DEVICE AND METHOD FOR MANUFACTURING WOOD-PLASTIC COATED LUMBER COMPOSITE

Abstract

A wood-plastic/lumber composite co-extrusion feeder includes a frame, wherein at least one group of toothed conveying units, a tooth mark milling unit for milling tooth marks on an outer surface of a lumber, and a lumber co-extrusion mold are arranged on the frame in sequence, each toothed conveying unit includes a lower toothed pressure roller installed on a first fixed bearing seat and an upper toothed pressure roller installed on a first movable bearing seat, and after the first fixed bearing seat and the first movable bearing seat are connected by an adjustment unit, a first conveying channel having an adjustable height is formed between the upper toothed pressure roller and the lower-toothed pressure roller.

Claims

1. A wood-plastic/lumber composite co-extrusion feeder, comprising a frame, wherein at least one group of toothed conveying units, a tooth mark milling unit for milling tooth marks on an outer surface of a lumber, and a lumber co-extrusion mold are arranged on the frame in sequence, each toothed conveying unit comprises a lower toothed pressure roller installed on a first fixed bearing seat and an upper toothed pressure roller installed on a first movable bearing seat, and after the first fixed bearing seat and the first movable bearing seat are connected by a first adjustment unit, a first conveying channel having an adjustable height is formed between the upper toothed pressure roller and the lower-toothed pressure roller.

2. The wood-plastic/lumber composite co-extrusion feeder according to claim 1, wherein at a front side of the toothed conveying unit a rubber pressure roller unit is arranged which comprises a lower rubber roller installed on a second fixed bearing seat and an upper rubber roller installed on a second movable bearing seat, after the second fixed bearing seat and the second movable bearing seat are connected by a second adjustment unit, a second conveying channel having an adjustable height is formed between the upper rubber roller and the lower rubber roller, and an elastic rubber layer is sheathed on outer surfaces of the upper rubber roller and the lower rubber roller.

3. The wood-plastic/lumber composite co-extrusion feeder according to claim 1, wherein the first adjustment unit comprises: a first sliding rod, a first fixed-length sleeve sheathed outside the first sliding rod, a first adjusting nut for adjustment and a first compressed spring with one end pressed against the first adjusting nut.

4. The wood-plastic/lumber composite co-extrusion feeder according to claim 1, wherein each toothed conveying unit is provided with a group of limiting rubber roller sets, each limiting rubber roller set comprises a left limiting rubber roller and a right limiting rubber roller, and a limiting space is formed between the left limiting rubber roller and the right limiting rubber roller.

5. The wood-plastic/lumber composite co-extrusion feeder according to claim 45, wherein two toothed conveying units are provided, and the two toothed conveying units are located between two groups of limiting rubber roller sets.

6. The wood-plastic/lumber composite co-extrusion feeder according to claim 1, wherein the tooth mark milling unit comprises a first tooth mark milling mechanism for milling upper and lower surfaces of a lumber and a second tooth mark milling mechanism for milling left and right surfaces of the lumber, the first tooth mark milling mechanism comprises a first milling cutter frame and a first tooth mark roller located at a rear side of the first milling cutter frame, the second tooth mark milling mechanism comprises a second milling cutter frame and a second tooth mark roller located at a rear side of the second milling cutter frame, and the first milling cutter frame and the second milling cutter frame are respectively provided with a milling cutter.

7. A method for manufacturing a wood-plastic coated lumber composite, comprising the following steps: 1) feeding a lumber core by a wood-plastic/lumber composite co-extrusion feeder, and processing the lumber core to form point-like gear pressing marks on the lumber core, wherein the wood-plastic/lumber composite co-extrusion feeder comprises a frame, at least one group of toothed conveying units, a tooth mark milling unit for milling tooth marks on an outer surface of a lumber, and a lumber co-extrusion mold are arranged on the frame in sequence, each toothed conveying unit comprises a lower toothed pressure roller installed on a first fixed bearing seat and an upper toothed pressure roller installed on a first movable bearing seat, and after the first fixed bearing seat and the first movable bearing seat are connected by a first adjustment unit, a first conveying channel having an adjustable height is formed between the upper toothed pressure roller and the lower-toothed pressure roller; 2) weaving or winding a continuous high-strength fiber on a surface of the lumber core to form a fiber mesh; and 3) co-extruding outside the fiber mesh to form a wood-plastic layer to obtain a wood-plastic coated lumber composite.

