JP2000136579A - Panel and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain high surface hardness and a smooth surface and to improve dimensional stability to temperature and humidity and crack resisting performance by laminating and integrating a surface decorative veneer on the surface of base material provided with a low moisture permeable material layer on the surface, through a moisture permeable material layer so as to prevent swelling, bursting, or the like generated to the surface decorative veneer. SOLUTION: A surface decorative veneer 3 is laminated and integrated on the surface of base material 2 provided with a low moisture permeable material layer 21 at least on the surface, through a moisture permeable material layer 4 to constitute a panel. With such constitution, when the surface decorative veneer 3 is bonded by heating, moisture evaporated by heat is absorbed into the moisture permeable material layer 4 to disperse moisture at the bonding interface to the surface decorative veneer 3, so that the surface decorative veneer 3 and the low moisture permeable material layer 21 can be bonded without swelling, bursting, or the like generated to the surface decorative veneer 3. Surface hardness, smoothness and dimensional stability to temperature and humidity which are properties of the base material 2 are not impaired so as to manufacture the panel holding these properties.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a panel and a method for manufacturing the panel.

[0002]

2. Description of the Related Art Conventionally, wet veneers (surface veneer veneers, decorative sheets, etc.) have been used as panels used on floors and walls of residential buildings for the purpose of surface makeup on plywood, MDF, particle board and the like. ) Are bonded by hot pressing. Water vapor generated from the wet veneer at the time of hot pressing is absorbed by a substrate made of a wood material.

[0003] However, the surface hardness of a conventional base material made of a woody material is liable to cause scratches or dents due to the use of furniture with casters, impacts such as falling objects, and the surface is not very smooth. In addition, stockings in the V-groove (decorative groove) provided on the surface and the socks are easily caught. Further, problems such as crack generation and dimensional change of the veneer veneer are likely to occur.

Therefore, in order to improve the surface hardness, smoothness and dimensional stability, there is known a panel in which a material such as resin is used as a base material instead of a wood-based material, and a wet veneer is mounted on the surface thereof. Have been.

[0005]

However, in a panel using a resin, which is a low moisture permeable material, as a substrate as described above, a low moisture permeable material layer having a low moisture absorption rate as compared with a wood-based material. We will be installing a wet veneer on the surface of
In this case, since there is no escape place of the moisture evaporated by the heat when mounting by applying heat and pressure by the mold, the swelling or puncture occurs as shown in FIG. There was a problem. In FIG. 13, 1 'is a panel, and 2 is a plywood substrate.

[0006] The present invention has been made in view of the above points, the object is to swell the veneer veneer,
Another object of the present invention is to provide a panel which can prevent occurrence of punctures and the like, has a high surface hardness and a smooth surface, has high dimensional stability against temperature and humidity, and has excellent crack resistance, and a method for manufacturing the same. It is an object of the present invention to provide a panel capable of solving problems such as adhesiveness and warping of a flooring material, and at the same time, increasing bending rigidity and improving caster resistance, and a method of manufacturing the same.

[0007]

In order to solve the above-mentioned problems, the invention according to claim 1 is provided on at least the surface of the substrate 2 having the low moisture permeable material layer 21 on the surface via the moisture permeable material layer 4. The surface decorative veneer 3 is laminated and integrated. With this configuration, when the surface decorative veneer 3 is bonded by heating, the moisture evaporated by heat is removed by the moisture permeable material layer 4. And thus, the decorative veneer 3
Of the decorative veneer 3
The surface decorative veneer 3 and the low moisture permeable material layer 21 can be bonded to each other without swelling and puncturing. Therefore, it is not necessary to change the mounting specification of the conventional decorative surface veneer 3 such as a press machine. Further, the moisture-permeable material layer 4
By adjusting the interlaminar strength, density, and the effect of impregnating the adhesive, compared to the case of directly bonding to the low moisture permeable material layer 21,
The adhesion performance of the veneer veneer 3 is improved. In addition, it is possible to manufacture a panel that retains the performance without impairing the surface hardness, smoothness, and dimensional stability due to temperature and humidity, which are the characteristics of the base material 2, and furthermore, it is possible to produce cracks in the surface decorative veneer 3. Problems such as generation and dimensional change do not occur.

According to a second aspect of the present invention, in the first aspect, the low moisture-permeable material layer 21 of the base material 2 is made of a thermoplastic resin composite material, and the thermoplastic resin composite material has at least wood powder and heat. It is characterized by being made of a wood powder resin composite material that is composited with a thermoplastic resin, and by having such a configuration, the surface hardness and flexural rigidity of the base material 2 in terms of physical properties such as the flexural rigidity are higher than in the case of a thermoplastic resin alone. In addition to the improvement, it is possible to prevent a decrease in adhesiveness, which is a disadvantage of the resin material. In particular,
Even when a water-based adhesive is used, the effect of shortening the bonding time and securing the bonding strength can be obtained by absorbing moisture from the bonding surface.

According to a third aspect of the present invention, in the second aspect, the base material 2 is composed of a plurality of upper and lower layers, and at least the base upper layer 2A is a wood flour resin composite material 10 in which wood flour and a thermoplastic resin are compounded. It is characterized by comprising, in this configuration, when the base material lower layer is composed of a plywood layer or the like, even if the plywood surface has defects such as fine cracks, holes and the like. In addition, the wood powder resin composite material can increase the bending rigidity and ensure caster resistance.

According to a fourth aspect of the present invention, in the second aspect, the base material 2 is composed of a plurality of upper and lower layers, and each layer is composed of a wood flour resin composite material in which wood flour and a thermoplastic resin are composited. The mixing ratio of the wood flour in the wood flour resin composite material 10A farthest from the surface decorative veneer 3 is greater than the wood flour mixing ratio in the wood flour resin composite material 10B closest to the surface decorative veneer 3. With such a configuration, the moisture-permeable material layer 4 is located on the upper wood powder resin composite material 10A, and the highly moisture-permeable wood powder resin composite material 10B is located below the wood powder resin composite material 10A. The warp force on the front side and the warp force on the back side of the panel 1 in which the decorative veneer 3 is adhered to the surface of the base material 2 can be made substantially equal, and warpage can be suppressed. Therefore, the warpage of the entire panel 1 can be suppressed only by the specifications of the wood powder resin composite material 10, and for example, a panel product without warpage can be easily obtained while the performance as a building material or the like can be freely set. .

According to a fifth aspect of the present invention, in any one of the second to fourth aspects, an intermediate moisture-permeable layer 11 is interposed between the upper substrate layer 2A and the lower substrate layer 2B. With this configuration, at the time of bonding between the base material upper layer 2A and the base material lower layer 2B, the adhesive penetrates by the intermediate moisture-permeable layer 11 interposed therebetween, and a practical adhesive force can be secured. In addition, since water during manufacturing is absorbed by the intermediate moisture permeable layer 11, it is possible to prevent puncture and ensure adhesive strength.

The invention according to claim 6 is characterized in that, in any one of claims 2 to 4, the wood powder resin composite material 10 contains 30 to 70 wt% of wood powder. , The wood powder resin composite material 1
It is possible to prevent the problem of moisture permeability while increasing the hardness of 0.

According to a seventh aspect of the present invention, in the second, third, fourth, or sixth aspect, the thickness of the wood flour resin composite material layer is at least 0.1 mm or more. With such a configuration, the surface hardness, smoothness,
Dimensional stability due to temperature and humidity can be prevented from being impaired.

According to an eighth aspect of the present invention, in the second, third, fourth, sixth, or seventh aspect, an olefin resin is used as the thermoplastic resin in the wood powder resin composite material 10. And, maleic acid-modified polyolefin is added, or is characterized by being modified by the addition of maleic acid.
The dispersibility of the wood powder and the thermoplastic resin can be improved, and the rigidity can be improved.

According to a ninth aspect of the present invention, the wood powder resin composite material layer has a bending Young's modulus of at least 40,000 kgf according to the second, third, fourth, sixth, seventh, or eighth aspect. / Cm ² or more. With this configuration, when the base material lower layer 2B is made of plywood or the like, the surface of the plywood layer 60 may have fine cracks and holes. Even with such disadvantages, by increasing the bending rigidity of the wood powder resin composite layer,
It is possible to ensure the caster resistance of the plywood layer 60.

According to a tenth aspect of the present invention, in the first or fifth aspect, the moisture-permeable material is paper, nonwoven fabric, or wood flour. It is easy to obtain, and an inexpensive material can be used.

According to an eleventh aspect of the present invention, in the first or the fifth aspect, the decorative veneer 3 is made of a natural veneer or a veneer sheet. The adhesive can be easily bonded by hot-pressing, and the moisture of the adhesive and the wet veneer can be absorbed by the moisture-permeable material layer 4 under the surface decorative veneer 3, so that the surface of the hot-pressed surface can be easily applied. The puncture of the veneer 3 can be prevented, and the adhesive strength can be secured.

According to a twelfth aspect of the present invention, in manufacturing a panel in which the decorative veneer 3 is laminated and integrated on the surface of the base material 2 having the low moisture permeable material layer 21 at least on the surface, Is laminated in this order, and the low moisture-permeable material layer 21 and the veneer veneer 3 are heat-bonded via the moisture-permeable material layer 4, so that the veneer veneer It is characterized in that the moisture permeable material layer 4 is interposed between the low-moisture permeable material layer 3 and the low moisture permeable material layer 21. With this configuration, when the surface decorative veneer 3 is bonded by heating, it is evaporated by heat. The absorbed moisture is absorbed by the moisture-permeable material layer 4, so that the dispersion of the moisture at the bonding interface with the surface decorative veneer 3 causes the surface decorative veneer 3 to swell and generate no puncture. 3 and the low moisture permeable material layer 21 can be bonded to each other. Therefore, it is not necessary to change the mounting specification of the conventional decorative surface veneer 3 such as a press machine.
Furthermore, due to the effect of adjusting the interlayer strength and density of the moisture-permeable material layer 4 and the effect of impregnating the adhesive, the adhesive performance of the decorative surface veneer 3 is improved as compared with the case where the surface decorative veneer 3 is directly adhered to the low moisture-permeable material layer 21. In addition, it is possible to manufacture a panel that retains the performance without impairing the surface hardness, smoothness, and dimensional stability due to temperature and humidity, which are the characteristics of the base material 2, and furthermore, it is possible to produce cracks in the surface decorative veneer 3. Problems such as generation and dimensional change do not occur.

