JP2005048319A - Resin-impregnated cured sheet, method for producing resin-impregnated cured sheet, and plate for building obtained by using the resin-impregnated sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin-impregnated cured sheet by which dent resistance is improved by being laminated on a decorative sheet, of which adhesion to the decorative sheet is improved and which has a light weight compared to an MDF board to enable the sheet to be used for a wall, a ceiling or the like. <P>SOLUTION: The resin-impregnated cured sheet A is obtained by impregnating a single layered paper base material 1 with a thermoset resin 2, and curing the thermoset resin 2, and is regulated so that the amount of the resin at the surface layer part may be smaller than that at the center part in the thickness direction. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a resin-impregnated cured sheet obtained by impregnating and curing a paper base material with a resin, a method for producing the resin-impregnated cured sheet, and a building board using the resin-impregnated sheet.

Conventionally, in order to provide dent resistance in a wooden floor material, there has been provided a building board in which a resin-impregnated cured sheet obtained by impregnating and curing a paper base material between a decorative board and a plywood is provided. (For example, refer to Patent Document 1). Such a resin-impregnated cured sheet is formed by impregnating a paper substrate with a resin and curing it with hot pressure or the like.
Japanese Patent Laid-Open No. 2002-86420

  By the way, in the case of the above conventional example, when the decorative paper is bonded to the resin-impregnated cured sheet with an adhesive such as an SBR adhesive, the resin-impregnated cured sheet shines on the surface of the paper substrate and is mirrored with a cured resin. Since the adhesive does not penetrate into the paper substrate of the resin-impregnated cured sheet, there is a problem that sufficient adhesive force cannot be obtained.

  Although it is conceivable to use an MDF board (medium density fiberboard) having the same performance instead of the resin-impregnated cured sheet, there are the following problems. In the case of the MDF board, although the amount of resin on the surface layer is large, it is hard to see. Also, when using an MDF board or the like, the specific gravity is high and heavy, making it difficult to use it on ceilings and walls.

  The present invention has been made in view of the above-mentioned conventional problems, and can be improved in dent resistance by being laminated on a decorative board, and can be further improved in adhesiveness with the decorative board, and further is an MDF board. It is an object of the present invention to provide a resin impregnated cured sheet that is lighter in weight than can be used for walls and ceilings, a method for producing the resin impregnated sheet, and a building board using the resin impregnated sheet.

  In order to solve the above problems, a resin-impregnated cured sheet A according to claim 1 of the present invention is a resin-impregnated cured sheet obtained by impregnating a thermosetting resin 2 into a single-layer paper base material 1 and curing it. It is characterized in that the resin amount of the portion is reduced as compared with the central portion in the thickness direction.

  Since the resin-impregnated cured sheet A formed in this way is hard, when the building board B is formed by laminating the decorative board 3 on one side as in claims 5 and 6, the building board having dent resistance is formed. B can be obtained. Further, when the decorative plate 3 is laminated and bonded with an adhesive by reducing the resin in the surface layer portion of the resin-impregnated sheet A, the adhesive penetrates into the paper substrate 1 of the resin-impregnated cured sheet A and the resin-impregnated sheet A and Adhesiveness with the decorative board 3 can be improved. Moreover, since there is much resin amount inside the resin impregnation hardening sheet A, unlike MDF board, it is excellent in peeling property. Further, since the resin-impregnated cured sheet A as described above is used, it can be made lighter than the MDF board, and the building board B can be used on a wall, a ceiling, etc., and the use is expanded.

  In the method for producing a resin-impregnated cured sheet according to claim 2 of the present invention, after impregnating the thermosetting resin 2 on the single-layer paper substrate 1, the resin in the surface layer is deposited and removed, and then heated. And is cured.

  By manufacturing as described above, even when the thermosetting resin 2 is impregnated in the entire paper base material 1, the surface layer portion can be easily reduced in the amount of resin in the central portion in the thickness direction. The resin-impregnated cured sheet A can be easily manufactured with a small amount of resin compared to the central portion in the thickness direction.

  The method for producing a resin-impregnated cured sheet according to claim 3 of the present invention is characterized in that, in claim 2, curing by heating is performed in two stages of preheating and main curing for suppressing resin fluidity.

  By manufacturing as described above, the resin impregnated cured sheet A can be cured so that the resin does not flow when cured by heating, and the resin amount of the surface layer portion is smaller than that of the central portion in the thickness direction. Can get to.

  According to a fourth aspect of the present invention, there is provided a method for producing a resin-impregnated cured sheet according to the second or third aspect, wherein the thickness is adjusted by further applying heat pressure after being cured by heating.

  By manufacturing as described above, the resin-impregnated cured sheet A having a good thickness accuracy can be obtained. In addition, the moisture evaporation inside the resin can be eliminated, and the peel strength of the paper substrate 1 can be increased.

