JP2001105405A - Wood finished material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent warpage from occurring. SOLUTION: This wood finished material is obtained by laminating a prepreg- state sheer 2 containing a heat-curable resin on the surface of a base board 1 which allows resin impregnation and further, a facing 3 which allows resin impregnation in the sheer 2 and thermally pressing/bonding the described constituents. In addition, a backing material 4 with a moisture transmission resistance value of 5 g/24 h.m2-50 g/24 h.m2 is laminated on the back of the base board 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wood material used as a surface finishing material for floors, walls, ceilings and the like, a decorative material for columns, furniture and cabinets, an interior material for automobiles, and a surface material for various structures. Regarding finishing materials.

[0002]

2. Description of the Related Art In recent years, wood finishing materials have been rapidly increasing from the viewpoint of prevention of occurrence of ticks and the like, but there has been an increasing demand for improvement in scratch resistance of the surface. A common wood finishing material is a veneer (decorative material), which is a thin wooden plate for decorative application, stuck on a base plate, and a WPC process developed so that the surface of this veneer is hardly damaged. Have been. WP
C is an abbreviation of Wood-Plastic Combination. The veneer is placed in a heating / pressurizing container, and the veneer impregnated with plastic is hot-pressed and bonded to a base plate coated with adhesive. .

[0003]

The conventional WPC process has a disadvantage that it is expensive and furthermore, since it is laminated with a base plate and hot-pressed, warpage occurs due to an unbalanced dimensional behavior of each member. there were. In particular, the warpage was a cause of inconveniences such as poor processing during production and difficulty in construction.

Accordingly, an object of the present invention is to provide an inexpensive wooden finish excellent in scratch resistance and preventing warpage.

[0005]

In order to achieve the above-mentioned object, the present invention is to superimpose a sheet in a prepreg state containing a thermosetting resin on a surface of a base plate capable of impregnating with a resin. A wooden finishing material which is laminated with a decorative material capable of impregnating a resin and hot-pressed and bonded to each other, and has a moisture permeation resistance value of 5 g / 24 h · m ^{2 on} the back surface of the base plate.
It is a product obtained by laminating back materials of up to 50 g / 24 h · m ² .

[0006]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

In the embodiment shown in FIG. 1, a sheet (prepreg sheet) 2 containing a thermosetting resin is stuck on a base plate 1, and a decorative material 3 is stuck on the sheet 2. Further, a back surface member 4 is provided on the back side of the base plate 1. This sheet-like backing material 4
About paper, woven fabric, non-woven fabric, thin wooden board (thickness 0.2
mm-1 mm), synthetic resin, etc., and the bonding is done with an adhesive. As the paper used for the backing material 4, a paper-reinforced paper impregnated with a resin, reinforced paper, titanium paper, ceramic paper, kraft paper, tissue paper, water-resistant paper, oil-resistant paper can be preferably used. ,
An organic woven or nonwoven fabric made of polyethylene, polypropylene, or the like, or an inorganic woven or nonwoven fabric made of glass fiber can be preferably used. In addition, as the thin wooden board, one or more composite materials of plywood, MDF, particle board, and OSB can be used, and as the synthetic resin, a polyolefin resin such as polyethylene, polypropylene, and polybutylene is suitable for use. . As the adhesive, PVA, melamine, acryl, vinyl acetate-based adhesive can be suitably used. However, if the material has self-adhesive properties,
It is possible to bond together without using an adhesive. Materials having self-adhesive properties include phenolic resins, epoxy resins, cyanoacrylates, urethane resins, polyesters, and EVA. Although not shown here, a synthetic resin may be applied to the back surface of the base plate 1, impregnated, or fused. For example, the base plate 1 is placed on a belt conveyor with the back side facing up, and a roller coater method of applying a roller to the back surface of the base plate 1 being conveyed from above, or similarly on the back surface of the base plate 1 being conveyed There is a method of spraying an adhesive, and a laminating method in which an adhesive sheet is placed on the back surface of the base plate 1 being conveyed, and a back material 4 is stacked thereon and pressure is applied from above by a roller. In any case, the moisture-permeation resistance value of the back material 4 on the back surface of the base plate 1 is in the range of 5 g / 24 h · m ² (JIS Z 0208) to 50 g / 24 h · m ² (JIS Z 0208). . Originally, paper, woven fabric, and nonwoven fabric having a high moisture permeability resistance (easy to transmit moisture) can reduce the moisture permeability resistance by increasing the amount of the adhesive used at the time of bonding. As the base plate 1, a material that can be impregnated with a resin, for example, a plywood, a wood fiber board, a particle board, a wafer board, or a composite board thereof is preferably used. The sheet 2 is obtained by impregnating a sheet base material 20 (see FIG. 2) of paper, woven fabric, or nonwoven fabric with a thermosetting resin. The thermosetting resin is any one or a mixture of two or more of a phenol resin, an epoxy resin, a urethane resin, and a urea resin. Gypsum board paper, kraft paper, rayon paper, or the like can be suitably used as the paper as the sheet base material 20. Glass fibers, vinylon fibers, polyester fibers, and the like can be suitably used as the fiber material of the nonwoven fabric or woven fabric. As the decorative material 3, a thin wooden board and paper for decorative upholstery that can be impregnated with a resin can be preferably used.
The thickness is preferably 1 mm or less. The texture is improved when the grain is printed on paper and the surface is embossed along the grain. Further, as the decorative material 3, a composite material of wood and synthetic resin such as WPC, which is further colored, a composite material of paper and synthetic resin, or a synthetic resin sheet is used.

