JP2005178096A - Manufacturing method of woody building material - Google Patents
Manufacturing method of woody building material Download PDFInfo
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- JP2005178096A JP2005178096A JP2003419991A JP2003419991A JP2005178096A JP 2005178096 A JP2005178096 A JP 2005178096A JP 2003419991 A JP2003419991 A JP 2003419991A JP 2003419991 A JP2003419991 A JP 2003419991A JP 2005178096 A JP2005178096 A JP 2005178096A
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この出願の発明は、木質系建材の製造方法に関するものである。さらに詳しくは、この出願の発明は、住宅等の内装材として用いられる遊離ホルムアルデヒド量の少ない木質系建材の製造方法に関するものである。 The invention of this application relates to a method for manufacturing a wooden building material. More specifically, the invention of this application relates to a method for manufacturing a wooden building material with a small amount of free formaldehyde used as an interior material for a house or the like.
住宅等の内装材として用いられる木質系建材は、通常、合板やパーティクルボード等の木質系基板に、接着剤を介して木材の単板や樹脂シートを化粧層として接着して得られている。このような木質系建材の製造方法では、接着剤として、熱硬化性のユリア樹脂、メラミン樹脂、フェノール樹脂等に、架橋剤としてホルムアルデヒドを混合したものが使用されている。 A wood-based building material used as an interior material for a house is usually obtained by bonding a wood veneer or a resin sheet as a decorative layer to a wood-based substrate such as plywood or particle board via an adhesive. In such a wooden building material manufacturing method, a thermosetting urea resin, melamine resin, phenol resin, or the like mixed with formaldehyde as a crosslinking agent is used as an adhesive.
一方、建材や家具等から放散される揮発性有機化合物（VOC）等の化学物質に対してアレルギー症状を示すシックハウス症候群が大きな社会問題となっており、化学物質による環境や人体への悪影響に対する関心が高まっている。なかでもホルムアルデヒドは、木材中に天然由来成分として存在する上、前記のとおり木質系建材の製造において使用される接着剤の硬化剤として一般的に用いられており、未反応分や重合物の加水分解により発生する遊離分がシックハウス症候群の主な原因物質の一つとして挙げられている。 On the other hand, sick house syndrome, which shows allergic symptoms to chemical substances such as volatile organic compounds (VOC) emitted from building materials and furniture, has become a major social problem, and interest in the adverse effects of chemical substances on the environment and the human body. Is growing. In particular, formaldehyde exists as a naturally-derived component in wood and is generally used as a curing agent for adhesives used in the production of wooden building materials as described above. One of the main causative substances of sick house syndrome is the free content generated by decomposition.
室内空気中のホルムアルデヒド量を低減するには、居住者が積極的に十分な換気を行うことが必要であるが、必要以上の換気は住宅の断熱性を低下させるため、快適な室内温度を維持するためにエネルギー消費量が多くなるという問題がある。また、換気方法を誤れば、室内の気圧が低下し、通常室温下では放散されないような建材内部に存在するホルムアルデヒドや、ホルムアルデヒド以外の揮発性の低い室内空気汚染物質もが促進放散される結果となり、逆効果を及ぼす場合もある。 To reduce the amount of formaldehyde in indoor air, residents need to be actively ventilated, but excessive ventilation reduces the thermal insulation of the house and maintains a comfortable indoor temperature. Therefore, there is a problem that energy consumption increases. In addition, if the ventilation method is incorrect, the atmospheric pressure in the room will decrease, and formaldehyde present in building materials that is not normally emitted at room temperature and indoor air pollutants with low volatility other than formaldehyde will be accelerated and released. In some cases, it has the opposite effect.
そこで、木質系建材からのホルムアルデヒド類の放散量を低減する方法として、接着剤中のホルムアルデヒド量を調整して遊離ホルムアルデヒドを削減したり、木質系建材にホルムアルデヒドと反応して化学的に無害な物質に変化させるアルデヒドキャッチャー剤を加える方法が提案されている（例えば、特許文献１〜２）。 Therefore, as a method of reducing the amount of formaldehyde emitted from wooden building materials, the amount of formaldehyde in the adhesive is adjusted to reduce free formaldehyde, or the wooden building materials react with formaldehyde and are chemically harmless. There has been proposed a method of adding an aldehyde catcher agent to be changed (for example, Patent Documents 1 and 2).