The invention according to claim 13 is the invention according to claim 12.
, The base material 2 is composed of a plurality of upper and lower layers, and the base material upper layer 2
A is made of a wood powder resin composite material 10 in which at least wood flour and a thermoplastic resin are compounded, and the base material lower layer 2B is made of plywood, and the bonding between the plywood and the wood powder resin composite material 10 is performed by heat fusion. With such a configuration, the physical properties such as the surface hardness and the bending rigidity of the base material 2 are improved as compared with the case of the thermoplastic resin alone, and this is a disadvantage of the resin material. Adhesion can be prevented from lowering,
Further, even if the surface of the plywood has a defect such as a fine crack or a hole, the bending rigidity can be increased by the wood powder resin composite material, so that the caster resistance performance can be secured.

The invention according to claim 14 is the invention according to claim 13.
, The base material upper layer 2A and the base material lower layer 2B are each made of a wood flour resin composite material 10 in which wood flour and a thermoplastic resin are compounded, and the wood flour resin composite material 10A farthest from the surface decorative veneer 3 It is characterized in that the mixing ratio of the wood flour in the inside is made larger than the mixing ratio of the wood flour in the wood powder resin composite material 10B closest to the surface decorative veneer 3. Material layer 4 on wood powder resin composite material 10A, and wood powder resin composite material 10 with high moisture permeability below
B is located, and the warpage force on the front side and the warpage force on the back side of the panel 1 in which the decorative veneer 3 is adhered to the surface of the base material 2 can be made substantially equal, and the warpage can be suppressed. Therefore,
The warpage of the entire panel 1 can be suppressed only by the specifications of the wood powder resin composite material 10, and a panel product without warpage can be easily obtained, for example, while the performance as a building material or the like can be freely set.

The invention according to claim 15 is the invention according to claim 13.
The intermediate moisture-permeable layer 11 is interposed between the base material upper layer 2A and the base material lower layer 2B according to any one of claims 14 to 15, and the base material upper layer 2A and the base material At the time of bonding with the material lower layer 2B, the adhesive penetrates by the intermediate moisture-permeable layer 11 interposed therebetween, and a practical adhesive strength can be ensured, and the moisture at the time of production is reduced.
By absorbing water, it is possible to prevent puncture and ensure adhesive strength.

The invention of claim 16 is the invention of claim 13
In any one of claims 15 to 15, a cutout groove 12 for preventing warpage is formed on the lower surface side of the base material lower layer 2B. With such a configuration, the amount of swelling and shrinkage of the base material 2 can be reduced. The warpage caused by the difference can be reduced by the cut groove 12, and therefore, for example, even if the base material lower layer 2B is a plywood or the like, the surface decorative veneer 3 on the front surface side
And the swelling and shrinking of the plywood layer are balanced with the swelling and shrinking of the plywood layer, so that the warpage as a whole can be reduced.

The seventeenth aspect of the present invention is the seventeenth aspect of the present invention.
, Characterized in that a cushion material 25 is provided on the lower surface of the base material lower layer 2B in which the notch groove 12 for preventing warpage is formed, and with such a configuration, the cushion material 25 can be used to attach to a soundproof floor or the like. Application is also possible, and furthermore, the warp suppressing effect is further improved together with the cut grooves 12, so that expansion and contraction due to environmental changes such as temperature and humidity are small, and pushing up and gaps can be prevented.

The invention according to claim 18 is the invention according to claim 13
In any one of claims 14 to 14, the base material upper layer 2A is made of a wood powder resin composite material, and the base material lower layer 2B is made of a non-woven fabric, glass fiber, paper, plywood, veneer, etc. The back moisture permeable layer 26 is characterized by being fused to the wood powder resin composite material 10 by heat. With this configuration, the base material 2 The moisture-permeable material layer 4 interposed between the facing decorative veneers 3 is located, and the back moisture-permeable layer 26 is located below the wood flour resin composite material 10. Can be made substantially uniform, and an effect of suppressing warpage can be obtained. In addition, the nonwoven fabric, glass fiber, paper, plywood, veneer, and the like constituting the back moisture permeable layer 26 can be fused to the molten wood flour resin composite material 10, thus significantly reducing the bonding cost. A multi-layer configuration is possible without any increase. Furthermore, since the wood powder resin composite material 10 can be manufactured by continuous extrusion, the above-mentioned step of fusing the multiple layers can be continuously performed, and the productivity is greatly improved.

According to a nineteenth aspect of the present invention, a surface decorative veneer is provided on at least the surface of a substrate 2 having a thermoplastic resin composite material layer in which a thermoplastic resin and a heat-resistant moisture-permeable powder are combined. In manufacturing a panel in which the laminate 3 is laminated and integrated, the surface of the thermoplastic resin composite material layer is polished to expose the moisture-permeable powder at the bonding interface with the surface decorative veneer 3, and then the thermoplastic resin composite material layer The surface veneer veneer 3 is characterized by being heated and bonded thereon. With this configuration, the moisture-permeable powder is exposed at the bonding interface with the surface veneer veneer 3, whereby the surface veneer veneer 3 is exposed. In addition to improving the bonding strength when bonding the veneer, the moisture permeation state at the bonding interface can be improved, and the veneer veneer and puncture of the veneer veneer do not occur, and the veneer veneer can be used. 3 and substrate 2 are heated Bondable to become. Furthermore, it is possible to manufacture a panel that retains the performance without impairing the surface hardness, smoothness, and dimensional stability due to temperature and humidity, which are the characteristics of the base material 2.
The problems such as crack generation and dimensional change do not occur.

[0026]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below. As shown in FIGS. 1 and 3, a surface decorative veneer is provided on at least the surface of a substrate 2 having a low moisture permeable material layer 21 on the surface. According to the present invention, when manufacturing the panel 1 on which the laminate 3 is laminated, the moisture-permeable material layer 4 is interposed between the low-moisture-permeable material layer 21 and the decorative veneer 3, and the low moisture-permeable material layer 4 is interposed therebetween. It is characterized in that the moisture-permeable material layer 21 and the decorative surface veneer 3 are bonded to each other. Reference numeral 5 in FIG. 3 denotes a real part for floor bonding composed of a male real part 5a and a female real part 5b, and 8 denotes a decorative groove.

Here, as the moisture-permeable material layer 4,
For example, paper, nonwoven fabric, and wood flour are used. The thickness of the moisture-permeable material layer 4 is preferably 0.1 mm or less.

The substrate 2 is made of, for example, a resin, and is adhered and fixed on a base 9 (FIG. 4) such as a concrete slab. In this example, at least the surface of the substrate 2 is a low moisture permeable material layer 21. The low moisture permeable material layer 21 is made of a wood powder resin composite material in which wood powder and a thermoplastic resin are blended. Here, as the thermoplastic resin to be blended,
For example, olefin-based thermoplastic synthetic resins such as polypropylene and polyethylene are used. In addition, in addition to the wood powder and the thermoplastic synthetic resin, a thermoplastic synthetic resin denatured with an acid anhydride may be added to the wood powder resin composite material. If necessary, an inorganic substance may be added in addition to the above. Further, the blending ratio of wood flour to the total amount of the wood flour resin composite material is desirably 60% or less (weight ratio), and the wood flour resin composite material is formed by heating and pressing at such a blend ratio. . The particle size of the wood flour is desirably 100 mesh or less. Regarding the thickness of the wood flour resin composite material layer, the thickness is not limited as long as the surface hardness and smoothness of the wood flour resin composite material and the dimensional stability due to temperature and humidity are not impaired. The above is desirable.

As shown in FIG. 2, the wood flour resin composite material includes a male part 5a and a female part 5b which are arranged on the side surface of the floor material and connect adjacent floor materials. Real part 5
Is provided.

As the surface decorative veneer 3, it is preferable to use a natural veneer or veneer sheet. The coating of the veneer is not particularly limited, and may be, for example, urethane or amino coating on the floor. In order to improve abrasion resistance and the like, an additive or the like for abrasion resistance may be added to the paint.

Thus, as described above, the low moisture permeable material layer 21 made of the wood powder resin composite material is laminated on the surface of the base material 2,
A moisture-permeable material layer 4 made of paper is laminated thereon, an adhesive 22 is applied thereon, and the decorative veneer 3 is mounted thereon, followed by heating and pressing to adhere. By interposing the moisture permeable material layer 4 between the decorative face veneer 3 and the low moisture permeable material layer 21 in this manner, the water vaporized by heat when mounted by hot pressing with a mold can be used as the moisture permeable material layer 4. The surface veneer veneer 3 and the low moisture-permeable material layer 21 do not swell due to the dispersion of moisture at the bonding interface with the veneer veneer 3 and do not generate punctures. Can be bonded. Therefore, it is not necessary to change the mounting specification of the conventional decorative surface veneer 3 such as a press machine.

Further, by adjusting the interlayer strength and density of the moisture-permeable material layer 4 and impregnating the adhesive, the low moisture-permeable material layer 21 is formed.
Adhesive performance of the decorative surface veneer 3 is improved as compared with the case where the surface decorative veneer 3 is directly adhered. In other words, the surface of the base material is made of a low moisture permeable material layer, and the moisture permeable material layer 4 is interposed between the surface of the base material and the surface decorative veneer plate 3. When the board is mounted, moisture evaporated by heat is absorbed by the moisture-permeable material layer 4, so that the base material and the surface decorative veneer 3
By dispersing the water present at the bonding interface with the surface veneer, the surface veneer veneer 3 can be heated and adhered to the base material without swelling and puncturing.
Therefore, it is not necessary to change the mounting specification of the conventional decorative surface veneer 3 such as a press machine. Furthermore, due to the adjustment of the interlaminar strength and density of the paper layer (the moisture-permeable material layer) 4 and the effect of impregnating the adhesive, the adhesive performance of the decorative surface veneer 3 is improved as compared with the case where the decorative surface veneer is directly adhered to the base material. improves.

