JPH01120302A - Manufacture of molded flitch - Google Patents

Abstract

PURPOSE: To produce formed plywood in which hardness is high and durability is good and generation of bubbles is inhibited and film thickness is large by forming a resin film consisting of powdery resin respectively on the inner surface of a forming mold and on the surface of decorative material and thereafter heating and contact-bonding both the decorative material and base material.. CONSTITUTION: Resin films 1a, 2a are formed respectively by applying powdery resin on the inner surface of a forming mold 1 and on the surface of decorative material 2. Thereafter, the resin films 1a, 2a are passed through the insides of a heating oven or an infrared irradiation oven, fused and solidified respectively on the surfaces of the forming mold 1 or the decorative material 2. Then, the decorative material 2 with the formed resin film 2a and a plurality of base materials 3, 3... coated with an adhesive are laminated according to a prescribed lamination order and thereafter the obtained laminate is introduced into the forming mold 1 with the formed resin film 1a, heated and pressurized. Since the respective resin films provided on the inner surface of the forming mold and on the surface of decorative material together become the surface protective layer of formed plywood, the formed plywood, in which film thickness is large and hardness is high, is obtained.

Description

Detailed Description of the Invention [Industrial Application Field] This invention relates to a manufacturing method in which a resin film for surface protection is formed at the same time as molding of molded plywood. By providing a resin film made of powdered resin on the surface of the material, a protective layer with a particularly large film thickness and suppressed bubble generation can be obtained, making it possible to produce molded plywood with a thick film that is hard and highly durable. This is what I did.

[Prior Art] Conventionally, the manufacturing method of molded plywood in which a decorative material and a base material are laminated and integrated has generally involved applying an adhesive to one or both of the decorative material and the base material, laminating them, and then forming the plywood. A method is known in which a desired molded plywood is obtained by charging the material into a mold and molding it by heating and pressurizing it, and then painting the surface to form a resin film as a protective layer. This method aims to improve properties such as durability and design by providing a protective layer on the surface.

[Problems to be Solved by the Invention] However, in this method, the protective layer is formed by painting after manufacturing the molded plywood by molding, so it is difficult to form a thick protective layer. there were. In particular, when the molded plywood to be obtained has a three-dimensional shape and the surface to be painted is not a flat surface, or when painting is performed using powdered resin, it is necessary to apply the powdered resin evenly. Because it is extremely difficult to do so, the above-mentioned problems are even more serious.

For this reason, it has been difficult to obtain sufficient properties such as rigidity and durability of molded plywood. Also, in this method,
When the thickness of the formed protective layer exceeds 150 μm, defoaming in the protective layer tends to be insufficient, which often causes the problem of bubble generation.

It is an object of the present invention to solve the above-mentioned problems and provide a method for obtaining a molded plywood having a large film thickness, which is hard and durable, and suppresses the generation of bubbles.

[Means for Solving the Problems] This invention involves forming resin films made of powder resin on the inner surface of a mold and the surface of a decorative material, respectively, and then applying the decorative material and base material to the mold. The solution is to charge the material and heat and press it.

Hereinafter, an example of the method for manufacturing molded plywood of the present invention will be explained in detail in the order of steps based on the drawings.

[Step 1] First, a mold, a decorative material, and a plurality of base materials are prepared.

FIG. 1 shows an example of a mold, a decorative material, and a base material used in the present invention.

Reference numeral I in FIG. 1 is a mold. The mold 1 usually has a non-flat surface such as a curved surface or a spherical surface on a part or all of its inner surface. Then, as a surface treatment for forming a resin film, which will be described later, it is preferable to apply a mold release agent to the mirror-finished inner surface of the mold 1 and bake it at approximately 150'C for approximately 20 minutes to perform mold release treatment. . By performing this pretreatment, the effect of facilitating the final release of the molded plywood from the mold 1 can be obtained.