  Further, the building board B of claim 5 of the present invention is characterized in that the decorative board 3 is laminated and integrated on one surface of the resin-impregnated sheet A of claim 1, and the building board B of claim 6 comprises: The decorative board 3 is laminated and integrated on one surface of the resin-impregnated sheet A of claim 1, and the plywood 4 is laminated and integrated on the other surface of the resin-impregnated sheet A.

  The present invention provides a resin-impregnated sheet and a decorative plate that penetrates the paper base of the resin-impregnated cured sheet when the decorative plate is laminated and bonded with an adhesive by reducing the resin in the surface layer portion of the resin-impregnated sheet. Unlike the MDF board, it has the effect of excelling in peelability because the amount of resin inside the resin-impregnated cured sheet is large, and the MDF board uses a resin-impregnated cured sheet. Compared to, it can be made lighter and the building board can be used on walls, ceilings, etc., and there is an effect that the use is expanded.

  Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.

The resin-impregnated cured sheet A is formed by impregnating a thermosetting resin 2 into a single-layer paper base material 1 such as waste paper, and curing the thermosetting resin 2 by heating. The resin layer is formed so that the amount of resin in the surface layer portion is small and the amount of resin in the center in the thickness direction is large. A paper substrate 1 such as waste paper has a thickness of about 0.5 to 2 mm, and is impregnated with a thermosetting resin 2 such as a melamine resin, a phenol resin, a urea resin, or an epoxy resin. As resin conditions at that time, for example, in the case of melamine resin, melamine resin: latex: water: curing agent: surfactant = 76: 19: 5: 0.288: 0.1 (weight ratio), and the liquid temperature is 30 to 50 ° C. A paper base material 1 such as waste paper is immersed therein for 20 seconds, and impregnated with about 500 to 900 g / m ² before the resin is dried.

The resin-impregnated sheet A ′ obtained by impregnating the paper base material 1 with the thermosetting resin 2 as described above is passed between the pair of sponge rolls 6 in the sponge roll process as shown in FIG. Remove excess adhering resin on the upper and lower surface layers. The resin-impregnated sheet A ′ from which excess adhering resin has been removed by the sponge roll 6 is sent to a resin deposition step as shown in FIG. 1B before drying, and between a pair of hard rolls 7 formed of cured rubber, iron or the like. By passing through the resin-impregnated sheet A ′ and pressing, the resin in the surface layer portion is precipitated, and the resin impregnation amount of the surface layer portion is reduced to about ½ of the resin impregnation amount in the central portion in the thickness direction. At this time, the press pressure is about 98100 to 490000 Pa (1.0 to 5.0 kgf / cm ² ) to deposit the resin in the upper and lower surface layer portions, and the depth of the upper and lower surface layer portions is 0.05 to 0.10 mm. The resin amount is halved.

  As described above, the resin-impregnated sheet A ′ in which the resin amount of the upper and lower surface layers is halved is sent to the preheating process as shown in FIG. A 'is placed and preheated by applying hot air of 60 to 100 ° C to the resin impregnated sheet A' for 15 to 20 minutes, and the resin on the upper and lower surface layers of the resin impregnated sheet A 'is cured in order to suppress the resin fluidity Thus, the resin-impregnated sheet A ′ is brought into a semi-cured state. The semi-cured resin-impregnated sheet A ′ is sent to the main curing process and cured by irradiation with infrared rays or hot air. In the example shown in the figure, it is hardened by applying hot air, and a resin-impregnated sheet A ′ is disposed between a pair of hot air blowing devices 9, for example, hot air of about 160 ° C. is applied for 3 to 20 minutes, and the book Cured.