Next, one example of a method for manufacturing the panel 1 is shown in FIG. Here, paper (intermediate moisture-permeable layer 11) and wood flour resin composite material 10 are laminated on the surface of plywood (base lower layer 2B) to form base 2. Then, a paper layer (moisture-permeable material layer 4) is laminated on the surface of the base material 2, an adhesive 22 is applied thereon, and the decorative surface veneer 3 is mounted thereon, and heated and pressed to adhere. Let it.

In this example, the wood powder resin composite material 10 is formed by extrusion, the wood powder resin composite material 10 is formed, the wood powder resin composite material 10 is fused with paper, and the base material 2 is formed.
A case in which the step of fusing the resin and the wood powder resin composite material 10 by heat is performed continuously (or simultaneously) will be described. As shown in FIG. 2, a paper 28 (a moisture-permeable material layer) supplied from a paper roll 29 is laminated on the surface of the wood powder resin composite material 10 extruded by an extruder 27 with a T-die,
After being fused by heat with a roll press 30, it is sent to a cooling zone, cooled by a pressure cooling roll 31, cut into a predetermined width, an adhesive 22 is applied to the upper surface of the paper, and then an adhesive is applied. The veneer veneer 3 is placed from above and pressed by the press machine 32. After extrusion molding with T die,
In order to make the thickness uniform, a polishing roll or a touch roll may be used. Alternatively, the pressing may be performed simultaneously with the extrusion, or the surface may be melted again after the wood powder resin composite material 10 is formed. In addition, fusion may be performed using a synthetic resin that is melted by heat. As described above, by adopting the continuous construction method by extrusion, continuous molding can be performed simultaneously with paper fusion. Thereby, the paper 28 and the wood flour resin composite material 10 can be continuously laminated, and the productivity is improved. In addition, by bonding the paper 28 and the wood flour resin composite material 10 by heat fusion, there is no need to reheat the material, and further, after the paper 28 is fused, continuous pressure cooling is possible. Therefore, there is an advantage that the warpage of the laminated material is suppressed without lowering the productivity.

Here, the thickness of the moisture-permeable material layer 4 is set to 0.1 m.
m or less, the characteristics of the base material 2 such as surface hardness, smoothness, and dimensional stability due to temperature and humidity are not impaired, so that it is possible to manufacture the panel 1 maintaining those performances. The use of furniture on casters, the occurrence of cracks due to the impact of falling objects, and other problems such as dimensional changes do not occur. In addition, due to the smooth surface, stockings in V-grooves (decorative grooves) and socks may be caught. Thus, the walking feeling can be improved while improving the appearance design by the decorative groove.

The wood flour resin composite material 10 contains 30 to 70 wt% of wood flour (preferably 30 to 60 wt%).
%). Wood flour mixing ratio is 7
If it exceeds 0 wt%, the wood powder resin composite material 10 becomes brittle, and if it is less than 30 wt%, a problem occurs in moisture permeability.
The type of wood flour is not particularly limited. Particle size of wood flour is 10
It is preferably 0 mesh or less. Specifically, 95% of the whole wood flour
Is preferably 300 μm or less. By using the wood powder resin composite material 10 as the low moisture permeable material layer 21 as described above, the physical properties such as the surface hardness and the bending rigidity of the base material 2 can be improved as compared with the case of using only the thermoplastic resin. At the same time, a decrease in adhesiveness, which is a disadvantage of the resin material, can be prevented. In particular, even when a water-based adhesive is used, moisture is absorbed from the bonding surface, thereby shortening the bonding time,
This is effective in securing the adhesive strength.

In order to secure the above-mentioned properties such as sufficient surface hardness, the thickness of the wood powder resin composite material layer is preferably 0.1 mm or more. If the thickness is 0.1 mm or less, the surface hardness, smoothness, and dimensional stability due to temperature and humidity, which are characteristics of the substrate 2, may be impaired. Note that the upper limit of the thickness of the wood powder resin composite material layer is not particularly limited, and is appropriately selected depending on cost, necessary physical properties, and the like. When the thickness of the moisture-permeable material layer 4 is 0.1 mm or less,
Since the characteristics of the low moisture-permeable material layer 2121 such as surface hardness, smoothness, and dimensional stability due to temperature and humidity are not impaired, it is possible to manufacture the panel 1 having those performances. Cracks due to impacts such as dropping of objects and the occurrence of cracks and dimensional changes do not occur. In addition, due to the smooth surface, stocking into V-grooves (make-up grooves) and socks are not caught. The walking feeling can be improved while improving the appearance design by the groove.

As the thermoplastic resin in the wood powder resin composite material 10, for example, an olefin resin such as polypropylene or polyethylene is preferably used. The olefin resin is preferably modified with a maleic acid-modified polyolefin or by addition of maleic acid. Olefin resins are more advantageous than other synthetic resins in terms of material availability and cost. The type of the olefin-based resin can be appropriately selected depending on physical properties such as rigidity after compounding with wood flour. Further, addition of maleic acid-modified polyolefin as described above, or modification by addition of maleic acid, is preferred in terms of improvement in dispersibility of wood powder and thermoplastic resin, improvement in rigidity, and the like. Wood powder resin composite material 1
0 physical properties are determined.

Further, in order to increase the bending rigidity of the wood powder resin composite material layer, the wood powder resin composite material layer preferably has a bending Young's modulus of at least 40,000 kgf / cm ² or more. Thereby, for example, even if the plywood has defects such as fine cracks and holes in its surface layer, the bending rigidity can be increased with the wood powder resin composite material, and the caster resistance performance can be secured. It becomes possible. In addition, even when the base material 2 is thin, such as when used for a soundproof floor having a cut in the plywood surface, caster resistance performance can be similarly secured.
The rigidity of the wood powder resin composite material 10 may be approximately 50,000 to 80000 kgf / cm ^2, which is equivalent to that of general plywood.
Incidentally, in the case of a conventional flooring material, a natural veneer or the like is adhered to the surface of a plywood, an MDF, a particle board or the like to form a surface decoration. In addition, high caster resistance is required due to changes in lifestyle in recent years.
F is compounded to form the base material 2.
In the case of the F composite plywood, the dent resistance (caster resistance) can be improved, but there is a problem in water resistance. In other words, swelling due to moisture,
Although there is a problem such as a decrease in hardness due to deformation, warping, or repeated moisture absorption and desorption, in the present invention, by interposing the moisture-permeable material layer 4 between the base material 2 and the decorative surface veneer 3, In addition to solving problems such as adhesion, warpage of flooring material, etc., it is possible to improve castor resistance by increasing bending rigidity.

Further, as the thermoplastic resin composite material, a wood powder resin composite material 10 in which at least wood powder and a thermoplastic resin are combined is used, and the base material 2 and the wood powder resin composite material 10 are used.
By performing the adhesion between the heat by fusion,
Productivity is improved, which is advantageous in terms of cost. Moreover, even if the plywood portion of the base material lower layer 2B has defects such as minute cracks and holes on its surface, the wood powder resin composite material 10 is melted on the plywood layer 60, pressed and bonded. By filling the defective portion with the wood powder resin composite material 10, the performance such as caster resistance and the like can be improved, and the smoothness of the surface can be ensured. As a result, it is possible to improve the adhesiveness and prevent the floor material from warping. Can be planned.

4 to 6 show another embodiment.
In this example, the base material upper layer 2A and the base material lower layer 2B are each made of a wood flour resin composite material 10 in which wood flour and a thermoplastic resin are compounded, and the wood flour resin composite material far from the surface decorative veneer 3 The blending ratio of wood flour in 10A was larger than the blending ratio of wood flour in wood powder resin composite material 10 on the side closer to surface decorative veneer 3. Here, wood flour is a concept including heat-resistant powder. Conventionally, a base material 2 made of a wood powder resin composite material 10
In the case of a building board with a veneer veneer 3 bonded to the surface of
When used in an environment where the humidity changes, the surface veneer veneer 3
Since there is a difference between the dimensional change rate of the wood powder resin composite material 10 and the dimensional change rate, there is a problem that warpage occurs. Generally, since the dimensional change due to moisture absorption of the wood powder resin composite material 10 is smaller than that of the decorative veneer 3, for example, a concave warp is generated on the surface decorative veneer 3 side in a dry state. Further, at the time of manufacturing the wood powder resin composite material 10,
When manufacturing a plate material in which a sheet such as paper is fused to one surface of the melted wood powder resin composite material 10, warpage occurs because the difference in dimensional change between the front and back surfaces is greatly different. Therefore, in the present invention, the wood flour resin composite material 10 is composed of two layers to form the base material 2, and the blending ratio of the wood flour in the wood flour resin composite material 10 A on the side far from the surface veneer veneer 3 is determined. Since the mixing ratio of the wood flour in the wood flour resin composite material 10B closer to the plate 3 was larger than that of the wood flour resin composite material 10A, the moisture permeable material layer 4 was placed above the wood flour resin composite material 10A, and the wood flour having high moisture permeability was placed below. Since the resin composite material 10B is located, the warpage force on the front side and the warpage force on the back side of the panel 1 formed by attaching the decorative veneer 3 to the surface of the base material 2 can be made substantially equal, and the warpage can be reduced. Can be suppressed. Therefore, the warpage of the entire panel 1 can be suppressed only by the specifications of the wood powder resin composite material 10, and the panel 1 without warpage can be easily obtained, for example, while the performance as a building material or the like can be freely set. Things.

As a method of suppressing warpage, it is conceivable to use the same material on both sides (for example, the same decorative veneer on both sides), but in this case, it is necessary to apply an adhesive on both sides, and the manufacturing process becomes complicated. However, in the present invention, it is not necessary to apply an adhesive on the back surface, and the wood powder resin composite material 10 has a two-layer structure, so that the thermal fusion of the wood powder resin composite materials 10 is easy. Therefore, the manufacturing process can be simplified. Moreover, since the wood powder resin composite material 10 can be manufactured by continuous extrusion, composite lamination of the wood powder resin composite material 10 becomes easy, and the productivity can be further enhanced.