しかし、これらの方法では、架橋反応に寄与する接着剤中のホルムアルデヒド量が減少するため熱硬化反応が十分に進行しなくなり、化粧層の木質系基板への接着性が低下するという問題があった。 However, these methods have a problem in that the amount of formaldehyde in the adhesive that contributes to the crosslinking reaction is reduced, so that the thermosetting reaction does not proceed sufficiently, and the adhesiveness to the wooden substrate of the decorative layer is lowered. .
また、ノンホルムアルデヒド系接着剤やノンホルムアルデヒド系木質系建材の開発も進められているが、これらは価格が高いという問題があった。 In addition, development of non-formaldehyde adhesives and non-formaldehyde wood-based building materials is also in progress, but these have the problem of high prices.
そのため、実際には、ホルムアルデヒド等の室内空気汚染物質を低減する方法としては、新築住宅への入居前に、予め暖房器具等により室温を高め、室内空気汚染物質を促進放散させるベークアウトが行われているのである。 Therefore, in practice, as a method of reducing indoor air pollutants such as formaldehyde, before entering a newly built house, the room temperature is raised in advance by using a heater or the like, and a bake-out that promotes and releases indoor air pollutants is performed. -ing
しかし、このようなベークアウトは、家屋を傷める恐れがある上、暖房器具を用いるためその温度範囲が制限され、室内空気汚染物質が十分に促進放散されない場合があった。また、木質系建材内部に留まっている室内空気汚染物質が表面近傍まで溶出することにより、ベークアウト後に室内空気汚染物質の放散量が増加する場合もあった。
そこで、この出願の発明は、以上のとおりの事情に鑑みてなされたものであり、従来技術の問題点を解消し、接着剤中の架橋剤の成分や量を変更することなく、木質系建材からのホルムアルデヒド放散量を効果的に低減させることのできる木質系建材の製造方法を提供することを課題としている。 Therefore, the invention of this application has been made in view of the circumstances as described above, solves the problems of the prior art, and without changing the components and amount of the crosslinking agent in the adhesive, the wooden building material It is an object of the present invention to provide a method for producing a wooden building material that can effectively reduce the amount of formaldehyde emitted from the building.
この出願の発明は、上記の課題を解決するものとして、第１には、木質系基板、接着剤、および化粧層を順に積層し、プレスにより熱圧着する木質系建材の製造方法であって、プレスの天板と化粧層の間に通気層を設け、熱圧着を行うことを特徴とする木質系建材の製造方法を提供する。 The invention of this application is a method for manufacturing a wood-based building material in which, firstly, a wood-based substrate, an adhesive, and a decorative layer are laminated in order and thermocompression-bonded by a press, Provided is a method for producing a wooden building material, wherein a ventilation layer is provided between a top plate and a decorative layer of a press and thermocompression bonding is performed.
この出願の発明は、第２には、木質系基板、接着剤、および化粧層を順に積層し、プレスにより熱圧着する木質系建材の製造方法であって、プレスの天板に脱気機構を設け、脱気しながら熱圧着を行うことを特徴とする木質系建材の製造方法を提供する。 The invention of this application is, secondly, a manufacturing method of a wooden building material in which a wooden substrate, an adhesive, and a decorative layer are sequentially laminated, and thermocompression-bonded by a press, and a deaeration mechanism is provided on the top plate of the press. Provided is a method for producing a wood-based building material, characterized by performing thermocompression bonding while providing deaeration.
この出願の発明は、第３には、木質系基板、接着剤、および化粧層を順に積層した後、化粧層表面に水を塗布し、熱圧着を行う前記いずれかの木質系建材の製造方法を提供する。 Thirdly, according to the invention of the present application, thirdly, the wooden substrate, the adhesive, and the decorative layer are sequentially laminated, then water is applied to the surface of the decorative layer, and thermocompression bonding is performed. I will provide a.
この出願の発明は、第４には、前記いずれかの木質系建材の製造方法において、１回目の熱圧着を行った後、得られた木質系建材表面に水を塗布し、１回目の熱圧着温度よりも高い温度で２回目の熱圧着を行う木質系建材の製造方法をも提供する。 In the invention of this application, fourthly, in any one of the methods for producing a wooden building material, after performing the first thermocompression bonding, water is applied to the surface of the obtained wooden building material, and the first heat is applied. There is also provided a method for producing a wooden building material in which a second thermocompression bonding is performed at a temperature higher than the pressure bonding temperature.