As described above, the resin-impregnated sheet A ′ that has been hardened in the main hardening step is sent to the pressing step as shown in FIG. 1 (e), where it is hot-pressed to form a predetermined thickness, and the resin is further hardened. Be made. The resin of the paper substrate 1 of the resin-impregnated sheet A ′ is 98-100 to 490000 Pa (1.0 to 5) in a hot press 10 (for example, 160 ° C.) or a heat roll (for example, 200 ° C.) in the pressing step while the resin of the paper base 1 is melted by 30 to 50%. A pressure of about 0.0 kgf / cm ² ) is applied to suppress bleed of the resin to the surface layer side, and at the same time to eliminate the void of moisture evaporation inside the resin in order to increase the peel strength of the paper substrate 1. In this way, the resin-impregnated cured sheet A as shown in FIG. 1 (f) is formed to a level equivalent to the thickness of the paper base 1 before impregnating the resin by hot pressing in the pressing step. The amount of resin after drying and curing of the resin-impregnated cured sheet A thus formed is about 200 to 400 g / m ^{2. The} building board B is formed using the resin-impregnated cured sheet A configured as described above. In some cases, for example, the process shown in FIG. As shown in FIG. 2A, a resin-impregnated cured sheet A is placed on a press stand 11, an adhesive 12 is applied on one side of the resin-impregnated cured sheet A, and a decorative board 3 such as a veneer is used as an adhesive. 12 is placed on the resin-impregnated cured sheet A, pressed as shown by an arrow a in FIG. 2B and hot pressed, and the decorative plate is placed on the resin-impregnated cured sheet A as shown in FIG. The building board B in which 3 is integrated is formed. As the adhesive 12 for adhering the decorative board 3, for example, a urea resin + vinyl acetate mixed adhesive is used and applied at a rate of 150 g / m ² . The conditions for hot pressing are, for example, a pressure of 390000 Pa (4 kgf / cm ² ), a time of 55 seconds, and a temperature of 120 ° C. with 15 stages. After the decorative plate 3 is bonded, the surface of the decorative plate 3 is polished, a fruit or a surface groove is formed, or painting is performed. The building board B formed as described above forms, for example, a building board B having a thickness of 5 mm, although the thickness of the resin-impregnated cured sheet A is 2 mm and the thickness of the decorative board 3 is 0.3 mm. It is also possible.

As another example, a building board B may be formed as shown in FIG. 3A, the plywood 4 is placed on the press table 11, the adhesive 12 is applied onto the plywood 4, and the resin-impregnated cured sheet A is placed on the plywood 12 via the adhesive 12. The adhesive 12 is applied onto the resin-impregnated cured sheet A, the decorative board 3 such as a veneer is placed on the resin-impregnated cured sheet A via the adhesive 12, and the arrow a in FIG. The building board B in which the decorative board 3 is integrated on the plywood 4 via the resin impregnated cured sheet A is formed as shown in FIG. When the building board B is used as a flooring, the plywood 12 has a thickness of 9 to 15 mm. For example, a urea resin + vinyl acetate resin mixed adhesive is used as the adhesive 12 and is applied at a rate of 150 g / m ² . The conditions for hot pressing are, for example, a pressure of 390000 Pa (4 kgf / cm ² ), a time of 55 seconds, and a temperature of 120 ° C. with 15 stages. After the decorative plate 3 is bonded, the surface of the decorative plate 3 is polished, a fruit or a surface groove is formed, or painting is performed. In the building board B formed as described above, for example, the thickness of the resin-impregnated cured sheet A is 2 mm, the thickness of the decorative board 3 is 0.3 mm, and the overall thickness of the building board B is 12 mm. is there.

In the above example, the resin impregnated cured sheet A is adhered to the plywood 12 by hot pressing, but may be performed by cold pressing. In this case, for example, an adhesive such as an aqueous vinyl urethane resin is applied on the plywood 12, and the resin-impregnated cured sheet A is stacked thereon and cold-pressed to bond the plywood and the resin-impregnated cured sheet A. When the decorative board 3 is bonded on the resin impregnated cured sheet A with the adhesive 15, it is performed by hot pressing. The hot pressing conditions are, for example, a temperature of 120 ° C., a time of 1 minute, and a pressure of 690000 Pa (7 kgf / cm ² ).

(A) thru | or (f) is explanatory drawing explaining an example of the process of forming the resin impregnation hardening sheet | seat of this invention. (A) (b) (c) is explanatory drawing explaining an example of the process of forming the board for building same as the above. (A) (b) (c) is explanatory drawing explaining the other example of the process of forming the board for building same as the above.

Explanation of symbols

A Resin impregnated cured sheet B Architectural board
DESCRIPTION OF SYMBOLS 1 Paper base material 2 Thermosetting resin 3 Decorative board 4 Plywood

Claims (6)

A resin-impregnated cured sheet obtained by impregnating a single-layer paper base material with a thermosetting resin and curing the resin, wherein the resin amount of the surface layer portion is smaller than that of the central portion in the thickness direction. Cured sheet. A method for producing a resin-impregnated cured sheet, comprising impregnating a single-layer paper base material with a thermosetting resin, then depositing and removing the surface layer resin, and then curing by heating. The method for producing a resin-impregnated cured sheet according to claim 2, wherein the curing by heating is performed in two stages of preheating and main curing for suppressing the fluidity of the resin. The method for producing a resin-impregnated cured sheet according to claim 2 or 3, wherein the thickness is adjusted by further applying heat pressure after curing by heating. A building board comprising a decorative board laminated and integrated on one surface of the resin-impregnated sheet according to claim 1. A building board comprising a decorative board laminated and integrated on one surface of the resin-impregnated sheet of claim 1, and a laminated board integrated on the other surface of the resin-impregnated sheet.

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