JP2011173285A - Woody plate - Google Patents
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- JP2011173285A JP2011173285A JP2010037715A JP2010037715A JP2011173285A JP 2011173285 A JP2011173285 A JP 2011173285A JP 2010037715 A JP2010037715 A JP 2010037715A JP 2010037715 A JP2010037715 A JP 2010037715A JP 2011173285 A JP2011173285 A JP 2011173285A
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本発明は、住宅用の床材や壁材、扉等に用いられる木質板に関するものである。 The present invention relates to a wooden board used for a floor material, a wall material, a door or the like for a house.
住宅用の床材や壁材、扉等に用いられる木質板は、通常、合板等の木質基材の表面側に複合材が配設され、その上に表面化粧材が配設された後に、表面から複合材にまで達する深さの化粧溝加工が施され、さらに表面に塗膜が形成された構造となっている。 Wooden boards used for residential flooring and wall materials, doors, etc., usually after the composite material is arranged on the surface side of the wooden substrate such as plywood, and the surface decorative material is arranged on it, It has a structure in which a decorative groove having a depth reaching the composite material from the surface is applied and a coating film is formed on the surface.
近年では、前記複合材として、熱可塑性樹脂に無機フィラー、木粉を添加し、混練して得られる木粉樹脂複合材が用いられている（例えば特許文献１、２参照）。本出願人においてはこの複合材をウッドプラスチックボード（ＷＰＢ：Wood Plastic Board）と称して用いている。 In recent years, a wood powder resin composite material obtained by adding an inorganic filler and wood powder to a thermoplastic resin and kneading is used as the composite material (see, for example, Patent Documents 1 and 2). In the present applicant, this composite material is used as a wood plastic board (WPB).
このような木粉樹脂複合材は、一般に公知の複合材である中密度繊維板（ＭＤＦ：Medium Density Fiberboard）に比べて樹脂成分が多く配合されている。このため、吸水時の膨潤が少なく耐水性に優れ、また着色剤を添加することにより表面色に応じた化粧溝の着色が可能である等の点で優れている。 Such a wood powder resin composite material contains a larger amount of resin components than a medium density fiberboard (MDF) which is a generally known composite material. For this reason, there is little swelling at the time of water absorption, it is excellent in water resistance, and it is excellent in the point that the cosmetic groove can be colored according to the surface color by adding a colorant.
しかしながら、化粧溝加工が施された木質板の表面に塗膜を形成する場合、化粧溝に露出した木粉樹脂複合材に配合されているポリエチレンやポリプロピレン等の熱可塑性樹脂によって、化粧溝の塗膜密着性が低下して、溝白化や割れ等の外観不良が生じやすいという問題があった。 However, when a coating film is formed on the surface of a wood board that has been subjected to a decorative groove, the decorative groove is applied by a thermoplastic resin such as polyethylene or polypropylene that is blended in the wood powder resin composite exposed in the decorative groove. There was a problem that film adhesion was lowered and appearance defects such as groove whitening and cracking were likely to occur.
そこで、塗膜密着性の向上を目的に、表面改質処理としてコロナ放電処理が試みられている。しかしながら、化粧溝が断面Ｖ形状等になっているために、化粧溝深部までコロナ放電の電極を近接させることが容易でなく、平坦な表面に比べて十分に表面改質をすることができず、コロナ放電処理の効果が十分に得られにくいという問題があった。 Therefore, corona discharge treatment has been attempted as surface modification treatment for the purpose of improving coating film adhesion. However, since the decorative groove has a V-shaped cross section and the like, it is not easy to bring the corona discharge electrode close to the deep part of the decorative groove, and the surface cannot be sufficiently modified compared to a flat surface. There was a problem that the effect of the corona discharge treatment was not sufficiently obtained.
本発明は、以上の通りの事情に鑑みてなされたものであり、木粉樹脂複合材（ＷＰＢ）を配設する木質板において、表面塗膜の配設に際しての化粧溝での塗膜密着性を向上させることのできる木質板を提供することを課題とする。 The present invention has been made in view of the circumstances as described above, and in a wood board on which a wood powder resin composite material (WPB) is disposed, the adhesion of the coating film in the decorative groove when the surface coating film is disposed. It is an object of the present invention to provide a wooden board capable of improving the quality.
本発明の木質板は、上記の課題を解決するために、以下のことを特徴としている。 In order to solve the above-mentioned problems, the wood board of the present invention is characterized by the following.