FIG. 2 shows an example of a method for impregnating a storage tank of a thermosetting resin solution 10 with a woven or nonwoven fabric (sheet base material 20) such as paper, glass fiber, vinylon fiber, and polyester fiber. As the paper impregnated with the thermosetting resin, gypsum board paper, kraft paper, rayon paper and the like can be suitably used. As the woven fabric, for example, 1200
Denier glass fiber 3 / cm vertically, 3 horizontally
What is set to book / cm can be used suitably. The nonwoven fabric has a basis weight of 10 to 1000 g in terms of impregnation, defoaming, sheet base strength, handling, and scratch resistance of the molded product.
/ M ^2, more preferably 50 to 250 g / m ² , using a glass nonwoven fabric in which short fibers having a short fiber length and long fibers having a length of 10 mm or more (50 mm or less) are mixed, and a thermosetting resin solution 10 having a solid content of 128 g / m ² was applied at a rate of m ² can be obtained sheet 2. If the glass nonwoven fabric used as the sheet substrate 20 has a basis weight of less than 10 g / m ² , it is difficult to exhibit scratch resistance, and if the basis weight is more than 1000 g / m ² , it becomes difficult to impregnate the resin. In the case of short fibers having a glass fiber length of 3 mm or less, the reinforcing effect is low. On the other hand, in the case of long fibers exceeding 50 mm,
It is difficult to form a uniform sheet, and as a result, an excellent reinforcing effect cannot be obtained. Further, it is preferable that the short fiber content is 20 to 100% from the viewpoint of strength (reinforcing property) and uniformity of the nonwoven fabric. If the short fibers are less than 20%, uniformity of the nonwoven fabric cannot be achieved. Mixing short fiber cellulose pulp or the like in addition to these fiber materials may be used. When glass fibers are used, the reinforcing effect can be enhanced by coating the fiber surfaces with a silane coupling agent. Further, the nonwoven fabric as the sheet base material 20 may be formed by mechanically, chemically, thermally or using a solvent by bonding or intertwining raw fibers such as glass fiber, cotton, rayon, or both. Are formed in a sheet shape by the combination of. As the fiber raw material, a material obtained by matting fibers cut to 3 to 50 mm by a wet papermaking or dry nonwoven fabric manufacturing method and binding them with a binder resin can be suitably used.

As the sheet 2, a sheet substrate 20 made of any one of paper, woven fabric and nonwoven fabric and impregnated with a thermosetting resin is not used alone. A sheet obtained by laminating a woven fabric on a sheet impregnated with a thermosetting resin can also be used as the sheet 2.
For example, if the uncured phenolic resin is impregnated into paper and a woven fabric is bonded to the paper, the overall strength and dimensional stability are dramatically improved.