Furthermore, since the surface of the decorative material 2 often comes into contact with the human eye, it is preferable to use a wood material with a beautiful grain pattern, such as a decorative veneer such as bird's eye maple, but it is not limited to this. , Other decorative veneers such as natural wood boards and artificial wood boards, these decorative veneers lined with backing material such as non-woven fabric, or decorative veneers with wood-based boards,
Decorative plywood laminated to plywood wood cement boards, natural wood parquet, etc., with a thickness of 0.2 to 1. A material with a diameter of approximately 0 mm is used. As a pretreatment for forming a resin film, which will be described later, the surface of these decorative materials 2 may be subjected to grinding, cutting, etc., and if necessary, a coloring agent may be applied to the surface to give it an appropriate color. can.

Sandpaper of about #180 to #320 is used for grinding, and for coloring, dyes and pigments are dissolved in a solvent, or a small amount of resin, such as polyurethane resin, is dissolved in this. are preferably used.

In addition, as the base material 3, in addition to wood materials such as natural wood, plywood, verticle board, decorative veneer, and decorative veneer laminated plywood, metal plates such as aluminum alloy plates and steel plates may be used. A material having a thickness of about 0.5 to 10 mm is preferably used. Here, when the above-mentioned wood material is used, a material with excellent flexibility suitable for molding, such as a beech veneer, is preferably used, but the material is not limited thereto. In addition, when the above metal plate is used,
In order to improve adhesion, it is preferable to use a material that has been previously subjected to surface treatment such as degreasing or phosphate treatment.

[Step 2] Next, powder resin is applied on the inner surface of the mold I and the surface of the decorative material 2 to form a resin film la and a resin film 2, respectively.
form a.

As the powder resin used here, for example, unsaturated polyester resin, epoxy resin, phenol resin, polybutadiene, acrylic urethane, acrylic silicone, fluororesin, and mixtures thereof are preferably used. be done.

In addition, if necessary, light stabilizers, ultraviolet absorbers,
Those to which antioxidants, crosslinking agents, etc. are added may also be used.

In particular, since the resin films 1a and 2a formed on the inner surface of the mold 1 and the surface of the decorative material 2 are the outermost layers of the final product, the wood grain on the surface of the underlying decorative material 2 is In order for the pattern to look beautiful on the outside, it is desirable to use a transparent film, and for example, a powder resin made of a mixture of saturated polyester resin and epoxy resin is preferably used.

The resin film 2a formed on the surface of the decorative material 2 is made of a resin having a heat distortion temperature (hereinafter abbreviated as HDT) higher than that of the powder resin used for the resin film 1a on the inner surface of the mold l. If used, the resin film 2a, which will become the base layer, will have a higher HDT and be harder among these two resin films, which will become the surface protection layer 4 of the final product, so as a molded plywood, This has the advantage of being a more stable and high quality product.

The coating may be applied to the surface of the mold 1 or the decorative material 2 heated to room temperature or about 150° C. by an air spray method, but preferably an electrostatic coating method is used. Specifically, this electrostatic coating method uses an electrostatic coating device that includes, for example, a high-voltage direct current generator, a spray device that sprays powder paint, and a support section that supports the object to be coated. A positive DC high voltage is applied to the object to be painted, and a negative DC voltage is applied to the spraying device, and an electrostatic force is generated between the two, and the atomized paint charged by the spraying device is sprayed onto the object by this electrostatic force. The powder is sprayed towards the object to form a coating film made of powdered resin on the surface of the object to be coated.

Here, when the object to be coated is mold I, the amount of powder resin applied is about 150 to 300 g/m'', and in the case of decorative material 2, it is about 50 to 150 g/m''. It is preferable that the film thickness is adjusted to be relatively thick, such as about 135 to 270 μm and 45 to 135 μm, respectively.

