It is reported that in 1998, 30% of China's particleboard has been veneer processing. In 2000, the output of laminate flooring exceeded 50 million m 2 . The above figures show that China's wood-based panel secondary processing industry has great potential for development. However, the gap between enterprises is very large, and a considerable number of enterprises' products cannot meet the quality requirements of GB/T15l02-94 "Dipped paper-coated wood-based panel". From April to June 1998, the National Wood-based Panel Quality Supervision and Inspection Center and the Nanjing Wood-based Panel Quality Supervision and Inspection Station conducted a unified sampling inspection of 54 companies in 15 provinces and Beijing, Shanghai and Tianjin. For 45 companies, 9 products were unqualified. A considerable number of enterprises in the country have not been sent for inspection and have not been sampled. The quality situation needs to be improved.
1 The main cause of product failure
1.1 Raw materials and semi-finished products and product quality inspection systems are not sound
Most companies lack testing methods for purchased chemical materials. We found that there are more than 30 impregnation production lines in the town of Jiangsu Province, accounting for about 1/3 of the national production line. It is one of the key production bases in China. However, they did not systematically test the chemical raw materials entering the factory. For example, melamine found three “three no products†in a chemical raw material market (no manufacturer, no quality standard, no product brand), no Chinese on the packaging bag. Only English "Made in China". In addition, some companies produce impregnated resins without quality standards and inspection procedures, and lack of inspection systems.
1.2 Equipment performance does not meet the process requirements
The veneer process technology content is high, and the requirements for each process are very strict. However, some enterprises do not really master the technology, and there is a lack of analysis and resolution of quality problems. In addition, some equipment performance does not meet the process requirements, so the quality The problem is not uncommon. We found that some enterprise rubber equipment is simple, there is no "return device". When the internal temperature rises to 80'C after feeding, the formaldehyde gas overflows, the operator on the console can't stay, and escapes to the remote door of the workshop. "Reactor. Waiting for the reaction time. Even more, a large-diameter steel pipe is installed on the reaction vessel cover, and a large amount of formaldehyde gas is discharged directly to the outside, causing pollution in the production environment, wasting chemical raw materials, and increasing the production cost. Ensure that the main active ingredients in the formula are fully involved in the chemical reaction, and therefore the quality of the resin: they are very dissatisfied with this production situation, and do not know how to improve. In a town in Jiangsu Province, we help a company in the existing On the basis of the equipment, the transformation was carried out because of the simple operation. The two 1000-liter reactors cost more than 10,000 yuan, increased the reflux device, modified some pipelines, and implemented the pipeline feed for the liquid raw materials. Formaldehyde smell, the operator can monitor the resin reaction through the “vacuum sampler†according to the resin process.
1.3 The formulation and process of impregnating resin is not relevant
The core technology of low-pressure short-cycle veneer is the formulation and production process of impregnating resin. Only the production of impregnating resin with excellent performance can guarantee the surface quality and intrinsic quality of the product. At present, some enterprises have mixed sources of impregnating resin and different processes. The impregnated resin produced has poor stability and can only be stored for 2-3 days at 20 ° C to 25 ° C. Some are shorter, only a few hours, the resin is degraded, smashed, and precipitated, which directly affects the quality of the impregnated film paper, and even the problem of sticking steel plate during hot pressing. China has a vast territory and different climatic conditions, 20C-25. The storage conditions of C are difficult to achieve all year round, and it is urgent to develop a stable impregnating resin.
1.4 Hot pressing process is unreasonable
Individual enterprises blindly pursue production. Some enterprises implement the “piece-rate wage systemâ€. The hot-pressed output is directly linked to wages. Therefore, the faster the pressure, the shorter the pressure time, and the intrinsic quality of the product. The result is: The resin can not be completely cured, can not form a complete resin film, directly affects the product's wear resistance, pollution resistance, water vapor resistance and other properties, resulting in product failure, can not pass the GB/T15102-94 national standard.
