JP2003103703A - Method for manufacturing woody decorative veneer clad floor material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a woody decorative veneer clad floor material using an electron beam curable resin to obtain capacity necessary as the floor material and capable of obtaining capacity equal to that of a general woody material even from an aspect of a design. SOLUTION: Woody decorative veneer 3 comprising woody thin veneer is laminated to a base material 1 having a barrier layer 2 provided on its surface to obtain a substrate 4 which is, in turn, heated to penetrate a colored electron beam curable resin 5 into the surface of the substrate 4 under pressure using a roll coater. Subsequently, the excessive resin adhering to the surface of the substrate 4 is scraped off and the resin penetrated into the woody decorative veneer 3 is cured by electron beam from a low energy type electron beam irradiator and the surface of the woody decorative veneer 3 is subjected to sanding treatment to remove the bonded resin before coating finish is applied to the surface of the woody decorative veneer 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a wooden decorative veneer flooring material, and more particularly, to a low VOC wooden veneered flooring material which has been surface-strengthened by impregnating and curing an electron beam curable resin. It belongs to the technical field relating to a method for efficiently and efficiently producing a line by using an energy-type electron beam irradiation apparatus, which is well designed.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a floor material, a method of sticking a veneer or the like impregnated with resin on the surface of a thin wooden veneer by a pressure reduction method in a pressure kettle or a thin wooden material on a base material is used. A method in which a single plate is adhered to a floor material by coating and impregnating it with a thermosetting resin, and the floor material is cured by hot pressing under high temperature conditions of 130 ° C to 140 ° C is generally performed. . The performance required for floor materials is harsh, and in order to improve various performances such as surface hardness, chemical resistance, cigarette resistance, etc., conventionally, acetylated wood, WPC, etc.
Improvement methods such as the above method have been studied.

However, in order to obtain desired performance as a flooring material with the above thermosetting resin, there are the following problems.
That is, in the method of infiltrating the resin into the veneer or the like, a batch system using a pressure kettle is used and the productivity is poor. On the other hand, in the hot pressing method, it takes a long time for heat curing, resulting in extremely poor productivity.
Energy costs and the like for applying heat of 30 ° C. to 140 ° C. are required, and enormous production costs are required.

Specifically, in the case of line production, the resin impregnation process and the thermosetting process are factors that determine the line speed. Therefore, a method for efficiently carrying out curing impregnation and a method other than the thermosetting resin are used. There has been a demand for improvement of wood-based materials using resins.

In view of these, the application of electron beam curing technology to building materials is being studied. Manufacturing of decorative boards using this electron beam curable resin has been carried out since the 1960s,
The use of electron beam curable resins has the following advantages. That is, as a feature of the product, since the electron beam curable resin has a small volume shrinkage when being cured, the dimensional accuracy after curing is good. Therefore, the surface after curing is smooth,
The product can be made with a minimum of sanding, and a thin surface veneer can be used. By adopting a specific electron beam resin, a very hard and highly tough decorative material can be obtained.

The manufacturing method is characterized in that it can be cured at room temperature and in a short time by EB irradiation (energy saving). Since the curing speed of electron beam curable resin is extremely fast, it is possible to increase the overall line speed, and the productivity is greatly improved.

Taking advantage of these characteristics, for example, Japanese Unexamined Patent Publication No. Hei 11
As disclosed in Japanese Patent Application Laid-Open No. 207918/2000 and Japanese Patent Application Laid-Open No. 2000-25190, use as a coating material for the surface of a decorative material has been mainly studied.

Further, as a surface decorative sheet, it has been investigated as a top coat of a decorative paper used on the surface of a building material, as disclosed in, for example, JP-A-10-44331 and JP-A-10-86309. . The decorative material using electron beam resin-impregnated paper shown in each of these publications is already on the market. In that case, the decorative material using electron beam resin-impregnated paper is mainly used for doors and storage face materials. It has been.

[0009]

However, when the above-mentioned electron beam resin-impregnated paper is used for the floor, it is extremely difficult to obtain desired performance as a floor material, and in comparison with general wood materials in terms of design. Then, there is a disadvantage that it is inferior. Therefore, instead of paper as a surface decorative material, a surface decorative method of impregnating and curing an electron beam curable resin in a thin wood veneer has been studied.