上記第１の発明の木質系建材の製造方法では、木質系基板、接着剤、および化粧層を順に積層し、化粧層とプレス天板との間に通気層を設け、熱圧着する。このとき、接着剤は加熱され、架橋反応が進行するが、未反応の架橋剤に含まれるホルムアルデヒドは遊離ホルムアルデヒドとなり、通気層から木質系建材の外部に放出される。また、加熱により木質系基板に含まれる防腐剤や接着剤からも室内空気汚染物質が発生するが、これらも木質系建材表面へと移動し、通気層から木質系建材の外部に放出される。これにより、ホルムアルデヒドをはじめとする室内空気汚染物質が木質系建材中に残留することがなく、木質系建材中のホルムアルデヒドが効果的に除去される。したがって、木質系建材使用時のホルムアルデヒド放散量が大幅に低減される。 In the method for producing a woody building material according to the first aspect of the present invention, a woody substrate, an adhesive, and a decorative layer are sequentially laminated, a ventilation layer is provided between the decorative layer and the press top plate, and thermocompression bonding is performed. At this time, the adhesive is heated and the crosslinking reaction proceeds, but formaldehyde contained in the unreacted crosslinking agent becomes free formaldehyde and is released from the ventilation layer to the outside of the wooden building material. In addition, indoor air pollutants are also generated from preservatives and adhesives contained in the wooden substrate by heating, but these also move to the surface of the wooden building material and are released from the ventilation layer to the outside of the wooden building material. Thereby, indoor air pollutants including formaldehyde do not remain in the wooden building material, and formaldehyde in the wooden building material is effectively removed. Therefore, the amount of formaldehyde emission when using wooden building materials is greatly reduced.
同様に、上記第２の発明の木質系建材の製造方法では、木質系基板、接着剤、および化粧層を順に積層し、脱気機構を設けたプレスで脱気しながら熱圧着することにより、接着剤が加熱され、架橋反応が進行する。未反応の架橋剤に含まれるホルムアルデヒドは遊離ホルムアルデヒドとなり、プレスの天板に設けられた脱気機構から木質系建材の外部に放出される。また、加熱により木質系基板に含まれる防腐剤や接着剤から発生した室内空気汚染物質も木質系建材表面へと移動し、脱気機構から木質系建材の外部に放出される。これにより、ホルムアルデヒド等の室内空気汚染物質が木質系建材中に残留することがなく、効果的に木質系建材中のホルムアルデヒドが除去される。したがって、木質系建材の使用時におけるホルムアルデヒドの放散量が大幅に低減される。 Similarly, in the method for producing a wooden building material according to the second aspect of the present invention, by sequentially laminating a wooden substrate, an adhesive, and a decorative layer, and thermocompression bonding while deaeration with a press provided with a deaeration mechanism, The adhesive is heated and the crosslinking reaction proceeds. Formaldehyde contained in the unreacted cross-linking agent becomes free formaldehyde and is released from the degassing mechanism provided on the top plate of the press to the outside of the wooden building material. In addition, indoor air pollutants generated from the preservative and adhesive contained in the wooden substrate by heating also move to the surface of the wooden building material, and are released from the degassing mechanism to the outside of the wooden building material. As a result, indoor air pollutants such as formaldehyde do not remain in the wooden building material, and formaldehyde in the wooden building material is effectively removed. Therefore, the amount of formaldehyde emitted when using wood-based building materials is greatly reduced.
さらに、上記第３の発明の木質系建材の製造方法では、木質系基板、接着剤、および化粧層を順に積層した後、化粧層表面に水を塗布し、その直後に熱圧着を行うことにより、化粧層表面近傍に存在する遊離ホルムアルデヒドが水に溶解し、加熱されて水蒸気とともに木質系建材の外部に放出される。 Furthermore, in the manufacturing method of the woody building material according to the third aspect of the invention, after sequentially laminating the woody substrate, the adhesive, and the decorative layer, water is applied to the surface of the decorative layer, and immediately after that, thermocompression bonding is performed. The free formaldehyde present in the vicinity of the surface of the decorative layer is dissolved in water, heated, and released to the outside of the wooden building material together with water vapor.
