JP2006305981A - Method for manufacturing woody synthetic board building material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To efficiently manufacture a woody synthetic board with a woody touch having a well-defined woody grain formed on the surface, through printing a grained pattern on the surface of a synthetic board building material or extrusion-molding without applying a coating material. <P>SOLUTION: A wavy face with numerous ridges 6 with irregular height, depth and width dimensions, is formed on the surface of a substrate 1, in the longitudinal direction of the substrate 1, when a mixture material of woodflour 3 and a thermoplastic synthetic resin 2 is extrusion-molded. Then the surface of the ridges 6 is cut after the extrusion-molding. Thus the wood synthetic board building material is obtained which shows, in a sharp contrast, a mixed color tone of the woodflour 3 color and a raw material resin 2 color and a rich color tone, of the raw material resin layer, which is revealed by adjusting the degree of cutting force of a groove part. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  Of the building materials used for building decks, terraces, fences, handrails, pillars, benches, etc., the present invention is particularly formed from a mixed material of wood powder such as building waste and thermoplastic resin as a raw material. The present invention relates to a method for manufacturing a wooden composite board building material.

  Wood has generally been used as a building material in the past, but recently, wood-based synthetic board building materials for building formed by mixing wood powder and thermoplastic resin using building wood are known. It has come to be used for various building materials such as decks, fences, interior panels, exterior wall decorative materials, and various furniture materials. (For example, see Patent Document 1)

  Also, among this kind of wood composite board building materials, it is necessary to increase the thickness of the cross section so that the deck material can exhibit the predetermined strength, but if the cross section is extruded and solid, it is difficult to form For reasons such as requiring extra material, increasing weight and increasing costs, a hollow cavity along the length of the plate is provided in the cross section. (For example, see Patent Document 3)

JP 2002-187116 A JP-A-9-216500 Japanese Patent Laid-Open No. 2003-3660

  The wood composite board building materials described in the above-mentioned patent documents 1 and 2 can be used to form a wood composite board with a wood texture that reproduces the grain pattern and color tone close to natural wood. As the manufacturing process, the synthetic material of wood and thermoplastic synthetic resin is extruded while the surface is flat, and then the surface of this molded product is ground by sanding. After the rough surface is formed so that a surface with a wood texture can be formed, a wood grain pattern is printed in the next step, and finally a step of overcoating with a paint is performed.

  For this reason, the manufacturing process is complicated and expensive in terms of expressing the wood grain pattern by printing, and the durability and durability of the printing and paint are not excellent. As an exterior material, it has the problem of being unsuitable.

  Moreover, in this type of woody synthetic board building material in the past, for the purpose of economy, it is known to use a discarded thermoplastic synthetic resin as defined in the Containers and Packaging Recycling Law for the raw material resin. However, since this type of raw material resin is mixed with various types, if this recycled resin is used in large quantities as nearly 50% as the main raw material, it will not be completely dissolved on the surface of the molded product. The remaining untreated strips are exposed, and it is difficult to obtain a high-quality product, and even if the untreated strips are dissolved, there are problems that the moldability is deteriorated due to different temperature conditions and the like. Therefore, this type of recycled resin has a problem that it can be used only as an additive supplementing about half of the blended resin of 40 to 60% by weight.

  Further, in the building material in which a hollow cavity portion along the length direction of the plate is provided in the cross section as in the wood composite board building material of Patent Document 3, in order to save the amount of material as much as possible, Although there is a tendency to increase the space, if the space in the cavity is increased without sufficient consideration, the heat shrinkage caused by the temperature drop with respect to the wall thickness of each part of the section where the space in the cavity is increased and not increased Is not obtained evenly, and as a result, a dent deformation due to thermal contraction occurs on the plate surface of the plate thickness portion having a large space, and a product of uniform quality cannot be manufactured.

  The present invention eliminates the problems associated with conventional wood composite board building materials of this type, and does not require a wood grain pattern to be printed on the surface of the composite board building material or applied paint, and is recycled as a raw material. Even when the plastic was used in an amount of nearly 50% by weight, the exposed strips did not appear noticeably different in color or in an undissolved state, and a clear woody streak was formed on the surface. A wooden building material with a wooden texture can be efficiently manufactured, and a hollow hollow portion provided in the cross-section along the length direction of the plate can be obtained with equal extrusion pressure and heat shrinkage of each part throughout the cross-section. By providing such a shape, a method for producing a wood composite board building material in which dent deformation due to heat shrinkage does not occur on the board surface is provided.

