JP2006219855A - Woody flooring and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide woody flooring capable of preventing also symtoms such as sick house syndrome and chemical substance sensitivity reaction, etc. by deodorizing indoor contaminants such as formaldehyde, a volatile organic compound (VOC), etc. to be released during the use of them from now on as well as fundamental physical integrities such as durability of the flooring of a building, the external appearance (architectural design property), chemical resistance and abrasion resistance for the flooring of the building manufactured from normal plywood or reinforced plywood, particle board, MDF and other woody substrate. <P>SOLUTION: It is so characterized that a top coat layer 26 finally applied to the woody substrate F1 is formed of a hardening coated film of a non-solvent-based ultraviolet radiation hardening resin paint mixing a particled deodorization composition having a fine-grain of photocatalyst activity titanium oxide. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a wooden floor material capable of deodorizing harmful odors emanating from paints, colorants, preservatives, and other various contained chemical substances, and a simple production method therefor.

  In recent years, building floor materials manufactured from ordinary plywood, reinforced plywood, particle board, MDF, and other wood-based boards have basic properties such as durability, appearance (design), chemical resistance, and scratch resistance. In addition to physical properties, it is also required to deodorize indoor pollutants such as formaldehyde and volatile organic compounds (VOC) that will be emitted during use to prevent symptoms such as sick house syndrome and chemical sensitivity. Has reached.

  In this regard, Japanese Patent No. 3533901 discloses an antibacterial deodorant composition containing porous composite particles composited and integrated with a granular semiconductor photocatalyst and particulate amorphous calcium phosphate, and a binder. Is also commercially available from Sekisui Plastics Co., Ltd., the patentee, under the trade name Apamicron.

And this patent gazette states that “antibacterial treatment of ceilings and walls can be performed by using it for various building materials” (paragraph [0046]), “amorphous calcium phosphate particles contain various fungi and Because it can be expected to have a synergistic effect of adsorbing odorous substances with viruses, aldehyde groups, ammonia groups, etc., SOx, NOx, etc., and effectively decomposing the semiconductor photocatalyst, it has excellent antibacterial and deodorant properties It is also described that “a coating film or a molded product having the above can be obtained” (paragraph [0065]).
Japanese Patent No. 3533901

  Therefore, when considering the application of the above-mentioned patented invention to a wooden floor material, the antibacterial deodorant composition (the above-mentioned trade name: Apamicron) of the patented invention is a white porous spherical particle. In order to make it tightly integrated with the top coat layer of the material and maintain the inherent durability, appearance, scratch resistance, etc. of the floor material, it must be mixed with the paint and used.

  Then, the porous spherical particles of the composition itself not only exhibit antibacterial and deodorizing effects, but also as antibacterial and deodorant effects as a cured coating film for paints that form the top coat layer of flooring. It needs to be demonstrated and sustained permanently.

  However, in the above-mentioned patented invention, when using an antibacterial deodorant composition as a paint, an organic solvent can be used in addition to the binder. The organic solvent is not particularly limited, but has a low boiling point and volatilization. Those having a strong property have a problem that the viscosity changes due to evaporation during construction, and those having a high boiling point require time for the drying process, and therefore, a solvent having a boiling point of about 70 to 160 ° C. is preferable ”(paragraph). [0032]).

  Furthermore, even if the preferred boiling point is about 70 to 160 ° C., as long as it is a paint using the “organic solvent”, the volatile organic compound (VOC) will still be emitted from this. A complete antibacterial and deodorant effect cannot be expected.

  Furthermore, in the above-mentioned patented invention, when the antibacterial deodorant composition is used as a paint, there is a correlation between the thickness of the cured coating film and the film thickness and the porous composite particle diameter, and the composition occupies the paint. There is no suggestion of mixing ratios, painting methods for various building materials, or other specific implementation conditions.

  For the purpose of improving the above-mentioned problem, the present invention is intended only for a wooden floor material. In claim 1, the top coat layer finally applied to the wooden substrate has fine particles of photocatalytically active titanium oxide. It is characterized by comprising a cured coating film of a solventless UV curable resin paint mixed with a particulate deodorant component.

  In addition, in claim 2, as a constitution of the wood-based floor material subordinate to claim 1, the mixing ratio of the particulate deodorant component in the solventless UV curable resin coating is 5 to 30% by weight. To do.