そして、上記第４の発明の木質系建材の製造方法では、木質系基板、接着剤、および化粧層を順に積層し、１回目の熱圧着を行った後、得られた木質系建材表面に水を塗布し、２回目の熱圧着を行うことにより、接着剤に残存した未反応の架橋剤からの遊離ホルムアルデヒドを水に溶解して水蒸気とともに木質系建材から放出させることができる。また、１回目の熱圧着温度よりも高い温度で２回目の熱圧着を行うことにより、木質系基板に含まれる防腐剤や接着剤から発生するホルムアルデヒド以外の室内空気汚染物質の残留分をも促進放散させることができる。 And in the manufacturing method of the wooden building material of said 4th invention, after laminating | stacking a wooden substrate, an adhesive agent, and a decorative layer in order, and performing the 1st thermocompression bonding, water is obtained on the surface of the obtained wooden building material. Is applied, and the second thermocompression bonding is performed, whereby free formaldehyde from the unreacted crosslinking agent remaining in the adhesive can be dissolved in water and released from the wooden building material together with water vapor. Also, by performing the second thermocompression bonding at a temperature higher than the first thermocompression bonding temperature, the residual amount of indoor air pollutants other than formaldehyde generated from the preservative and adhesive contained in the wooden substrate is also promoted. Can be dissipated.
この出願の発明の木質系建材の製造方法は、木質系基板、接着剤、および化粧層を順に積層し、プレスにより木質系基板上に化粧層を熱圧着するものであり、プレスの天板と化粧層との間に通気層を設けることを特徴とするものである。また、この出願の発明の木質系建材の製造方法は、木質系基板、接着剤、および化粧層を順に積層し、天板に脱気機構を設けたプレスにより、脱気しながら熱圧着を行うことを特徴とするものである。 The manufacturing method of the wood-based building material of the invention of this application is a method of laminating a wood-based substrate, an adhesive, and a decorative layer in order, and thermocompression-bonding the decorative layer on the wooden substrate by pressing, A ventilation layer is provided between the decorative layer and the decorative layer. Further, in the manufacturing method of a woody building material of the invention of this application, a woody substrate, an adhesive, and a decorative layer are sequentially laminated, and thermocompression bonding is performed while deaeration by a press provided with a deaeration mechanism on the top plate. It is characterized by this.
この出願の発明の木質系建材の製造方法において使用される木質系基板の種類や大きさはとくに限定されない。例えば、木材を小片化し、合成樹脂接着成分を用いて成形、熱圧したパーティクルボードやＭＤＦ、原木を薄く剥いた単板（Veneer：ベニヤ）を乾燥させ、奇数枚の単板を繊維方向（木目方向）が交差するように積層接着し、１枚の板にした合板などが適用される。また、これらはさらに、強度や耐久性を高めるための様々な処理が施されたものであってもよい。 The type and size of the wooden substrate used in the method for manufacturing a wooden building material of the invention of this application are not particularly limited. For example, a small piece of wood, particleboard or MDF that has been molded and heat-pressed using a synthetic resin adhesive component, and veneer that has been thinly peeled off are dried, and odd-numbered veneers are placed in the fiber direction (wood grain) Plywood or the like that is laminated and bonded so that the direction) intersects is applied. Further, these may be subjected to various treatments for enhancing strength and durability.
このような木質系基板の原料として使用される接着成分や防腐剤は、ホルムアルデヒド等の室内空気汚染物質を含まないものとすることが好ましい。しかし、この出願の発明の木質系建材の製造方法では、木質系基板から放散されるホルムアルデヒド等の室内空気汚染物質の量も効果的に低減できることから、ホルムアルデヒドやそれ以外の室内空気汚染物質を含有する安価なものを適用してもよい。 It is preferable that the adhesive component and the preservative used as a raw material for such a wooden substrate do not contain indoor air pollutants such as formaldehyde. However, in the method for producing a wood-based building material of the invention of this application, since the amount of indoor air pollutants such as formaldehyde released from the wood-based substrate can also be effectively reduced, formaldehyde and other indoor air pollutants are contained. An inexpensive one may be applied.