8. The method according to claim 7, wherein the wood-plastic coated lumber composite comprises the lumber core coated with a wood-plastic composite layer, and the surface of the lumber core is provided with the point-like gear pressing marks; the continuous fiber mesh is further coated outside the lumber core with the point-like gear pressing marks, and the fiber mesh is coated and restrained by the wood-plastic composite layer; and the high-strength fiber is at least one of a carbon fiber, a glass fiber, a basalt fiber, an aramid fiber, a polyester fiber, a polyamide fiber and a polyacrylonitrile fiber.

9. The method according to claim 8, wherein the high-strength fiber is a fiber pre-soaked with a prepreg resin matrix, and the prepreg resin matrix is at least one of a wood-plastic composite or polypropylene, polyethylene, polyvinyl chloride, polylactic acid and polystyrene; the wood-plastic composite layer comprises a first wood-plastic layer and a second wood-plastic layer which are connected, wherein the first wood-plastic layer is completely coated on the lumber core and the point-like gear pressing marks and forms a nail structure in the point-like gear pressing marks, the continuous fiber mesh is arranged between the first wood-plastic layer and the second wood-plastic layer, and the second wood-plastic layer is completely coated on the fiber mesh.

10. The method according to claim 7, wherein a pressing mark depth is 0.5 mm to 4 mm independently; and a pressing mark density is 1 piece/cm2 to 20 pieces/cm2 independently, and is preferably 4 pieces/cm2 to 10 pieces/cm2.

11. The method according to claim 7, wherein thicknesses of the first wood-plastic layer and the second wood-plastic layer are 0.1 mm to 2 mm and 1 mm to 5 mm respectively.

12. The wood-plastic/lumber composite co-extrusion feeder according to claim 2, wherein the second adjustment unit comprises: a second sliding rod, a second fixed-length sleeve sheathed outside the second sliding rod, a second adjusting nut for adjustment and a second compressed spring with one end pressed against the second adjusting nut.

13. The method according to claim 8, wherein at a front side of the toothed conveying unit a rubber pressure roller unit is arranged which comprises a lower rubber roller installed on a second fixed bearing seat and an upper rubber roller installed on a second movable bearing seat, after the second fixed bearing seat and the second movable bearing seat are connected by a second adjustment unit, a second conveying channel having an adjustable height is formed between the upper rubber roller and the lower rubber roller, and an elastic rubber layer is sheathed on outer surfaces of the upper rubber roller and the lower rubber roller.

14. The method according to claim 8, wherein the first adjustment unit comprises: a first sliding rod, a first fixed-length sleeve sheathed outside the first sliding rod, a first adjusting nut for adjustment and a first compressed spring with one end pressed against the first adjusting nut.

15. The method according to claim 13, wherein the second adjustment unit comprises: a second sliding rod, a second fixed-length sleeve sheathed outside the first sliding rod, a second adjusting nut for adjustment and a second compressed spring with one end pressed against the second adjusting nut.

16. The method according to claim 8, wherein each toothed conveying unit is provided with a group of limiting rubber roller sets, each limiting rubber roller set comprises a left limiting rubber roller and a right limiting rubber roller, and a limiting space is formed between the left limiting rubber roller and the right limiting rubber roller.

17. The method according to claim 16, wherein two toothed conveying units are provided, and the two toothed conveying units are located between two groups of limiting rubber roller sets.

18. The method according to claim 8, wherein the tooth mark milling unit comprises a first tooth mark milling mechanism for milling upper and lower surfaces of a lumber and a second tooth mark milling mechanism for milling left and right surfaces of the lumber, the first tooth mark milling mechanism comprises a first milling cutter frame and a first tooth mark roller located at a rear side of the first milling cutter frame, the second tooth mark milling mechanism comprises a second milling cutter frame and a second tooth mark roller located at a rear side of the second milling cutter frame, and the first milling cutter frame and the second milling cutter frame are respectively provided with a milling cutter.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to explain the technical solutions in the embodiments of the present disclosure more clearly, the accompanying drawings needed to be used in description of the embodiments are briefly described hereinafter. Obviously, the described accompanying drawings are only some but not all of the embodiments of the present disclosure, and those skilled in the art may also obtain other design schemes and accompanying drawings according to these accompanying drawings without going through any creative work.