The object of the present invention is to impregnate an electron beam curable resin into a thin veneer of wood and cure it to produce a wooden veneer-covered flooring by devising a process to obtain the performance required as a flooring. In order to obtain a wooden decorative veneer flooring material having the same characteristics as those of general wooden materials in terms of design.

[0011]

In order to achieve the above object, the present invention has the following points.

1. As a floor material, desired performance is realized by an electron beam curable resin.

2. The wooden decorative veneer attached to the surface is 0.
The thing of 15-0.5 mm is used.

3. An electron beam curable resin is uniformly impregnated on a wood decorative veneer attached to the surface in a heated state.

4. As an electron beam irradiation device, 150 to 3
A low energy type electron beam irradiation device of about 00 keV is used.

5. An electron beam curable resin colored with a dye or a pigment is press-fitted to be completely cured, and an uncured resin does not remain.

6. After curing, the sanding thickness before painting is minimized to improve the yield.

Specifically, in the method for manufacturing a wooden decorative veneer flooring according to the present invention, a wooden decorative veneer made of a thin wooden veneer is attached to a base material having a barrier layer on the surface thereof to form a substrate. Adhesive veneer bonding process, heating process that heats the substrate with this wood decorative veneer, and resin press-penetration in which the electron beam curable resin is press-fitted into the surface of the heated substrate using a roll coater. Step, a resin scraping step of scraping off the excess resin adhering to the substrate surface, a resin curing step of curing the resin that has penetrated into the interior of the wood decorative veneer with an electron beam irradiation device of a low energy type, The method is characterized by including a resin removing step of sanding the substrate surface to remove the attached resin, and a finishing step of applying a paint finish to the sanded substrate surface. The low-energy electron beam irradiation device is about 150 to 300 keV.

According to the above construction, in the veneer bonding step, the wood decorative veneer made of wood thin veneer is attached to the base material having the barrier layer on the surface, and the wood decorative veneer is attached to the surface of the base material. The attached substrate is heated in the subsequent heating process. In the next resin press-in / infiltration step, the electron beam curable resin is press-infiltrated into the surface of the heated substrate by using a roll coater, and then in the excess resin scraping step, excess resin adhered to the substrate surface is removed. Be scraped off. After that, in the resin curing step, the resin that has penetrated into the wood decorative veneer is electron beam cured by a low energy type electron beam irradiation device, and in the resin removal step, the substrate surface is sanded to remove the adhered resin. Then, in the finishing process, the sanded substrate surface is painted. As a result, a resin-reinforced wood veneer flooring material having excellent surface hardness and excellent scratch resistance / wear resistance, crack resistance and stain resistance can be produced in line with good design, at low cost, and efficiently.

Further, since the wood decorative veneer to be attached to the base material in the veneer bonding step is a wood thin veneer and a base material provided with a barrier layer is used, 150 to 300 k
Even with a low-energy electron beam irradiation device such as eV, the electron beam curable resin impregnated into the thin wood veneer on the surface can be completely cured, and the uncured electron beam curable resin remains in the floor material. There is no such thing.

In the heating step, the substrate is heated in advance,
Since the electron beam curable resin is applied to the heated wood decorative veneer, the resin can be uniformly impregnated into the surface wood decorative veneer.

Furthermore, since the electron beam curable resin is solvent-free, the floor material as a product has a low VOC.

In the second aspect of the present invention, the wood decorative veneer is a thin wood veneer of 0.15 to 0.50 mm. By using the thin wood veneer having a thickness of 0.15 to 0.50 mm as the wood decorative veneer, the flooring material can be manufactured at low cost. It should be noted that, by selecting and using an appropriate electron beam curable resin, it becomes hard and has high toughness after curing.
Even a thin wooden veneer having a thickness of up to 0.50 mm can achieve desired performance as a floor material.

According to the third aspect of the present invention, in the resin press-fitting permeation step, the roll used for coating the electro-curable resin is a rubber roll and has a durometer hardness of 20-9.
It shall be 0. In this case, by adjusting the clearance with respect to the surface of the wooden decorative veneer to, for example, about -1.5 mm, the resin can be uniformly and suitably impregnated into the wooden decorative veneer. Further, if the surface of the rubber roll has irregularities, it can be more uniformly and suitably impregnated.