  According to a third aspect of the present invention, the average thickness of the topcoat layer is 5 to 15 μm as a structure of the wood-based flooring that is also dependent on the first aspect.

  Furthermore, in claim 4, as the constitution of the wood-based flooring that is also dependent on claim 1, the average particle diameter (R) of the particulate deodorizing component and the average film thickness (T) of the top coat layer are 1 / 3T. <R <2T is satisfied.

  On the other hand, in claim 5, first, only the sealer layer is applied to the surface of the wooden substrate, or the sealer layer and the colored layer are applied simultaneously or sequentially separately, followed by the undercoat layer and the intermediate coat. It is a manufacturing method of a wooden floor material in which coating of a layer and a top coat layer is sequentially performed, and in applying the final top coat layer,

  A solvent-free UV curable resin paint mixed with particulate deodorant components having fine particles of photocatalytically active titanium oxide is brought to an average film thickness of 5 to 15 μm by a natural roll coater, and the particulate deodorant components come into contact with the outside air. After coating to get a smooth state,

  The coated top coat layer is cured by irradiation with ultraviolet rays.

  In claim 6, as a method for producing a wooden floor material subordinate to claim 5, a solvent-free ultraviolet curable resin paint is applied at a paint temperature of 30 to 50 ° C. with a viscosity of 40 to 1500 mPa · s. It is characterized by.

  Further, in claim 7, as a method for producing a wooden floor material that is also dependent on claim 5, immediately after the application of the undercoat layer and / or the intermediate coat layer, it rotates in a direction opposite to the conveying direction of the wooden substrate. By pressing the reverse roll coater, the undercoat layer or / and the intermediate coat layer are finished into a coating film having a smooth surface.

  According to the said structure of Claim 1, the topcoat layer exposed as a final finishing layer of a wood type flooring mixed the particulate deodorizing component which has the fine particle of a photocatalytically active titanium oxide, The solventless type ultraviolet curing resin Because it is formed from a cured coating film of paint, it can effectively deodorize indoor air pollutants such as formaldehyde and volatile organic compounds that are emitted from conventional floor materials during use. Durability, appearance (design), chemical resistance, scratch resistance, and other basic physical properties can be maintained.

  That is, the cured coating film of the ultraviolet curable resin coating has a mechanism for receiving a UV ray to form a film rapidly and has a relatively porous composition. Therefore, the particulate deodorant component mixed with this can also be directly contacted with indoor air pollutants under a large surface area of the flooring, and can completely eliminate the harmful odor. It is.

  The photocatalytic titanium oxide, which is widely exposed from the top coat layer of the flooring, decomposes formaldehyde and volatile organic compounds by a strong oxidizing action, and exhibits excellent deodorizing performance. Since the mixed ultraviolet curable resin paint is a solventless type, there is no possibility that indoor air pollutants are generated from this paint.

  In that case, as the particulate deodorant component, if the photocatalytically active titanium oxide fine particles fixed on the surface of the amorphous calcium phosphate particles are employed, the porous amorphous calcium phosphate particles can form the formaldehyde or It can adsorb harmful odors such as volatile organic compounds positively, and it can give up its deodorizing effect more and more, and it can also give antibacterial effect to the top coat layer of flooring that human body touches directly It can be used, and is useful as a flooring material for schools, hospitals, and gymnasiums.

  Moreover, if the structure of Claim 2 is employ | adopted, the mixing ratio of the said particulate deodorizing component which occupies for an ultraviolet curable resin coating can be made into the minimum required, and the deodorizing effect by this can be achieved rationally, The smoothness of the cured coating film forming the top coat layer can also be maintained.

  If the configuration of claim 3 or claim 4 is adopted, the particulate deodorant component sinks deeply into the cured coating film of the ultraviolet curable resin paint, does not touch the outside air, does not exhibit deodorant performance, Effectively prevent the cured film from being exposed too tall, and the overall smoothness, durability, appearance (design), and scratch resistance of the topcoat layer may be reduced. Can do.