第１：木質基材の上に、熱可塑性樹脂、無機フィラー及び木粉からなる木粉樹脂複合材と、表面化粧材とが順次に配設され、表面化粧材から木粉樹脂複合材に達する深さの化粧溝が形成されて、表面に塗膜が形成された木質板であって、木粉樹脂複合材に含まれる無機フィラーが平均粒径５０〜３００μｍの範囲内の炭酸カルシウムを含有する。 First: A wood powder resin composite material composed of a thermoplastic resin, an inorganic filler, and wood powder and a surface decorative material are sequentially disposed on the wood base material, and reaches the wood powder resin composite material from the surface decorative material. A wooden board having a decorative groove having a depth and a coating film formed on the surface thereof, wherein the inorganic filler contained in the wood powder resin composite contains calcium carbonate having an average particle diameter of 50 to 300 μm. .
第２：前記第１の発明の木質板において、炭酸カルシウムの配合量が、木粉樹脂複合材全体の１５〜６５質量％の範囲内である。 Second: In the wood board of the first invention, the amount of calcium carbonate is in the range of 15 to 65% by mass of the whole wood powder resin composite material.
第３：前記第１又は第２の発明の木質板において、表面化粧材が木質単板である。 Third: In the wood board of the first or second invention, the surface decorative material is a wood veneer.
上記第１の発明によれば、木粉樹脂複合材に配合する無機フィラーを平均粒径５０〜３００μｍの範囲内の炭酸カルシウムを含有するので、化粧溝の木粉樹脂複合材の露出面には割れた炭酸カルシウムの凹凸が形成されることから、塗膜の密着性を向上させることができる。 According to the first aspect of the invention, since the inorganic filler to be blended in the wood powder resin composite contains calcium carbonate having an average particle size of 50 to 300 μm, Since the unevenness | corrugation of the broken calcium carbonate is formed, the adhesiveness of a coating film can be improved.
第２の発明によれば、炭酸カルシウムの配合量を木粉樹脂複合材全体の１５〜６５質量％の範囲内としたので、第１の発明の効果を確実に顕著なものとすることができる。 According to the second invention, since the blending amount of calcium carbonate is within the range of 15 to 65% by mass of the whole wood powder resin composite material, the effects of the first invention can be reliably made remarkable. .
また、第３の発明によれば、表面化粧材を木質単板としたので、意匠性に優れ、また、寸法安定性、耐クラック性、耐傷性等に優れた木質板とすることができる。 Further, according to the third invention, since the surface decorative material is made of a single wood plate, it is possible to obtain a wood plate having excellent design properties and excellent dimensional stability, crack resistance, scratch resistance, and the like.
以下、本発明を実施するための形態について詳細に説明する。 Hereinafter, embodiments for carrying out the present invention will be described in detail.
本発明の木質板では、図１及び図２に示すように、木質基材１の表面側に木粉樹脂複合材２を配設し、さらにその上に表面化粧材４を配設し、表面化粧材４から木粉樹脂複合材２に達する深さの化粧溝６を形成し、表面に塗膜５を形成した構造となっている。なお、表面化粧材４が木質単板の場合には、用途に応じて木質単板の表面に着色をした後、塗膜５を設ける。 In the wood board of the present invention, as shown in FIGS. 1 and 2, the wood powder resin composite material 2 is disposed on the surface side of the wood substrate 1, and the surface decorative material 4 is further disposed thereon, A decorative groove 6 having a depth reaching the wood powder resin composite material 2 from the decorative material 4 is formed, and a coating film 5 is formed on the surface. In the case where the surface decorative material 4 is a wood veneer, the surface of the wood veneer is colored according to the use, and then the coating film 5 is provided.
本発明の木質板に用いられる木質基材１としては、汎用のものを用いることができ、例えば合板、中密度繊維板等を用いることができる。 As the wood substrate 1 used for the wood board of the present invention, a general-purpose material can be used, for example, a plywood, a medium density fiber board, or the like.
木粉樹脂複合材２は、熱可塑性樹脂、無機フィラー、そして木粉からなり、これらを混練、混合して成形することにより製造することができる。 The wood powder resin composite material 2 is made of a thermoplastic resin, an inorganic filler, and wood powder, and can be manufactured by kneading, mixing, and molding.
木粉樹脂複合材２に用いられる熱可塑性樹脂としては、公知の熱可塑性樹脂を用いることができ、例えば、塩化ビニル樹脂、ＡＢＳ樹脂、オレフィン系樹脂等を挙げることができる。これらのなかでも安価で耐熱性に優れたポリプロピレン樹脂、ポリエチレン樹脂等のオレフィン系樹脂を好ましく用いることができる。これら熱可塑性樹脂は１種単独で用いてもよいし、２種以上を併用して用いてもよい。 As the thermoplastic resin used for the wood powder resin composite material 2, a known thermoplastic resin can be used, and examples thereof include a vinyl chloride resin, an ABS resin, and an olefin resin. Of these, olefinic resins such as polypropylene resins and polyethylene resins that are inexpensive and excellent in heat resistance can be preferably used. These thermoplastic resins may be used alone or in combination of two or more.