2 Recent advances in impregnation equipment and processes
2.1 Improve equipment and reduce energy consumption
The horizontal impregnation production line “removed†the infrared drying group (80kw in total) and changed it to two ovens, which greatly reduced the installed capacity and reduced the power consumption. According to the manufacturer, each paper can reduce the cost. 2 yuan. In recent years, newly introduced equipment from abroad has only one dipping tank. The melamine resin is changed from dipping to “scraping processâ€, which reduces the amount of resin and reduces the production cost. The impregnation speed can be increased to more than 40m/min.
2.2 Improving the properties and production process of impregnating resin
At present, the stability of melamine resin we have developed has been greatly improved. Under room temperature conditions, the resin remains clear and transparent within 40 days, which creates conditions for commercialization and can be shipped to all parts of the country. The above resins are more suitable for the existing conditions of Chinese enterprises, creating more relaxed conditions for production, which is conducive to production management and guarantee product quality.
The newly developed melamine resin greatly reduces the moisture absorption of the impregnated film paper. It can be stored in the common warehouse in Beijing area (no cooling, dehumidification equipment) for 3 months, basically no moisture absorption, no adhesion, hot pressing The production is normal. In the southern region, it is generally reflected that the moisture absorption is greatly improved.
The veneered artificial board produced by the enterprise using the above impregnated resin has passed the GB/T15102-94 national standard by the National Artificial Board Quality Supervision and Inspection Center.
At present, some companies only immerse melamine resin, which increases the cost of impregnating film paper. The urea-formaldehyde impregnating resin we developed costs only about 1.3 yuan/kg, and is subjected to two impregnations, that is, the first impregnation of furfural resin and the second impregnation of melamine resin. According to preliminary estimates, each film (4" x 8") can reduce the cost by about 2 yuan, and a production line can save thousands of dollars in one working day, and the economic benefits are considerable.
We have also successfully developed a CK-1 type super-hard resin, which can eliminate imported wear-resistant surface paper when producing laminate flooring. The wear-resisting performance of the laminate flooring can reach more than 10,000 rpm.
At present, veneered wood-based panels have entered the stage of development, and the technology is changing with each passing day. After China enters the “offâ€, the product quality will be the “focus†of competition. The author is willing to cooperate with the industry to further improve product quality and create better social benefits. Work hard with economic benefits.
1 The main cause of product failure
1.1 Raw materials and semi-finished products and product quality inspection systems are not sound
Most companies lack testing methods for purchased chemical materials. We found that there are more than 30 impregnation production lines in the town of Jiangsu Province, accounting for about 1/3 of the national production line. It is one of the key production bases in China. However, they did not systematically test the chemical raw materials entering the factory. For example, melamine found three “three no products†in a chemical raw material market (no manufacturer, no quality standard, no product brand), no Chinese on the packaging bag. Only English "Made in China". In addition, some companies produce impregnated resins without quality standards and inspection procedures, and lack of inspection systems.
1.2 Equipment performance does not meet the process requirements
The veneer process technology content is high, and the requirements for each process are very strict. However, some enterprises do not really master the technology, and there is a lack of analysis and resolution of quality problems. In addition, some equipment performance does not meet the process requirements, so the quality The problem is not uncommon. We found that some enterprise rubber equipment is simple, there is no "return device". When the internal temperature rises to 80'C after feeding, the formaldehyde gas overflows, the operator on the console can't stay, and escapes to the remote door of the workshop. "Reactor. Waiting for the reaction time. Even more, a large-diameter steel pipe is installed on the reaction vessel cover, and a large amount of formaldehyde gas is discharged directly to the outside, causing pollution in the production environment, wasting chemical raw materials, and increasing the production cost. Ensure that the main active ingredients in the formula are fully involved in the chemical reaction, and therefore the quality of the resin: they are very dissatisfied with this production situation, and do not know how to improve. In a town in Jiangsu Province, we help a company in the existing On the basis of the equipment, the transformation was carried out because of the simple operation. The two 1000-liter reactors cost more than 10,000 yuan, increased the reflux device, modified some pipelines, and implemented the pipeline feed for the liquid raw materials. Formaldehyde smell, the operator can monitor the resin reaction through the “vacuum sampler†according to the resin process.