It is desirable that the thermosetting resin impregnated in the sheet base material 20 is in a cured state in the latter half of the impregnation, the sheet 2 is in a prepreg state, and the sheet 2 is stacked on the base plate 1 and a decorative sheet is placed on the prepreg sheet 2. When the materials 3 are overlapped and hot-pressed, they are firmly bonded to each other. The prepreg is the half of the reinforced plastic made by mixing a fiber reinforcing material, a thermosetting resin, and, if necessary, a thermoplastic resin, a coloring agent, a curing catalyst, etc., before the curing is completed, while maintaining the adhesiveness and moldability. It is a molding material in a hardened state, and a preferable gel time is 30 to 800 seconds at 150 ° C.

The thermosetting resin impregnated in the sheet base material 20 using the fiber raw material contains a fiber ratio of 100% or more,
Desirably, it is about 200 to 300%. Sheet base material 2
As the thermosetting resin to be impregnated with 0, a resin having necessary properties as a surface material is selected, for example, a phenol resin obtained by a reaction between phenols and aldehydes, and having a reactive epoxy group at a terminal. Epoxy resins, urea resins, and urethane resins obtained by adding a curing agent to the oligomer can be suitably used. These resins are used alone or as a mixture of two or more, and are mainly combined with the fiber material by impregnation. The resin solution to be impregnated may be any of an aqueous solution, a solvent varnish, an emulsion, and the like, and may be a method of spraying solid resin powder. Among them, it is preferable to use those dissolved or dispersed in water, alcohol, or the like from the viewpoint of cost and safety. In addition, various fillers,
For example, lead stearate, dibutyltin dilaurate, carbon black, calcium carbonate, titanium white, mica, glass spheres, aluminum hydroxide, antimony oxide,
A heat stabilizer, a reinforcing agent, a flame retardant, an antistatic agent, and the like are used in combination with tri (2,3 dibromopropyl) phosphate, an aliphatic sulfonate, a higher alcoholate, and the like. As a catalyst required for the production of a phenol resin, alkylamine, ammonia, sodium hydroxide, barium hydroxide and the like are preferable. In particular, alkylamine and ammonia have higher molecular weights than the other two and have low hydration properties in terms of molecular structure, so that the water resistance after bonding is remarkably improved. At this time, the phenol resin is preferably dissolved or dispersed in water so as to have a solid content of 20 to 80% from the viewpoint of easy impregnation. If the solid content is less than 20%, it becomes difficult to impregnate the required amount,
If it exceeds 0%, impregnation becomes difficult due to an increase in viscosity.

Thermosetting resin impregnated in sheet base 20
Is a solid content of 50 to 500 g / m²Preferably 150-3
50g / m²It is preferable that 50g
/ M ²If less than 500 g, it is difficult to develop sufficient scratch resistance.
/ M²If not below, it takes a long time to cure,
There is also a problem with the appearance such as the appearance.

The drying conditions for the thermosetting resin impregnated in the sheet base material 20 to be in a cured state in the latter half of the impregnation are as follows: the completed moisture content of the sheet 2 is 5 to 15% by weight, and further 8 to 10% by weight. %, Preferably 5% by weight
If it is less than 15%, poor adhesion to the decorative material 3 and the base plate 1 will occur, and
When the weight is not less than%, blocking occurs between sheets. A preferred semi-cured sheet can be obtained at a temperature of 80 to 120 ° C. and a drying time of 2.5 to 30 minutes.

[0014] The tensile strength of the prepreg sheet is 10 kgf / cm ² for a sufficient scratch resistance.
It is preferable that it is above. If it is less than 10 kgf / cm ² , sufficient scratch resistance will not be exhibited. The measurement of the breaking strength was performed by sandwiching the sheet 2 in the prepreg state between two release papers,
The test was performed after the resin was cured by hot pressing at 10 ° C. for 5 minutes at 10 kgf / cm ² .