無機フィラーとしては、少なくとも炭酸カルシウムを用い、その平均粒径は５０〜３００μｍ、好ましくは１００〜２００μｍの範囲内である。このような比較的大きな平均粒径の無機フィラーを用いると、化粧溝６に露出する炭酸カルシウムの表面に大きな凹凸が形成され、塗膜５との密着性が優れた木質板となる。 As the inorganic filler, at least calcium carbonate is used, and the average particle size is in the range of 50 to 300 μm, preferably 100 to 200 μm. When such an inorganic filler having a relatively large average particle diameter is used, large irregularities are formed on the surface of the calcium carbonate exposed in the decorative groove 6 and a wood board having excellent adhesion to the coating film 5 is obtained.
平均粒径が５０μｍ未満では、化粧溝加工により露出した木粉樹脂複合材２の表面に、十分な炭酸カルシウムによる凹凸が形成されず優れた塗膜密着性を得ることができない場合がある。また３００μｍを超えると木粉樹脂複合材２表面の凹凸が大きくなり外観不良となる場合がある。 If the average particle size is less than 50 μm, there may be a case where unevenness due to sufficient calcium carbonate is not formed on the surface of the wood powder resin composite material 2 exposed by the decorative groove processing, and excellent coating film adhesion cannot be obtained. On the other hand, if the thickness exceeds 300 μm, the unevenness of the surface of the wood powder resin composite material 2 may be increased, resulting in poor appearance.
炭酸カルシウムの配合量は、木粉樹脂複合材２全体に対して１５〜６５質量％、好ましくは４０〜６０質量％の範囲内である。 The compounding quantity of calcium carbonate is 15-65 mass% with respect to the whole wood powder resin composite material 2, Preferably it exists in the range of 40-60 mass%.
配合量が１５質量％未満では、化粧溝加工により露出した木粉樹脂複合材２表面の炭酸カルシウムによる凹凸面積が不十分となり、優れた塗膜密着性が確保できないおそれがあり、６５質量％を超えると均一な成形体が得られなくなるおそれがある。 If the blending amount is less than 15% by mass, the uneven surface area due to calcium carbonate on the surface of the wood powder resin composite material 2 exposed by the decorative groove processing becomes insufficient, and there is a possibility that excellent coating film adhesion cannot be secured, and 65% by mass When it exceeds, there exists a possibility that a uniform molded object may not be obtained.
また、上記炭酸カルシウムのほか、本発明の効果を阻害しない範囲で、他の無機フィラーを併用することができる。他の無機フィラーとしては、マイカ、アルミナ、タルク等を挙げることができ、これらを１種、又は２種以上を混合したものを炭酸カルシウムと併用して用いてもよい。これらの無機フィラーを併用する場合、その平均粒径は、一般的には５〜３０μｍの範囲内がよいが、従来と同様であってもよい。 In addition to the above calcium carbonate, other inorganic fillers can be used in combination as long as the effects of the present invention are not impaired. Examples of other inorganic fillers include mica, alumina, talc, and the like, and one or a mixture of two or more thereof may be used in combination with calcium carbonate. When these inorganic fillers are used in combination, the average particle size is generally in the range of 5 to 30 μm, but may be the same as in the past.
また、その配合量については、炭酸カルシウムとの合計量が木粉樹脂複合材２の全体に対し、炭酸カルシウム単独の場合と同様の前記１５〜６５質量％の範囲内とすることが好ましい。そして、炭酸カルシウムに対しての質量比としては、３倍未満とすることが好ましい。 Moreover, about the compounding quantity, it is preferable to make the total amount with a calcium carbonate in the said 15-65 mass% range similar to the case of calcium carbonate with respect to the whole wood powder resin composite material 2. And as mass ratio with respect to calcium carbonate, it is preferable to set it as less than 3 times.
木粉としては、例えば、おがくず、廃木材、合板、中密度繊維板、パーチクルボード等を粉末にしたものを用いることができる。この木粉は、分散性、成形性を考慮して平均粒径が１０〜１５０メッシュのものを好ましく用いることができる。 As the wood powder, for example, sawdust, waste wood, plywood, medium density fiberboard, particle board or the like can be used. The wood powder having an average particle size of 10 to 150 mesh can be preferably used in consideration of dispersibility and moldability.