1.3 The formulation and process of impregnating resin is not relevant
The core technology of low-pressure short-cycle veneer is the formulation and production process of impregnating resin. Only the production of impregnating resin with excellent performance can guarantee the surface quality and intrinsic quality of the product. At present, some enterprises have mixed sources of impregnating resin and different processes. The impregnated resin produced has poor stability and can only be stored for 2-3 days at 20 ° C to 25 ° C. Some are shorter, only a few hours, the resin is degraded, smashed, and precipitated, which directly affects the quality of the impregnated film paper, and even the problem of sticking steel plate during hot pressing. China has a vast territory and different climatic conditions, 20C-25. The storage conditions of C are difficult to achieve all year round, and it is urgent to develop a stable impregnating resin.
1.4 Hot pressing process is unreasonable
Individual enterprises blindly pursue production. Some enterprises implement the “piece-rate wage systemâ€. The hot-pressed output is directly linked to wages. Therefore, the faster the pressure, the shorter the pressure time, and the intrinsic quality of the product. The result is: The resin can not be completely cured, can not form a complete resin film, directly affects the product's wear resistance, pollution resistance, water vapor resistance and other properties, resulting in product failure, can not pass the GB/T15102-94 national standard.
2 Recent advances in impregnation equipment and processes
2.1 Improve equipment and reduce energy consumption
The horizontal impregnation production line “removed†the infrared drying group (80kw in total) and changed it to two ovens, which greatly reduced the installed capacity and reduced the power consumption. According to the manufacturer, each paper can reduce the cost. 2 yuan. In recent years, newly introduced equipment from abroad has only one dipping tank. The melamine resin is changed from dipping to “scraping processâ€, which reduces the amount of resin and reduces the production cost. The impregnation speed can be increased to more than 40m/min.
2.2 Improving the properties and production process of impregnating resin
At present, the stability of melamine resin we have developed has been greatly improved. Under room temperature conditions, the resin remains clear and transparent within 40 days, which creates conditions for commercialization and can be shipped to all parts of the country. The above resins are more suitable for the existing conditions of Chinese enterprises, creating more relaxed conditions for production, which is conducive to production management and guarantee product quality.
The newly developed melamine resin greatly reduces the moisture absorption of the impregnated film paper. It can be stored in the common warehouse in Beijing area (no cooling, dehumidification equipment) for 3 months, basically no moisture absorption, no adhesion, hot pressing The production is normal. In the southern region, it is generally reflected that the moisture absorption is greatly improved.
The veneered artificial board produced by the enterprise using the above impregnated resin has passed the GB/T15102-94 national standard by the National Artificial Board Quality Supervision and Inspection Center.
At present, some companies only immerse melamine resin, which increases the cost of impregnating film paper. The urea-formaldehyde impregnating resin we developed costs only about 1.3 yuan/kg, and is subjected to two impregnations, that is, the first impregnation of furfural resin and the second impregnation of melamine resin. According to preliminary estimates, each film (4" x 8") can reduce the cost by about 2 yuan, and a production line can save thousands of dollars in one working day, and the economic benefits are considerable.
We have also successfully developed a CK-1 type super-hard resin, which can eliminate imported wear-resistant surface paper when producing laminate flooring. The wear-resisting performance of the laminate flooring can reach more than 10,000 rpm.
At present, veneered wood-based panels have entered the stage of development, and the technology is changing with each passing day. After China enters the “offâ€, the product quality will be the “focus†of competition. The author is willing to cooperate with the industry to further improve product quality and create better social benefits. Work hard with economic benefits.
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