この出願の発明の木質系建材の製造方法では、以上のとおりの木質系基板上に化粧層を熱圧着させるが、このとき、木質系基板と化粧層の間には接着剤を施す。接着剤は、木質系基板の表面に塗布してもよいし、化粧層の裏面に塗布してもよい。また、予め裏面に接着剤を有する化粧層を用いてもよい。もちろん、接着剤の塗布量や塗布厚さは木質系基板表面に化粧層を熱圧着するのに十分なものであればよく、とくに限定されない。さらに、このとき使用される接着剤は、ホルムアルデヒド等の室内空気汚染物質を含まないものとすることが好ましいが、この出願の発明の木質系建材の製造方法によれば、ホルムアルデヒド等の室内空気汚染物質が効果的に放出、除去されるので、ホルムアルデヒドを含有するものを用いてもよい。具体的には、熱硬化性のユリア樹脂系、メラミン樹脂系、あるいはフェノール樹脂系接着剤であって、硬化剤としてホルムアルデヒドを含有するものが例示される。 In the manufacturing method of the wooden building material of the invention of this application, the decorative layer is thermocompression bonded onto the wooden substrate as described above. At this time, an adhesive is applied between the wooden substrate and the decorative layer. The adhesive may be applied to the surface of the wooden substrate or may be applied to the back surface of the decorative layer. In addition, a decorative layer having an adhesive on the back surface may be used in advance. Of course, the application amount and the application thickness of the adhesive are not particularly limited as long as they are sufficient for thermocompression bonding of the decorative layer to the surface of the wooden substrate. Furthermore, it is preferable that the adhesive used at this time does not contain indoor air pollutants such as formaldehyde. However, according to the method for producing a wooden building material of the invention of this application, indoor air pollutants such as formaldehyde A substance containing formaldehyde may be used because the substance is effectively released and removed. Specifically, thermosetting urea resin-based, melamine resin-based, or phenol resin-based adhesives that contain formaldehyde as a curing agent are exemplified.
また、この出願の発明の木質系建材の製造方法において使用される化粧層は、特に限定されるものではなく、木材の単板やポリプロピレン、ポリエステル等の樹脂化粧シートなどを使用することができる。 In addition, the decorative layer used in the method for producing a woody building material of the invention of this application is not particularly limited, and a single veneer of wood, a resin decorative sheet such as polypropylene or polyester, and the like can be used.
以上のとおりのこの出願の発明の木質系建材の製造方法では、木質系基板、接着剤および化粧層を積層した後、プレスによる熱圧着を行うが、このときのプレス温度は、接着剤の加熱硬化温度前後とすることが望ましく、例えば、100〜160℃とすることができる。また、プレス圧力についても、一般的に木質系基板表面に化粧層を熱圧着するのに適当な圧力であればよく、とくに限定されない。これにより、接着剤が加熱され、ホルムアルデヒドによる架橋反応が進行し、化粧層が木質系基板と密着して一体化される。一方、未反応のホルムアルデヒドは遊離ホルムアルデヒドとなり、加熱により揮発性となって木質系建材表面へ移動する。また、木質系基板中に含まれる防腐剤や接着成分からもホルムアルデヒドを初めとする室内空気汚染物質が発生し、木質系基板および化粧層内を移動する。 In the manufacturing method of the wood-based building material of the invention of this application as described above, after laminating the wood-based substrate, the adhesive and the decorative layer, thermocompression bonding is performed by a press. The pressing temperature at this time is the heating of the adhesive It is desirable that the temperature be around the curing temperature, for example, 100 to 160 ° C. Also, the press pressure is not particularly limited as long as it is suitable for thermocompression bonding of the decorative layer to the surface of the wood substrate. Thereby, an adhesive agent is heated, the crosslinking reaction by formaldehyde advances, and a decorative layer adheres and integrates with a wooden substrate. On the other hand, unreacted formaldehyde becomes free formaldehyde, becomes volatile by heating, and moves to the surface of the wooden building material. Also, indoor air pollutants such as formaldehyde are generated from preservatives and adhesive components contained in the wooden substrate and move in the wooden substrate and the decorative layer.
従来の木質系建材の製造方法では、このようにして熱圧着時に発生した遊離ホルムアルデヒドや室内空気汚染物質は、木質系建材表面まで移動するものの、木質系建材表面がプレスの天板により覆われているために木質系建材表面から十分に放散されず、木質系建材内部に残留してしまう。 In the conventional manufacturing method of wood-based building materials, free formaldehyde and indoor air pollutants generated during thermocompression are moved to the surface of the wood-based building material, but the surface of the wood-based building material is covered with a press top plate. Therefore, it is not sufficiently dissipated from the surface of the wooden building material and remains inside the wooden building material.
しかし、この出願の発明の木質系建材の製造方法においては、遊離ホルムアルデヒド等の室内空気汚染物質は、プレス天板と化粧層の間に設けられた通気層、あるいはプレス天板に設けられた脱気機構から木質系建材の外部に放出される。したがって、ホルムアルデヒド等が木質系建材中に残留することがなく、簡便かつ効果的に木質系建材中のホルムアルデヒド量が低減される。 However, in the method for producing a woody building material of the invention of this application, indoor air pollutants such as free formaldehyde are removed from the ventilation layer provided between the press top plate and the decorative layer or from the press top plate. Released from the air mechanism to the outside of the wooden building materials. Therefore, formaldehyde or the like does not remain in the wooden building material, and the amount of formaldehyde in the wooden building material is reduced easily and effectively.