熱可塑性樹脂（Ａ）及び炭酸カルシウム（他の無機フィラー併用の場合も含む）（Ｂ）、そして木粉（Ｃ）からなる木粉樹脂複合材２の全体に対しての配合比率（質量％）は一般的には次の範囲内になるように考慮する。
（Ａ）熱可塑性樹脂 ５〜７５
（Ｂ）炭酸カルシウム １５〜６５
（Ｃ）木粉 １０〜３０
木粉樹脂複合材２の成形方法としては、例えば、二軸混練押出機を用いて混練と押し出しを同時に行う方法や、混練した後に金型成形する方法、また、カレンダー加工により成形する方法等により成形することができる。
Thermoplastic resin (A) and calcium carbonate (including other inorganic fillers in combination) (B), and blending ratio (mass%) with respect to the whole wood powder resin composite material 2 comprising wood flour (C) Is generally considered to be within the following range.
(A) Thermoplastic resin 5-75
(B) Calcium carbonate 15-65
(C) Wood flour 10-30
As a molding method of the wood powder resin composite material 2, for example, a method of simultaneously kneading and extruding using a twin-screw kneading extruder, a method of molding after kneading, a method of molding by calendering, etc. Can be molded.
また、本発明の木質板の表面化粧材４としては、木質単板、樹脂シート等を用いることができる。樹脂シートとしては、例えば表面に印刷を施したポリプロピレンシート等のオレフィン系樹脂シートを用いることができる。 Moreover, as the surface decorative material 4 of the wooden board of this invention, a wooden single board, a resin sheet, etc. can be used. As the resin sheet, for example, an olefin resin sheet such as a polypropylene sheet having a printed surface can be used.
本発明においては、表面化粧材４として木質単板を用いることがより好ましい。木質単板を用いることにより木質の外観を有するとともに、寸法安定性、耐クラック性、耐傷性等に優れた木質板とすることができる。また、表面塗装の前に木質単板の表面を研磨することにより表面平滑性を向上させることができる。 In the present invention, it is more preferable to use a wood veneer as the surface decorative material 4. By using the wood veneer, it is possible to obtain a wood plate having a woody appearance and excellent in dimensional stability, crack resistance, scratch resistance, and the like. Further, the surface smoothness can be improved by polishing the surface of the wood veneer before the surface coating.
以上のような木質板を構成する各材料の間には、他の材料を適宜挟むことができる。他の材料としては中密度繊維板や、図２の断面図にも示した紙３等を挙げることができる。 Other materials can be appropriately sandwiched between the materials constituting the wood board as described above. Other materials include medium density fiberboard and paper 3 shown in the cross-sectional view of FIG.
本発明の木質板は、例えば以下のようにして製造することができる。 The wood board of the present invention can be manufactured, for example, as follows.
まず、木粉樹脂複合材２と木質基材１を接着剤により接着し、さらに、裏側に接着剤を塗布した木質単板と木粉樹脂複合材２を貼り合わせた後熱圧プレスにより加圧接着する。 First, the wood powder resin composite material 2 and the wood base material 1 are bonded with an adhesive, and further, the wood veneer with the adhesive applied to the back side and the wood powder resin composite material 2 are bonded together and then pressed by a hot press. Glue.
接着剤としては、ウレタン系反応型ホットメルト接着剤（ＰＵＲ）や、エマルジョン系接着剤等を適宜選択して用いることができる。 As the adhesive, a urethane-based reactive hot melt adhesive (PUR), an emulsion-based adhesive, or the like can be appropriately selected and used.
なお、本発明の木質板の構成において、表面化粧材４を木質単板とする場合には、木質単板と木粉樹脂複合材２との間に前記の紙３を配設するのが好ましい。紙３を配設することにより木質単板や接着剤中に含まれる水分等を逃がすことができる。 In the configuration of the wood board of the present invention, when the surface decorative material 4 is a wood veneer, the paper 3 is preferably disposed between the wood veneer and the wood powder resin composite material 2. . By disposing the paper 3, moisture contained in the wood veneer or the adhesive can be released.
さらに、この紙３と木粉樹脂複合材２とを接着する場合、接着を確実にするために、あらかじめ木粉樹脂複合材２表面にコロナ放電処理を施すのが好ましい。 Further, when the paper 3 and the wood powder resin composite material 2 are bonded, it is preferable to perform a corona discharge treatment on the surface of the wood powder resin composite material 2 in advance in order to ensure adhesion.
表面化粧材４として樹脂シート等を用いる場合には、紙３の配設は不要であり、直接木粉樹脂複合材２と樹脂シート等を接着すればよい。 When a resin sheet or the like is used as the surface decorative material 4, it is not necessary to dispose the paper 3, and the wood powder resin composite material 2 and the resin sheet or the like may be directly bonded.