  The present invention, as a specific means for that, is a method for producing a wooden synthetic board building material comprising a substrate obtained by extrusion molding a mixture of thermoplastic synthetic resin and wood powder. A plurality of vertical hole-shaped hollow portions oriented parallel to the side surface of the substrate are provided so as to penetrate along the length direction of the substrate at predetermined intervals. The thickness of each thick portion between both ends and the upper and lower surfaces of the substrate and the thickness of the partition provided on both sides are both provided within a range of 10% to 30% of the plate thickness of the substrate, and Some of the hollow portions are provided with a horizontal hole cut in a horizontal direction in a partition wall between adjacent hollow portions.

  On the other hand, the surface of the substrate is provided with a corrugated surface having a large number of ridges that are irregular in height, depth, and width along the length direction of the substrate. On the surface, the top of the ridge is cut while adjusting the pressing force against the surface of the ridge with a grinding device, so that the color of the wood powder and the color of the raw resin on the cut surface of each ridge It is characterized in that the color tone and the color tone of the abundant raw material resin layer that is exposed to the concave groove valley portion that is difficult to receive cutting force are contrasted.

  When extruding a mixture of thermoplastic synthetic resin and wood powder, dents may be formed on the surface of the substrate due to heat shrinkage during the molding process. In order to suppress the influence, in the part where the dent is generated, it is molded in advance so that the height position of the top of the ridge is provided larger, and the top of the ridge that has been provided in advance after molding is It is preferable to adjust the surface of the substrate to a uniform flat surface with a wood texture by cutting with a brushing device or the like.

  The plurality of through-holes provided in the cross section of the substrate include a vertically long I-shaped hole arranged so as to penetrate in parallel along the length direction of the substrate and a pair of adjacent I-shaped holes. It is preferable that it is comprised from the combination with the H-shaped hole which connected the intermediate part of this horizontally by the horizontal hole.

  In addition, the substrate has a shape in which concave grooves for engaging with joists etc. are provided on both side surfaces along the length direction, and both side surfaces along the length direction of the substrate. It is preferable to prepare a flat surface having no concave grooves.

  The raw material resin should use 40 to 60% by weight of recycled plastic and 30 to 59% by weight of recycled plastic as main raw materials, and 1 to 10% by weight of compatibilizer, moldability improver and pigment as auxiliary raw materials. It is preferable to comprise.

  The wood composite board building material according to the present invention is not a relatively thin wood composite board that prints a wood grain pattern on a conventionally known surface, but is an exterior material such as a deck material, and has a high strength. A wood synthetic board with a large required thickness is molded with a mixed material of wood powder and thermoplastic synthetic resin, but the molded substrate has a uniform shape in the cross section along the length direction. Because it is provided so that a plurality of hollow parts are arranged, even a woody synthetic board with a large thickness can be efficiently extruded at a relatively high molding speed, and it is strong and lightweight. The substrate can be molded.

  Further, this wood composite board building material has a large number of ridges whose height, depth and width are irregular to each other on the surface of the substrate when a mixed material of wood powder and thermoplastic synthetic resin is extruded. After forming, the top of this ridge is cut with a grinding device, so that the color of the wood powder and the color of the raw resin on the cut surface of each ridge top is mixed with the waveform. In contrast to the rich tone of the raw material resin layer that is exposed to the concave groove valleys that are difficult to receive the cutting force, a synthetic board building material with a wood texture due to an irregular stripe pattern can be obtained.

  Since the wood composite board building material of the present invention uses recycled plastic as a main raw material for nearly 50% of the whole, untreated strips that remain undissolved in a part of the surface of the molded product are exposed. Even if there is, a corrugated surface with irregular ridges and grooves having irregular height, depth, and width dimensions is formed on the surface of the product, and the top of the ridges on the corrugated surface is formed by a brushing device. By cutting, it is possible to form striped stripes with natural wood texture on the surface of the substrate, so the remaining untreated strips are striped with this varied wood texture It can be made into a building material that does not feel strange on the surface.