In the invention of claim 4, a low-viscosity resin which is colored and has a viscosity of 100 mPa · s or less at 40 ° C. is applied to the surface of the substrate after the heating step and before the resin press-fitting and infiltration step, and thereafter. A low-viscosity resin coating step is provided to scrape off the excess resin adhering to the substrate surface. If the low-viscosity resin coating process is performed in multiple stages, more preferable results can be obtained.

Thus, the viscosity at 40 ° C. is 100 mPa · s
By coating the following resin on the substrate surface with a flow coater, the wood fiber portion can be effectively WPC-formed. Further, it becomes possible to manufacture a resin-reinforced flooring material even for tree species with few conduit portions, and the range of tree species selection for the wood decorative veneer used for the surface is broadened.

In the fifth aspect of the invention, in the surplus resin scraping step or the low-viscosity resin coating step, the surface resin is cooled before scraping off the surplus resin adhering to the substrate surface. By cooling the resin on the surface in this way, the viscosity of the resin is increased, and since the resin is scraped after that, it is possible to scrape only the surplus range.

[0028]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 2 shows a wood decorative veneer flooring material A according to an embodiment of the present invention, and FIG. 1 shows the steps of its manufacturing method. As shown in FIG. 1, this manufacturing method includes a veneer bonding step S1, a heating step S2, a resin press-fitting permeation step S3, an excess resin scraping step S4, a resin curing step S5,
A resin removing step S6 and a finishing step S7 are provided.

(Veneer Bonding Step S1) The veneer bonding step S
In 1, the wood-made decorative veneer 3 made of a wood thin veneer is attached to the base material 1 having the barrier layer 2 (see FIG. 2) on the surface thereof to form the substrate 4
And The base material 1 is made of wood-based or gypsum board such as plywood, LVL, MDF, particle board, and OSB laminated wood, calcium silicate board, inorganic material such as volcanic vitreous multi-layer board, or a multilayer of these thin boards. Use what you have.

The barrier layer 2 on the surface of the base material 1 is formed of a resin or a resin-impregnated sheet. As the resin in the former case, a thermosetting resin, a modified thermosetting resin, or a mixed resin in which a thermosoftening resin is mixed with a thermosetting resin is used. Specific examples include melamine-based resins, urea-based resins, urea / melamine-based resins, phenol-based resins, polyester resins, epoxy-based resins, acrylic-based resins, vinyl acetate-based resins, or modified products or mixtures of these resins. To be In this case, a resin having an appropriate toughness when cured is preferable, and in particular, a mixture of melamine resin and vinyl acetate resin, ethylene-modified vinyl acetate resin, acrylic emulsion resin or a methylol group of methylol melamine is acrylic-modified or allyl-modified. What was done is used suitably.

On the other hand, when the barrier layer 2 is formed of a resin-impregnated sheet like the latter, the sheet is
A delicate sheet material capable of preventing the resin from soaking into the base material 1, for example, a paper non-woven glass fiber sheet or the like can be used. As the resin to be impregnated, a thermosetting resin, a modified thermosetting resin, or a mixed resin in which a thermosetting resin is mixed with a thermosoftening resin is used. Specific examples include melamine-based resins, urea-based resins, urea / melamine-based resins, phenol-based resins, polyester resins, epoxy-based resins, acrylic-based resins, vinyl acetate-based resins, or modified products or mixtures of these resins. To be Also in this case, a resin having moderate toughness when cured is preferable, and particularly, a melamine-based resin and a vinyl acetate resin, an ethylene-modified vinyl acetate resin, a mixture of an acrylic emulsion resin or a methylol group of methylol melamine is acryl-modified or allyl. A modified product is preferably used.

Furthermore, by coloring the resin used for the barrier layer 2, a suitable design can be realized. Specifically, in order to give a transparent design, it is colored in a color similar to that of the wood decorative veneer 3 to be attached to the surface. In order to produce a deep design, the wood decorative veneer 3 is colored darker than the wood decorative veneer 3 and is of a similar color. It is possible to realize the same excellent design as when the veneer is used.