木質板の意匠性を高めるために、本発明においては化粧溝加工を施す。この化粧溝加工は、チップソー等を用いて適宜加工することができる。形成された化粧溝６は図２にも示したように表面化粧材４から木粉樹脂複合材２に達する深さであり、通常断面Ｖ字形状を有している。もちろん、この化粧溝６については意匠性を考慮して、本数、長さ、断面形状等を適宜設定することができる。 In order to enhance the design of the wooden board, a decorative groove is applied in the present invention. This decorative groove processing can be appropriately performed using a tip saw or the like. The formed decorative groove 6 has a depth reaching the wood powder resin composite material 2 from the surface decorative material 4 as shown in FIG. 2, and usually has a V-shaped cross section. Of course, the number, length, cross-sectional shape and the like of the decorative groove 6 can be appropriately set in consideration of design properties.
さらに、木質板の意匠性を高めるために最表面に塗装を行い図２のように塗膜５を形成する。塗装は通常、着色、下塗り、中塗り、上塗の工程により行う。 Furthermore, in order to improve the designability of the wood board, the outermost surface is coated to form a coating film 5 as shown in FIG. The coating is usually performed by coloring, undercoating, intermediate coating, and topcoating processes.
着色は、所望の色調に応じた着色染料や着色顔料により行う。表面化粧材４として印刷された樹脂シートを用いる場合には着色は不要である。 Coloring is performed with a coloring dye or coloring pigment according to a desired color tone. Coloring is not necessary when a resin sheet printed as the surface decorative material 4 is used.
下塗り、中塗り、上塗りには生産性や環境面を考慮して、通常、無溶剤のＵＶ塗料が用いられる。 In consideration of productivity and environmental aspects, a solventless UV coating is usually used for the undercoat, intermediate coat, and topcoat.
塗装には、ロールコーターやフローコーターを用い、化粧溝６部分は、下塗り又は中塗り塗料のスポンジロールによる塗布と、金属リバースロールによるかきとりやフローコーターによる塗布によって塗装する。 For the coating, a roll coater or a flow coater is used, and the decorative groove 6 is applied by applying a primer roll or intermediate coating with a sponge roll, scraping with a metal reverse roll, or applying with a flow coater.
通常、木質板に寒熱の温度が繰り返し加えられた場合、図３（Ａ）から図３（Ｂ）のように、化粧溝６部分では塗膜５の収縮により内側に引っ張ろうとする残留応力７が働く。また、耐汚染性や耐傷性等の塗膜物性向上のために、１回の塗布で厚膜を形成することができるフローコーターを用いた場合、化粧溝６部分の塗膜５が厚くなると、より大きな残留応力７が働き、塗膜剥離８が発生しやすくなる。 Usually, when a cold temperature is repeatedly applied to a wooden board, as shown in FIGS. 3 (A) to 3 (B), a residual stress 7 that tends to be pulled inward due to contraction of the coating film 5 in the decorative groove 6 portion. work. In addition, when using a flow coater that can form a thick film by a single application in order to improve the film properties such as stain resistance and scratch resistance, The larger residual stress 7 works, and the coating film peeling 8 is likely to occur.
本発明の木質板では、チップソー等を用いて形成された化粧溝６には、削られた木粉樹脂複合材２が露出する。そして露出した木粉樹脂複合材２の表面には、図４の（１）光学顕微鏡写真（×５０倍）並びに（２）レーザー顕微鏡写真（×５０倍）に示すような割れた炭酸カルシウムによる凹凸９が形成される。この炭酸カルシウムによる凹凸９形状及び、木粉及び炭酸カルシウムに塗料が染み込む効果により塗膜密着性が飛躍的に向上する。 In the wood board of the present invention, the shaved wood powder resin composite material 2 is exposed in the decorative groove 6 formed using a chip saw or the like. Then, the exposed surface of the wood powder resin composite material 2 has irregularities due to broken calcium carbonate as shown in (1) optical micrograph (× 50 times) and (2) laser micrograph (× 50 times) of FIG. 9 is formed. The coating film adhesion is remarkably improved by the shape of the unevenness 9 by the calcium carbonate and the effect of the paint soaking into the wood powder and calcium carbonate.
従って、本発明の木質板によれば、化粧溝６部分において塗膜５の収縮による残留応力７が働いたとしても、塗膜５の剥離、溝白化、割れ等の外観不良の発生は抑えられる。 Therefore, according to the wood board of the present invention, even if the residual stress 7 due to the shrinkage of the coating film 5 acts on the decorative groove 6 portion, occurrence of appearance defects such as peeling, groove whitening, and cracking of the coating film 5 can be suppressed. .
以下、実施例により本発明をさらに詳しく説明するが、本発明はこれらの実施例に何ら限定されるものではない。 EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these Examples at all.