4 to 6, the base material upper layer 2A is made of a wood powder resin composite material 10 in which wood powder and a thermoplastic resin are combined, and the base material lower layer 2B is made of plywood, MDF, particle board, or the like. May be. In manufacturing this panel, the bonding between the plywood and the thermoplastic resin composite material layer can be performed by heat fusion. For example, as shown in FIG. 5, a paper 28 supplied from a paper roll 29 is laminated on the surface of the wood powder resin composite material 10 extruded by an extruder 27 with a T-die, and on a plywood serving as a base material lower layer 2B. It is extruded and fused by heat with a roll press 30. Then, it is sent to a cooling zone, cooled by a roll for press cooling 31, cut into a predetermined width, an adhesive 22 is applied on the upper surface of the paper 28, and then the decorative veneer 3 is put on the adhesive 22. It is placed and pressed by a press machine 32. In this way, by adopting the continuous construction method by extrusion, continuous molding is performed simultaneously with paper fusion (for example, extrusion of the real part 5 including the male part 5a and the female part 5b for floor bonding shown in FIG. 6). Molding, molding of the V-groove 8 in the extrusion direction, etc.)
Since the paper layer, the wood flour resin composite material 10 and the plywood (substrate lower layer 2B) can be continuously laminated, productivity is improved and
This is advantageous in cost. Further, the multilayer structure of the plywood and the wood powder resin composite material allows the plywood to be bent by the wood powder resin composite material even if the plywood has defects such as fine cracks and holes in its surface layer. Rigidity can be increased, and caster resistance can be ensured.

FIG. 7 shows still another embodiment.
In this example, the base material 2 is configured by laminating the wood powder resin composite material 10 on the surface of the plywood layer 60 (base material lower layer 2B) via the moisture-permeable material layer 4 such as paper. That is, the plywood, the paper layer (the moisture-permeable material layer 4), and the wood flour resin composite material 10 are laminated in this order to form the substrate 2, and the upper surface of the substrate 2
The paper layer (moisture-permeable material layer 4) and the decorative surface veneer 3 are laminated in this order to form the panel 1. The paper layer of the base material 2 is fused to the wood powder resin composite material 10 by heat.
By thus configuring the base material 2 with the plywood layer 60, the paper layer, and the wood powder resin composite material 10, the back surface of the base material 2 has a high moisture absorption rate and is laminated on the wood powder resin composite material 10. With the moisture permeable material layer 4 and the plywood layer 60 laminated below, the upper and lower dimensional change rates of the wood powder resin composite material 10 can be made substantially uniform, and a warpage suppressing effect can be obtained. In addition, between the plywood layer 60 and the wood flour resin composite material 10, there is a moisture permeable material layer 4 such as paper.
, The moisture absorbed by the plywood layer 60 can be released to the moisture-permeable material layer 4, and the plywood layer 60 can be prevented from swelling at the same time.

Here, when a paper layer is interposed in the middle of the base material 2, for example, a basis weight of 10 to 80 g / m ² and a thickness of 1
It is preferable to use a paper material of less than 00 μm. At present, as a surface decoration of a flooring material, a natural veneer is bonded in a wet state by hot-pressing using an aqueous adhesive, and at that time, an adhesive or a wet-type adhesive is applied to the wood material constituting the base material 2. By moving the water of the veneer or removing the water by evaporation from the surface, the puncture of the surface decorative veneer 3 at the time of hot pressing is prevented, and the adhesive strength is further secured. Therefore, when the base material 2 is made of only a thermoplastic resin having no water absorption, a puncture phenomenon of the surface decorative veneer 3 occurs at the time of manufacturing, which causes poor adhesion. Therefore, wooden materials and veneer veneer 3
The adhesiveness can be improved by interposing a paper layer between the paper layer and the paper layer.
By setting the thickness to 80 g / m ² and the thickness of 100 μm or less, the adhesive penetrates between the papers with a general amount of the adhesive applied, thereby preventing the puncture phenomenon at the time of bonding the surface decorative veneer 3 and realizing the practical use. Adhesive strength can be secured. In addition, since the wood powder resin composite material 10 is laminated on the paper layer, moisture during the production is absorbed not only by the paper layer but also by the wood powder resin composite material 10 containing wood powder. This also makes it possible to prevent puncture and ensure adhesive strength. Further, by providing a paper layer (moisture-permeable material layer 4) also between the veneer veneer and the base material, an environment in which moisture becomes vapor and more easily scattered can be created, and the adhesiveness is further improved.

FIG. 8 shows that, in the base material 2 in which the base material upper layer 2A is made of a thermoplastic resin composite material and the base material lower layer 2B is made of plywood, the wood powder resin composite material 1 is used as the thermoplastic resin composite material.
0 shows the case where the notch 12 for preventing warpage is formed on the back surface of the plywood layer 60. The wood powder resin composite material 10 improves physical properties such as surface hardness and flexural rigidity as compared with the case of a single thermoplastic resin, and also has an adhesive property, which is a drawback of the resin material, particularly an adhesive face when using an aqueous adhesive. Is effective in shortening the bonding time and securing the bonding strength by absorbing moisture from the wood powder resin composite material 10.
Has the effect of reducing the warpage by reducing the coefficient of thermal expansion compared to resin, but if the thickness of the wood powder resin composite material layer is increased to some extent within a certain range, the warpage during manufacturing and use May be large. This is because when the thickness of the wood powder resin composite material layer is thin between different materials composed of the wood powder resin composite material 10 and plywood, the amount of swelling and shrinkage of the wood powder resin composite material 10 in the entire thickness is reduced. Although the influence of the difference between the front and the back is small, warpage is likely to occur when the thickness increases. Therefore, in the present invention, the cut grooves 12 are formed on the back surface of the plywood.
Is provided, it is possible to reduce the warpage caused by the difference in the amount of swelling and shrinking between different materials. Also,
It is preferable that the cut groove 12 is provided at a depth that does not reach at least the back surface of the plywood to the wood powder resin composite material 10. This makes it possible to balance the swelling and shrinking of the veneer veneer 3 on the front side with the swelling and shrinking of the plywood layer 60 to reduce the warpage as a whole. Also,
The cut groove 12 is preferably arranged, for example, in parallel with the product width. In order to reduce the warpage in the product width direction, it is preferable to form the cut groove 12 in the product length direction.
Further, if necessary, the cut grooves 12 can be provided in both the width direction and the longitudinal direction of the product. The cut groove 12 is for preventing warpage of the plate material together with the cushion material 25 on the rear surface, and is different from a groove provided for conventional non-landing. Further, in the present invention, when the cut groove 12 is provided on the back surface of the plywood, it is preferable that the thickness of the wood powder resin composite material layer of the base material upper layer 2A be 1 mm or more.

Further, a cushion material 25 is provided on the lower surface of the base material lower layer 2B in which the cut grooves 12 are formed. The cushion material 25 enables application to a soundproof floor and the like, and furthermore, since the base material upper layer 2A is a wood powder resin composite material 10, the rigidity is high and the caster resistance is secured even if there is a surface defect of plywood. It is possible to improve caster resistance, which has conventionally been a problem with soundproof floors. The cushion material 25 includes, for example, a nonwoven fabric and urethane foam, but is not limited to this. Also,
As the base material lower layer 2B, for example, MDF composite plywood may be used in addition to plywood and veneer. In this case, prevention of warpage due to water resistance of MDF and improvement of caster resistance at the time of moisture absorption are achieved. Soundproof performance can be further secured. Furthermore, despite the structure in which dissimilar materials are bonded, expansion and contraction due to environmental changes such as temperature and humidity are small, and pushing up and gaps can be prevented.

FIG. 9 shows that the base material upper layer 2A is made of a wood powder resin composite material 1.
0, the base material lower layer 2B is composed of a back moisture permeable layer 26 made of nonwoven fabric, glass fiber, paper, plywood, veneer, etc., respectively, and the back moisture permeable layer 26 is fused to the wood powder resin composite material 10 by heat. This shows the case of wearing. Here, the thickness of the base material 2 including the wood powder resin composite material 10 and the back moisture permeable layer 26 is, for example, 2 to 15 mm. By laminating the back surface moisture-permeable layer 26 such as a nonwoven fabric, glass fiber, paper, plywood, or veneer on the back surface of the wood powder resin composite material 10 as described above, warpage can be suppressed. That is, the moisture-permeable material layer 4 laminated on the wood powder resin composite material 10 and the back moisture-permeable layer 2 laminated below
By virtue of 6, the vertical dimensional change rate of the wood powder resin composite material 10 can be made substantially uniform, and a warp suppressing effect can be obtained. In addition, the moisture permeable material layer 4 located above the wood powder resin composite material 10 and the back moisture permeable layer 26 located below the wood powder resin composite material 10 are each melted into the molten wood powder resin composite material 10. And thus a multi-layer construction is possible without significantly increasing the bonding costs. Further, since the wood powder resin composite material 10 can be manufactured by continuous extrusion, the above-described step of fusing the multiple layers can be continuously performed, and the productivity is greatly improved.

FIG. 10 shows still another embodiment. In this example, the surface of the base material 2 having at least the surface of the thermoplastic resin composite material layer 16 of the thermoplastic resin and the moisture-permeable powder 14 having heat resistance is polished to grind the thermoplastic resin composite material layer 16.
Is exposed to the surface of the veneer, that is, the bonding interface 15 with the veneer veneer 3, and then the veneer veneer 3 (FIG. 1) is heated and softened on the thermoplastic resin composite material layer 16 by softening. The panel 1 is manufactured by bonding.
The method of heating and pressurizing the surface decorative veneer 3 is the same as in the embodiment of FIG.

Here, an olefin resin such as polypropylene or polyethylene is used as the thermoplastic resin. Further, as the heat-resistant moisture-permeable powder 14, for example, wood powder including sawdust, pulp powder, particle board cutting powder, and the like is used. And the surface veneer veneer 3 swells,
In order to effectively prevent puncturing, the mixing ratio of the moisture-permeable powder 14 contained in the composite material comprising the thermoplastic resin and the heat-resistant moisture-permeable powder 14 is set to 40% or more (weight ratio). Is preferred. That is, the higher the mixing ratio of the wood powder, the higher the adhesiveness. In addition, the mixing ratio of wood flour is 40%
If less than the amount, the amount of the moisture-permeable powder 14 exposed at the bonding interface 15 with the surface decorative veneer 3 during the surface polishing is reduced,
This is because moisture permeability becomes a problem.