[0032] FIG. 1 is a structure diagram of some embodiments of a wood-plastic/lumber composite co-extrusion feeder according to the present disclosure;

[0033] FIG. 2 is a top view of some embodiments of the wood-plastic/lumber composite co-extrusion feeder according to the present disclosure; and

[0034] FIG. 3 is a cross-section view in a direction A-A of FIG. 2.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0035] The concept, the specific structure and the generated technical effect of the present disclosure are clearly and completely described hereinafter with reference to the embodiments and the accompanying drawings to fully understand the objectives, the features and the effects of the present disclosure. Obviously, the described embodiments are only some but not all of the embodiments of the present disclosure, and based on the embodiments of the present disclosure, other embodiments obtained by those skilled in the art without going through any creative work all belong to the scope of protection of the present disclosure. In addition, all coupling/connection relationships mentioned therein do not indicate direct connection between members only, but indicate that a better coupling structure may be formed by adding or reducing a coupling accessory according to specific implementation conditions.

[0036] With reference to FIG. 1 to FIG. 3, a wood-plastic/lumber composite co-extrusion feeder includes a frame 10. At least one group of toothed conveying units 6, a tooth mark milling unit 8 for milling tooth marks on an outer surface of a lumber, and a lumber co-extrusion mold 9 are arranged on the frame 10 in sequence. Each toothed conveying unit 6 includes a lower toothed pressure roller 61 installed on a first fixed bearing seat and an upper toothed pressure roller 60 installed on a first movable bearing seat, and after the first fixed bearing seat and the first movable bearing seat are connected by an adjustment unit, a first conveying channel having an adjustable height is formed between the upper toothed pressure roller 60 and the lower-toothed pressure roller 61. The frame 10 is further provided with a speed regulating motor 2, at an output end of the speed regulating motor 2, a speed reducer 3 is installed and connected with the toothed conveying unit 6 and a rubber pressure roller unit 5 by a chain drive 4.

[0037] The speed regulating motor 2 and the speed reducer 3 control a speed at which the lumber enters the mold by the chain drive, and the rubber pressure roller unit 5 controls an irregular error when the lumber enters initially. The toothed conveying unit 6 accurately controls a forward speed of the lumber and offsets a reverse resistance generated during operation of the milling cutter set in the tooth mark milling unit 8, and the two groups of limiting rubber roller sets define and maintain a forward linear position of the lumber. The lumber is milled into a precise-sized lumber by the milling cutter on a fine tooth mark milling machine and the tooth marks are pressed thereon, and then the lumber enters the wood-plastic/lumber composite co-extrusion mold 9.

[0038] Hard alloy sharp teeth are densely distributed on the upper toothed pressure roller 60 and the lower toothed pressure roller 61, and bite into the surface of the lumber, so as to accurately control the forward speed of the lumber and offset the reverse resistance generated during operation of the milling cutter set in the tooth mark milling unit 8. By replacing the middle fixed-length sleeve, it is suitable for the lumbers with different size requirements. A compressed spring and an adjusting nut are used for maintaining a pressure of the upper toothed pressure roller 60.

[0039] At a front side of the toothed conveying unit 6, a rubber pressure roller unit 5 is arranged which includes a lower rubber roller 51 installed on a second fixed bearing seat and an upper rubber roller 50 installed on a second movable bearing seat. After the second fixed bearing seat and the second movable bearing seat are connected by an adjustment unit, a second conveying channel having an adjustable height is formed between the upper rubber roller 50 and the lower rubber roller 51, and an elastic rubber layer is sheathed on outer surfaces of the upper rubber roller 50 and the lower rubber roller 51. The upper rubber roller 50 and the lower rubber roller 51 have a large friction force and a corresponding elasticity, thus being able to adapt to the irregular error when the lumber enters initially. By replacing the middle fixed-length sleeve, it is suitable for the lumbers with different size requirements. The compressed spring and the adjusting nut are used for maintaining the pressure of the upper rubber roller 50.

[0040] The adjustment unit includes a sliding rod, a fixed-length sleeve sheathed outside the sliding rod, an adjusting nut 63 for adjustment and a compressed spring 62 with one end pressed against the adjusting nut 63. One end of the adjusting nut 63 is respectively inserted into a corresponding movable bearing seat, one end of the compressed spring 62 is pressed against the corresponding movable bearing seat, and the other end of the compressed spring 62 is pressed against the adjusting nut 63.

[0041] Each toothed conveying unit 6 is provided with a group of limiting rubber roller sets 7, each limiting rubber roller set 7 includes two holding brackets, a left limiting rubber roller and a right limiting rubber roller, and a plurality of bearing seats are arranged on each holding bracket. The left limiting rubber roller and the right limiting rubber roller are installed between two bearing seats of the corresponding holding brackets. A limiting space is formed between the left limiting rubber roller and the right limiting rubber roller.

