The limiting factors and application of wood-plastic materials in the furniture industry
Wood -plastic composite (WPC) is a new type of composite material developed in recent years . It is light in weight, rigid, acid and alkali resistant, waterproof and insect proof, and environmentally friendly. It can be nailed, drilled, planed and sawn like wood . Gluing and painting , as well as thermoplastic processing and surface decoration printing, is currently widely used in construction materials, municipal facilities, packaging materials and other fields. In addition to the above advantages, its feel is very similar to wood, so it is considered that the application in the field of furniture has great potential. However, the current application of wood-plastic materials in the furniture industry is still not much, what is the cause of this phenomenon? This paper explores this issue from the aspects of material properties and consumers.
First, the limiting factors of the application of wood-plastic materials in the furniture industry
Production method
At present, the production of wood-plastic materials mainly adopts extrusion molding, that is, the wood powder and the molten plastic are mixed and extruded into the die holes to obtain various profiles and plates , and the growth rate of the profiles is much higher than that of the plates. In order to reduce the amount of raw materials, companies use micro-foaming technology to reduce the density of materials and produce fine through-holes in the profiles through mold technology. The surface can be decorated and protected by painting or ink printing technology. The printing technology can not only obtain very realistic wood and stone texture, but also the surface scratching within a certain range will not have a great impact on the appearance due to the penetration of the ink into the material. . The production method of wood plastic materials has the following restrictions on furniture design and manufacture:
(1) Low degree of freedom of modeling
Due to the extrusion molding, wood-plastic materials can only be in a straight line state in most cases, and there is almost no curve shape and smooth transition. Therefore, it is difficult to reflect the affinity and comfort that the furniture should have, and the design for furniture production. Freedom is greatly reduced. From the current situation, the production method of developing furniture products with wood-plastic materials is closer to that of panel furniture, and the appearance is similar, but the cost is slightly higher and the market competitiveness is weak. Therefore, if the appearance does not have the main features of solid wood furniture, the development of wood-plastic furniture will be subject to great market resistance.
(2) High requirements for end face processing
The through hole of the profile can reduce the weight and save the material, which is the main reason for the low cost of the wood plastic material. However, the end face of the profile has low strength and is vulnerable to collision or local force damage, and the force node of the furniture is often at the end of the material, so special treatment is needed on the end to increase the strength and improve the strength. Cost and technical difficulty; In addition, consumers have higher requirements for details when they appreciate furniture. They require end face treatment not only to consider the force, but also to consider the aesthetics and changes of the form, the cleaning and comfort requirements of the use process, which are all wood plastic. The use of materials in the field of furniture presents difficulties.
(3) Limited connection method
At present, the common connection method of wood-plastic materials is through the joint of the tongue and socket, nailing and bonding. The joint of the tongue and mouth can well restrict the activities of the two dimensions between the materials, and the structure is reliable, but the use is limited to the combination of the faces, and it is difficult to be used as the support structure; the nailing requirement has sufficient anchor depth, and generally needs to be inside the hollow profile. Filling the wooden block, the production efficiency is low; the bonding has high requirements on the contact surface, the production is difficult to achieve automation, and the glue may flow to the surface to affect the appearance.
2. Surface quality
(1) Surface flatness is an important factor in the quality of furniture. Whether it is solid wood furniture or panel furniture, this requirement is very demanding. For wood-plastic materials, this requirement is particularly demanding. After the wood plastic material is extruded from the hole, local deformation will occur due to internal stress. Although the influence of environmental humidity on the wood plastic material is negligible, the large temperature difference will cause the warpage deformation of the flat sheet. At present, the problem that the office partition made of wood-plastic materials encountered at the time of export is the deformation of the product caused by the temperature difference between the place of origin and the country of export.
(2) The low surface hardness of wood-plastic materials is also an unfavorable factor affecting its application in the furniture industry. Furniture may be subject to various collisions during installation, transportation, and use. If the surface hardness of the furniture is low, surface defects may easily occur. The surface of the wood-plastic profile can be traced with a key or even a nail. Although the printed wood grain can serve as a cover, it is a big disadvantage as a furniture material.
(3) The surface texture of the material using the printed surface is regularly repeated by the diameter of the printing roller, which affects the realism when used in a large area. Some woods, such as eucalyptus, have a dotted pattern with no large patterned texture. There is no obvious artificial trace after repeated appearance, while rosewood and rosewood have obvious linear texture, and the same texture repeats. It feels very unnatural afterwards.