[Step 3] Since the resin films 1a and 2a formed in the above manner are made of powder resin, the shape of the powder remains on the surface, and there are no irregularities. Moreover, it contains air bubbles. Therefore, after this, the resin film 1a and the resin film 2a are passed through a heating furnace or an infrared irradiation furnace to fuse and assimilate the resin film onto the surface of the mold l or the decorative material 2, respectively. At this time, it is desirable that the resin film 1a formed on the inner surface of the mold l be melted and brought into a semi-hardened state. Specifically, for example, 1
This is carried out by causing the melt to flow for about IO minutes in a heating furnace at about 50°C. Furthermore, when the resin film 2a formed on the surface of the decorative material 2 is fused and solidified, the conditions are somewhat milder than the conditions for fusion and solidification of the resin film 1a on the inner surface of the mold I, that is, the crosslinking reaction does not proceed. It is done to a certain degree. Specifically, it may be carried out by passing through a heating furnace at a temperature of about 150°C for about I minutes;
It is preferable to irradiate the resin film 2a with infrared rays of ˜400 μm and carry out the irradiation for about 1 to 0.3 minutes under irradiation conditions such that the surface temperature of the resin film 2a is about 100 to 120° C. In particular, it is preferable to use far infrared rays with a wavelength of 1 to 100 μm because the heating effect is high. Specifically, for example, one or more irradiation devices each having a planar type, parallel type, or condensing type reflector attached to an irradiation panel equipped with a plurality of infrared lamps are arranged above the conveyor in the direction of movement of the conveyor. This is carried out by emitting infrared rays from the above-mentioned irradiation device while the object to be coated is placed on a conveyor and moved. By changing the distance between the irradiation device and the conveyor, the irradiation intensity, that is, the surface temperature, can be changed. Therefore, by appropriately changing the number of infrared lamps in the irradiation device, their output, the distance from the conveyor, etc., the desired heating effect can be obtained with a short irradiation time of about 0.1 to 0.2 minutes, and continuous processing using the conveyor can be achieved. can be done.

In this way, by making the resin film 1a formed on the inner surface of the mold 1 into a semi-hardened state, the flow of the resin is prevented or suppressed even by heating and pressurizing during the molding process described later, and the predetermined flow is prevented or suppressed. It becomes possible to ensure the film thickness. On the other hand, the resin film 2a formed on the surface of the decorative material 2 is not brought into a semi-hardened state but simply fused and solidified to ensure fluidity of the resin film 2a during the molding process described later. Therefore, the decorative material 2 can be easily deformed into the same shape as the mold I.

[Step 4] On the other hand, prepare the required number of base materials 3, and make the base materials 3゜3...
・Apply adhesive to the surface to form adhesive layers 3a and 3a, respectively.
... to form. Powder or liquid adhesives such as epoxy resin, vinyl chloride, unsaturated polyester resin, thermosetting acrylic resin, and urethane resin are used as adhesives, among which Evokin resin powder adhesive is used. are preferable, and epoxy resin-based ones using imidazoles as a curing agent are particularly preferable. The powder adhesive is applied by an air spray method, the electrostatic coating method described above, or the like. The liquid adhesive is applied by a roll coater, a spin coater, a brush coating method, or the like, and is applied to one or both sides of the base material.

The coating weight is preferably adjusted to about 100 to 200 g/m'' when coated on one side, and the thickness of the adhesive layer after bonding is adjusted to be thick, about 50 to 150 μm.

Next, the adhesive layers 3a, 3a... are melted and solidified. At this time, the required number of base materials 3.3.
The adhesive layers 3a, 3a... may be melted and solidified with the adhesive layers 3a, 3a... stacked on top of each other, and the base materials 3.3... may be laminated and integrated. Alternatively, each sheet may be melted and solidified separately. Melting assimilation is a method of melting and solidifying the adhesive layers 3a, 3a... by heating, or by irradiating the base materials 3, 3... with infrared rays.
This is done by melting and solidifying... The heating conditions and infrared irradiation conditions at this time vary depending on the type of adhesive, the type of base materials 3, 3, etc., the number of laminated sheets, etc., and are usually at a temperature of 100 to 120°C and a time of 1 to 0.3 minutes. The range of