このとき、プレス天板と化粧層の間に設けられる通気層は、プレス温度および圧力により変性や変形を生じないものであればよく、とくに限定されない。例えば、金属製のメッシュや耐熱性の多孔質材料などが例示される。一方、脱気機構としては、プレス天板に微細な通気口を多数設けてもよいし、天板そのものをメッシュ状のものとしてもよい。そして、これらの通気口やメッシュを通して、木質系建材から放散されるホルムアルデヒド等の室内空気汚染物質を吸引脱気できるものとする。 At this time, the air-permeable layer provided between the press top plate and the decorative layer is not particularly limited as long as it does not cause modification or deformation due to the press temperature and pressure. For example, a metal mesh, a heat resistant porous material, etc. are illustrated. On the other hand, as the deaeration mechanism, a number of fine ventilation holes may be provided in the press top plate, or the top plate itself may be a mesh-like one. And, through these vents and meshes, indoor air pollutants such as formaldehyde diffused from the wooden building materials can be sucked and degassed.
この出願の発明の木質系建材の製造方法では、さらに、木質系基板、接着剤、および化粧層を順に積層した後、化粧層表面に水を塗布し、熱圧着を行ってもよい。ホルムアルデヒドは水への溶解性が高いことから、これにより遊離ホルムアルデヒドが水に溶解し、加熱されて水蒸気とともに木質系建材の外部に放出される。このとき、水の塗布量はとくに限定されないが、例えば、10〜100 g/m2とすることによりとくに高い効果が得られる。化粧層への水の塗布方法についてもとくに限定されず、刷毛塗り、シャワー、スプレー等が適用できる。 In the method for producing a wood-based building material of the invention of this application, a wood-based substrate, an adhesive, and a decorative layer may be sequentially laminated, and then water may be applied to the surface of the decorative layer and thermocompression bonded. Since formaldehyde is highly soluble in water, free formaldehyde is dissolved in water, heated, and released together with water vapor to the outside of the wooden building material. At this time, the application amount of water is not particularly limited, but for example, a particularly high effect can be obtained by setting it to 10 to 100 g / m 2 . The method for applying water to the decorative layer is not particularly limited, and brushing, showering, spraying, and the like can be applied.
さらに、この出願の発明の木質系建材の製造方法では、以上のとおりの方法により１回目の熱圧着を行った後、得られた木質系建材表面に水を塗布し、１回目の熱圧着温度よりも高い温度で２回目の熱圧着を行ってもよい。これにより、木質系建材中に少量残留したホルムアルデヒドをも揮発させ、水に溶解して水蒸気とともに木質系建材から放出させることができる。接着剤に残存した未反応の架橋剤からの遊離ホルムアルデヒドを水に溶解して水蒸気とともに木質系建材から放出させることができる。また、１回目の熱圧着温度よりも高い温度で２回目の熱圧着を行うことにより、木質系基板に含まれる防腐剤や接着剤から発生するホルムアルデヒド以外の室内空気汚染物質の残留分をも促進放散させることができる。 Furthermore, in the manufacturing method of the wooden building material of the invention of this application, after performing the first thermocompression bonding by the method as described above, water is applied to the surface of the obtained wooden building material, and the first thermocompression bonding temperature. The second thermocompression bonding may be performed at a higher temperature. Thereby, a small amount of formaldehyde remaining in the wooden building material can also be volatilized, dissolved in water, and released from the wooden building material together with water vapor. Free formaldehyde from the unreacted crosslinking agent remaining in the adhesive can be dissolved in water and released together with water vapor from the wooden building material. Also, by performing the second thermocompression bonding at a temperature higher than the first thermocompression bonding temperature, the residual amount of indoor air pollutants other than formaldehyde generated from the preservative and adhesive contained in the wooden substrate is also promoted. Can be dissipated.
以下、実施例を示し、この発明の実施の形態についてさらに詳しく説明する。もちろん、この発明は以下の例に限定されるものではなく、細部については様々な態様が可能であることは言うまでもない。 Hereinafter, examples will be shown, and the embodiments of the present invention will be described in more detail. Of course, the present invention is not limited to the following examples, and it goes without saying that various aspects are possible in detail.