3. Consumer values
Nowadays, most consumers think that solid wood furniture is better than panel furniture. On the one hand, because of the large-scale mechanized production of panel furniture, its cost is reduced. The market price is far lower than that of solid wood furniture. On the other hand, due to the forest resource crisis, people are facing The value of wood is judged to increase, and the value of solid wood furniture is growing. In addition, in order to improve their own market value, some enterprises combine the precious wood and the extraordinary carving skills of the master craftsmen to produce several sets of treasures of the town shop, marking the sky-high price of hundreds of thousands and guiding consumers' value judgment. In contrast, the value of artificial boards such as MDF and plywood is obviously low. This value determines that it is difficult for PVC plastic furniture to squeeze into the furniture market with a large profit margin . Without large profits, new materials are difficult to enter the market.
Second, the response to the proposal
1. Using secondary processing technology and applicable plastic and hardware design to make up for the lack of production technology.
(1) Bending test of the proof wood profiles single line style wood profile can be changed, and the bending curve shape can appear on wood furniture. The test methods and processes are as follows:
According to the pilot enterprise data and preliminary tests, the deformation temperature range is determined to be about 155 degrees. With reference to the metal pipe bending process and preliminary test, the method of selecting the hot sand to be bent in the mold is determined; the bending radius and the angle range are determined according to the design target; The preferred deformation temperature is determined according to the previous stage test; the bending technique is adjusted according to the results of each test; and the conclusion is drawn based on the test record analysis.
This test has a total of 39 curved profiles and 37 recorded values ​​(part of the test sample attached). After analysis, it is concluded that the good deformation temperature of solid material is about 155 degrees Celsius; the deformation temperature of hollow material is about 162 degrees Celsius; the minimum bending radius of 90 degree angle is 20mm for JF11020 and 40mm for JF7040; The small bending radius of the time: JF11020 is 31mm. From the experimental results, the modeling freedom and corner angle of wood-plastic profiles used in furniture design and production can be solved, and the bending process is conducive to the production of modeling features.
(2) Foaming molding technology is a production technology that has been maturely applied by pilot enterprises. Currently, it is used in the manufacture of wood-plastic door. The basic principle is to fill the foaming agent between two wood-plastic panels and use the heat generated by the foaming agent. And the pressure causes the wood-plastic sheet to be pressed against the inner surface of the mold to produce tensile deformation, and after cooling, it is naturally bonded to the integral door panel. The door panel thus produced can be embedded with hinges, handles, linings and pipes for circuits and locks, and has high production efficiency, low cost, and the appearance quality of solid wood doors.
This technology can be used to produce parts such as furniture door panels, panels, and integral backrests with embedded parts. It is not only low cost, high efficiency, and easy to install, but also can use the mold to obtain different relief patterns, so that the furniture shape and There are more choices in the form of surface decoration.
(3) Solving the problem of sealing and joining of wood-plastic profiles with special hardware and plastic parts. Usually aluminum alloy profiles are closed by colored or electroplated plastic fasteners. Wood-plastic profiles can not only learn from this method, but also use the elasticity of the material to make the fasteners and profiles more tightly combined, thus providing a more overall vision. effect. A good example is the installation of wood-plastic decorative velvet: the decorative money has a nail groove with a seal, and the decorative line is fixed with a nail, and then the seal is stuck on the groove, so that the nail hole does not affect the appearance. .
The design of the special joints for wood-plastic parts should consider the following factors: the inner hole size of wood-plastic profiles is not as precise as that of aluminum alloy profiles, and the joints must have greater adaptability; the thin-wall strength is smaller than that of metal materials, and the hardware and wood-plastic profiles are fixed. It is necessary to have a large enough contact area; the inner cavity space of the profile is used to install a delicate mechanism to achieve certain special functions; the foaming technology can be used to embed the hardware inside the profile.
2. Use design methods to improve surface quality
(1) Light deformation of the material affects the appearance of the furniture, and affects the use of the furniture. Whether it is solid wood furniture or panel furniture, this problem is faced. At present, paint or veneer is usually used to keep the moisture content inside the material stable to prevent deformation, or to use a color or engraving pattern to cover the deformation and play a decorative role on a large area of ​​furniture parts. Since the main cause of deformation of wood-plastic materials is temperature change, the method of separating with paint does not help, which makes surface decoration design a very important task. In addition to common surface decoration techniques such as carving, inlaying, segmentation, and texture change, wood-plastic materials also have their own unique decorative methods, such as printing, splicing, molding, and so on.
(2) The surface hardness of wood-plastic materials can be improved by coating high-hardness paint layers. Some companies have developed wood-plastic flooring. Although the hardness cannot be compared with laminate flooring, it is not a problem for furniture surfaces.
(3) By increasing the diameter of the printing roller to solve the high repetition cost of the surface texture but the effect is limited, it is conceivable to replace the existing roller printing method with an ink jet printer. At present, the inkjet printers produced by Agfa in Germany can print large-format posters, billboards and signboards, and the surface quality of the wood-plastic panels can be greatly improved by adapting the technology to the surface printing of the board.
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