＜実施例１＞
次の工程に従って木質板を作製した。以下、図１及び図２に示す実施形態に基づいて説明する。
（１）ポリエチレン及びポリプロピレンからなる熱可塑性樹脂３０質量％、４５メッシュの木粉１０質量％、無機フィラーとして平均粒径１５０μｍの炭酸カルシウム６０質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した。
（２）この木粉樹脂複合材２の表裏面にコロナ放電処理を行い、厚さ５０μｍの紙３にウレタン系反応型ホットメルト接着剤を塗布して、ロールラミネーターにて圧締することにより木粉樹脂複合材２と紙３を接着した。
（３）紙３を接着した木粉樹脂複合材２を裁断し、厚さ１１．２ｍｍの木質基材１の合板に水性ビニルウレタン系接着剤を塗布した後、紙３を接着していない木粉樹脂複合材２の面と木質基材１の合板を常温で接着した。
（４）紙３の表面に、水性ラテックス系樹脂にメラミン樹脂を添加した接着剤を塗布して、表面化粧材４として厚さ０．２ｍｍの湿式木質単板を熱圧にて接着して木質板原板を作製した。
（５）作製した木質板原板の表面化粧材４である木質単板の継ぎ目に沿って、木粉樹脂複合材２に達する深さを有する断面がＶ形状の化粧溝６を形成した。
（６）化粧溝６加工を施した木質板原板表面に、水性着色剤をスポンジロールで塗布した後、リバースロールにてかきとり、さらにゴムロールにて塗布して、木質単板と化粧溝６に着色を施した。
（７）着色した木質板原板に、下塗りとして無溶剤のＵＶ塗料をスポンジロールで塗布した後、リバースロールにてかきとり２．５ｇ／尺２塗布し、さらにゴムロールにて１．５ｇ／尺２塗布した後、紫外線を照射して硬化させた。
（８）下塗りを施した木質板原板に、中塗りとして無溶剤のＵＶ塗料を２連のゴムロールで１．５ｇ／尺２塗布した後、紫外線を照射して硬化させた。
（９）中塗りを施した木質板原板に、＃３２０の研磨紙により表面を研磨した。
（１０）表面を研磨した木質板原板に、上塗りとして無溶剤のＵＶ塗料をスポンジロールとゴムロールで１．５ｇ／尺２塗布した後、フローコーターにて７ｇ／尺２塗布し、紫外線を照射して硬化させて塗膜５を配設した木質板を作製した。
＜実施例２＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂３０質量％、４５メッシュの木粉３０質量％、無機フィラーとして平均粒径１５０μｍの炭酸カルシウム４０質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜実施例３＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂４０質量％、４５メッシュの木粉１５質量％、無機フィラーとして平均粒径１５０μｍの炭酸カルシウム４５質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜実施例４＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂４５質量％、４５メッシュの木粉１０質量％、無機フィラーとして平均粒径１５０μｍの炭酸カルシウム４５質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜実施例５＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂３０質量％、４５メッシュの木粉１０質量％、無機フィラーとして平均粒径１５０μｍの炭酸カルシウム２５質量％と、平均粒径１５μｍのタルク３５質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜比較例１＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂４５質量％、４５メッシュの木粉１０質量％、無機フィラーとして平均粒径１５μｍの炭酸カルシウム４５質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜比較例２＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂３０質量％、４５メッシュの木粉１０質量％、無機フィラーとして平均粒径１５μｍのタルク６０質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜比較例３＞
ポリエチレン及びポリプロピレンからなる熱可塑性樹脂４５質量％、４５メッシュの木粉１０質量％、無機フィラーとして平均粒径３０μｍの炭酸カルシウム４５質量％を配合し、カレンダー成形にて厚さ０．６ｍｍの木粉樹脂複合材２を作製した以外は、実施例１と同様にして木質板を作製した。
＜評価方法＞
実施例１〜５及び、比較例１〜３の木質板について、化粧溝６部分の塗膜密着性を評価するため、ＪＡＳ規格に準拠して寒熱繰り返しＢ試験を行い、溝白化や割れの発生を評価した。その結果を表１に示す。
<Example 1>
A wood board was produced according to the following process. Hereinafter, description will be made based on the embodiment shown in FIGS.
(1) 30% by mass of thermoplastic resin composed of polyethylene and polypropylene, 10% by mass of 45 mesh wood flour, 60% by mass of calcium carbonate having an average particle size of 150 μm as an inorganic filler, and a thickness of 0.6 mm by calender molding Wood powder resin composite material 2 was produced.
(2) The wood powder resin composite material 2 is subjected to corona discharge treatment on its front and back surfaces, coated with urethane-reactive hot-melt adhesive on paper 3 having a thickness of 50 μm, and pressed with a roll laminator. The powder resin composite material 2 and the paper 3 were bonded.