Thus, as shown in FIG. 10A, the base material 2 is composed of a composite material of the thermoplastic resin and the heat-resistant moisture-permeable powder 14, and thereafter, as shown in FIG. 10B. By polishing the surface of the thermoplastic resin composite material layer 16, the moisture permeable powder 14 is exposed at the bonding interface 15 with the surface decorative veneer 3, thereby bonding the surface decorative veneer 3 (wet veneer). In addition to improving the bonding strength at the time of bonding, the moisture permeation state at the bonding interface 15 can be improved,
The veneer veneer 3 and the substrate 2 can be adhered by heating without causing swelling and puncture of the veneer veneer 3.
That is, by polishing the thermoplastic resin composite material layer 16 on the surface of the substrate 2, the surface hardness, smoothness,
The dimensional stability due to temperature and humidity, and the load resistance, crack resistance, and scratch resistance are improved, and by using such a base material 2, the surface decorative veneer 3 (wet veneer) is swollen and bonded without puncturing. The adhesive strength of the panel 1 thus obtained is equal to or higher than the material breaking strength of the wooden base material 2.

FIGS. 11 (a) to 11 (c) show that the adhesive 22a is applied to the surface of the substrate 2 having at least the surface formed of the low moisture permeable material layer 21, and the moisture permeable material layer 4 is laminated thereon. And
A case is shown in which an adhesive 22 is applied thereon, and the decorative veneer 3 is mounted thereon, and the two are bonded by heating and pressing. This makes it possible to further improve the adhesiveness between the decorative veneer plate 3 and the base material 2 via the moisture-permeable material layer 4.

The panel 1 manufactured in each of the above embodiments can be used not only as a flooring material but also as a wide variety of building materials.

[0054]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments 1 to 6 of the embodiment of the present invention shown in FIGS.

Example 1 As a substrate having a low moisture-permeable material layer, wood powder: polypropylene = 50: 50 (weight ratio)
Was used. Examples of the moisture-permeable material include paper, nonwoven fabric, and wood powder, which are easily available. However, it is preferable to use a material having a high interlayer strength of the moisture-permeable material itself. (Thickness 70 μm, weight 5
0 g / m ² ). Other weight (20 ~ 7
0) and different thicknesses (30 μm to 1000 μm), but the strength can be adjusted by the state of impregnation of the adhesive into the moisture-permeable material layer. As the reinforcing paper, a sample fused to the base material was prepared. The specifications of the surface decorative veneer and the adhesive are as shown in Table 1 below.

[0056]

[Table 1]

The samples prepared under the conditions shown in Table 1 above were evaluated as shown in Table 2 below. As a result, the samples having a moisture-permeable material exhibited poor adhesion and crack resistance (repeated cold / hot test). It turns out that superior results can be obtained. In Table 2 below, the surface decorative veneer was bonded while the moisture-permeable material layer (reinforced paper) was fused to the base material. The cross cut test is based on JISK504008.5.
Based on the 1st grid method. The cold repetition test is based on the JAS special plywood cold repetition A test.

[0058]

[Table 2]

Hereinafter, Examples 2 to 7 of the embodiment of the present invention shown in FIGS. 4 to 6 will be described.

Example 2 Polypropylene was used as the thermoplastic resin of the wood powder resin composite material, and wood powder and talc were used as the heat-resistant powder. The mixing ratio is such that the wood flour resin composite material on the side closer to the veneer veneer uses a molding material of wood flour: talc: polypropylene = 30: 10: 60 (weight ratio) and is far from the veneer veneer. In the side wood flour resin composite material, wood flour: talc: polypropylene = 50: 10: 4
A molding material of 0 (weight ratio) was used. Then, a plate material was prepared by fusing paper as a moisture permeable material on the surface of the two-layer wood powder resin composite material. On the other hand, as a comparison object, a plate material was prepared by fusing paper to the surface of a single wood flour resin composite material of wood flour: talc: polypropylene = 30: 10: 60 (weight ratio), and the warpage amount of both was determined. Compared. Incidentally, the purpose of fusing the paper to the wood flour resin composite material is to attach a decorative surface veneer thereon and heat-bond it.

Then, a wood flour resin composite material (composite layer) melted experimentally at 180 ° and a paper having a basis weight of 50 g / m ² as a moisture permeable material are laminated, and pressed into a plate shape at a pressure of 25 kg / cm ^2. After that, it was left at normal temperature of 25 ° C. Table 3 below
Table 5 shows the specifications of the wood powder resin composite material layer, such as the thickness and the bending Young's modulus, and the measurement results of the warpage.

[0062]

[Table 3]

[0063]

[Table 4]

[0064]

[Table 5]

When the board specifications A and the board specifications B shown in Table 4 are compared for each layer material shown in Table 3 above, the warpage amount is significantly smaller in the board specification B in which the wood powder resin composite material is used as the composite layer. You can see that it is. In addition, Table 5 shows the results of calculation for predicting warpage due to the combination of paper and wood flour resin composite material, and wood flour resin composite material and wood flour resin composite material. This is a result of performing a prediction calculation using the values shown in Table 2-1 with reference to a generally known bimetallic formula. As a result, it is theoretically expected that warping forces having equal and opposite directions are generated above and below the composite layer configuration in the plate specification A.

(Example 3) Polypropylene resin 45w
t%, wood flour 50 wt% (rice hemlock, # 100 mesh) and maleic acid-modified polypropylene 5 wt% are kneaded, and then extruded at a thickness of 0.5 mm by a 300 mm-wide extruder with a T-die, and simultaneously with a basis weight of 10 g /
m ^2, subjected to heat fusion by a roll pressing the plywood with a surface simultaneously disadvantages when fusing the paper thickness 40μm thermally, 1
A substrate having a thickness of 2 mm was prepared. Thereafter, an aqueous urea-SRB adhesive was applied at 100 g / m ² to the surface to which the paper was attached, and a wet natural veneer having a thickness of about 0.2 mm was bonded by hot pressing. The bonding conditions are 6 kg / cm ² and 120 °
× Performed for about 1 minute. Thereafter, the floor material was prepared through surface polishing, processing, and painting.

(Example 4) Polypropylene resin 40w
t%, 55 wt% of wood flour (Lawan plywood cut powder, # 200 mesh) and 5 wt% of maleic acid-modified polypropylene, and then extruded with a 300 mm wide T-die extruder to a thickness of 0.5 mm, and at the same time, the weight per table 70
A paper having a g / m ² and a thickness of 80 μm was fused by heat to prepare a wood powder resin composite material sheet attached to the paper. Thereafter, the back surface was sanded with # 120 paper, and this sheet was laminated on a plywood with an aqueous vinyl urethane adhesive by cold pressure. Thereafter, a floor material was prepared in the same manner as in Example 3.

Comparative Example 1 A polypropylene resin having a width of 3
0.5mm by extruder with 00mm T-die
At the same time, paper having a basis weight of 100 g / m ² and a thickness of 130 μm was fused on the front and back by heat to prepare a resin composite material sheet attached to the front and back papers. Thereafter, flooring materials were prepared in the same manner as in Example 3-1 except for sanding.

Comparative Example 2 A polypropylene resin having a width of 3
0.5mm by extruder with 00mm T-die
At the same time, paper having a basis weight of 100 g / m ² and a thickness of 130 μm was fused to the front by heat to prepare a resin composite material sheet attached to the front and back papers. Thereafter, a floor material was prepared in the same manner as in Example 3.

The results of Examples 3 and 4 and Comparative Examples 1 and 2 are shown in Table 6 below. In addition, the tests A and B in Table 6 were performed in a size of 1 × 6. The test C adheres the jig 20mm angle to the surface of the test specimen of 40mm square, cut conducted plane tensile test put by cutter veneer part, ○ a 4 kgf / cm ² or more evaluation, following Is indicated by x. Test D is a jig 20mm angle to the surface of the test specimen of 40mm square was bonded to the resin part, and cuts up to plate portion conducted plane tensile test, ○ a 4 kgf / cm ² or more evaluation, the following X. In test E, a 25 kg load was 35
The dent amount after reciprocating 1000 times with a resin caster having a diameter of mm was measured.

[0071]

[Table 6]

According to Table 6 above, in a building material in which a paper layer and a decorative veneer were laminated in this order on the surface of a base material composed of a plywood layer 60 and a thermoplastic resin composite material layer, at least It was found that by using a wood flour resin composite material in which wood flour and a thermoplastic resin were compounded, it had excellent dent resistance (caster resistance) and sufficient adhesion performance. In addition, by bonding the plywood and the wood flour resin composite material by heat fusion, it is not necessary to bond the plywood and the wood flour resin composite material as a separate process after manufacturing the base material, which is excellent in productivity and cost. It has been found that a manufacturing method can be provided.

(Example 5) Polypropylene resin 45w
t%, wood flour 50 wt% (rice hemlock, # 100 mesh) and maleic acid-modified polypropylene 5 wt%, and then extruded at a thickness of 0.5 mm using a 950 mm wide extruder with a T-die, and simultaneously with a basis weight of 10 g /
Paper having a thickness of m ² and a thickness of 40 μm was fused by heat to prepare a wood flour resin composite material sheet attached to the front and back papers. For the evaluation of physical properties, a 1.5 mm thick wood powder resin composite material was also extruded. This wood flour resin composite material sheet is laminated on plywood by cold pressing with an aqueous vinyl urethane adhesive, and then
Apply an aqueous urea-SRB adhesive to the surface pasted on paper.
200 g / m ² was coated wet natural veneer of approximately 0.2mm thickness was bonded by hot pressing. The bonding condition is 6 kg / cm
² was performed at 120 ° × about 1 minute. Thereafter, the floor material was prepared through surface polishing, processing, and painting.

(Example 6) Polypropylene resin 40w
After kneading t%, 55 wt% of wood flour (Lauan plywood cut powder, # 200 mesh) and 5 wt% of maleic acid-modified polypropylene, extruding with a thickness of 0.2 mm using a 950 mm wide extruder with a T-die, and simultaneously applying weight on both sides 7
A paper of 0 g / m ² and a thickness of 80 μm was fused by heat to prepare a wood powder resin composite material sheet attached to the front and back papers. Thereafter, a floor material was prepared in the same manner as in Example 4-1.