The pressing conditions for the base plate 1, prepreg sheet 2 and decorative material 3 are preferably 130 to 180 ° C., more preferably 140 to 160 ° C. If the temperature is lower than 130 ° C., the curing of the resin is not sufficient and the scratch resistance cannot be expressed,
If the temperature is higher than 180 ° C., the curing of the resin is too fast, the adhesion to the base plate 1 and the decorative material 3 becomes insufficient, and the warpage of the base plate 1 becomes large. The pressure is 1 to
20 kgf / cm ² is preferable, and more preferably 5 to 1
5 kgf / cm ^{2, if} it is lower than 1 kgf / cm ^{2, the} exudation of the resin to the decorative material 3 is insufficient, so that the scratch resistance becomes low. If it is larger than 20 kgf / cm ² , the warpage of the base plate 1 becomes large. Disadvantages occur. Further, the pressing time is preferably from 2.5 to 20 minutes, more preferably from 4 to 12.5 minutes. If it is shorter than 2.5 minutes, the curing of the resin is not sufficient, and the scratch resistance is reduced. If it is longer than 20 minutes, the resin is deteriorated, the scratch resistance is reduced, and the warpage of the base plate 1 is increased.

[0016]Example 1  Base plate 1 ... Plywood 12 mm thick Cosmetic material 3 ... Single oak veneer 0.3 mm thick Non-woven fabric ... Fiber diameter 10 μm, mixed fiber of short fiber and long fiber
100 g / m basis weight of fiber²Glass fiber alone
of. Thermosetting resin: water-dispersed phenol with a solid content of 40%
Resin Solid content at resin impregnation: 200 g / m²  Back material 4: 10 μm thick polyethylene and basis weight 35
g / m²Is laminated with thin paper of
Resistance value 30g / 24h ・ m²  The above glass nonwoven fabric impregnated with phenolic resin
(Solid content 200g / m²) At 105 ° C for 10 minutes
To give a sheet 2 in a semi-cured state. More melamine
After applying a resin adhesive to the back of the base plate 1 (8 g / shakaku),
The backing material 4 is pressed at a temperature of 120 ° C. and a pressure of 7 kgf / c.
m²On the base plate 1 obtained by bonding with a press time of 45 seconds.
The sheets 2 are overlapped, and the decorative material 3 is overlapped on the sheets 2
Press temperature 150 ℃, pressure 10kgf / cm²,
A wood finish was manufactured in less than 5 minutes.

[0017]Comparative Example 1  Polyethylene with a thickness of 40 μm as the backing material 4 and a basis weight of 35
g / m²Is laminated with the thin paper of
Resistance value is 3g / 24h ・ m²And other articles
Same as Example 1 except that the press time for lamination was 4 minutes.
A wood finish was produced in the same manner.

[0018]Comparative Example 1 '  The tree manufactured in Example 1 without attaching the back material 4
The quality finishing material was Comparative Example 1 '.

[0019]Example 2  58% solids methanol-soluble resin as thermosetting resin
The same conditions as in Example 1 except that an enol resin was used.
A wood finish was manufactured below. The moisture permeability resistance of the backing material 4 is
30 g / 24 h · m as in Example 1²It is.

[0020]Example 3  Polyethylene of 20 μm thickness and basis weight 35 as backing material 4
g / m²With thin paper, moisture resistance value 10g /
24h ・ m²The other conditions were the same as in Example 2.
A wood finish was produced in the same manner.

[0021]Example 4  Polyethylene of 30 μm thickness and basis weight of 35 as backing material 4
g / m²With a thin paper, moisture resistance 5g / 2
4h ・ m²The other conditions were the same as in Example 2.
A wood finish was produced in the same manner.

[0022]Comparative Example 2  Polyethylene with a thickness of 40 μm as the backing material 4 and a basis weight of 35
g / m²3g / 2 moisture permeation resistance value
4h ・ m²The other conditions were the same as in Example 2.
A wood finish was produced in the same manner.

[0023]Comparative Example 3  The tree manufactured in Example 2 without attaching the back material 4
The quality finish was Comparative Example 3.