(3) The wood powder resin composite material 2 to which the paper 3 is bonded is cut, and after applying an aqueous vinyl urethane adhesive to the plywood of the wood base material 1 having a thickness of 11.2 mm, the paper to which the paper 3 is not bonded The surface of the powder resin composite material 2 and the plywood of the wood substrate 1 were bonded at room temperature.
(4) The surface of the paper 3 is coated with an adhesive obtained by adding a melamine resin to an aqueous latex resin, and a wet wood veneer having a thickness of 0.2 mm is adhered to the surface decorative material 4 by hot pressure. A plate blank was prepared.
(5) A V-shaped decorative groove 6 having a depth reaching the wood powder resin composite material 2 was formed along the seam of the wood veneer which is the surface decorative material 4 of the produced wood plate original plate.
(6) Applying a water-based colorant with a sponge roll to the surface of the wood board that has been subjected to the decorative groove 6 processing, scraping with a reverse roll, and further applying with a rubber roll, coloring the wood veneer and the decorative groove 6 Was given.
(7) After applying a solvent-free UV coating as a primer to the colored wood board with a sponge roll, scrape 2.5 g / scale 2 with a reverse roll, and then apply 1.5 g / scale 2 with a rubber roll. Then, it was cured by irradiating with ultraviolet rays.
(8) A solvent-free UV coating was applied as an intermediate coating to an undercoated wood board original plate by 1.5 g / scale 2 with two rubber rolls, and then cured by irradiation with ultraviolet rays.
(9) The surface was polished with a # 320 polishing paper on an intermediate coated wood board.
(10) Apply a solvent-free UV paint 1.5 g / scale 2 with a sponge roll and a rubber roll as a top coat onto a wooden board with a polished surface, then apply 7 g / scale 2 with a flow coater and irradiate with ultraviolet rays. A wood board provided with the coating film 5 was cured.
<Example 2>
30% by mass of thermoplastic resin composed of polyethylene and polypropylene, 30% by mass of 45 mesh wood flour, 40% by mass of calcium carbonate with an average particle size of 150 μm as an inorganic filler, and 0.6 mm thick wood powder by calendar molding A wood board was produced in the same manner as in Example 1 except that the resin composite material 2 was produced.
<Example 3>
40% by mass of a thermoplastic resin composed of polyethylene and polypropylene, 15% by mass of 45 mesh wood flour, and 45% by mass of calcium carbonate having an average particle size of 150 μm as an inorganic filler, and calendering a 0.6 mm thick wood flour A wood board was produced in the same manner as in Example 1 except that the resin composite material 2 was produced.
<Example 4>
45% by mass of thermoplastic resin composed of polyethylene and polypropylene, 10% by mass of 45 mesh wood powder, 45% by mass of calcium carbonate having an average particle size of 150 μm as an inorganic filler, and calender molding to make a 0.6 mm thick wood powder A wood board was produced in the same manner as in Example 1 except that the resin composite material 2 was produced.
<Example 5>
A blend of 30% by mass of a thermoplastic resin composed of polyethylene and polypropylene, 10% by mass of 45 mesh wood flour, 25% by mass of calcium carbonate with an average particle size of 150 μm and 35% by mass of talc with an average particle size of 15 μm as an inorganic filler, A wood board was produced in the same manner as in Example 1 except that the wood powder resin composite material 2 having a thickness of 0.6 mm was produced by molding.
<Comparative Example 1>
45% by mass of thermoplastic resin composed of polyethylene and polypropylene, 10% by mass of 45-mesh wood flour, 45% by mass of calcium carbonate having an average particle size of 15 μm as an inorganic filler, and calendering a 0.6 mm thick wood flour A wood board was produced in the same manner as in Example 1 except that the resin composite material 2 was produced.
<Comparative example 2>
30% by mass of thermoplastic resin composed of polyethylene and polypropylene, 10% by mass of 45 mesh wood powder, 60% by mass of talc having an average particle size of 15 μm as an inorganic filler, and 0.6 mm thick wood powder resin by calendar molding A wood board was produced in the same manner as in Example 1 except that the composite material 2 was produced.
<Comparative Example 3>
45% by mass of thermoplastic resin composed of polyethylene and polypropylene, 10% by mass of 45 mesh wood flour, 45% by mass of calcium carbonate having an average particle size of 30 μm as an inorganic filler, and calender molding to make a wood flour of 0.6 mm thickness A wood board was produced in the same manner as in Example 1 except that the resin composite material 2 was produced.
<Evaluation method>
For the wood boards of Examples 1 to 5 and Comparative Examples 1 to 3, in order to evaluate the coating film adhesion of the decorative groove 6 part, a cold repeated B test was performed in accordance with the JAS standard, and groove whitening and cracking occurred. Evaluated. The results are shown in Table 1.