The wood-made decorative veneer 3 is 0.15 to 0.5.
It is desirable that the wood thin veneer is 0 mm. Since a thin wood veneer of 0.15 to 0.50 mm can be used in this way, it can be manufactured at low cost.

Further, by selecting an appropriate electron beam curable resin, it becomes hard and has high toughness after curing.
Even a thin wooden veneer of 15 to 0.50 mm can achieve desired performance as the flooring material A.

(Warming Step S2) In the next heating step S2,
The substrate 4 having the decorative wood veneer 3 attached to the surface of the base material 1 is heated. For heating the substrate 4, an infrared heater or a jet dryer is preferably used. As a method of impregnating wood with resin, as proposed by the present applicant (see Japanese Patent Application No. 2000-71472), the temperature of wood is 40 to 80 ° C. and the temperature of resin is less than 40 ° C. It is valid. Therefore, the surface temperature of the substrate 4 is set to 40
Warm to -80 ° C, preferably about 45-55 ° C.

(Resin-press-fit infiltration step S3) Thereafter, in the resin-press-fit infiltration step S3, the electron beam curable resin 5 is press-fitted and infiltrated into the surface of the heated substrate 4 by using a roll coater. The electron beam curable resin 5 may be an oligomer such as polyester acrylate, epoxy acrylate,
Urethane acrylate or a mixture of these acrylates and silicon acrylate is used as the resin liquid. Moreover, a polyfunctional acrylate monomer or a polyfunctional methacrylate monomer is used as a crosslinking agent. These resin liquid or cross-linking agent or a mixture of the resin liquid and cross-linking agent is an essential component.

The diluent is used when the viscosity of the resin liquid or the crosslinking agent or the mixture of the resin liquid and the crosslinking agent is high. 40 ° C
The amount of the diluent is adjusted so that the viscosity at 1000 is about 3500 mPa · s. A monofunctional acrylate monomer is used as the diluent. A colorant such as a dye or a pigment is mixed in the resin 5 as needed.

A roll coater is used to press-fit the electron beam curable resin 5 into the surface of the substrate 4.
The roll may be metallic or rubber. Preferably, when a rubber roll having a durometer hardness of about 20 to 90 is used and the clearance is adjusted to about -1.5 mm, the resin 5 is preferably impregnated into the wood decorative veneer 3 on the surface of the substrate 4. At this time, the resin 5 is more preferably impregnated by re-pressing with a reverse roll. Also, if the surface of the rubber roll is embossed with unevenness, it is possible to preferably press fit.

(Excess resin scraping step S4) In the next surplus resin scraping step S4, the surplus resin 5 attached to the surface
Scrape off. The scraping off of the excess resin 5 can be carried out by a reverse coater, but it is preferable to carry out scraping with a plate-like object such as a spatula.

For a plate-like object such as a spatula, the use of a rubber spatula gives an appearance finish in which unevenness of the surface is utilized. If you use a metal spatula, it will have an appearance finish with less surface irregularities. That is, when a spatula made of metal is used, it is not possible to follow the irregularities on the surface, so that the surface can be finished more smoothly.

When scraping with a rubber spatula or a rubber reverse coater, the unevenness of the surface is followed, so that the surplus resin on the surface can be suitably removed.
In this case, it is possible to finish the coating evenly after sanding. However, it has a design appearance in which unevenness remains on the surface.

The metal spatula, the rubber spatula, and the rubber reverse can be appropriately selected depending on the appearance finish demand.

(Resin Curing Step S5) Next, in the resin curing step S5, the resin that has penetrated into the interior of the wood decorative veneer 3 is electron beam cured by a low energy type electron beam irradiation device of about 150 to 300 keV.

That is, in the present invention, since the wooden decorative veneer 3 made of a thin wooden veneer is used, a low energy type device having an accelerating voltage of 150 to 300 keV or less is used as the electron beam irradiation device. . Although it can be used up to about 500 keV, if it exceeds 1000 keV, not only the apparatus itself becomes large, but also the wood decorative veneer 3 on the surface is deteriorated, which is not preferable. When a wood veneer impregnated with an electron beam curable resin is irradiated with an electron beam, 200
It is known that about 300 μm from the surface is cured with keV and about 500 μm from the surface with 300 keV. It has been confirmed that when the method proposed in Japanese Patent Application No. 2000-71472 is carried out, the resin penetrates up to 300 μm to several mm depending on the combination of the veneer tree species and the resin to be impregnated. In this case, when a wood thick veneer exceeding 0.5 mm is used as the surface decorative material,
In a low energy type electron beam irradiation device of 0 to 300 keV, it is assumed that the uncured resin remains.