＜実施例１＞
ホルムアルデヒドの発散量がＦ☆☆☆等級（温度28℃、相対湿度50 %、ホルムアルデヒド濃度0.1 mg/m3において、ホルムアルデヒド発散速度が0.005 mg/m2h超0.02 mg/m2h以下）で、厚みが9 mmのクロス合板を30 cm角に切断し、ユリアメラミン系接着剤（株式会社サンベーク製）を100 g/m2で塗布した。次いで、厚み0.3 mmのオーク単板を積載し、温度120℃、プレス圧力6 kg/cm2で60秒間熱圧着し、評価用試料を得た。
<Example 1>
The formaldehyde emission rate is F ☆☆☆ (temperature 28 ° C, relative humidity 50%, formaldehyde concentration 0.1 mg / m 3 , formaldehyde emission rate is more than 0.005 mg / m 2 h and 0.02 mg / m 2 h or less), A 9 mm thick cloth plywood was cut into 30 cm square, and urea melamine adhesive (manufactured by Sunbake Co., Ltd.) was applied at 100 g / m 2 . Next, an oak veneer having a thickness of 0.3 mm was loaded and thermocompression bonded at a temperature of 120 ° C. and a press pressure of 6 kg / cm 2 for 60 seconds to obtain a sample for evaluation.
なお、熱圧着の際、試料とプレス天板の間にステンレス製のメッシュ（圧密時の厚み1 mm）を挿入し、通気層とした。 During thermocompression bonding, a stainless steel mesh (thickness 1 mm during consolidation) was inserted between the sample and the press top plate to form a ventilation layer.
得られた評価用試料について、JIS A 1901「建築材料の揮発性有機化合鬱（VOC）、ホルムアルデヒド及び他のカルボニル化合物放散測定方法−小型チャンバー法」に準拠した容積20 Lの小型チャンバーを用い、温度28℃、相対湿度50 %、換気回数0.5回／h、試料負荷率2.2 m2/m3の条件において、試料設置24時間後のチャンバー内空気を採取し、JIS A 1901に準拠した方法によりホルムアルデヒド放散速度を測定した。 About the obtained sample for evaluation, a small chamber with a volume of 20 L conforming to JIS A 1901 “Measurement method for volatile organic compound (VOC), formaldehyde and other carbonyl compounds emission of building materials—small chamber method” was used. Under conditions of temperature 28 ° C, relative humidity 50%, ventilation rate 0.5 times / h, sample load factor 2.2 m 2 / m 3 , the air in the chamber was sampled 24 hours after the sample was installed, and the method conformed to JIS A 1901 The formaldehyde emission rate was measured.
結果を表１に示した。
＜実施例２＞
試料とプレスの間に通気層を設ける代わりに、プレス天板に直径2 mmの通気口を1 cm間隔で設け、熱圧着時に0.03 hPaの吸引圧によって吸引脱気した以外は、実施例１と同様の方法により評価用試料を作製した。
The results are shown in Table 1.
<Example 2>
Instead of providing a ventilation layer between the sample and the press, a vent hole with a diameter of 2 mm was provided at 1 cm intervals in the press top plate, and suction deaeration was performed with a suction pressure of 0.03 hPa during thermocompression bonding. A sample for evaluation was produced by the same method.
実施例１と同様の方法により評価用試料からのホルムアルデヒド放散速度を測定し、結果を表１に示した。
＜実施例３＞
熱圧着前に、オーク単板上に水をスプレーにより50 g/m2塗布した以外は、実施例１と同様の方法により評価用試料を作製し、そのホルムアルデヒド放散速度を測定した。
The formaldehyde emission rate from the sample for evaluation was measured by the same method as in Example 1, and the results are shown in Table 1.
<Example 3>
Prior to thermocompression bonding, a sample for evaluation was prepared in the same manner as in Example 1 except that water was applied onto an oak veneer by spraying 50 g / m 2 , and the formaldehyde emission rate was measured.
結果を表１に示した。
＜実施例４＞
実施例１の方法により得られた試料を自然放冷した後、表面に水をスプレーにより50 g/m2塗布し、さらに温度140℃、プレス圧力2 kg/cm2で60秒間熱圧着を行い、評価用試料を得た。
The results are shown in Table 1.
<Example 4>
The sample obtained by the method of Example 1 was allowed to cool naturally, then water was sprayed onto the surface by spraying 50 g / m 2 , and thermocompression bonded at a temperature of 140 ° C. and a press pressure of 2 kg / cm 2 for 60 seconds. A sample for evaluation was obtained.
なお、２回目の熱圧着の際にも、試料とプレス天板の間には、ステンレス製のメッシュ（圧密時の厚み1 mm）を挿入し、通気層とした。 In the second thermocompression bonding, a stainless steel mesh (thickness 1 mm during consolidation) was inserted between the sample and the press top plate to form a ventilation layer.