[0042] Two toothed conveying units 6 are provided, and the two toothed conveying units 6 are located between two groups of limiting rubber roller sets 7, which means that the two groups of limiting rubber roller sets 7 are installed at two sides of two groups of toothed conveying units 6 to limit and maintain the forward linear position of the lumber. The left limiting rubber roller and the right limiting rubber roller have a corresponding elasticity, thus being able to adapt to the irregular error when the lumber enters initially.

[0043] The tooth mark milling unit 8 includes a first tooth mark milling mechanism for milling upper and lower surfaces of a lumber and a second tooth mark milling mechanism for milling left and right surfaces of the lumber. The first tooth mark milling mechanism includes a first milling cutter frame and a first tooth mark roller 81 located at a rear side of the first milling cutter frame, the second tooth mark milling mechanism includes a second milling cutter frame and a second tooth mark roller 82 located at a rear side of the second milling cutter frame, and the first milling cutter frame and the second milling cutter frame are respectively provided with a milling cutter. The first tooth mark milling mechanism and the second tooth mark milling mechanism are respectively provided with a high-speed milling cutter motor.

[0044] In the embodiment, the first tooth mark milling mechanism is located at a front side of the second tooth mark milling mechanism. After the lumber passes through the first tooth mark milling mechanism and the second tooth mark milling mechanism in sequence, and the corresponding milling cutters respectively process the upper and lower surfaces and the left and right surfaces of the lumber, the lumber is milled into the precise-sized lumber, and the tooth marks are pressed on the corresponding surfaces of the lumber by the first tooth mark roller 81 and the second tooth mark roller 82. The lumber enters the wood-plastic/lumber composite co-extrusion mold 9, and the tooth marks on the precise-sized lumber form an anchor chain effect with wood-plastic composite melt in the co-extrusion mold, thus increasing an interface bonding strength.

[0045] A method for manufacturing a wood-plastic coated lumber composite, which includes the following steps:

[0046] 1) feeding a lumber core by the wood-plastic/lumber composite co-extrusion feeder as described according to the first aspect of the present disclosure and processing the lumber core to form point-like gear pressing marks on the lumber core;

[0047] 2) weaving or winding a continuous high-strength fiber on a surface of the lumber core to form a fiber mesh; and

[0048] 3) co-extruding outside the fiber mesh to form a wood-plastic layer to obtain a wood-plastic coated lumber composite.

[0049] In some embodiments of the manufacturing method, the wood-plastic coated lumber composite includes the lumber core, the lumber core is coated with a wood-plastic composite layer, and the surface of the lumber core is provided with the point-like gear pressing marks. The continuous fiber mesh is also coated outside the lumber core with the point-like gear pressing marks, and the fiber mesh is coated and restrained by the wood-plastic composite layer.

[0050] The high-strength fiber is at least one of a carbon fiber, a glass fiber, a basalt fiber, an aramid fiber, a polyester fiber, a polyamide fiber and a polyacrylonitrile fiber.

[0051] In some embodiments of the manufacturing method, the high-strength fiber is a fiber pre-soaked with a prepreg resin matrix, and the prepreg resin matrix is at least one of a wood-plastic composite or polypropylene, polyethylene, polyvinyl chloride, polylactic acid and polystyrene.

[0052] In some embodiments of the manufacturing method, the wood-plastic composite layer includes a first wood-plastic layer and a second wood-plastic layer which are connected, wherein the first wood-plastic layer is completely coated on the lumber core and the point-like gear pressing marks and forms a nail structure in the point-like gear pressing marks, the continuous fiber mesh is arranged between the first wood-plastic layer and the second wood-plastic layer, and the second wood-plastic layer is completely coated on the fiber mesh.

[0053] In some embodiments of the manufacturing method, a pressing mark depth is 0.5 mm to 4 mm independently; and a pressing mark density is 1 piece/cm.sup.2 to 20 pieces/cm.sup.2 independently, and is preferably 4 pieces/cm.sup.2 to 10 pieces/cm.sup.2.

[0054] In some embodiments of the manufacturing method, thicknesses of the first wood-plastic layer and the second wood-plastic layer are 0.1 mm to 2 mm and 1 mm to 5 mm respectively.