  Further, in the woody synthetic board building material of the present invention, in order to reduce the weight of the substrate and perform the molding efficiently, the hollow portion provided in the cross section along the length direction of the substrate is provided with the hollow portion. The width width of each portion, the thickness of each thick portion between the upper and lower ends of the hollow portion and the upper and lower surfaces of the substrate, and the thickness of the partition provided on both sides are all 10% to 30% of the plate thickness of the substrate. Since the I-shaped hole provided in the range and the H-shaped hole having the I-shaped hole as a basic pattern, the extrusion pressure and heat shrinkage of the resin material to the entire cross section when the hollow portion is formed in the cross section of the substrate Can be made uniform to achieve a balanced shape.

  As described above, the hollow portion is not only a vertically long I-shaped hole, but also an H in which these I-shaped holes are connected by a horizontal hole in order to reduce the weight of the substrate and perform molding efficiently. Although a shape hole is provided to reduce the weight, the portion where the H-shaped hole is provided has a larger space compared to the I-shaped hole portion, so that a thick portion resin is formed on the surface of the molded product. A dent is generated by the shrinkage accompanying cooling.

  In order to prevent such a problem, in the wood composite board building material of the present invention, the thick portion provided with a large space such as an H-shaped hole contracts to prevent the substrate surface from being dented. In the part where the dent is expected to occur, the height of the ridge is provided in advance, and the top of the ridge of this part is cut with a brushing device etc. after molding, so that the dent generated on the surface of the substrate It is possible to adjust to a uniform flat surface with a wood texture by cutting the top of the ridge and cutting the top of the ridge.

  When forming the wood composite board building material of the present invention, a plurality of hollow portions provided in the cross section of the substrate are arranged in a vertically long I shape arranged so as to penetrate in parallel along the length direction of the substrate at intervals. It is preferable that the hole is combined with an H-shaped hole in which an intermediate portion between a pair of adjacent I-shaped holes is horizontally connected by a horizontal hole. Further, a corrugated surface having a large number of ridges having irregular height, depth, and width dimensions is provided on the surface of the substrate along the length direction of the substrate, and the ridges are thereafter formed by a brushing device. The color tone of the mixed material of the color of the wood powder and the color of the raw resin on the cut surface of each convex ridge, and the color tone of the rich raw material resin layer exposed in the concave valleys that are not cut much Are preferably expressed in contrast.

  Next, a description will be given of an example in which the method for producing a wood composite board building material according to the present invention is carried out with respect to a deck material. 51% by weight of recycled thermoplastic synthetic resin 2 obtained by processing plastic containers and packaging materials, 41% by weight of wood powder 3 crushed to about 200 to 300 μm from building waste materials, etc., and calcium stain and polyethylene as auxiliary materials A substrate 1 is formed by extruding a compatibilizing agent such as wax, charcoal calf, liquid paraffin, glycerin, and a moldability improver, and a raw material mixed therewith in a proportion of 8% by weight of the pigment.

  At the time of molding, a plurality of hollow portions 4 are arranged in the cross section of the substrate 1 so as to penetrate in parallel along the length direction of the substrate 1 at intervals, and on the surface of the substrate 1, As shown in FIG. 1 and FIG. 3, along the length direction of the substrate 1, there are a large number of ridges 6 and grooves 5 between them that are irregular in height T, depth D, and width W. Shape the corrugated surface.

  The plurality of through-holes 4 provided in the cross section of the substrate 1 are formed of a vertically long I-shaped hole 7 arranged so as to penetrate in parallel along the length direction of the substrate 1 and a pair of adjacent ones. The I-shaped holes 7 and 7 are basically composed of a combination with an H-shaped hole 8 in which intermediate portions of the I-shaped holes 7 and 7 are horizontally connected to each other by a lateral hole 9.

  The H-shaped hole 8 has the advantage that it can be appropriately reduced in weight without reducing the strength of the substrate 1 and can be efficiently formed. Therefore, the width of the substrate 1 shown in FIG. The arrangement is made in consideration of the balance with the number of I-shaped holes 7 so that a large number of Y-shaped holes 7 are provided when Y is large.

  As shown in FIG. 3, the hollow portion 4 has an interval of the lateral width R1, and the thickness of the thick portion E indicated by the width R2 between the upper and lower ends 4a of the hollow portion and the upper and lower surfaces of the substrate 1 (chain line L in FIG. 3). The thickness of the partition wall F indicated by the width R3 between the respective hollow portions 4 is set within a range of 10% to 30% of the plate thickness K of the substrate 1. Some of them are configured to communicate with each other by providing a horizontal hole 9 cut in the horizontal direction in the partition wall F between the I-shaped holes 7 and 7 adjacent to each other. The thickness R4 of the horizontal hole 9 is preferably the same as the horizontal width R1 of the hollow portion 4.