Table 1 shows the results of measurement of the amount of warpage (mm) and the amount of warpage fluctuation (mm) of Examples 1-4 and Comparative Examples 1-3. Here, as shown in FIG. 3, when measuring the amount of warpage, as shown in FIG. 3, a thread is attached to both ends of a 310 × 1818 (mm) wooden finishing material in the longitudinal direction, and the midpoint of the yarn and the surface of the wooden finishing material (decoration). This is a measure of the amount of deflection occurring between the material 3 side)
As shown in FIG. 3, when both ends are directed upward, (−) is shown, and when both ends are directed downward, (+) is shown. The amount of warpage indicates a maximum value and a minimum value in an environmental test. In the environmental test, the amount of warpage is measured by leaving the wood-based finishing material continuously for 7 days under conditions of 90%, 40%, 93%, and 43% humidity.

[0025]

[Table 1]

The amount of change in the warpage is as shown in the graph of FIG. In FIG. 4, reference symbol A denotes the second embodiment, reference symbol B denotes the third embodiment, reference symbol C denotes the fourth embodiment, and reference symbol D denotes the second comparative example.
, And the symbol E indicates Comparative Example 3.

The warpage can be used as a product if the warpage is within a range of ± 20 mm and the warpage variation is 20 mm or less. To be within this range, the moisture resistance of the backing material 4 is 5 g / 24 h · m.
² and ~50g / 24h · ^{m 2,} to a warp variation and 10mm or less ^{10g / 24h · m 2 ~30g /} 24h ·
m ² is preferable.

When a polyolefin resin sheet 4A is directly adhered to the base plate 1 as the back material 4 provided on the back side of the base plate 1, a general adhesive is used after plasma discharge treatment or corona discharge treatment. And can be easily and quickly applied. By performing such a discharge treatment on the polyolefin resin sheet 4A, the surface of the sheet 4A is activated, and the sheet 4A can be attached to the base plate 1 with an adhesive. When the sheet 4A, which is not subjected to the discharge treatment, is attached to the base plate 1, the sheet 4A cannot be bonded with an adhesive, and after the sheet 4A is laminated on the base plate 1, it is melt-bonded by a hot press or the like. However, the bonding reliability by fusion bonding was significantly inferior to the bonding reliability using an adhesive having a chemical bond. By performing the discharge treatment on the sheet 4A, an adhesive can be used, and the bonding durability and bonding reliability are improved.

FIG. 5 is a process chart for performing a corona discharge treatment. The paper 4B wound around the roll 30 is fed out, and the molten polyolefin resin in the resin tank 32 is extruded onto the paper 4B on the drum 31 to form a paper. A laminate is formed by laminating the sheet 4A on 4B. Next, the laminate (sheet 4
A and the paper 4B) are passed between the electrodes 34 of the corona discharge device 33 to perform electric discharge machining. Rolled body with electric discharge machine roll 3
Wrap around 5. The laminate wound around the roll 35 is cut into the size of the base plate 1, and the sheet 4A side is cut with an adhesive.
Paste in. The output of the corona discharge device 33 is 2000
W, processing time 0.1-0.6 seconds, frequency 45KHz
However, the output was 10 to 5000 W and the processing time was 0.0
It was possible to attach the sheet 4A to the base plate 1 with an adhesive within a range of 1 to 30 seconds and a frequency of 30 to 60 KHz.

[0030]Example 5  For the base plate 1, the decorative material 3, the nonwoven fabric, and the thermosetting resin,
It was the same as in Example 1, and the back material 4 was as follows. Back material 4: 35 g / m basis weight²Polyethylene on thin paper
Laminated at a thickness of 10 μm,
Ethylene surface with voltage 2000W, frequency 45KHz
Under the conditions, a corona discharge treatment was performed for 0.1 second. In Example 5, the sheet 4A of the polyolefin resin was directly
It can be easily attached to the back surface of the base plate 1.