The electron beam irradiation device is not limited to the scanning type or the non-scanning type. In addition, the electron beam irradiation condition of the electron beam irradiation apparatus is set to the acceleration voltage of 15 as described above.
It is set to 0 to 300 keV. Since the wooden decorative veneer 3 used in the present invention is a thin wooden veneer of about 0.15 to 0.5 mm, if the thin wooden veneer is 0.15 mm, it is 150
When the acceleration voltage is set to keV, the acceleration voltage is set to 200 keV for a thin wood veneer of 0.2 mm, and the acceleration voltage is set to 300 keV or higher for a thin veneer of 0.5 mm, the impregnated resin is completely cured. .

The electron beam irradiation dose is appropriately selected within the range of 5 to 20 Mrd (50 to 200 kGy) depending on the resin characteristics.

(Resin Removal Step S6) Then, in the resin removal step S6, the surface of the substrate 4 is sanded to remove the attached resin. This step is a step for removing the resin adhering to the surface of the substrate 4 after the coating by the roll coater and the resin impregnated by the electron beam irradiation in the previous resin curing step S5 are removed. Then, a sanding of 0.02 to 0.10 mm is applied to the surface. A belt sander is preferably used for sanding.

(Finishing Step S7) Finally, finishing step S7
At 7, the surface of the sanded substrate 4 is painted to form a coating film 6. The paint or the like used for coating in this step is not limited and can be appropriately selected. When an electron beam curable resin is used, an electron beam curable coating material or a UV curable coating material is preferable. The coating is not limited to one layer, but may be divided into multiple layers. A dye, a pigment or the like is added to the paint as a colorant as needed. In order to improve abrasion resistance, a multi-layer coating in which an anti-friction agent is added to the undercoating material and a final coating is further applied is preferable.

Through the above steps, the wooden decorative veneered flooring material A is manufactured. The wood decorative veneer flooring material A thus produced is a resin-reinforced type wood veneered flooring material having excellent surface hardness, scratch resistance, abrasion resistance, crack resistance, and stain resistance. It is possible to efficiently and efficiently produce a lined flooring material A in a line at a low cost.

(Other Embodiments) In the manufacturing method according to the above embodiment, the viscosity at 40 ° C. is 100 mPa · s after the heating step S2 and before the resin press-fit infiltration step S3.
The following low-viscosity resin may be applied to the surface of the substrate 4 and then a low-viscosity resin applying step S2 ′ (see FIG. 1) for scraping off the excess resin adhering to the surface of the substrate 4 may be provided.

That is, wood has a conduit portion and a wood fiber portion. General electron beam curable resin has a high viscosity, and when this high viscosity resin is pressed in with a roll coater,
The resin mainly enters the large diameter conduit. But,
Some trees have extremely small conduits, which makes it difficult for resin to enter. Even in such a case, according to the manufacturing method of the above embodiment, the substrate 4 is preferably 45 to 55.
The temperature of the resin is raised to about 40 ° C. by being heated to the temperature of the substrate 4 by applying a resin of about 30 ° C. with a flow coater. Therefore, at this temperature of about 40 ° C., a resin having a low viscosity of 100 mPa · s or less is applied to the substrate 4
When it is applied to, it will penetrate into the wood fiber portion, and the desired performance can be realized after electron beam irradiation and curing of the resin. Further, when press-fitting is performed using a roll coater instead of the flow coater, more preferable results are obtained, and it is preferable that the roll surface is provided with uneven embossing. Further, it is also effective that the press-fitting of the low-viscosity resin by the roll is performed in multiple stages.

In the low viscosity resin coating step S2 ', when scraping off the surplus low viscosity resin adhering to the surface of the substrate 4, it is desirable to scrape off the surplus resin with a rubber spatula or a rubber reverse coater. The reason is the same as that explained in the surplus resin scraping step S4.