  On the other hand, according to the configuration of claim 5, the solvent-free ultraviolet curable resin paint mixed with the particulate deodorant component is used as a smooth topcoat layer having an average film thickness of 5 to 15 μm by a natural roll coater. It can be reliably and stably applied, and its deodorant wooden flooring can be conveniently and inexpensively manufactured without special modification of conventional manufacturing processes and coating machines, etc. Excellent.

  In that case, if the configuration of claim 6 is adopted, a solventless UV curable resin paint having a high viscosity at room temperature is applied to the top coat layer in a continuous smooth state at a suitable viscosity within the specified numerical range. Has an effect that can be applied stably, and the durability as a cured coating film is also improved.

  Furthermore, if the structure of claim 7 is adopted, since the surface of the undercoat layer or / and the intermediate coat layer is finished into a smooth coating film, the top coat layer applied to the final laminated state after that, There is an effect that it is possible to maintain a smooth state having a specified film thickness, and to obtain a high-quality wood-based flooring material with high dimensional accuracy.

  Hereinafter, the present invention will be described in detail with reference to the drawings. In the cross-sectional view of FIG. 1 showing the product of the wooden floor material, (F1) is a wooden substrate and has a thickness of about 12 mm. This is a combination of ordinary plywood just laminated Lauan and other South Sea materials, special reinforced plywood impregnated with phenol resin, particle board, MDF, other base plate (10), and the base plate (10) It consists of a Japanese paper (11) that is sequentially laminated to the surface in a laminated state and a decorative veneer (so-called veneer) (12) of natural name wood.

  However, instead of the Japanese paper (11) and the decorative veneer (12), an olefin resin sheet or other decorative sheet (13) having various printed patterns as shown in the sectional view of FIG. There is also a wood substrate (F2) bonded to the surface of (10). In the present invention, two kinds of wood substrates (F1) and (F2) are selectively used. The base plate (10) has a thickness of about 11.7 mm, the Japanese paper (11) has a thickness of about 0.05 mm, and the decorative veneer (12) has a thickness of about 0.2 to 0.25 mm. The thickness of (13) is about 0.15 to 0.2 mm.

  In any case, in producing the woody flooring of the present invention, as suggested by the process diagram of FIG. 3, the process of transporting the woody substrates (F1) and (F2) along the automatic line. First, the sealer layer (15) and then the colored layer (16) are coated on the surfaces of the substrates (F1) and (F2) by a coating machine such as a natural roll coater (14) or a flow coater.

  As the coating material for the sealer layer (15), a two-component ultraviolet curable resin coating material is used, and as the coating material for the coloring layer (16), a coating material containing an aqueous colorant is used. (17) and (18) are an ultraviolet irradiation device for curing the sealer layer (15) and a drying device for curing the colored layer (16).

  In that case, the coating of the sealer layer (15) is indispensable, but the coating of the colored layer (16) may be omitted. The sealer layer (15) and the colored layer (16) are divided into two steps, respectively, and the sealer layer (15 ) And the colored layer (16) can be applied simultaneously in one step. Therefore, only one layer of the sealer layer (15) is shown in FIGS.

  And after the coating film of the sealer layer (15) coated in this way or the coating film of the sealer layer (15) and the colored layer (16) is cured, the natural roll coater (19 ) The undercoat layer (21) and the intermediate coat layer (22) are sequentially applied by a coating machine such as (20). As a coating material for applying these, a solvent-free ultraviolet curable resin coating is used. (23) and (24) are ultraviolet irradiation devices for curing the undercoat layer (21) and the intermediate coat layer (22), respectively.

  Such coating of the undercoat layer (21) and the intermediate coat layer (22) can be effectively performed by using the natural roll coater (19) (20), but immediately after the undercoat layer (21) is applied. Or / and immediately after applying the intermediate coating layer (22), and before each coating film is cured by the ultraviolet irradiation devices (23) and (24), the wooden substrates (F1) and (F2) A reverse roll coater (25) that rotates in a direction opposite to the conveying direction (A) is preferably brought into pressure contact with the surface of the coating film.

  By doing so, the coating film of the undercoat layer (21) and the coating film of the intermediate coating layer (22) are homogenized to a constant film thickness, and these can be finished in a smooth state on the surface. As a result, the top coat layer (26) to be applied can be reliably formed as a stable coating film. The average film thickness of the undercoat layer (21) and the intermediate coat layer (22) is almost the same as that of the topcoat layer (26).