  As described above, when the hollow portion 4 provided in the cross section of the substrate 1 is constituted by the I-shaped hole 7 and the H-shaped hole 8, as shown in FIG. When the mounting screw 12 is inserted from the front surface of the substrate 1 toward the back surface in order to fix the screw, the screw 12 can be easily inserted into the plate surface by inserting the screw 12 so as to pass through the I-shaped hole 7. In addition to being able to be inserted, it can be effectively tightened without impairing the strength of the substrate as compared with a case where screws are inserted into a space wider than the I-shaped hole. Such an advantage can be obtained not only in the case of the I-shaped hole but also in the case of the H-shaped hole 8 because the screw 12 may be inserted into any one of the I-shaped holes forming the H-shaped hole 8. .

  Further, as shown in FIG. 1, on both side surfaces 1 a of the substrate 1, when the substrate 1 is fixed to a joist member or the like on the lower surface (not shown) with the fixing bracket 10, A bonding groove 11 is provided along the length direction of the substrate 1. In this embodiment of the deck material, the joining groove 11 is constituted by a single I-shaped hole 7 and a lateral hole 9 provided between the side surface 1a of the substrate.

  On the other hand, the substrate 1 is used on a side surface or one surface along the length direction of the substrate 1 for use other than the deck material, for example, a column member as shown in FIG. The flat surface 13 having a large number of the concave grooves 5 and the convex stripes 6 provided on the surface of the substrate 1 may be provided without providing the bonding grooves 11.

  As shown in FIG. 2, the raw material resin 2 mixed with the wood powder 3 flows in a state in which the wood powder 3 is dispersed when the material resin 2 flows in the mold 17 due to the extrusion force. Although the force for moving 3 is received as a resistance force, since the resin 2 easily flows on the surface portion of the molded product that comes into contact with the inner surface of the mold 17, the substrate 1 as the molded product. A rich resin layer 2a having a small content of the wood powder 3 is formed on the surface portion of the material as compared with the inside of the molded product.

When extruding the mixed material of the resin 2 and the wood powder 3 from the mold 17, as shown in FIG. 3, the height T and the depth along the length direction of the substrate 1 on both the front and back surfaces of the substrate 1. Extrusion is performed so that a large number of irregular ridges 5 and convex grooves 6 therebetween are formed with irregularity D and width W.
In addition, the magnitude | size of the ditch | groove 5 and the protruding item | line 6 provided in the front and back both surfaces of the board | substrate 1 is a magnitude | size actually shown in FIG. In order to make it easier to understand the difference in shape, it is shown enlarged.

  On the other hand, as described above, in this deck material, a hollow portion 4 such as a vertically long I-shaped hole 7 or an H-shaped hole 8 is provided in the cross section of the substrate 1 so that molding can be performed efficiently. However, as shown in FIG. 4, the hollow portion 4 such as the H-shaped hole 8 has a larger space with a horizontal width C that is hollow than the I-shaped hole 7. A dent may be generated on the surface of the surface due to shrinkage caused by cooling of the thick-walled resin.

  As described above, when the hollow portion 4 such as the I-shaped hole 7 or the H-shaped hole 8 is provided in the cross section of the substrate 1, the surface of the substrate 1 is caused by thermal contraction as shown in FIG. Although the dent 14 may be formed, in order to suppress the generation of such a dent, the present invention sets the height T of the ridge 6 in the portion where the dent 14 is generated, as shown in FIG. The surface treatment is carried out by a grinding device such as a wire brush roll.

  The surface treatment by the grinding device at this time is preferably performed on the tops of all the ridges 6 on the corrugated surface of the substrate surface, but the height T of the ridges 6 is set in advance by predicting the occurrence of the dents 14. In the portion provided higher, the height of the top of this portion is adjusted so as to be the same level as the top of the other ridge portions by adjusting the pressing force or the like.

  As a result, as shown in FIG. 5, the top of the ridge 6 has a relatively bright color tone of the raw material resin layer 2 c where a large amount of the wood powder 3 is exposed, and both shoulders of the ridge top, that is, the ridge 6 and In the middle inclined portion 6 a of the concave stripe 5, since the shaving amount is not enough, the color tone of the intermediate brightness of the resin layer 2 b so that the wood powder 3 cannot be seen or seen, and in the valley portion of the concave stripe 5 Since the cutting force does not reach, the tone of the resin layer 2a in which the wood powder 3 is not exposed is shown in contrast, and the surface of the substrate 1 is made uniform with a wood texture. A plane.