In the surplus resin scraping step S4,
When scraping off the surplus resin adhering to the surface of the substrate 4, a step of cooling the resin applied to the surface may be provided before scraping off the surplus resin.

That is, 40 to 80 ° C., preferably 45
Since the resin is applied to the substrate 4 that has been warmed to ˜55 ° C., when the resin is applied, the resin is warmed and the viscosity decreases,
When it is scraped off, the resin impregnated at the corner is scraped off because of its low viscosity. On the other hand, when scraping is performed after increasing the viscosity of the resin by cooling, only the surplus resin on the surface can be scraped during scraping.

The temperature at the time of scraping depends on the viscosity characteristics of the resin. Viscosity of resin when scraping is 2500-5000
mPa · s, preferably 3000 to 3500 mPa · s
s is good. Specifically, the resin viscosity is 3000 to 3500.
It is preferable to scrape after cooling to mPa · s.

[0056]

EXAMPLES Next, concretely implemented examples will be described.

(Example 1) Paper having the surface impregnated with a resin obtained by allyl-modifying a methylol group of methylol melamine was pasted on a plywood having a thickness of 12 mm by hot pressing to form a base material. A thin wood veneer of 25 mm oak wood was adhered using a vinyl acetate adhesive to form a substrate. Next, this substrate was adjusted to 50 ° C. with a jet dryer. On the surface, 50 g / m ² of a resin mixed solution of the following formulation 1 was applied by a roll coater. At this time, a rubber roll having a durometer hardness of 50 was used. After allowing to cool at room temperature for 3 minutes, excess resin on the surface was scraped off with a metal spatula.
After that, the substrate is inserted into an electron beam irradiation apparatus, and an accelerating voltage of 20 is applied.
The resin in the veneer was cured by irradiation with an electron beam under irradiation conditions of 0 keV and an irradiation dose of 10 Mrad. Next, after the surface was ground by 0.05 mm with a belt sander, coating was performed with a urethane acrylate-based paint, which was UV-cured to obtain a resin-reinforced floor material.

<Formulation 1> Viscosity: 2500 mPa · s (liquid temperature 40 ° C.) Oligomer: epoxy acrylate 90 parts by weight Crosslinking agent: trimethylolpropane ethoxytriacrylate 15 parts by weight Diluent: monofunctional acrylate monomer 15 parts by weight Coloring dye 0 0.5 parts by weight (Example 2) Paper having a surface impregnated with a resin obtained by allyl-modifying a methylol group of methylol melamine to a thickness of 12 mm
It was attached to the plywood of No. 2 by hot pressing as a base material, and a thin wood plate of 0.25 mm oak wood was adhered to this base material using a vinyl acetate adhesive to form a substrate. Next, this substrate was adjusted to 50 ° C. with a jet dryer. After that, apply a resin solution of the following formulation 2 on the substrate surface with a flow coater,
After allowing to cool for 2 minutes, excess resin on the surface was scraped off with a rubber spatula. Furthermore, 50 g / m ² of the above resin mixture of Formulation 1 was applied on the surface by a roll coater. At this time, a rubber roll having a durometer hardness of 50 was used. After allowing to cool at room temperature for 3 minutes, excess resin on the surface was scraped off with a metal spatula. Inserted in electron beam irradiation device, accelerating voltage 200
The resin in the veneer was cured by irradiation with an electron beam under the irradiation conditions of keV and an irradiation dose of 10 Mrad. Next, after the surface was ground by 0.05 mm with a belt sander, coating was performed with a urethane acrylate-based paint, and this was UV-cured to obtain a resin-reinforced floor material.

<Formulation 2> Viscosity: 70 mPa · s (liquid temperature 40 ° C.) Oligomer: Epoxy acrylate 20 parts by weight Crosslinking agent: Trimethylolpropane ethoxytriacrylate 60 parts by weight Diluent: Monofunctional acrylate monomer 25 parts by weight Coloring dye 0 0.5 parts by weight (Comparative Example 1) In contrast to Example 1 described above, only the step of warming the substrate to 50 ° C. with a jet dryer was omitted. The other steps are the same as in Example 1.