  After the coating of the intermediate coating layer (22) is completed and the coating film is cured by being irradiated with ultraviolet rays, the final topcoat layer (26) for the wood based substrates (F1) and (F2) is obtained. As a coating material for applying the top coat layer (26), the same solvent-free UV curable resin coating material as the undercoat layer (21) and the intermediate coating layer (22) is used. A special paint in which deodorant components having fine particles of photocatalytically active titanium oxide are mixed in a certain ratio is used.

As for the details of the ultraviolet curable resin coating used for the coating of the top coat layer (26), this is 5 to 50% by weight of the UV curable acrylate oligomer having a number average molecular weight of 500 to 10,000, and UV curable. 5 to 60% of particulate deodorizing component containing 20 to 60% of monomer and 1 to 10% by weight of radical photopolymerization initiator and having 100% by weight of these non-volatile components and photocatalytically active titanium oxide fine particles. 30% by weight a coating composition is mixed, even it is better to be cured under ultraviolet irradiation amount 80~250mJ / cm ^2.

  As the particulate deodorant component, in particular, the fine particles of titanium oxide having the photocatalytic activity are porous composite particles fixed on the surface of the amorphous calcium phosphate particles, and the average of such particulate deodorant components What set the particle diameter (R) to 5-10 micrometers is preferable.

  Then, as will be apparent from the examples of the present invention described later, not only an excellent deodorizing effect can be obtained, but the porous amorphous calcium phosphate particles are contaminated with indoor air such as formaldehyde and volatile organic compounds. This is because not only substances but also viruses are adsorbed and these are decomposed by photocatalytically active titanium oxide, so that antibacterial effects can also be expected.

  The reason for setting the mixing ratio of the particulate deodorizing component to 5 to 30% by weight assuming that the non-volatile component UV curable resin coating is 100% by weight is the example of the present invention described later. As can be seen from the results, if the amount is less than 5% by weight, the desired deodorant performance is hardly exhibited. This is because an improvement in the odor effect cannot be expected and not only is it wasted, but also the smoothness of the coating film forming the top coat layer (26) is hindered.

  As the UV curable oligomer having a number average molecular weight of 500 to 10,000 used for the coating composition of the top coat layer (26), characteristics such as hardness, gloss and stain resistance required for the top coat layer (26). It is possible to use known materials such as bisphenol A type, novolak type, polybutadiene type epoxy (meth) acrylate and polyether type urethane (meth) acrylate, all of which are used in one or a mixture of two or more. it can.

  In addition, as the ultraviolet curable monomer, a known monofunctional monomer, bifunctional monomer, trifunctional or higher polyfunctional monomer suitable for coating the topcoat layer (26) is also used alone or in a mixed system of two or more. Can be used.

  Furthermore, the photo radical polymerization initiator is a compound that generates radicals upon irradiation with ultraviolet rays, and can be used alone or in combination of two or more of its conventionally known hydrogen abstraction type and photocleavage type. It is also possible to use a photosensitizer in combination with such a radical photopolymerization initiator. In addition to these, additives such as matting agents, plasticizers, and colorants can be added.

  In any case, the ultraviolet curable resin coating used in the present invention can be easily produced by a method such as mixing and stirring of the above composition, and this is a solventless type because of its high viscosity at room temperature. In its use, it is preferable to keep the coating temperature at 30 to 50 ° C., and apply it as a viscosity of 40 to 1500 mPa · s, so that it is natural like the undercoat layer (21) and the intermediate coat layer (22). Using the roll coater (27), it is possible to easily obtain a smooth coating film of the topcoat layer (26) having a uniform film thickness.

  Then, the wood-based substrates (F1) and (F2) that have been coated with the topcoat layer (26) are passed through the ultraviolet irradiation device (28), thereby applying the topcoat layer (26). As a result, it is cured as a film, and the particulate deodorant component is finished as a wooden floor material that exhibits deodorizing performance. In the process diagram of FIG. 3, for the sake of simplicity, only one coating machine such as a natural roll coater (14) (19) (20) (27) is shown. Of course, it is possible that the number of coatings and the number of coatings are increased.

  In that case, the average film thickness (T) of the cured coating film forming the topcoat layer (26) is preferably set to 5 to 15 μm. This correlates with a numerical value of 5 to 10 μm mentioned as a preferable average particle diameter (R) of the particulate deodorant component.