Comparative Example 3 A polypropylene resin having a width of 9
0.2mm by extruder with 50mm T-die
At the same time, paper having a basis weight of 100 g / m ² and a thickness of 130 μm was fused on the front and back by heat to prepare a resin composite material sheet attached to the front and back papers. Thereafter, a floor material was prepared in the same manner as in Example 5.

The results of Examples 5 and 6 and Comparative Example 3 are shown in Table 7 below. In addition, the test A in Table 7 was implemented in 1-shoulder x 6-shelf size. The test B is to adhere the jig 20mm angle to the surface of the test specimen of 40mm square, cut conducted plane tensile test put by cutter veneer part, ○ a 4 kgf / cm ² or more evaluation, following Is indicated by x. In test C, a 25 kg load was applied to a resin caster having a diameter of 35 mm, and the amount of dent after reciprocating 1,000 times was measured.
50 μm or less was evaluated as ○ and above as ×. Test D is J
The measurement was performed in the measurement direction and the extrusion direction according to ISK7230.

[0077]

[Table 7]

According to the above Table 7, the building material in which the paper layer and the surface decorative veneer are laminated in this order on the surface of the base material made of the plywood layer 60, the paper layer, and the wood powder resin composite material has excellent caster resistance. It was found that it was possible to secure sufficient adhesive performance.

Next, a seventh embodiment of the present invention shown in FIG. 7 will be described.

(Example 7) Polypropylene resin 45w
t%, wood flour 50 wt% (rice hemlock, # 100 mesh) and maleic acid-modified polypropylene 5 wt%, and then extruded with a T-die extruder having a width of 950 mm to a thickness of 0.5 mm, and at the same time, a weight of 50 g / m
^{2. A} 70-μm thick paper is fused by heat and, at the same time, heat-bonded to a plywood with a surface defect by roll pressing.
A substrate having a thickness of m was prepared. Thereafter, an aqueous urea-SRB adhesive was applied at 100 g / m ² to the surface to which the paper was attached, and a wet natural veneer having a thickness of about 0.2 mm was bonded by hot pressing. The bonding conditions are 6 kg / cm ² and 120 ° ×
Performed for about 1 minute. Thereafter, the floor material was prepared through surface polishing, processing, cushioning, and painting. Also, saw grooves were formed at a pitch of 15 mm in the product width direction from the back surface at a depth of 6 mm, and the soundproofing property and dimensional stability were evaluated.

(Comparative Example 4) A plywood was cold-pressed on an MDF having a thickness of 3 mm with aqueous vinyl urethane, a natural veneer was adhered to the surface of the MDF in the same manner as in Example 5, and thereafter a floor material was similarly formed. Then, from the back to the MDF layer, 15
Saw grooves were formed at a depth of 6 mm at a pitch of mm to evaluate soundproofing and dimensional stability.

(Comparative Example 5) A polypropylene resin having a width of 9
0.5mm by extruder with 50mm T-die
At the same time, paper having a basis weight of 100 g / m ² and a thickness of 130 μm was fused on the front and back by heat to prepare a resin composite material sheet attached to the front and back papers. Thereafter, a floor material was prepared in the same manner as in Example 5.

The results are shown in Table 8 below. Test A in Table 8
B was performed in a size of 1 × 6. Test C is 40
bonding the jig 20mm angle to the surface of the specimen in mm square, put a cut by a cutter into veneer unit conducted plane tensile test, a 4 kgf / cm ² or more evaluation ○, and as × less. In test D, 2 mm was applied to the surface of a 40 mm square specimen.
A 0 mm square jig was adhered to the resin part, a cut was made up to the plywood part, a plane tensile test was performed, and the evaluation was 4 kgf /
cm ² or more ○, was × the following. In test E, a 25 kg load was applied to a 35 mm diameter resin caster to
The amount of dent after reciprocation was measured. Dimensional stability test F is 40 ° C, 90% RH
The dimensional change rate when left in the atmosphere for 120 hours, and the equivalent level of plywood, 0.15 to 0.2%, was evaluated as ○, and more than that was evaluated as ×. The soundproof test G was measured according to JIS A1419, and the L45 level was evaluated as ○ and L45 to L50 °.
(Note that the cushioning material used for the measurement is a soft urethane foam cushioning material with a non-woven fabric on the back, and the thickness is 4 mm.
Met. )

[0084]

[Table 8]

From Table 8, it can be seen that excellent dent resistance (caster resistance) and adhesion were obtained, and that the floor was excellent in soundproofing, moisture resistance and water resistance.

Next, Examples 8 and 9 of the embodiment of the present invention shown in FIG. 8 will be described.

(Example 8) Polypropylene resin 45w
After kneading t%, wood flour 50wt% (rice hemlock, # 100 mesh) and maleic acid-modified polypropylene 5wt%, the mixture was extruded at a thickness of 0.5mm by an extruder with a 300mm width T-die, and at the same time, 25g / m
^{2. A} 40-μm thick paper is fused by heat and, at the same time, heat-bonded to a plywood with a surface defect by roll pressing to 9 m
A substrate having a thickness of m was prepared. Thereafter, an aqueous urea-SRB adhesive was applied at 100 g / m ² to the surface to which the paper was attached, and a wet natural veneer having a thickness of about 0.2 mm was bonded by hot pressing. The bonding conditions are 6 kg / cm ² and 120 ° ×
Performed for about 1 minute. Thereafter, the floor material was prepared through surface polishing, processing, and painting. 15mm groove with 6mm depth from the back
They were provided at a pitch in parallel with the product width.

(Example 9) Polypropylene resin 65w
t%, 30% by weight of wood flour (US $ 100, # 100 mesh) and 5% by weight of maleic acid-modified polypropylene, and the mixture was extruded with a 300 mm width T-die extruder.
The sheet was extruded with a thickness of 50 mm, and at the same time, paper having a basis weight of 50 g / m ² and a thickness of 70 μm was fused by heat to prepare a wood-flour resin composite sheet attached to the paper. Thereafter, the back surface was sanded with # 120 paper, and this sheet was laminated on a plywood with an aqueous vinyl urethane adhesive by cold pressure to prepare a 5 mm thick base material. Thereafter, a floor material was prepared in the same manner as in Example 5-2. Thereafter, grooves having a depth of about 2 mm were provided at a pitch of 15 mm in parallel with the product width from the back surface to a position where a single piece of wood constituting the plywood layer 60 on the side in contact with the wood powder resin composite material was left. A groove was provided in parallel with the product length.

(Comparative Example 6) A commercially available MDF having a thickness of 3 mm and a plywood were laminated under cold pressure with an aqueous vinyl urethane adhesive to produce a base material having a thickness of 9 mm. Thereafter, a floor material was prepared in the same manner as in Example 5-2. Thereafter, grooves having a depth of 6 mm from the rear surface were provided at a pitch of 15 mm in parallel with the product width.

(Comparative Example 7) A polypropylene resin having a width of 3
The extruder was extruded with a thickness of 2 mm using an extruder with a 00 mm T-die, and a polyolefin laminate paper having a basis weight of 50 g / m ² and a thickness of 70 μm was fused to the front and back by heat to prepare a resin composite material sheet. This sheet was laminated on a plywood with an aqueous vinyl urethane adhesive by cold pressure to prepare a base material having a thickness of 5 mm. Thereafter, an aqueous urea SBR-based adhesive was applied at 100 g / m ² to the surface on which the paper was attached, and a wet natural veneer having a thickness of about 0.2 mm was bonded by hot pressing. The bonding was performed at 6 kg / cm ² at 120 ° × about 1 minute. Thereafter, the floor material was prepared through surface polishing, processing, and painting.

The results of Examples 8 and 9 and Comparative Examples 6 and 7 are shown in Table 9 below. In addition, the test A in Table 9 is 1 × 6.
The measurement was performed in a shaku size. The test B is to adhere the jig 20mm angle to the surface of the test specimen of 40mm square, cut conducted plane tensile test put by cutter veneer part, ○ a 4 kgf / cm ² or more evaluation, following Is indicated by x. Test C was conducted at 40 ° C. and 90% RH for 120 hours.
The dimensional change rate of the plywood when it was left was determined, and the evaluation was x for dimensional change of plywood or more, Δ for equivalent, and ○ for plywood or less. Test D is
Was applied to a resin caster having a diameter of 25 mm with a load of 25 kg, and the amount of dent after reciprocating 1,000 times was measured.

[0092]

[Table 9]

From Table 9, it can be seen that warpage during use and during manufacture is reduced, and excellent dent resistance (caster resistance) and adhesiveness are obtained.

Next, a description will be given of a tenth embodiment of the present invention shown in FIG.

(Example 10) As a wood flour resin composite material,
Polypropylene was used as the thermoplastic resin, and wood powder and talc were used as the heat-resistant powder. The compounding ratio is as follows: wood powder: talc: polypropylene = 30: 2 as a wood powder resin composite material
A molding material of 0:50 (weight ratio) was used. As a wood powder resin composite material for comparison, a sheet material obtained by fusing paper to a single board of wood powder: talc: polypropylene = 30: 20: 50 (weight ratio) and then bonding a surface decorative veneer was used. Show. Incidentally, the purpose of fusing the paper to the wood flour resin composite material is to attach a decorative surface veneer thereon and heat-bond it.

(Example 11) The base material upper layer 2A was made of a wood powder resin composite material 10, and the base material lower layer 2B was made of a nonwoven fabric (glass fiber, paper,
Plywood, veneer, etc.). Table 10 below shows a comparison of the amount of warpage when the wood powder resin composite material is used to form the above-described multilayer structure.

[0097]

[Table 10]

[0098] From Table 10 above, it can be seen that in the case of the base material having a multilayer structure of the present invention, the effect of reducing the amount of warpage can be obtained.

Next, an embodiment 11 of the embodiment shown in FIG. 10 of the present invention will be described.