(Comparative Example 2) This is a manufacturing method in which the electron beam curable resin is replaced with the following compounding 3 as compared with Example 1 above.

<Formulation 3> Viscosity: 4500 mPa · s (liquid temperature 40 ° C.) Oligomer: epoxy acrylate 90 parts by weight Crosslinking agent: trimethylolpropane ethoxytriacrylate 10 parts by weight Diluent: monofunctional acrylate monomer None Coloring pigment 0.5 Parts by weight (Comparative Example 3) In contrast to Example 1, the resin was applied by a roll coater, and then the resin was cured by irradiating with an electron beam without scraping off the surplus resin on the surface. Then, after removing the cured excess resin by sanding with a belt sander,
As in Example 1, urethane acrylate based paint was applied to obtain a resin reinforced floor material. Grinding with a belt sander including surplus resin on the surface was about 0.1 mm, and the remaining thickness of the thin wood veneer on the surface was about 0.2 mm.

(Comparative Example 4) This is a conventional method. 0.
Put a 5 mm thick oak wood veneer into the pressure kettle and set the inside of the pressure kettle to 2.
After the pressure is reduced to 67 kPa, unsaturated polyester resin is injected into the pressure kettle, and the pressure kettle is further heated to 960 kP.
The resin was injected under reduced pressure under pressure to a. The synthetic resin-injected veneer thus obtained is heated and pressed by a hot press to harden the resin to obtain a resin-reinforced veneer, which is 12 m in length.
It was bonded to a m-thick plywood using a vinyl urethane adhesive.
Next, this surface layer was ground by 0.3 mm with a belt sander and coated with a urethane acrylate-based paint in the same manner as in Example 1. The thickness of the remaining veneer was about 0.2 mm.

For the above Examples 1 and 2 and Comparative Examples 1 to 4, a pencil scratching test (according to JIS K5400) and a cold heat repetition B test (according to JAS special plywood) were conducted. In the cold heat repetition B test, the test confirmation was performed using a test piece of 15 cm × 15 cm. The surface was ground using a wear tester to measure the resin penetration depth into the decorative veneer. In addition, appearance evaluation (confirmation of smoothness) was performed on these surfaces. The results are shown in Table 1. Table 1
In the “Appearance” section, the symbol “◯” indicates a good condition, and the symbol “Δ” indicates a poor condition.

[0064]

[Table 1]

From the results shown in Table 1, it can be seen that, in terms of appearance, Examples 1 and 2 and Comparative Examples 3 and 4 provided flooring materials having a suitable design with no irregularities on the surface. Moreover, in terms of performance,
2 and Comparative Example 4 had equivalent performance. But,
Comparative Example 3 was inferior to Examples 1 and 2 and Comparative Example 4 in the pencil scratching test and the cold heat repetition B test. This is because the surplus resin on the surface has been cured and the uncured portion remains on the internal resin. It can be seen that in order to completely cure the resin impregnated inside, it is necessary to scrape off the surplus resin on the surface as a pre-process of electron beam irradiation.

Comparative Examples 2 and 3 were clearly inferior in appearance and performance to the other examples.
It is considered that this is because the impregnation of the resin is not performed well.

From the above, it is understood that the heating of the base material and the adjustment of the resin viscosity are essential.

[0068]

As described above, according to the first aspect of the present invention, as a method for producing a wooden decorative veneer flooring material, a wooden decorative veneer made of a thin wooden veneer is attached to a base material having a barrier layer on its surface. Attach it as a substrate, heat this substrate and press-infiltrate the surface of the substrate with an electron beam curable resin using a roll coater, then scrape off the excess resin adhering to the substrate surface, and then use wood makeup. The resin that has penetrated into the inside of the veneer is electron beam cured by a low energy type electron beam irradiation device, the surface of the resin is sanded to remove the adhering resin, and then the surface is painted. Further, in the invention of claim 2, the wood decorative veneer is a thin wood veneer of 0.15 to 0.50 mm. According to these inventions, the surface hardness is excellent and the scratch resistance is
A resin-reinforced wood veneer flooring material having excellent wear resistance and crack resistance can be produced in a line with good design, at low cost, and efficiently.