  That is, when the average film thickness (T) of the topcoat layer (26) is thinner than 5 μm and the average particle diameter (R) of the particulate deodorant component is larger than 10 μm, the particulate deodorant component. To the cured coating of the top coat layer (26) in a stable and strong manner, as well as the smoothness as the top coat layer (26), as well as durability, scratch resistance, appearance ( It also obstructs basic physical properties such as design properties.

  On the other hand, when the average film thickness (T) of the topcoat layer (26) is thicker than 15 μm and the average particle diameter (R) of the particulate deodorant component is smaller than 5 μm, the particulate deodorant. Since the component sinks into the cured coating film of the top coat layer (26) and does not reliably contact the outside air, the deodorizing performance cannot be exhibited.

  In this regard, as can be confirmed from the exposed state of the particles (29) extracted and enlarged in FIG. 4 and the examples of the present invention described later, the average film thickness (T) of the topcoat layer (26) and the particulate deodorant component The average particle diameter (R) is most effectively set to a numerical value range that satisfies the relationship of 1 / 3T <R <2T (where 1 / 3T = 1/3 × T). This is a wood-based flooring that can simultaneously exhibit the above-mentioned various physical properties of the top coat layer (26) and the deodorizing performance of the indoor air pollutant at the same time.

<Example>
Hereinafter, although an example and a comparative example of the present invention are given and explained concretely, the present invention is not limited only to the example.

  A total of 4 types of paints 1 to 4 were produced by mixing and stirring under the composition and weight percent shown in Table 1. The components described in Table 1 are as follows.

“Oligomer”: Acrylate oligomer component, Unidic V-5508 (Dainippon Ink and Chemicals: Epoxy acrylate)
"Monomer": Tripropylene glycol diacrylate (Toagosei: Aronix M-220)
"Photoradical polymerization initiator": Irgacure 184 (Ciba Specialty Chemicals)
“Matte”: 12 parts calcium carbonate, 3 parts Cyloid ED-50 (Grace Japan), Micron White 5000A (Hayashi Kasei)
“Particulate deodorant component having titanium oxide fine particles exhibiting photocatalytic activity”: Apamicron APU10SA (Sekisui Plastics Industries: average particle diameter of 5 to 10 μm)

1 is used as the top coat layer (26) of the wood substrate (F1) in which the base plate (10) shown in FIG. 1 is a normal plywood and the decorative veneer (12) is a cover. The coating was carried out so that the coating amount at the material temperature of 40 ° C. and the coating temperature of 40 ° C. and the average film thickness of the coating film were in the states shown in Examples 1 to 12 and Comparative Examples 1 to 12 in Table 2. All of the ultraviolet rays were irradiated at an irradiation amount of 160 mJ / cm ² at room temperature of 25 ° C. to cure the top coat layer (26).

  To conduct the odor test, soak triethylamine, 5% aqueous acetic acid, toluene, and xylene in 2 cm square absorbent cotton, place the above 30 cm square coated plate on the top, enclose it in a desiccator, and then expose to sunlight. In addition to evaluating the odor in the desiccator for 2 days under the conditions, the smoothness of the coating film was also evaluated visually and by touch. The test started at 8 pm in the summer and ended at 8 pm two days later. The weather was clear on both days, and the cloud took a little time. Table 2 shows the test results.

  As apparent from Table 2, the mixing ratio of the particulate deodorant component in the ultraviolet curable resin paint (non-volatile component) is the desired deodorant in the case of the paint 4 in which much of 30% by weight is mixed. While the effect can be achieved, the smoothness of the cured coating film forming the topcoat layer (26) tends to be reduced, while the paint 1 mixed with a small amount of 5% by weight conversely maintains the smoothness of the cured coating film. Although it sag, it tends to decrease the deodorizing effect.

  Based on such test results, in the present invention, in order to expect both the smoothness of the cured coating film in the top coat layer (26) and the deodorizing effect of indoor air pollutants, Depending on the mixing ratio set to 5-30 weight percent.