評価は以下の基準で行った。評価Ａ、Ｂは実用的に有意であることを示し、評価Ｃは不可であることを示している。
Ａ：優良、溝白化、割れなし
Ｂ：やや溝白化はあるものの割れなし
Ｃ：不良、溝白化、割れあり
Evaluation was performed according to the following criteria. Evaluations A and B indicate that they are practically significant, and evaluation C indicates that they are not possible.
A: Excellent, groove whitening, no cracking B: Slight whitening, but no cracking C: Defect, groove whitening, cracking
＜評価結果＞
無機フィラーとして平均粒径１５０μｍの炭酸カルシウムを、木粉樹脂複合材２全体の４０〜６０質量％の範囲内で配合して製造した木粉樹脂複合材２を用いた実施例１〜４の木質板は、溝白化や割れがなく優れた塗膜密着性が確認された。
<Evaluation results>
Wood quality of Examples 1 to 4 using wood powder resin composite material 2 produced by blending calcium carbonate having an average particle size of 150 μm as an inorganic filler within a range of 40 to 60 mass% of the whole wood powder resin composite material 2 The plate was confirmed to have excellent coating film adhesion without groove whitening or cracking.
図４に示す実施例１の木粉樹脂複合材２表面の（１）光学顕微鏡写真（×５０倍）及び（２）レーザー顕微鏡写真（×５０倍）を見てもわかるように、この優れた塗膜密着性は、化粧溝６の木粉樹脂複合材２表面に形成された、割れた炭酸カルシウムの凹凸９によるものであると考えられる。 As can be seen from the (1) optical micrograph (× 50 times) and (2) laser micrograph (× 50 times) of the surface of the wood powder resin composite material 2 of Example 1 shown in FIG. The coating film adhesion is considered to be due to cracked calcium carbonate irregularities 9 formed on the surface of the wood powder resin composite material 2 of the decorative groove 6.
炭酸カルシウムの配合量が２５質量％、タルクの配合量が３５質量％の実施例５は、やや溝白化はあるものの割れは発生しなかった。 In Example 5 in which the blending amount of calcium carbonate was 25% by mass and the blending amount of talc was 35% by mass, cracking did not occur although there was a slight whitening of the groove.
無機フィラーとして平均粒径が本発明の範囲から外れた炭酸カルシウムを用いた比較例１及び３と、無機フィラーとしてタルクのみを用いた比較例２では溝白化、割れが発生した。 Groove whitening and cracking occurred in Comparative Examples 1 and 3 using calcium carbonate having an average particle size outside the scope of the present invention as the inorganic filler and Comparative Example 2 using only talc as the inorganic filler.
図５に示す比較例２の木粉樹脂複合材２表面の（１）光学顕微鏡写真（×５０倍）及び（２）レーザー顕微鏡写真（×５０倍）を見てもわかるように、化粧溝６の木粉樹脂複合材２表面にはタルクによる凹凸は確認することができない。 As can be seen from the (1) optical micrograph (× 50 times) and (2) laser micrograph (× 50 times) of the surface of the wood powder resin composite material 2 of Comparative Example 2 shown in FIG. Unevenness due to talc cannot be confirmed on the surface of the wood powder resin composite material 2.
これらのことから、割れた炭酸カルシウムの凹凸が塗膜密着性の向上に極めて大きく関与していることが確認された。 From these facts, it was confirmed that the unevenness of the broken calcium carbonate was extremely involved in improving the adhesion of the coating film.
１ 木質基材
２ 木粉樹脂複合材
３ 紙
４ 表面化粧材
５ 塗膜
６ 化粧溝
７ 残留応力
８ 塗膜剥離
９ 凹凸
DESCRIPTION OF SYMBOLS 1 Woody base material 2 Wood powder resin composite material 3 Paper 4 Surface decorative material 5 Paint film 6 Makeup groove 7 Residual stress 8
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| JP2010037715A JP5297401B2 (en) | 2010-02-23 | 2010-02-23 | Wood board |
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| JP2017149127A (en) * | 2016-02-26 | 2017-08-31 | エルエフ センテニアル リミテッド | Conjugate thin sheet having woodgrain and texture of structure, conjugated thin sheet panel and method for manufacturing the same |
| US10220597B2 (en) | 2016-02-26 | 2019-03-05 | Living Style (B.V.I.) Limited | Bonded veneer with simulated wood grain and texture, bonded veneer panels and method of making the same |
| CN111683807A (en) * | 2018-01-26 | 2020-09-18 | I4F许可有限责任公司 | Flooring strips having a core comprising calcium carbonate and method of making the same |
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