[0031]

As described above, according to the present invention, a prepreg-containing sheet containing a thermosetting resin is superimposed on the surface of a base plate capable of impregnating a resin, and impregnation of the resin is performed on the sheet. A wooden finishing material which is laminated and hot pressed and adhered to each other, and has a moisture permeability resistance value of 5 g / 24 h · m ^{2 to} 50 g / 24 on the back surface of the base plate.
h · m ² are laminated, and the moisture permeation resistance value of the back surface of the base plate can be matched to the front surface side of the base plate. And the dimensional stability performance (warpage and expansion / contraction) is remarkably improved. Furthermore, during construction, if the ground is wooden, floor noise due to rubbing occurs at the contact part with the back of the base plate,
According to the present invention, since there is a back surface material at that portion, a problem due to floor noise does not occur. Furthermore, by providing the back material, it is possible to reduce the dimensional difference between the surface layer composed of the decorative material and the prepreg sheet and the base plate before and after pressing, prevent warpage, reduce the defect rate due to processing defects during production, and perform construction. The improvement of the performance can be achieved. Further, it can be manufactured easily and quickly as compared with the conventional WPC, has excellent scratch resistance, and has a low manufacturing cost.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a preferred embodiment of the present invention.

FIG. 2 is an explanatory view showing a production example of a sheet.

FIG. 3 is a view showing a warpage amount measuring method.

FIG. 4 is a graph showing the results of an environmental test.

FIG. 5 is a process chart of a corona discharge treatment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base plate 2 Sheet 3 Decorative material 4 Back material 20 Sheet base material

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Masaki Abe 412-1-106 Kawakami-cho, Totsuka-ku, Yokohama-shi, Kanagawa Prefecture (72) Inventor Tadaaki Funase 1274-1 Totsuka-cho, Totsuka-ku, Yokohama-shi, Kanagawa F-term (reference) 2B002 AA01 AA02 AA03 AA04 BA01 BB04 BB06 DA01 DA02 DA03 DA04 DA06 2B250 AA04 AA05 AA06 AA13 AA31 BA05 CA11 DA04 EA02 EA13 FA21 FA28 FA31 FA37 2E110 AA27 AA48 AB03 AB04 AB05 BA04 BB03 GB42 GBX32 GB42 GBX32 GBX32 GBX32 GBX32 GBX32 GBX32 GBX32 GBX32 GBX3 AK01D AK03D AK04 AK33D AK36G AP00A AP01D AP02 AR00D AS00A AS00C AT00C BA03 BA04 BA07 BA10A BA10C BA10D DG10 DG10D DG12D DG15D DH01B EC01 EC012 EC03 EC032 EH46 EH462 EJ55D04J08B08J82B EJ55D

Claims (7)

[Claims] 1. A prepreg sheet containing a thermosetting resin is superimposed on a base plate capable of impregnating a resin, and a decorative material capable of impregnating the resin is superimposed on the sheet and hot-pressed. Wood finishes bonded to each other with a moisture permeability resistance value of 5 g / 24 h · m ^{2 to} 50 g on the back side of the base plate
A wood finishing material characterized by laminating a back material of / 24 h · m ² . 2. The backing material comprises: (1) one or two or more sheets made of paper, woven fabric, nonwoven fabric, thin wooden board, synthetic resin, or the like, and (2) applying a synthetic resin The wood finishing material according to claim 1, wherein the wood finishing material is formed by any one of (3) impregnation with a synthetic resin, and (4) fusion of a synthetic resin. 3. The sheet according to claim 1, wherein a phenolic resin is added to a sheet base made of paper, woven fabric, or nonwoven fabric with a solid content of 50 to 500 g.
/ M ^2. The wood finishing material according to claim 1, wherein the wood finishing material is impregnated so as to be / m ² . 4. The wood finishing material according to claim 2, wherein a sheet of a polyolefin resin is used as the synthetic resin sheet forming the back material. 5. The method according to claim 1, wherein the polyolefin resin sheet is
The wood finishing material according to claim 4, wherein the wood finishing material is laminated on the back side of the base plate after the plasma discharge treatment or the corona discharge treatment. 6. The corona discharge treatment conditions include an output of 10 to 5000 W, a treatment time of 0.01 to 30 seconds, and a frequency of 30 to 60 KHz.
Wood finishing material described in. 7. The corona discharge treatment conditions include an output of 1000 to 3000 W and a treatment time of 0.05 to 15
The wooden finishing material according to claim 5, wherein the frequency is 40 to 50 KHz per second.