  Next, when attention is paid to the average film thickness (T) of the cured coating film forming the top coat layer (26), in Comparative Examples 1 to 4 (coating state) of 3 μm, the particulate erasure mixed in the coating material. Assuming that the particle size of the odor component is constant, the particulate deodorant component becomes relatively excessive and is exposed tall from the surface of the cured coating, so the smoothness and durability strength of the cured coating, etc. Decreases. On the other hand, in the case of Comparative Examples 5 to 12 in which the average film thickness (T) is 20 μm or more, the particulate deodorant component is similarly relatively small, and it sinks deeply into the cured coating film and touches the outside air. Since it is difficult, the deodorizing effect is reduced.

  Therefore, the average film thickness (T) of the cured coating film forming the top coat layer (26) and the average particle diameter (R) of the particulate deodorant component mixed with the paint are correlated with each other. The average particle diameter (R) and the average film thickness (T) are preferably set so as to satisfy the condition of 1 / 3T <R <2T.

  After all, according to Examples 1 to 12 (coating state) of the present invention in which the average film thickness (T) of the cured coating film is 5 to 15 μm, various physical properties such as smoothness and durability of the cured coating film. And the excellent deodorizing effect can be obtained at the same time, and in particular, the particles of Examples 2, 3, 6, 7, 10, 11 in which 15 to 25 weight percent of the particulate deodorizing component was mixed with the paint. According to the coating state, it can be said that the above-mentioned effect is further improved and the most profitable.

It is sectional drawing of the wood type board | substrate used for this invention. It is sectional drawing of another wood type board | substrate similarly. It is a schematic diagram which shows the manufacturing process of a wood type flooring. It is an enlarged view which shows the particulate deodorizing component exposed from the topcoat layer.

Explanation of symbols

(10) · Base plate (11) · Japanese paper (12) · Makeup veneer (13) · Makeup sheet (14) (19) (20) (27) · Natural roll coater (15) · Sealer layer (16) · Colored layer (17) (23) (24) (28) · UV irradiation device (18) · Drying device (21) · Undercoat layer (22) · Intermediate coat layer (25) · Reverse roll coater (26) · Top coat Layer (29)-Particles of particulate deodorant component (F1) (F2)-Wood substrate (R)-Average particle diameter of particulate deodorant component (T)-Average film thickness of topcoat layer

Claims (7)

  Curing of solvent-free UV curable resin paint in which the top coat layer (26) finally applied to the wood substrates (F1) and (F2) is mixed with particulate deodorant components having fine particles of photocatalytically active titanium oxide A wooden floor material characterized by comprising a coating film.   The woody flooring according to claim 1, wherein the mixing ratio of the particulate deodorant component in the solvent-free ultraviolet curable resin coating is 5 to 30 percent by weight.   The woody flooring according to claim 1, wherein the topcoat layer (26) has an average film thickness (T) of 5 to 15 µm.   The average particle diameter (R) of the particulate deodorant component and the average film thickness (T) of the topcoat layer (26) are in a relationship of 1 / 3T <R <2T. Wooden flooring. First, only the sealer layer (15) is applied to the surface of the wood substrate (F1) (F2), or the sealer layer (15) and the colored layer (16) are applied simultaneously or sequentially. This is a method for producing a wooden floor material, which is performed separately, followed by sequential coating of the undercoat layer (21), the intermediate coat layer (22) and the topcoat layer (26), and the final topcoat layer (26 )
Using a natural roll coater (27), an average film thickness (T) of 5 to 15 μm is obtained from the solvent-free UV curable resin coating material in which particulate deodorant components having fine particles of photocatalytically active titanium oxide are mixed. After coating to a smooth state where the ingredients can come into contact with the outside air
A method for producing a wooden floor material, wherein the coated top coat layer (26) is cured by irradiation with ultraviolet rays.   6. The method for producing a wood-based flooring material according to claim 5, wherein the solventless ultraviolet curable resin coating is applied at a coating temperature of 30 to 50 [deg.] C. with a viscosity of 40 to 1500 mPa.s. Immediately after the application of the undercoat layer (21) and / or the intermediate coat layer (22), a reverse roll coater (25) that rotates in a direction opposite to the conveying direction of the wooden substrates (F1) and (F2) is brought into pressure contact. The method according to claim 5, wherein the undercoat layer (21) and / or the intermediate coat layer (22) is finished into a coating film having a smooth surface.

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