  Of the different color tones, a large amount of resin is scraped off, and the top of the ridge 6 is scraped off to form a resin layer 2c having a low reflectance of light from which the wood powder 3 is exposed. In the inclined portion 6a, the light reflectivity is larger than that of the resin layer 2c and the color tone is brighter, and in the valley portion of the concave groove 5, a rich resin as shown in FIG. As it is, the resin layer 2a having a high light reflectance and a rich color can be formed.

  By providing the hollow portion 4 in the cross section of the substrate 1, a dent 14 due to shrinkage may be generated on the surface of the substrate 1. Therefore, the height T of the ridge 6 is previously formed in a portion where such a dent 14 is generated. If the height is provided higher, the surface of the substrate 1 is adjusted by the grinding device later, and the top and the shoulders of the ridges 6 are cut so that the top and both shoulders are cut away. A synthetic board building material can be obtained.

  In the wood composite board building material of the present invention, it is not necessary to print a wood grain pattern on the molded substrate or to perform a top coating process with a paint in a later process, so that it is far more than a conventional deck structure of this type. Economical and highly available.

The perspective view which shows the structure which implemented the wooden synthetic board building material of this invention to the deck material. The partial expanded sectional view which shows the cross-sectional shape immediately after shaping | molding of this wood synthetic board building material. The partial expanded sectional view which shows the structure of this woody synthetic board building material. The partial expanded sectional view explaining phenomena, such as a dent which generate | occur | produces after shaping | molding. The partial expanded sectional view after grinding the surface of a board | substrate. Sectional drawing of the state which inserts a screw in a board | substrate hollow part as a fixing means of a board | substrate. The perspective view which shows the usage example of the board | substrate which does not have a joining groove | channel on a side surface.

Explanation of symbols

1: substrate
2: Thermoplastic synthetic resin,
2a, 2b, 2c: resin layer,
3: Wood flour,
4: Hollow part,
5: Groove,
6: ridges,
6a: inclined part,
7: I-shaped hole,
8: H-shaped hole,
9: Horizontal hole,
10: Fixing bracket,
11: Joining groove,
12: Screw,
13: flat surface,
14: dent,
16: joists
17: Mold

Claims (3)

It is a method for producing a wooden synthetic board building material comprising a substrate obtained by extruding a thermoplastic synthetic resin and wood powder mixture,
At the time of molding the substrate, a plurality of vertical hole-shaped hollow portions in a direction parallel to the side surface of the substrate are provided in the cross section of the substrate so as to penetrate along the length direction of the substrate at predetermined intervals.
In the hollow portion, the width of the width, the thickness of each thick portion between the upper and lower ends of the hollow portion and the upper and lower surfaces of the substrate, and the thickness of the partition F provided on both sides are all 10% of the thickness of the substrate. In the range of 30% to 30%,
And some of the hollow parts are provided with horizontal holes cut horizontally in the partition between adjacent hollow parts,
On the surface of the substrate, along the length direction of the substrate, a corrugated surface having a large number of ridges having irregular heights, depths, and width dimensions is provided.
By cutting the top of the ridges on the surface of the molded substrate while adjusting the pressing force against the surface of the ridges with a grinding device, the color of the wood powder and the raw resin on the cut surface of each ridge top A method for producing a woody synthetic board building material, characterized in that the color tone mixed with the color of the color is contrasted with the color tone of the rich raw material resin layer that is exposed to the concave groove valley portion that is difficult to receive cutting force.   A vertically long I-shaped hole in which a plurality of hollow portions provided in a cross section of the substrate are arranged in parallel at intervals along the length direction of the substrate, and an intermediate partition wall between a pair of adjacent I-shaped holes The manufacturing method of the woody synthetic board building material of Claim 1 comprised from the combination with the H-shaped hole horizontally connected by the horizontal hole.   The woody material of claim 1 using 40 to 60% by weight of recycled plastic and 30 to 59% by weight of recycled plastic as main raw materials, and 1 to 10% by weight of compatibilizer, moldability improver and pigment as auxiliary raw materials. A method of manufacturing synthetic board building materials.

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