According to the third aspect of the invention, in the step of press-fitting and infiltrating the electron beam curable resin, the roll used for coating the resin is a rubber roll and the hardness of the durometer is 20 to 90. The resin can be uniformly and preferably impregnated into the wood decorative veneer. Further, if the surface of the rubber roll has uneven embossing, more preferable results can be obtained.

According to the invention of claim 4, after the step of heating the substrate and before the step of injecting the resin by press-fitting, it is colored and
By applying a low-viscosity resin whose viscosity at 0 ° C is 100 mPa · s or less with a flow coater and then scraping off the excess resin adhering to the surface, the wood fiber part can be effectively WPC-formed. In addition to this, the range of selection of tree species for the wood decorative veneer used for the surface is broadened.

According to the fifth aspect of the present invention, by cooling the resin on the surface before scraping off the surplus resin on the substrate surface, it is possible to increase the viscosity of the resin and then scrape the resin. It can be finished smoothly.

[Brief description of drawings]

FIG. 1 is a process drawing showing a method for manufacturing a wooden decorative veneer flooring material according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a wooden decorative veneer flooring material.

[Explanation of symbols]

S1 veneer sticking process S2 heating process S2 'Low viscosity resin coating process S3 resin press-fit infiltration process S4 Excess resin scraping process S5 resin curing process S6 resin removal process S7 finishing process A wood decorative veneer flooring 1 base material 2 barrier layers 3 wood makeup veneer 4 substrates 5 Electron beam curable resin 6 coating film

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B32B 33/00 B32B 33/00 E04F 15/04 E04F 15/04 E 601 601Z (72) Inventor Yasushi Oyama Toyama 1 Inaba, Inami-cho, Higashitonami-gun, Higashi-ken 1-term in Daiken Kogyo Co., Ltd. (reference) 2B002 AA02 AA03 BA01 BA15 BA16 BB06 BB12 DA01 2B230 AA10 AA22 BA04 BA18 CB25 DA02 EB01 EB03 EB05 EB08 EB13 EB28 EB29 BA03 2B250 A05 DA04 EA02 EA13 FA21 FA26 FA28 FA31 FA33 FA37 GA03 HA01 4F100 AK01C AK36 AK51 AP00C AT00A BA03 BA07 BA10A BA10C EJ17 EJ42 EJ82C GB08 HB01C JA06 JB14C JD01B

Claims (5)

[Claims] 1. A veneer bonding step in which a wooden decorative veneer made of a thin wooden veneer is attached to a substrate having a barrier layer on the surface to form a substrate, and a heating process is performed to heat the substrate having the wooden decorative veneer. A heating step, a resin press-fitting permeation step of press-fitting and permeating an electron beam curable resin into the surface of the heated substrate using a roll coater, and an excess resin scraping step of scraping off the excess resin adhering to the surface of the substrate. And a resin curing process that cures the resin that has penetrated inside the wood decorative veneer with an electron beam irradiation device of low energy type, a resin removing process that sands the substrate surface to remove the adhered resin, and a sanding process. And a finishing process for applying a paint finish to the surface of the substrate. 2. The method for manufacturing a wooden decorative veneer flooring material according to claim 1, wherein the wooden decorative veneer is a thin wooden veneer of 0.15 to 0.50 mm. Manufacturing method. 3. The method for manufacturing a wooden decorative veneer flooring according to claim 1, wherein the roll used for coating the electro-curable resin in the resin press-fitting permeation step is a rubber roll and has a durometer hardness of 2 or less.
0-90, The manufacturing method of the wooden decorative veneer flooring characterized by the above-mentioned. 4. The method for producing a wooden decorative veneer flooring material according to claim 1, which is a low-viscosity resin that is colored and has a viscosity at 40 ° C. of 100 mPa · s or less after the heating step and before the resin press-in / infiltration step. Is applied to the surface of the substrate, and then a low-viscosity resin applying step of scraping off the excess resin adhering to the surface of the substrate is provided, and a method for producing a wooden decorative veneer flooring material. 5. The method for manufacturing a wooden decorative veneer flooring according to claim 1 or 4, wherein the resin on the surface is cooled before scraping off the excess resin adhering to the surface of the substrate. A method for manufacturing a wooden flooring.