[0055] A raw material for the wood-plastic composite includes all wood fiber materials and mixtures thereof, and a thermoplastic polymer, such as PP\PE\PVC\PS\polylactic acid and a blend of the mixtures thereof. For convenience of comparison, in the following embodiments and comparative embodiments, the wood-plastic composite consists of 40% (mass fraction) wood powder, 50t % (mass fraction) high-density polyethylene, 5% talcum powder, 3% coupling agent and 2% lubricant.

Embodiment 1

[0056] A wood-plastic coated lumber composite includes a lumber core. A cross section of the lumber core is 74 mm×34 mm. A surface of the lumber core is provided with point-like gear pressing marks with a depth of 2 mm and a density of 10 pieces/cm.sup.2. A continuous fiber mesh is further coated outside the lumber core, and the fiber mesh is coated and restrained by the wood-plastic composite layer.

[0057] The fiber mesh is formed by weaving or winding a continuous carbon fiber outside the lumber core.

[0058] The wood-plastic composite layer is coated on the lumber core and the fiber mesh in a co-extruded manner, wherein the wood-plastic composite layer includes a first wood-plastic layer and a second wood-plastic layer. The first wood-plastic layer has a thickness of 1 mm, and the second wood-plastic layer has a thickness of 2 mm. The first wood-plastic layer is completely coated on the lumber core and the point-like gear pressing marks and forms a nail structure in the point-like gear pressing marks. The continuous fiber mesh is arranged between the first wood-plastic layer and the second wood-plastic layer, and the second wood-plastic layer is completely coated on the fiber mesh.

Embodiment 2

[0059] The Embodiment 2 is the same as the Embodiment 1, except that the carbon fiber is pre-soaked with the wood-plastic composite.

Embodiment 3

[0060] The Embodiment 3 is the same as the Embodiment 1, except that the pressing mark depth is 4 mm.

Embodiment 4

[0061] The Embodiment 4 is the same as the Embodiment 1, except that the pressing mark depth is 0.5 mm.

Embodiment 5

[0062] The Embodiment 5 is the same as the Embodiment 3, except that the carbon fiber is pre-soaked with the wood-plastic composite.

Embodiment 6

[0063] The Embodiment 6 is the same as the Embodiment 2, except that the pressing mark density is 5 pieces/cm.sup.2.

Embodiment 7

[0064] The Embodiment 7 is the same as the Embodiment 2, except that the pressing mark density is 1 piece/cm.sup.2.

Embodiment 8

[0065] The Embodiment 8 is the same as the Embodiment 2, except that the pressing mark density is 25 pieces/cm.sup.2.

Comparative Embodiment 1

[0066] The Comparative Embodiment 1 is the same as the Embodiment 1, except that the pressing mark depth is 0.3 mm.

Comparative Embodiment 2

[0067] The Comparative Embodiment 2 is the same as the Embodiment 1, except that the continuous fiber mesh is not coated outside the lumber core.

Comparative Embodiment 3

[0068] The Comparative Embodiment 3 is the same as the Embodiment 1, except that the surface of the lumber core has no pressing mark.

Comparative Embodiment 4

[0069] The Comparative Embodiment 4 is the same as the Embodiment 1, except that the surface of the lumber core has no pressing mark, and the continuous fiber mesh is not coated outside the lumber core.

TABLE-US-00001 Interface bonding strength (MPa) Embodiment 1 1.07 to 1.26 Embodiment 2 1.28 to 1.59 Embodiment 3 1.21 to 1.49 Embodiment 4 0.51 to 0.75 Embodiment 5 1.55 to 1.91 Embodiment 6 1.11 to 1.34 Embodiment 7 0.92 to 1.10 Embodiment 8 1.33 to 1.67 Comparative Embodiment 1 0.42 to 0.64 Comparative Embodiment 2 0.40 to 0.61 Comparative Embodiment 3 0.33 to 0.54 Comparative Embodiment 4 0.22 to 0.37

[0070] The pressing marks on the surface of the lumber core and the coated continuous fiber mesh are able to greatly improve the interface bonding strength, and the pressing mark depth has a positive correlation with the interface bonding strength within a certain range. When the pressing mark depth is higher than a certain range, the interface bonding strength is not improved significantly. The carbon fiber pre-soaked with the wood-plastic composite can better improve the interface bonding strength. Increasing the pressing mark density in a certain range is beneficial for improving the interface bonding strength.

[0071] The foregoing describes the preferred embodiments of the present disclosure in detail, but the present disclosure is not limited to the embodiments. Those skilled in the art may further make various equivalent modifications or substitutions without violating the principle of the present disclosure, and these equivalent modifications or substitutions are all included in the scope defined by the claims of the present application.