実施例１と同様の方法により、得られた評価用試料からのホルムアルデヒド放散速度を測定し、結果を表１に示した。
＜比較例１＞
熱圧着の際に通気層を設けなかった以外は、実施例１と同様の方法で評価用試料を作製し、そのホルムアルデヒド放散速度を測定した。
The formaldehyde emission rate from the obtained sample for evaluation was measured by the same method as in Example 1, and the results are shown in Table 1.
<Comparative Example 1>
A sample for evaluation was prepared in the same manner as in Example 1 except that no vent layer was provided during thermocompression bonding, and the formaldehyde emission rate was measured.
結果を表１に示した。
＜比較例２＞
熱圧着の際に通気層を設けなかった以外は、実施例３と同様の方法で評価用試料を作製し、そのホルムアルデヒド放散速度を測定した。
The results are shown in Table 1.
<Comparative example 2>
A sample for evaluation was prepared in the same manner as in Example 3 except that no vent layer was provided during thermocompression bonding, and the formaldehyde emission rate was measured.
結果を表１に示した。 The results are shown in Table 1.
表１より、プレス天板と化粧層の間に通気層を設けて、あるいは、プレス天板に設けた脱気機構より脱気しながら熱圧着を行い製造された評価用試料では、ホルムアルデヒド放散速度が大幅に低減されることが確認された（実施例１および２）。また、化粧層表面に水を塗布し、プレス天板と化粧層の間に通気層を設けて熱圧着を行った場合（実施例３）や、プレス天板と化粧層の間に通気層を設けて熱圧着を行った後、表面に水を塗布し、再度プレス天板と化粧層の間に通気層を設けて熱圧着を行った場合（実施例４）には、とくに低いホルムアルデヒド放散速度が確認された。 From Table 1, in the sample for evaluation manufactured by providing a ventilation layer between the press top plate and the decorative layer, or thermocompression bonding while degassing from the deaeration mechanism provided on the press top plate, the formaldehyde emission rate Was confirmed to be significantly reduced (Examples 1 and 2). In addition, when water is applied to the surface of the decorative layer and an air-permeable layer is provided between the press top plate and the decorative layer and thermocompression bonding is performed (Example 3), or the air-permeable layer is provided between the press top plate and the decorative layer. After applying and thermocompression bonding, water is applied to the surface, and when the air pressure bonding is performed again by providing a ventilation layer between the press top plate and the decorative layer (Example 4), the formaldehyde emission rate is particularly low. Was confirmed.
一方、木質系基板、接着剤、化粧層を積層し、通気層や脱気機構を設けることなく、従来の方法により木質系基板に化粧層を熱圧着させた場合には、ホルムアルデヒド放散速度が大きいことが確認された（比較例１）。さらに、化粧層表面に水を塗布した後、通気層や脱気機構を設けることなく、従来の方法により木質系基板に化粧層を熱圧着させた場合には、ホルムアルデヒド放散速度に若干の低下が見られたものの、ホルムアルデヒド発散速度の絶対値は大きかった（比較例２）。 On the other hand, when a wooden substrate, an adhesive, and a decorative layer are laminated and a decorative layer is thermocompression bonded to the wooden substrate by a conventional method without providing a ventilation layer or a deaeration mechanism, the formaldehyde emission rate is high. (Comparative Example 1). Furthermore, when water is applied to the surface of the decorative layer and then the decorative layer is thermocompression bonded to the wooden substrate by a conventional method without providing a ventilation layer or a deaeration mechanism, the formaldehyde emission rate is slightly reduced. Although it was observed, the absolute value of the formaldehyde emission rate was large (Comparative Example 2).
したがって、本願発明の木質系建材の製造方法により、木質系建材からのホルムアルデヒド放散速度を効果的に低減できることが確認された。 Therefore, it was confirmed that the formaldehyde emission rate from the wooden building material can be effectively reduced by the method for manufacturing the wooden building material of the present invention.
以上詳しく説明したとおり、この発明によって、接着剤の架橋剤量や架橋剤成分を変更することなく、木質系建材から放散されるホルムアルデヒドの量を効果的に低減できる木質系建材の製造方法が提供される。 As described above in detail, the present invention provides a method for producing a wooden building material that can effectively reduce the amount of formaldehyde released from the wooden building material without changing the amount of the crosslinking agent or the crosslinking agent component of the adhesive. Is done.
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