[Step 5] Next, the decorative material 2 on which the resin film 2a has been formed and the plurality of base materials 3, 3, etc. coated with adhesive are laminated in a predetermined lamination order, and then as shown in FIG. As shown, the resin film 1a, the resin film 2a, and the adhesive layer 3a are charged into the mold l in which the resin film 1a is formed and heated and pressurized to melt and harden the resin film 1a, the resin film 2a, and the decorative material. 2 and the base material 3 or the base materials 3, 3, etc. are bonded and integrated. The heating and pressurizing conditions at this time include the types of resin film 1a and resin film 2a,
It varies depending on the type of adhesive, the type of decorative material 2, base material 3.3... and the number of laminated sheets, etc., and the normal pressure is 0.8 to 3 M.
The temperature is 130 to 150°C and the time is about 30 to IO minutes.

[Step 6] The molded plywood thus obtained is peeled from the mold I, and subjected to finishing treatments such as deburring to obtain the desired molded plywood.

FIG. 4 shows an example of the obtained molded plywood. This molded plywood is made up of a base material 3, an adhesive layer 3a, a decorative material 2, a resin film 2a, and a resin film 1a that are laminated and integrated in this order. A surface protective layer 4 consisting of a film 1a is provided.

Moreover, such molded plywood 5 is subjected to various woodworking processes as necessary, and further subjected to surface coloring and surface painting before being used.

In the molded plywood 5 manufactured by the above method, the resin film 1a and the resin film 2a provided on the inner surface of the mold l and the surface of the decorative material 2 are both on the surface of the molded plywood 5. Since it is a protective layer 1, the film thickness is large.
Molded plywood 5 having high hardness, durability, and weather resistance can be obtained.

In addition, by using powdered resin for the resin film 1a and the resin film 2a, the effect of forming a thick film is improved, and the film is sufficiently degassed during heat fusion, thereby preventing the generation of air bubbles. Or suppressed resin film 1a, resin film 2
a is obtained.

Furthermore, if the resin film 1a and the resin film 2a are formed using transparent powder resin, the surface having a wood grain pattern or the beautiful colored surface of the decorative material 2 disposed in the lower layer can be formed by the surface protective layer. 4, it is possible to obtain a molded plywood 5 with a rich woody feel or a rich sense of color. Furthermore, by changing the type of powder resin constituting the resin film 1a and the resin film 2a, or by applying a characteristic pattern or coloring to each, the resin film 1a and the resin film 2a can be made into a composite. It is also possible to make molded plywood 5 with a solid feel and high commercial value.

Furthermore, if the resin film Ia formed on the inner surface of the mold 1 is in a semi-cured state, even when heated and pressurized during the molding process,
Since flow of the resin can be prevented or suppressed, it becomes possible to form a thick and uniform resin film 1a.

Furthermore, if a powder resin having a higher HDT than the powder resin used for the resin film 1a formed on the inner surface of the mold l is used as the resin film 2a formed on the surface of the decorative material 2, the surface protective layer 4 of the final product can be used. Of the two resin films, the resin film 2a serving as the base layer has a higher HDT and is harder.
The molded plywood 5 also has the advantage of being a more stable and high quality product.

Here, an example has been described in which planar materials as shown in FIG. 3 are used as the decorative material 2 and the base materials 3, 3... A resin film 2a or an adhesive layer 3a is provided on each surface.

3a... may be preformed in advance to form substantially the same shape as the final product.

This preforming may be performed separately using the mold 1 at a pressure of IMPa and a temperature of 13 and 0. , multiple base materials 3, 3.
. . . may be carried out in an overlapping manner, or may be carried out together with the decorative material 2. By performing this preforming, a comparatively thick material can be used by binding the decorative material 2 or the base material 3.3, and even if a thick material is used, it has the advantage of not splitting or peeling. . In addition, since the general shape is obtained in advance through this preforming process, the molding process is performed, so there is no need to use very high pressure when heating and pressurizing during the molding process, so the flow of adhesive and resin film is reduced. There is also the effect that thicker adhesive layers 3a, 3a, . . . and resin film 2a can be obtained.

[Example] Molded plywood of Examples (6 examples) was manufactured by the method shown below.

(Example I) A mold release agent was applied to the inner surface of the mold, and this was heated at 150°C for 2 hours.
The mold was released by baking for 0 minutes. Next, while heated to 150°C, a powder resin consisting of a mixed resin of polyester resin and epoxy resin was electrostatically coated to a coating thickness of 1300 g/m'' to form a resin film.Next, this resin film was 1" was melt flowed and cured at a temperature of 50°C.

Here, the blending amount of the powder resin made of the mixed resin of the above polyester resin and epoxy resin is as follows: 90 parts by weight of saturated polyester resin 10 parts by weight of triglyrin diluison anurate 1 part by weight of benzoin
．． 0 parts by weight Triphenylphosphine 0.61
111 Flow adjuster 0.5 Since it is a part of Shigenobu, I used one with HDT of 60°C.

30 on the back of a bird's eye maple veneer board with a thickness of 0.2 mm.
The surface of the decorative material lined with g/m2 non-woven fabric is #240.
After grinding with sandpaper, it was colored with urethane colorant. A resin film was formed by electrostatically applying a powder resin made of a mixed resin of polyester resin and epoxy resin to this in a coating amount of 100 g/m'. Next, this resin film was irradiated with far infrared rays to melt and solidify it. Here, the blending amount of the powder resin made of a mixed resin of polyester resin and epoxy resin is as follows: Saturated polyester resin 85 parts by weight Triglycidyl isocyanurate 15 parts by weight Benzoin
1.0 weight 1 part triphenylphosphine 0.6 ffffil flow regulator
0.5 parts by weight, HDT- is 70
℃ was used.

Ten beech wood veneers with a thickness of 066 mm were prepared and preformed so that the final product had the same shape.

A powder adhesive made of epoxy resin was applied to each of these veneers to form an adhesive layer at a ffi of 100 g/m. Far infrared rays were irradiated on each of these to fuse the adhesive layer. Here, the blending amount of the epoxy resin powder adhesive was 50 parts by weight of Epicoat 1055 (manufactured by Yuka Shell Epoxy Co., Ltd.), 50 parts by weight of Epicoat 1001 (manufactured by Yuka Shell Epoxy Co., Ltd.), 50 parts by weight of 2-ethyl- 3 parts by weight of 4-methylimidazole and 0.71 parts by weight of behenic acid were melted and mixed, then ground to give a 100 mesh pass. A powder adhesive was used.

The above 10 base materials were stacked, the above decorative material was superimposed on the outermost layer, and the resultant was charged into the above mold and molded for 10 minutes at a temperature of 150° C. and a pressure of 2.5 MPa.

Thereafter, the product was released from the mold and subjected to deburring treatment to obtain a molded plywood.

(Example 2) A molded plywood was obtained in the same manner as in Example 1, except that the powder resin applied to the bird's eye maple veneer decorative material was an epoxy resin. Here, the blending amount of this epoxy resin is: 50 parts by weight of Epicoat +055 (manufactured by Chemical Shell Epoxy Co., Ltd.) 50 parts by weight of Epicoat 1001 (manufactured by Yuka Shell Epoxy Co., Ltd.) 2-ethyl-4-methylimidazole 2 1 part heavy undecyl imidazole 2 parts 1 part behenic acid
0.7 parts by weight, these were melt-mixed and then ground, and the HDT was 100°C.

(Example 3) A molded plywood was obtained in the same manner as in Example 1, except that urethane adhesive (manufactured by Sunstar Giken Co., Ltd.) was used as the adhesive for the base material made of the above-mentioned beech wood board.

(Example 4) Example except that an unsaturated polyester molding compound with a thickness of 6 mm was used for the base material part!
Molded plywood was obtained in the same manner as above.

