, when used in the manufacture of plastic SMC, obtained by the proposed method, the plastic quality is maintained.

Thus the proposed method allows to exclude transactions involving the impregnation of paper (preparation of the impregnating solution, the impregnation and drying the impregnated fabric). The advantage of the proposed method compared with the method of the prototype is also a significant increase in elastic cellulose composite material containing a binder is a urea-formaldehyde resin (fracture resistance increases 27-28 times), which leads to a reduction of the marriage SMC during formation of the package before pressing plastic.

A method of OBTAINING a DECORATIVE COMPOSITE MATERIAL mainly for the outer layers of the laminate, including the introduction of a suspension of milled cellulose filler, coagulant and flocculant, ebb paper web and the introduction of urea-formaldehyde resin in an amount of not less than 50% by weight cellulosic composite material, characterized in that the urea-formaldehyde resin is injected into the mass before the introduction of the coagulant used the carb is pensionnoi polycondensation of urea and formaldehyde in the presence of a protective colloid - copolymer of butyl acrylate, butyl methacrylate and methacrylic acid in their mass ratio, respectively 1 : (0,41 - 0,45) : (0,15 - 0,19) and the ratio of urea and protective colloid 1 : (0,05 - 0,12).

 

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