Example 12 A composite material comprising a heat-resistant moisture-permeable powder and a thermoplastic resin is easily available as a moisture-permeable powder, and is inexpensive, such as sawdust, pulp powder, and the like. Wood powder including particle board cutting powder was used. In addition, inorganic powders such as calcium carbonate, talc,
Shirasu balloons may be added. Here, wood flour was used. On the other hand, as the thermoplastic resin, an olefin resin which is easily available and inexpensive was used. For example, polypropylene (PP) and polyethylene (PE) are preferable.
In addition, polyvinyl chloride (PVC), polystyrene (P
S), an ABS resin or the like may be used. Furthermore, as a compounding ratio of the thermoplastic resin and the moisture-permeable powder, a range in which good molding is possible and adhesion of a wet veneer (surface decorative veneer) is good, for example, a moisture-permeable powder 40 to 60 % (Weight ratio) is preferred. Here, the experiment was performed with a moisture-permeable powder of 30 to 60%. The bonding between the composite material and the wet veneer was performed by polishing the surface of the thermoplastic resin composite material layer with a sander (about # 60), and then performing the heat bonding under the heating conditions shown in Table 1 above.

Further, when the items shown in the following Table 11 were evaluated using the samples prepared under the conditions shown in Table 1, it was found that a good adhesion state was exhibited when the wood powder blending ratio was 40 to 60%.

[0102]

[Table 11]

[0103]

As described above, according to the first aspect of the present invention, a decorative veneer is laminated on a surface of a substrate having a low moisture permeable material layer at least on the surface via a moisture permeable material layer. Since it is integrated, by interposing a moisture permeable material layer between the decorative surface veneer and the low moisture permeable material layer, when the surface decorative veneer is bonded by heating, moisture evaporated by heat is transmitted. It is absorbed by the wet material layer, and therefore, due to the dispersion of moisture at the adhesive interface with the surface decorative veneer, the surface decorative veneer swells without generating punctures, and the surface decorative veneer and the low moisture-permeable material layer Can be bonded. Therefore, it is not necessary to change the mounting specification of the conventional veneer veneer, for example, a press machine. Furthermore, the interlayer strength of the moisture-permeable material layer,
Due to the effect of adjusting the density and the effect of impregnating the adhesive, the adhesion performance of the veneer veneer is improved as compared with the case where the surface veneer is directly adhered to the low moisture permeable material layer. In addition, the surface hardness and smoothness that are the characteristics of the base material, dimensional stability due to temperature and humidity are not impaired,
It is possible to manufacture a panel maintaining these performances, and furthermore, there is no problem such as occurrence of cracks and dimensional change of the veneer veneer.

According to a second aspect of the present invention, in addition to the effect of the first aspect, the low moisture permeable material layer of the base material is made of a thermoplastic resin composite material, and the thermoplastic resin composite material is made of at least wood. Since it is made of a wood powder resin composite material in which powder and a thermoplastic resin are combined, the addition of wood powder improves the physical properties such as the surface hardness and flexural rigidity of the base material more than the thermoplastic resin alone. In addition to this, it is possible to prevent a decrease in adhesiveness, which is a disadvantage of the resin material. In particular, even when a water-based adhesive is used, the effect of shortening the bonding time and securing the bonding strength can be obtained by absorbing moisture from the bonding surface.

According to a third aspect of the present invention, in addition to the effect of the second aspect, the base material is composed of a plurality of upper and lower layers, and at least the upper layer of the base material is a wood flour resin in which wood flour and a thermoplastic resin are combined. Since it is made of a composite material, when the base material lower layer is a plywood layer,
Even if the surface of the plywood has defects such as fine cracks and holes, the bending rigidity can be increased by the wood powder resin composite material, and the caster resistance can be ensured.

According to a fourth aspect of the present invention, in addition to the effect of the second aspect, the upper layer of the base material and the lower layer of the base material are each formed of a wood flour resin composite material obtained by compounding wood flour and a thermoplastic resin. Since the blending ratio of wood flour in the wood flour resin composite material farthest from the veneer veneer was greater than the blending ratio of wood flour in the wood flour resin composite material closest to the veneer veneer,
The moisture-permeable material layer is located on the upper wood flour resin composite material and the highly moisture-permeable wood powder resin composite material is located below, and the surface of the panel is made by sticking a decorative veneer on the surface of the base material The warpage force on the side and the warpage force on the back side can be substantially equalized, and the warpage can be suppressed. Therefore, it is possible to suppress the warpage of the entire panel only by using the specifications of the wood powder resin composite material. For example, it is possible to easily obtain a panel product having no warpage while freely setting the performance as a building material or the like.

According to a fifth aspect of the present invention, in addition to the effect of any of the second to fourth aspects, an intermediate moisture-permeable layer is interposed between the upper and lower layers of the base material. When bonding the upper and lower layers of the base material, the adhesive penetrates through the intermediate moisture permeable layer interposed between the base layer and the base layer, ensuring practical adhesive strength, and absorbing moisture during manufacture into the moisture permeable material layer. By doing so, it is possible to prevent puncture and ensure adhesive strength. Therefore, good adhesion can be obtained even when the lower layer of the base material is made of plywood, MDF, particle board, or the like.

According to the invention of claim 6, in addition to the effect of any of claims 2 to 4, the wood flour resin composite material contains 30 to 70 wt% of wood flour. It is possible to increase the hardness of the resin-powder composite material and prevent the problem of moisture permeability.

According to the invention of claim 7, in addition to the effect of claim 2, claim 3, claim 4, or claim 6, the thickness of the wood powder resin composite material layer is at least 0.1.
mm or more, the surface hardness, smoothness, and dimensional stability due to temperature and humidity of the wood powder resin composite material can be prevented from being impaired.

The invention described in claim 8 provides the effect of claim 2 or claim 3 or claim 4 or claim 6 or claim 7 in addition to the olefin as a thermoplastic resin in the wood powder resin composite material. The use of maleic acid-modified polyolefin and the addition of maleic acid or modification by addition of maleic acid improve the dispersibility of wood flour and thermoplastic resin,
In addition, the rigidity can be improved.

According to a ninth aspect of the present invention, in addition to the effect of the second, third, fourth, sixth, seventh, or eighth aspect, the bending of the wood powder resin composite material layer is performed. Since the Young's modulus is at least 40000 kgf / cm ² or more, even if the base material lower layer is made of plywood or the like, even if the surface of the plywood has defects such as fine cracks, holes and the like, Since the bending rigidity can be increased by the wood powder resin composite material, it is possible to ensure caster resistance.

According to the tenth aspect of the present invention, in addition to the effects of the first or fifth aspect, since the moisture-permeable material is paper, nonwoven fabric, or wood flour, it is easily available as a moisture-permeable material. Inexpensive materials can be used.

According to the invention of claim 11, in addition to the effect of claim 1 or claim 5, since the decorative veneer is made of a natural veneer or a veneer sheet, the natural veneer or the like is kept wet. The adhesive can be easily bonded by hot-pressing using an aqueous adhesive, and the moisture of the adhesive and wet veneer is absorbed by the moisture-permeable material layer under the veneer veneer. The puncture of the veneer can be prevented, and the adhesive strength can be secured.

Further, according to the invention of claim 12, when manufacturing a panel in which a decorative veneer is laminated and integrated on the surface of a substrate having a low moisture-permeable material layer on at least the surface, the surface of the substrate is provided with a moisture-permeable material. The layers and the veneer veneer are laminated in this order, and the low-moisture-permeable material layer and the veneer veneer are heat-bonded via the moisture-permeable material layer. When the surface veneer is adhered by heating by interposing a moisture permeable material layer on the surface, moisture evaporated by heat is absorbed by the moisture permeable material layer. Due to the dispersion of the veneer, the veneer veneer can be bonded to the low-moisture-permeable material layer without causing swelling and puncture. Therefore, it is not necessary to change the mounting specification of the conventional veneer veneer, for example, a press machine. Furthermore, the interlayer strength of the moisture-permeable material layer,
Due to the effect of adjusting the density and the effect of impregnating the adhesive, the adhesion performance of the veneer veneer is improved as compared with the case where the surface veneer is directly adhered to the low moisture permeable material layer. In addition, the surface hardness and smoothness that are the characteristics of the base material, dimensional stability due to temperature and humidity are not impaired,
It is possible to manufacture a panel that retains these performances, and further, there is no problem such as occurrence of cracks or dimensional change of the veneer veneer.

The invention of claim 13 provides the invention of claim 12
In addition to the effects described, the substrate is composed of a plurality of upper and lower layers, the upper layer of the substrate is made of a wood powder resin composite material obtained by combining at least wood powder and a thermoplastic resin, and the lower layer of the substrate is made of plywood,
Since the bonding between the plywood and the wood flour resin composite material is performed by heat fusion, the upper layer of the base material is made of a wood flour resin composite material containing wood flour, so that the base material can be made easier than a thermoplastic resin alone. In addition to improving the physical properties such as surface hardness and bending rigidity of the resin material, it is possible to prevent a decrease in adhesiveness, which is a disadvantage of the resin material. In particular, even when using an aqueous adhesive,
By absorbing moisture from the bonding surface, the effect of shortening the bonding time and securing the bonding strength can be obtained. Further, even if the surface of the plywood has a defect such as a fine crack or a hole, the bending rigidity can be increased by the wood powder resin composite material, so that the caster resistance performance can be secured.

The invention according to claim 14 is the invention according to claim 13
In addition to the effects described above, the base material upper layer and the base material lower layer are each made of a wood flour resin composite material in which wood flour and a thermoplastic resin are compounded, and the wood flour resin composite material farthest from the surface decorative veneer Since the mixing ratio of the wood flour in the inside was larger than the mixing ratio of the wood flour in the wood flour resin composite material closest to the surface decorative veneer, the moisture permeable material layer was placed on the wood flour resin composite material above, The wood powder resin composite material with high moisture permeability is located below, and the warpage force on the front side and the warpage force on the back side of the panel made by sticking a decorative veneer on the surface of the base material are almost equal. And warpage can be suppressed. Therefore, it is possible to suppress the warpage of the entire panel only by using the specifications of the wood powder resin composite material. For example, it is possible to easily obtain the panel 1 having no warpage while freely setting the performance as a building material or the like.