(Example 5) This is an example except that a 7 mm x 6 mm fiberboard impregnated with epoxy resin was used as the base material portion. Molded plywood was obtained in the same manner.

(Example 6) A molded plywood was obtained in the same manner as in Example 1, except that no epoxy prepreg having a thickness of 0.1 mmmm was used as the base material.

In the molded plywood of Examples (6 examples) manufactured as described above, the surface protective layer consisting of two layers of resin film formed on the surface of the molded plywood was approximately 400 μm thick, which was compared with conventional molding. A very thick protective film was obtained compared to the thickness of the protective film on plywood. In addition, since these resin films were transparent, the wood grain pattern on the surface of the decorative material inside was reflected, giving them a beautiful appearance. In addition, the hardness was sufficiently high, the generation of bubbles was completely prevented, and the properties such as weather resistance and durability were good. Also, the adhesion of each layer.

Not only was this sufficient, but it was also excellent in terms of workability during molding.

[Effects of the invention] The manufacturing method of this invention is such that the decorative material and the base material are laminated and integrated,
A method of producing molded plywood having a surface protective layer formed on the outermost surface thereof using a mold, the method comprising forming a resin film made of powdered resin on the inner surface of the mold and on the surface of the decorative material, respectively. After forming, the decorative material and base are inserted into the mold and bonded under heat, so that the respective resin films provided on the inner surface of the mold and the surface of the decorative material are Since it becomes a surface protective layer of plywood, it is possible to obtain molded plywood with a large film thickness and high hardness.

Further, by using powdered resin as the resin film, the effect of forming a thick film is improved, and the generation of bubbles can be suppressed or prevented.

In addition, since a decorative material is placed below this surface protective layer, if transparent powder resin is used as the resin film, the surface of the decorative material will be reflected outside through this surface protective layer, so it can be used as a decorative material. If wood with a beautiful grain pattern or wood with various colors is used, the molded plywood can be made to have a rich wood feel or color, and its commercial value can be greatly improved.

In addition, if the resin film on the inner surface of the mold is semi-cured, the flow of the resin can be prevented or suppressed by heating and pressurizing during the molding process, making it possible to obtain a thick and uniform resin film. becomes possible.

In addition, as a resin film formed on the surface of the decorative material, f(D T
If a powder resin with a high HDT is used, of the two resin films that will serve as the surface protection layer of the final product, the resin film that will serve as the base layer will have a higher HDT and be harder, so it is suitable for molded plywood. , which has the advantage of being a more stable and better quality product. In this way, by changing the materials of the two layers of resin films, or by applying distinctive patterns or colors to each layer, it is easy to create a composite resin film, creating the desired product with a solid feel and high commercial value. Molded plywood can be obtained.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view showing an example of a mold, a decorative material, and a base material used in this invention, FIG. 2 is a schematic cross-sectional view showing an example of a molding method in this invention, and FIG. , is a schematic cross-sectional view showing an example of molded plywood manufactured according to the present invention. ■...Molding mold, Ia...Resin film, 2...Decorative material, 2a...Resin film, 3...Base material, 3a・・・・・・
Adhesive layer, 4...Surface protection layer, 5...
Molded plywood.

Claims (3)

[Claims] (1) A method for producing molded plywood in which a decorative material and a base material are laminated and integrated, and a surface protective layer is formed on the outermost surface, using a mold, the inner surface of the mold being and a method for producing molded plywood, which comprises forming a resin film made of powdered resin on the surface of each decorative material, and then charging the decorative material and base material into a mold and heat-pressing them. (2) The method for producing molded plywood according to claim 1, wherein the resin film formed on the inner surface of the mold is in a semi-cured state. (3) The molded plywood according to claim 1, wherein the heat deformation temperature of the resin film formed on the surface of the decorative material is higher than the heat deformation temperature of the resin film formed on the inner surface of the mold. manufacturing method.