The invention according to claim 15 is the invention according to claim 13.
In addition to the effect according to any one of claims 14 to 14, since an intermediate moisture-permeable layer is interposed between the upper substrate layer and the lower substrate layer, when bonding the upper substrate layer and the lower substrate layer, The adhesive penetrates through the intermediate moisture-permeable layer interposed between the layers, ensuring practical adhesive strength, and preventing moisture from being absorbed by the intermediate moisture-permeable layer during manufacturing, preventing puncture and ensuring adhesive strength. It becomes possible.

The invention of claim 16 is the invention of claim 13
In addition to the effect according to any one of claims 15 to 15, since a cut groove for preventing warpage is formed on the lower surface side of the base material lower layer, swelling of the base material, warp generated due to a difference in the amount of shrinkage is formed by the cut groove. It is possible to reduce, therefore, for example, even if the lower layer of the base material is a plywood or the like, the swelling and shrinking of the surface decorative veneer on the front side and the swelling and shrinking of the plywood layer are balanced,
Warpage as a whole can be reduced.

The invention according to claim 17 is based on claim 17.
In addition to the effects described, since the cushion material is provided on the lower surface of the base material lower layer where the cut groove for preventing warpage is formed,
The cushioning material can be applied to soundproof floors, etc.
In addition, the effect of suppressing warpage is further improved together with the cut grooves,
Therefore, expansion and contraction due to environmental changes such as temperature and humidity are small,
Pushing up and gaps can be prevented.

The invention according to claim 18 is the invention according to claim 13
In addition to the effect according to any one of claims 14 to 14, the upper layer of the base material is made of a wood powder resin composite material, and the lower layer of the base material is a non-woven fabric, glass fiber, paper, plywood, veneer, etc. Since the back moisture permeable layer is thermally fused to the wood flour resin composite material, a moisture permeable material layer interposed between the base material and the decorative veneer is placed on the wood flour resin composite material. Position to,
In addition, the back moisture permeable layer is located below the wood powder resin composite material, and therefore, the vertical dimensional change rate of the wood powder resin composite material can be made substantially uniform, and the effect of suppressing warpage can be obtained. Moreover, the nonwoven fabric, glass fiber, paper, plywood, veneer, etc. constituting the back moisture permeable layer can be fused to the molten wood flour resin composite material, thus significantly increasing the bonding cost. And a multi-layer configuration is possible. Furthermore, since the wood powder resin composite material can be manufactured by continuous extrusion, the above-mentioned step of fusing the multiple layers can be performed continuously, and the productivity is greatly improved.

Further, according to the nineteenth aspect of the present invention, a surface decorative veneer is provided on the surface of a substrate having a thermoplastic resin composite material layer in which a thermoplastic resin and a heat-resistant moisture-permeable powder are combined at least on the surface. In manufacturing a laminated integrated panel, the surface of the thermoplastic resin composite material layer is polished to expose the moisture-permeable powder at the bonding interface with the decorative veneer, and then the surface is placed on the thermoplastic resin composite material layer. Since the decorative veneer is heated and bonded, the moisture-permeable powder is exposed at the bonding interface with the surface decorative veneer, so that the bonding strength when bonding the surface decorative veneer can be improved, and at the bonding interface. Can improve the moisture permeability of the surface, swelling of the veneer veneer,
The surface decorative veneer and the substrate can be adhered by heating without generating puncture. In addition, it is possible to manufacture a panel that retains the properties of the base material without impairing the surface hardness, smoothness, and dimensional stability due to temperature and humidity, and furthermore, it is possible to produce cracks on the veneer surface. Also, problems such as dimensional changes do not occur.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of one embodiment of the present invention.

FIG. 2 is an explanatory diagram of a manufacturing process of the above panel.

FIG. 3 is a side view of the panel.

FIG. 4 is an explanatory diagram of another embodiment.

FIG. 5 is an explanatory view of a manufacturing process of the panel.

FIG. 6 is a side view of the panel.

FIGS. 7A and 7B are explanatory views of a manufacturing process according to still another embodiment.

FIG. 8 is an explanatory diagram of still another embodiment.

FIG. 9 is an explanatory diagram of still another embodiment.

10A and 10B show still another embodiment, in which FIG. 10A is a schematic sectional view of a composite material before polishing, and FIG. 10B is a schematic sectional view of the composite material after polishing.

FIGS. 11A to 11C are explanatory views of a manufacturing process according to still another embodiment.

FIG. 12 is a perspective view illustrating a construction state of the above panel.

FIG. 13 is a schematic diagram illustrating a swollen state of a decorative veneer panel in a conventional panel.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Panel 2 Base material 2A Base material upper layer 2B Base material lower layer 3 Surface decorative veneer 4 Moisture permeable material layer 10 Wood powder resin composite material 11 Intermediate moisture permeable layer 12 Cut groove 13 Thermoplastic resin 14 Moisture permeable powder 16 Thermoplastic resin Composite material layer 21 Low moisture permeable material layer 25 Cushion material 26 Back moisture permeable layer

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor: Satoru Konishi 1048, Kazuma Kadoma, Kadoma, Osaka Prefecture Inside Matsushita Electric Works, Ltd. (72) Inventor Arihiro Adachi 1048, Kazuma Kadoma, Kadoma, Osaka, Japan Inside Matsushita Electric Works, Ltd. (72) Inventor Norito Kameyama 1048, Kazuma, Kadoma, Osaka Pref.F-term in Matsushita Electric Works Co., Ltd. CC02 CC06 CE05 FC01 FC03 FC04 FD04 FD06 4F100 AG00C AK01A AK01C AK03A AK03K AK07 AK36G AK51G AK73G AL01G AL05A AL05C AL06A AP00A AP00B AP00C AP01B AP01C AP02C AR00A AR10BA00 BA01 BA02 BA10 BA01 BA02 BA10 BA01 BA02 EG002 EH012 EJ272 EJ422 EK04 GB07 HB00 HB00B JB16A JB16C JD04A JD04C JD04D JJ03A JK07 JK12 JK15 JK17E JL04 YY00

Claims (19)

[Claims] 1. A panel comprising a surface veneer veneer laminated and integrated via a moisture-permeable material layer on at least the surface of a substrate having a low moisture-permeable material layer on the surface. 2. The low moisture permeable material layer of the base material is composed of a thermoplastic resin composite material, and the thermoplastic resin composite material is made of at least a wood flour resin composite material in which wood flour and a thermoplastic resin are composited. The panel according to claim 1, wherein: 3. The panel according to claim 2, wherein the base material is composed of a plurality of upper and lower layers, and at least an upper layer of the base material is made of a wood flour resin composite material obtained by compounding wood flour and a thermoplastic resin. 4. A base material comprising a plurality of upper and lower layers, each layer comprising a wood flour resin composite material comprising a mixture of wood flour and a thermoplastic resin, wherein the wood flour resin composite furthest from the surface decorative veneer is provided. 3. The panel according to claim 2, wherein the blending ratio of the wood flour in the material is greater than the blending ratio of the wood flour in the wood flour resin composite material closest to the surface decorative veneer. 5. The panel according to claim 2, wherein an intermediate moisture-permeable layer is interposed between the upper substrate layer and the lower substrate layer. 6. The wood powder resin composite material is made of wood powder of 30 to 70 watts.
The panel according to any one of claims 2 to 4, wherein the panel contains t%. 7. The panel according to claim 2, wherein the thickness of the wood powder resin composite material layer is at least 0.1 mm or more. 8. The method according to claim 2, wherein an olefin-based resin is used as the thermoplastic resin in the wood flour resin composite material, and maleic acid-modified polyolefin is added or modified by adding maleic acid. The panel according to claim 3 or claim 4 or claim 6 or claim 7. 9. The wood powder resin composite material layer having a bending Young's modulus of at least 40000 kgf / cm ² or more. Item 10. The panel according to Item 8. 10. The panel according to claim 1, wherein the moisture-permeable material is paper, nonwoven fabric, or wood flour. 11. The panel according to claim 1, wherein the decorative veneer is a natural veneer or a veneer sheet. 12. When manufacturing a panel in which a surface decorative veneer is laminated and integrated on the surface of a substrate having a low moisture-permeable material layer at least on the surface, a moisture-permeable material layer and a surface decorative veneer are provided on the surface of the substrate. Are laminated in this order, and the low-moisture-permeable material layer and the decorative surface veneer are heat-bonded via the moisture-permeable material layer. 13. The base material is composed of a plurality of upper and lower layers, the upper base material layer is made of a wood powder resin composite material in which at least wood flour and a thermoplastic resin are compounded, and the lower base material layer is considerably plywood. 13. The panel manufacturing method according to claim 12, wherein the bonding with the powder resin composite material is performed by heat fusion. 14. The base material upper layer and the base material lower layer are each made of a wood flour resin composite material obtained by compounding wood flour and a thermoplastic resin, and the wood flour resin composite material farthest from the surface decorative veneer is in the wood flour resin composite material. 14. The method for manufacturing a panel according to claim 13, wherein the mixing ratio of the wood flour is greater than the mixing ratio of the wood flour in the wood flour resin composite material closest to the surface decorative veneer. 15. The method for producing a panel according to claim 13, wherein an intermediate moisture-permeable layer is interposed between the upper layer of the base material and the lower layer of the base material. 16. The panel manufacturing method according to claim 13, wherein a cut groove for preventing warpage is formed on the lower surface side of the base material lower layer. 17. The method for manufacturing a panel according to claim 16, wherein a cushion material is provided on a lower surface of the base material lower layer in which the cut groove for preventing warpage is formed. 18. The base material upper layer is made of a wood powder resin composite material, and the base material lower layer is made of a back moisture permeable layer of nonwoven fabric, glass fiber, paper, plywood, veneer or the like. The panel manufacturing method according to claim 13, wherein the panel is fused to the resin composite material by heat. 19. A panel in which a decorative veneer is laminated and integrated on a surface of a substrate having a thermoplastic resin composite material layer in which a thermoplastic resin and a heat-resistant moisture-permeable powder are composited on at least the surface. In doing this, the surface of the thermoplastic resin composite material layer is polished to expose the moisture-permeable powder at the bonding interface with the surface decorative veneer, and then the surface veneer veneer is heated and adhered onto the thermoplastic resin composite material layer. A method for manufacturing a panel, comprising: