JP2015020307A - Intermediate material of woody decorative plate and woody decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative plate where resin impregnation ability to the surface of wood is enhanced, where the removal of a woody fiber at a soft part is suppressed and which has appearance design more excellent in natural appearance when a resin is impregnated.SOLUTION: A fibrillated layer 1 where woody fibers are fibrillated to a degree that at least a part of the woody fibers is microfibrillated is formed on the surface of the woody decorative base material A1 by the collision energy of the water jet WJ due to the high speed collision on the surface of a woody decorative base material A1. A resin is impregnated in a portion including the fibrillated layer 1 and solidified and then a woody decorative plate A3 can be obtained.

Description

  The present invention relates to a wooden decorative board and a wooden decorative board intermediate formed on the way of manufacturing the wooden decorative board from a wooden decorative base, and in particular, the surface of the wooden decorative base is defibrated by a water jet. Regarding technology.

  Conventionally, as a surface treatment method of a wooden decorative board, this is done by spraying a blasting abrasive as a medium on the surface of a wooden decorative base material to perform shot blasting, grinding away the soft part of the surface and leaving a hard part. It is generally well known to perform a so-called floating process for forming irregularities on the surface of a wooden decorative base material. In such shot blasting, the soft part of the decorative material is ground by the impact force caused by the collision of the media.

  On the other hand, as shown in Patent Document 1, high-pressure water is jetted from a nozzle to produce a water jet (high-pressure water flow), and the water jet is applied to the surface of the wooden substrate to treat the surface. Proposed. In this processing method, the water jet spraying pressure is set to a threshold value (about 3 to 5 MPa) of the processing strength between the soft part and hard part of the wood surface, and the soft part is pressed to adjust the uneven state of the wood surface. I am doing so.

JP 2006-218564 A

  By the way, there is a technique called WPC (Wood Plastic Combination) in which voids on the wood surface are impregnated with a resin to modify the surface. In shot blasting, the wood fibers of the soft part of the surface layer are completely removed. The WPC decorative board obtained by impregnating the resin on the surface of the wood from which the wood fibers of the soft part have been removed, filling the removed part with resin, and sanding the surface uniform part has the wood fibers removed. A decorative portion having an artificial appearance is formed by the resin portion filled in the soft portion. Therefore, the WPC decorative board obtained by impregnating the resin has a problem that the surface has a design with a poor natural feeling.

  The present invention has been made in view of such points, and its purpose is to improve the water impregnation property of the wooden decorative base material by devising a water jet treatment method performed on the surface of the wooden decorative base material. The decorative board obtained when improving and suppressing the removal of the wood fiber of the soft part and impregnating the resin is to have a more natural appearance.

  In order to achieve the above object, in the present invention, a fiber on the surface of wood is raised by a water jet to make the surface fluffy, thereby forming a defibrated layer on the surface and impregnating the layer with a resin. I did it.

  Specifically, the wood decorative board intermediate material according to the first invention is characterized in that the surface has a defibrated layer in which the wood fibers are in a defibrated state by the collision energy of the water jet colliding at high speed. To do.

  In the first invention, a defibrating layer is formed on the surface of the wood decorative board intermediate material, in which the wood fibers are in a defibrated state by the collision energy when the water jet collides at a high speed. That is, when the water jet process is performed, the surface of the wood is roughened by the collision energy and becomes fuzzy, and the hard part remains and the soft part is removed as in the shot blast process with a normal blasting abrasive. The recess is not formed, but the soft part remains in the defibrated state, and the removal of the wood fiber is suppressed. As a result, in the defibrated layer, the wood fibers are also “spongy like plowed”, and the original shape of the fibers is more retained. As a result, when the surface defibrated layer is impregnated with resin and subjected to WPC treatment, the resin can easily enter between the wood fibers in the defibrated state, and the resin can be efficiently impregnated. The WPC-treated wood decorative board has a deep appearance design that is superior in nature than the fibers that are fastened. In the present invention, the liquid that becomes the water jet is not limited to water, but also includes alcohol, acetone, and other organic solvents.

  The second invention is characterized in that, in the first invention, the defibrating layer is in a defibrated state to such an extent that at least a part of the surface wood fibers are microfibrillated.

  In the second aspect of the invention, the defibrated state of the surface wood fibers is such that at least a part thereof is microfibrillated, so that a desirable defibrated state is obtained.

  The wood decorative board according to the third invention is characterized in that a resin is impregnated into a portion including the defibrated layer of the wood decorative board intermediate material of the first or second invention and solidified.

  In this third invention, the wood fiber is in a defibrated state in the defibrated layer on the surface of the wood decorative board intermediate material, and the resin containing the defibrated layer is impregnated and solidified. The wooden decorative board is a WPC wooden decorative board having a deep exterior design with a more excellent natural view than a resin in which a resin is efficiently impregnated between wooden fibers in a defibrated state.

  A fourth invention is characterized in that, in the third invention, a coating layer is provided on a surface impregnated and solidified with a resin.

  In this 4th invention, while the surface which the resin impregnated and solidified in the wooden decorative board is protected by the coating film layer, the external appearance design of a wooden decorative board can be improved.

  As described above, according to the first invention, the wood fiber in the surface is made into a defibrated state by the collision energy of the water jet colliding with the surface of the wooden decorative base material at a high speed. Removal of fibers is suppressed, and the wood fiber has a more original shape. When WPC treatment is performed, the resin can be efficiently impregnated between the wood fibers in the defibrated state, and the fibers are retained. In addition, a woody decorative board with a WPC appearance having a deep appearance design excellent in nature can be obtained.

  According to the second invention, a desired defibrated state can be obtained by setting the defibrated state to such an extent that at least a part of the surface wood fibers are microfibrillated.

  According to the third invention, the resin is impregnated between the wood fibers in the defibrated state by impregnating the resin into the part including the part in the defibrated state and solidified, and the fibers Thus, a WPC wood decorative board having a deep appearance design that is superior in nature and retained is obtained.

  According to the fourth invention, the coating layer is provided on the surface impregnated and solidified with the resin, so that the surface of the wooden decorative board is protected by the coating layer and the appearance design of the wooden decorative board is enhanced. be able to.

FIG. 1 is a cross-sectional view schematically showing a wood decorative board intermediate material according to an embodiment of the present invention in which a defibrating layer is formed on the surface by water jet treatment. FIG. 2 is a photomicrograph of the surface of the defibrated layer. FIG. 3 is a cross-sectional view schematically showing a wooden decorative board in which a portion including a defibrating layer is impregnated with a resin. FIG. 4 is a photomicrograph showing a cross-sectional structure of a wooden decorative board in which a portion including a defibrated layer is impregnated with a resin. FIG. 5 is a photomicrograph showing a cross-sectional structure of a wooden decorative board provided with a coating layer on the surface. FIG. 6 is a diagram showing the main steps of the method for manufacturing a wooden decorative board. FIGS. 7A and 7B schematically show an example when the surface of the wooden decorative base material is subjected to water jet treatment, FIG. 7A is a perspective view, and FIG. 7B is a bottom view of the nozzle. FIG. 8 schematically shows another example when the surface of the wooden decorative base material is subjected to water jet treatment, FIG. 8 (a) is a perspective view, FIG. 8 (b) is a bottom view of the nozzle, and FIG. 8 (c). ) Is a diagram showing the inclination angle of the water jet from the nozzle axis. FIG. 9 is a perspective view schematically showing still another example when the surface of the wooden decorative base material is subjected to water jet treatment.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.

(Wooden decorative board intermediate material)
FIG. 1 shows a wood decorative board intermediate material A2 according to an embodiment of the present invention. This wooden decorative board intermediate material A2 is formed while a wooden decorative board A3 (see FIG. 3) described later is manufactured from the wooden decorative base material A1. As the wooden decorative board intermediate material A2 (wood decorative base material A1), for example, a natural wooden material or a sliced piece obtained by slicing these laminates is used, and the tree species is not limited. For example, hard tree species such as oak, birch, beach and cherry, and soft tree species such as cedar, tsuga, hinoki and sawawagurumi are used. Any natural wood material can be used, such as conifers, hardwoods, and fast-growing trees. Moreover, what sliced the laminated body of natural wooden material is what is called an artificial veneer.

  Preferably, a conifer having a long fiber length is used. In softwood, the difference in surface hardness between the soft part and the hard part is large, and the soft part having a particularly low Mohs hardness and a long fiber length is selectively defibrated by the manufacturing method of the decorative board A3.

  Solid wood, solid laminated wood, laminated wood, dry veneer or raw veneer (wet veneer) can be used for the wooden decorative base material A1. When the dry veneer or raw veneer (wet veneer) is used, the thickness of the wooden decorative base material A1 is preferably about 0.15 to 5.0 mm, more preferably about 1.0 to 3.0 mm. . These may be attached to the surface of a desired substrate or used as they are.

  The hardness of the wooden decorative base A1 is preferably 2 or less to 3 or less in terms of Mohs hardness. Softwoods such as cedar have a Mohs hardness of about 2, soft hardwoods such as cherry have a Mohs hardness of about 3, hardwoods such as oak have a Mohs hardness of about 4 to 5, and African wood has a Mohs hardness of about 6.

  The wooden decorative board intermediate material A2 is formed by performing water jet treatment on the surface of the wooden decorative base A1 (see FIG. 6), and the water jet WJ is high on the surface of the wooden decorative base A1. By colliding at a speed, the wood fibers on the surface are in a defibrated state due to the impact energy of the water jet WJ, and the surface of the wood decorative board intermediate material A2 is a defibrated made of wood fibers in the defibrated state. A fine layer 1 is formed.

  The defibrating layer 1 is desirably in a defibrated state to such an extent that at least a part of the surface wood fibers are microfibrillated. Thus, by setting the defibrated state of the wood fiber to such an extent that at least a part thereof is microfibrillated, a desired defibrated state is obtained. As will be described later, a resin is provided in a portion including the defibrated layer 1. The wood decorative board A3 obtained when the resin is impregnated and solidified efficiently impregnates the resin between the wood fibers in the defibrated state, and has a deeper appearance design with a better natural view than the fibers held WPC wood decorative board having

  2 (a) and 2 (b) are photomicrographs showing the surface of the defibrating layer 1 formed on the surface of the wood decorative board intermediate material A2, and the defibrating layer 1 has a surface wood fiber. Is in a defibrated state to the extent that is partially microfibrillated. FIG. 2 (a) shows that the wooden decorative base material A1 is red pine and the water jet WJ is applied to the surface at a right angle. FIG. 2 (b) shows the wooden decorative base material A1 as a cedar. A water jet WJ is applied obliquely (45 °) to the surface. The angle of the water jet WJ with respect to the surface of the wooden decorative base material A1 will be described later.

(Wooden decorative board)
FIG. 3 shows a wooden decorative board A3 according to an embodiment of the present invention. This wooden decorative board A3 has a resin-impregnated layer 2 in which resin is impregnated into a portion including the defibrated layer 1 whose surface has been defibrated by the WPC treatment with respect to the wooden decorative board intermediate material A2. Is formed.

  Here, the resin impregnated in the portion including the defibrating layer 1 will be described in detail. As this resin, for example, two resins of an impregnation resin and a filling resin are used. Both of these impregnating resins and filling resins have both active energy ray curing characteristics and moisture curing characteristics. For this reason, compared with resin which has only a moisture hardening characteristic, resin can be hardened instantaneously by irradiation of an active energy ray. Only one or both of the impregnation resin and the filling resin may be used.

  Both resins are mainly composed of oligomers or polymers such as polyester acrylates, epoxy acrylates, urethane acrylates, polyether acrylates, or the like obtained by adding a reactive monomer to a mixture of them. Furthermore, both resins are made by adding 1% by mass or more and 15% by mass or less of polyisocyanate with respect to the main component.

  The oligomer, polymer, and reactive monomer used for both resins may be those generally used as resins having active energy ray curing characteristics. The following are mentioned as an example of the reactive monomer used for both resin.

  Examples of monofunctional monomers include lauryl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, 1,6-hexanediol monoacrylate, dicyclopentadiene acrylate, 2-hydroxylpropyl acrylate, phenoxydiethylene glycol acrylate, isobornyl acrylate , Β-carboxyethyl acrylate, acryloyl morpholine, 2-hydroxyethyl acryloyl phosphate, tetrahydrofurfuryl acrylate, N, N-diethylaminoethyl acrylate, N, N-dimethylaminoethyl acrylate, glycidyl acrylate, benzyl acrylate and the like.

  Examples of bifunctional monomers include ethylene glycol dimethacrylate, diethylene glycol diacrylate, diethylene glycol dimethacrylate, triethylene glycol diacrylate, triethylene glycol dimethacrylate, polyethylene glycol diacrylate, polyethylene glycol dimethacrylate, dipropylene glycol diacrylate. Acrylate, dipropylene glycol dimethacrylate, tripropylene glycol diacrylate, tripropylene glycol dimethacrylate, polypropylene diacrylate, polypropylene dimethacrylate, 1,6-hexanediol diacrylate, 1,4-butanediol diacrylate, 1 , 4-Butanediol dimethacrylate, neopentylglyco Diacrylate, neopentyl glycol dimethacrylate, 1,9-nonanediol diacrylate, 1,9-nonanediol dimethacrylate and the like.

  Examples of trifunctional monomers include trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, ethoxylated trimethylolpropane triacrylate, ethoxylated trimethylolpropane trimethacrylate, pentaerythritol triacrylate, pentaerythritol trimethacrylate, glycerin propoxy A triacrylate etc. are mentioned.

  Examples of the tetrafunctional or higher functional monomer include pentaerythritol tetraacrylate, ethoxylated pentaerythritol tetraacrylate, propoxylated pentaerythritol tetraacrylate, ditrimethylolpropane tetraacrylate, dipentaerythritol hexaacrylate, and the like.

  Moreover, it is preferable that an isocyanate type compound is added to both resin. This isocyanate compound absorbs moisture in the air and contributes to moisture curing of both resins. For this reason, the adhesiveness to woody decorative board intermediate material A2 of both resin can be improved more.

  Specific examples of isocyanate compounds include isocyanate monomers such as hexamethylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, norbornene diisocyanate, and biuret, isocyanurate, and trimethylolpropane adducts. And the like, and block bodies of these isocyanate monomers or polyisocyanate derivatives. Furthermore, it is preferable to use a non-yellowing type or a hardly yellowing type isocyanate compound. These isocyanate compounds are used alone or in combination.

  Further, a commonly used catalyst such as a tin compound, a zinc compound, or an amine compound may be added to both resins.

  This resin filling method will be described later.

  4 (a) and 4 (b) are micrographs showing the cross-sectional structure of the wooden decorative board A3 in which the resin is impregnated in the surface defibrating layer 1. In the defibrating layer 1, the resin is It is impregnated in the wood fiber which is in a defibrated state to such an extent that at least a part of the surface is microfibrillated.

  In the wooden decorative board A3, the coating layer 3 is provided on the surface impregnated with the resin and solidified. The coating layer 3 is made of, for example, an acrylic transparent resin paint or a urethane transparent resin paint. 5 (a) and 5 (b) are photomicrographs showing the cross-sectional structure of a wooden decorative board having a coating layer on the surface.

(Manufacturing method of wooden decorative board)
Next, the manufacturing method of the said wooden decorative board A3 is demonstrated based on FIG. FIG. 6 shows only main steps of the manufacturing method, and includes a water jet treatment step (defibration step), a resin drying step, an impregnation step, and a surface coating layer forming step.

(1) Waterjet processing step First, as shown in FIG. 6 (a), the waterjet WJ is caused to collide at a high speed on the surface of the wooden decorative base A1 that becomes the wooden decorative board A3 (wooden decorative board intermediate material A2). The wood decorative board in which the defibrated layer 1 is formed on the surface as shown in FIG. 6B by bringing the surface of the wood decorative base A1 into a defibrated state by the collision energy of the water jet WJ that has collided. Intermediate material A2 is obtained.

  When the surface of the wooden decorative base A1 is in a defibrated state, it is desirable to set the defibrated state to such an extent that at least a part of the wooden fibers on the surface of the wooden decorative base A1 is microfibrillated.

  FIGS. 7 to 9 show that when the water jet WJ collides with the surface of the wooden decorative base material A1 at a high speed, the nozzle 10 that injects high-pressure water to generate the water jet WJ and the water jet WJ are in contact with each other. The relationship with the surface of the wooden decorative base material A1 is illustrated (in addition to these examples, various settings can be made).

  FIG. 7 is an example in which the water jet WJ is applied perpendicularly to the surface of the wooden decorative base material A1, and in this example, the nozzle 10 is a cylindrical one that rotates about the axis O, as shown in FIG. 7 (b). As described above, a plurality of ejection holes 11, 11,... For ejecting high-pressure water in parallel with the axis O are opened at equiangular intervals around the bottom surface. As shown in FIG. 7 (a), high-pressure water is jetted from the jet holes 11, 11,... While rotating the nozzle 10 around the axis O to generate a plurality of water jets WJ, WJ,. On the other hand, the wooden decorative base material A1 is moved relative to the axis O of the nozzle 10 at a right angle so that the water jets WJ, WJ,... Are applied to the surface of the wooden decorative base material A1 at a right angle. By rotating the nozzle 10 in this way, a wider area of the surface of the wooden decorative base material A1 can be uniformly water jet processed.

  FIG. 8 is an example in which the water jet WJ is obliquely applied to the surface of the wooden decorative base material A1 at a predetermined inclination angle θ (for example, θ = 45 °). As shown in FIG. As shown in FIG. 8 (c), a plurality of ejection holes 11 that radiate high-pressure water radially around the circular bottom surface with an inclination with respect to the axis O as shown in FIG. 8C. , 11,... Are opened at equiangular intervals. As shown in FIG. 8A, a plurality of radial water jets WJ, WJ,... Are generated by injecting high-pressure water from the ejection holes 11, 11,. On the other hand, the wooden decorative base material A1 is moved relative to the axis O of the nozzle 10 at a right angle so that the water jets WJ, WJ,... Are obliquely applied to the surface of the wooden decorative base material A1.

  In this way, by applying the water jet WJ diagonally to the surface of the wooden decorative base material A1, the processing area of the water jet WJ increases as compared to the case where the water jet WJ is applied at a right angle, and a wider area of the surface is uniformly processed. There are advantages that can be made.

  In addition, the nozzle 10 can use things other than a column shape or a cone shape. For example, it may be a rectangular parallelepiped or a cube, and a plurality of ejection holes 11, 11,... May be opened at equal intervals on the bottom surface.

  Further, in order to apply the water jet WJ obliquely to the surface of the wooden decorative base material A1, nozzles that generate a plurality of water jets WJ, WJ,... Parallel to each other by injecting high-pressure water from the ejection holes 11, 11,. By tilting the axis O of 10 itself, the plurality of parallel water jets WJ, WJ,... May be obliquely applied to the surface of the wooden decorative base material A1.

  For example, FIG. 9 is an example in which the water jet WJ is obliquely applied to the surface of the wooden decorative base material A1 at a predetermined inclination angle (for example, 45 °), and the nozzle 10 has a cylindrical shape that rotates around the axis O. Around the bottom surface, a plurality of ejection holes 11, 11,... For ejecting high-pressure water in parallel with the axis O are opened at equal angular intervals. In a state where the axis O of the nozzle 10 is inclined with respect to the wooden decorative base material A1, a plurality of parallel high-pressure waters are jetted by jetting high-pressure water from the ejection holes 11, 11,. .., While the wooden decorative base material A1 is inclined with respect to the axis O of the nozzle 10 and moved relatively away from the water jet WJ, for example, so that these water jets WJ, WJ are generated. Are obliquely applied to the surface of the wooden decorative base material A1.

  In this case, it is preferably inclined obliquely so that the elevation angle is 15 to 75 °, preferably 30 to 60 °, with respect to the feeding direction of the base material A1. Furthermore, by setting the jet direction of the water jet WJ inclined obliquely to the same direction as the feeding direction of the base material A1, the water pressure of the water jet WJ is canceled, and it becomes possible to perform processing more preferably.

  When the feeding direction of the base material A1 and the WJ jetting direction of the water jet inclined obliquely are reversed, the effect of being ground increases, so that the processed marks are likely to remain.

  The distance between the nozzle 10 and the surface of the wooden decorative base A1 is preferably about 10 to 100 cm.

  Moreover, as for the injection pressure of the water jet WJ when high pressure water is injected from the nozzle 10, about 5-100 MPa is desirable, and 10-50 MPa is preferable in it. If woody base material A1 is a softwood, it is 10-30 MPa, and if it is a hardwood, it is good to be 20-50 MPa.

  This injection pressure is a pressure set on the apparatus side that generates high-pressure water, and the pressure decreases when the nozzle 10 is injected. If the injection distance from the nozzle 10 (distance to the substrate surface) is, for example, 20 mm, the pressure drops to 20 to 30%, so that the water jet collision pressure when the water jet WJ collides with the substrate surface. Is preferably about 1 (1.5) to 20 (30) MPa, and preferably 2 (3) to 10 (15) MPa.

  The feed rate for moving the wooden decorative base material A1 relative to the nozzle 10 is about 1 m / min to 30 m / min, depending on the tree type of the wooden decorative base material A1 and the water jet injection pressure (water jet collision pressure). Adjust it.

  At that time, the higher the water jet injection pressure (water jet collision pressure), the higher the processing ability to form the defibrating layer 1 on the surface of the wooden decorative base A1, and the relative feed rate of the base A1 is increased accordingly. However, there is a possibility that the uniform defibrating layer 1 is not formed on the surface of the base material A1, and a pattern such as a streak that is deeper than the other part is generated in a specific part thereof. However, such streaks and the like can also be utilized by changing the resin impregnation process described later or obtaining a characteristic appearance design.

  Further, when the surface of the wooden decorative base material A1 is subjected to water jet treatment, it is preferable that the surface of the wooden decorative base material A1 is in a high moisture content state in advance. By doing so, hemicellulose, which is a component of wood, is softened and is easily treated with the water jet WJ, and the water jet treatment can be performed with higher efficiency.

  Furthermore, the surface of the wooden decorative base A1 can be heated (heated) to, for example, 60 ° C. to 80 ° C. with a high water content. Such heating not only further softens hemicellulose, but also softens lignin, which is another component of wood. The softening temperature of this lignin varies depending on the tree species. Water jet treatment can be performed with high efficiency by softening hemicellulose and lignin. The heating condition is preferably a temperature that does not damage the cellulose fibers and softens hemicellulose and lignin. In the water-containing state, the wood surface is 40 to 100 ° C., preferably the wood surface is 60 to 80 ° C. as described above. It is preferable to heat so that it becomes.

  In the case where the surface of the wooden decorative base material A1 is brought into a high water content state or is heated in addition thereto, the following method can be adopted.

  (A) A water jet process is directly performed on the surface of the wooden decorative base material A1.

  (B) Water is applied to the surface of the wooden decorative base material A1 and left for a predetermined time, followed by water curing, followed by water jet treatment.

  (C) Water is applied to the surface of the wooden decorative base material A1 and then left for a predetermined time in a heated state, followed by water jet treatment.

  (D) Apply hot water to the surface of the wooden decorative base material A1, leave it for a predetermined period of time, and then treat it with water jet.

  (E) Steam is sprayed on the surface of the wooden decorative base material A1, and then water jet treatment is performed.

  (F) Water jet treatment is performed with the surface of the wooden decorative base material A1 warmed.

  (G) Water jet treatment with warm water in a state where the surface of the wooden decorative base material A1 is warmed.

  In addition, after making it into a sufficient water-containing state, it may be heated by a heating roll or a high frequency. In this case, a roll having a surface temperature of about 100 to 200 ° C. may be contacted, and heating may be performed in a range that does not damage the cellulose.

  In addition, regarding the water jet equipment, the liquid to be ejected is not limited to water, and alcohol, acetone, and other organic solvents may be used.

(2) Drying step After the defibrated layer 1 is formed on the surface of the wood decorative board intermediate material A2 in this manner, the wooden decorative board intermediate material A2 is dried as shown in FIG. 6 (c). In this drying process, drying is performed by natural drying, a dryer, a hot roll, a hot press, high frequency, or the like.

  Prior to drying, it is preferable that water on the surface of the treated base material A1 and its peripheral portion is previously blown off by, for example, jetting compressed air.

  Moreover, about water jet equipment, when alcohol, acetone, and other organic solvents are used as the liquid to be ejected, the organic solvent sprayed onto the wood base material A1 is volatilized (dried), and is provided with a step of collecting / regenerating. Is preferred.

(3) Resin impregnation step As shown in FIG. 6 (c), the portion of the surface of the wood decorative board intermediate material A2 including the defibrated layer 1 in the defibrated state is impregnated with resin and solidified (WPC treatment). And the resin impregnated layer 2 is formed.

  Specifically, either one of the above-mentioned impregnating resin and filling resin or both resins are applied to the entire surface of the wood decorative board intermediate material A2 treated and dried by the water jet WJ. Apply. For example, the impregnating resin is applied using a sponge roll coater, a natural reverse coater, a flow coater or the like. At this time, since the wood surface is in a sponge state and air is likely to be mixed in the impregnating resin, it is preferable to perform a treatment such as heat curing after impregnation, application of reduced pressure, or the like to remove air in the impregnating resin.

  Thus, the defibrating layer 1 is formed on the surface of the wood decorative board intermediate material A2, and the defibrating layer 1 is in a defibrated state to the extent that at least a part of the wood fibers are microfibrillated. The impregnation property of the resin with respect to the defibrating layer 1 becomes high, and the impregnating resin can penetrate into the interior of the wood decorative board intermediate material A2.

  In this case, the impregnating resin is preferably a resin having a low viscosity and a high impregnation property. Specifically, the impregnating resin preferably has a viscosity of 100 Pa · s or less when applied to the surface of the wooden decorative board intermediate material A2. Thus, the impregnation property can be further improved by making the impregnating resin have a low viscosity. The impregnating resin is adjusted so as to have the above-mentioned viscosity by being diluted with the above-described monomer or heated. Further, for example, by heating the wood decorative board intermediate material A2 so that the surface temperature is 40 ° to 50 ° in advance, and applying the impregnating resin that is 10 ° to 20 ° lower than the surface temperature. The impregnation property of the impregnating resin can be further improved.

  In order to harden or semi-harden the impregnating resin, active energy rays are irradiated from the surface side of the wooden decorative board intermediate material A2. Ultraviolet rays or electron beams are used for the active energy rays.

  When the active energy ray is ultraviolet light, a photopolymerization initiator is added to the impregnating resin. As the photopolymerization initiator, commonly used radical reaction type acetophenone-based, benzophenone-based, benzyl-based, benzoin-based carbonyl compounds, tetraalkylthiuram monosulfide, thioxanthone and other sulfur compounds are used alone or in combination. You may mix and use. However, in order to accelerate the curing of the impregnated resin, those having higher reactivity with respect to ultraviolet rays than the above general photopolymerization initiator are preferable.

  Specifically, as the photopolymerization initiator, the impregnating resin contains bisacylphosphine oxide in an amount of 0.1% by mass to 1.5% by mass, or monoacylphosphine oxide in an amount of 0.5% by mass to 5%. It is preferable to contain 0.0 mass% or less. Bisacylphosphine oxide or monoacylphosphine oxide has an absorption maximum at a long wavelength in which the wavelength region of ultraviolet rays is around 350 nm to 400 nm. Therefore, the impregnating resin can be cured more effectively by using a light emission method having an emission spectrum in a long wavelength region of 350 nm or more and 400 nm or less as a light source that emits ultraviolet rays. Specifically, a discharge lamp type metal halide lamp, an electrodeless type D bulb, a V bulb, a Q bulb, an M bulb, a pulse UV method, or the like is used.

  Further, when the active energy ray is ultraviolet light, an auxiliary agent such as a sensitizer, a light stabilizer, an ultraviolet absorber, or a storage stabilizer may be added to the impregnating resin. Further, coloring may be performed by adding a dye, a pigment or the like to the impregnated resin.

  Further, the filling resin is a resin for filling the concave portion of the surface of the wooden decorative base material A1 processed by the water jet WJ, and is different in that the viscosity is higher than that of the impregnation resin in order to improve the filling property.

  In addition, as the resin, a UV curable resin that can be easily cured online is taken as an example in consideration of productivity. For example, a thermosetting resin such as a melamine resin resin or a phenol resin can be used. May be applied and impregnated and cured by hot pressing, or may be applied and impregnated with moisture curable resin such as isocyanate resin and cured and cured in the presence of moisture, or silicon resin or epoxy resin A two-component cross-linking curable resin such as a resin may be applied and impregnated.

  Further, as another embodiment, the nonflammability of the decorative board A3 is improved by adding, for example, aluminum hydroxide powder or boron-based resin powder to the resin to be applied / impregnated to make the impregnated resin flame-retardant. May be. This is a preferred embodiment because it is impregnated and cured between the wood fibers in the defibrated state and a non-combustible resin layer is formed on the surface of the decorative board A3.

(4) Surface coating layer forming step Thereafter, the coating layer 3 is formed on the surface impregnated with the resin and solidified. Thus, the wooden decorative board A3 is manufactured.

  Therefore, in the above embodiment, the following operational effects can be obtained. The wooden decorative board intermediate material A2 obtained from the wooden decorative base material A1 is defibrated in which the wooden fibers are in a defibrated state by the collision energy of the water jet WJ that collided with the surface of the wooden decorative base material A1 at a high speed. Layer 1 is formed. By such a water jet process, the defibrating layer 1 has a structure as if the defibrated layer 1 is suppressed by removing the wood fibers.

  That is, if the surface of the wooden decorative base material A1 is shot blasted using a hard blasting abrasive such as stone or glass beads, the hard part remains soft on the surface of the resulting wooden decorative board intermediate material. Even if it is effective for strengthening the surface even if WPC treatment is performed by impregnating resin into the recess and solidifying it to form a resin layer, the obtained wood decorative board is obtained. Becomes an artificial WPC appearance in which only the impregnating resin or the filling resin exists in the concave portion of the soft part.

  On the other hand, in the embodiment of the present invention, unlike the shot blast treatment, the defibrating layer 1 on the surface of the wood decorative board intermediate material A2 remains in a state where the fibers of the soft portion of the fibers are also defibrated, The wood fibers become spongy as if they were plowed, and more wood fibers are retained. For this reason, when the WPC treatment in which the portion including the defibrating layer 1 on the surface is impregnated with a resin is solidified, the resin easily enters between the wood fibers in the defibrated state of the defibrating layer 1 and the resin is efficiently used. Can be impregnated. As a result, the WPC-treated wood decorative board A3 has a deep appearance design that is more natural and retains more defibrated fibers on the surface.

  Further, since the coating layer 3 is provided on the surface of the wood decorative board intermediate material A2 including the defibrating layer 1 on the surface where the resin is impregnated and solidified, the surface of the wooden decorative board A3 is the coating layer. 3 and the appearance design of the wooden decorative board A3 can be enhanced.

  Next, specific examples will be described.

(Example 1)
The wood decorative board substrate was used as a hip. Six nozzles having an inner diameter of 0.35 mm are opened at equal intervals in the circumferential direction, and six water jets parallel to each other are generated by water injected from the nozzle holes (see FIG. 7). The distance between the nozzle and the wooden decorative board substrate was 35 mm. Six water jets from the nozzle ejection holes were applied to the surface of the wooden decorative board substrate, and the surface of the wooden decorative substrate was defibrated. When jetted, the water jet spraying pressure was 50 MPa, the flow rate of the high-pressure water was 8.4 L / min, and the feed rate for moving the nozzle and the wooden decorative base material relative to each other was 1.0 m / min.

(Example 2)
The wood decorative board base material is cedar (cedar), and a nozzle in which six ejection holes with an inner diameter of 0.35 mm are opened at equal intervals in the circumferential direction. 20 mm. Six water jets parallel to each other from the nozzle ejection holes were applied to the surface of the wooden decorative board substrate, and the surface of the wooden decorative substrate was defibrated. When jetted, the water jet spraying pressure was 20 MPa, the flow rate of high-pressure water was 5.4 L / min, and the feed rate for moving the nozzle and the wooden decorative base material relative to each other was 1.0 m / min.

(Example 3)
A wood decorative board base material is pine (pine), and nozzles with six nozzle holes with an inner diameter of 0.35 mm are opened at equal intervals in the circumferential direction. 20 mm. Six water jets parallel to each other from the nozzle ejection holes were applied to the surface of the wooden decorative board substrate, and the surface of the wooden decorative substrate was defibrated. When jetted, the water jet spraying pressure was 50 MPa, the flow rate of the high-pressure water was 8.4 L / min, and the feed rate for moving the nozzle and the wooden decorative base material was 2.0 m / min.

(Example 4)
A wooden decorative board base material is used as a cedar, and six ejection holes with an inner diameter of 0.35 mm are opened at equal intervals in the circumferential direction, and the radial 6 is inclined by 15 ° with respect to the axis by the water ejected from the ejection holes. A nozzle (see FIG. 8) that generates two water jets was used, and the distance between the nozzle and the woody decorative board substrate was 90 mm. Six inclined water jets from the nozzle ejection holes were applied to the surface of the wooden decorative board substrate, and the surface of the wooden decorative substrate was defibrated. At this time, the water jet hits the surface of the wooden decorative base material at an inclination angle of 75 °. When jetted, the water jet spraying pressure was 40 MPa, the flow rate of high-pressure water was 7.8 L / min, and the feed rate for relative movement of the nozzle and the wooden decorative base was 5.0 m / min.

  In any of Examples 1 to 4, the surface of the wooden decorative base material was in a defibrated state, and a defibrated layer could be formed on the surface. And the wooden decorative board which impregnated resin to this surface defibration layer and WPC-treated, and provided the coating film layer on the surface has a deep appearance design that is superior to nature and has a more natural appearance. Became.

  The present invention forms a defibrated layer with more wood fiber original shapes on the surface, and can efficiently impregnate resin between the wood fibers in the defibrated state. Since a wooden decorative board with a WPC appearance having an excellent deep appearance design is obtained, it is extremely useful and has high industrial applicability.

A1 Wood decorative base material A2 Wood decorative board intermediate material A3 Wood decorative board 1 Defibration layer 2 Resin impregnation layer 3 Coating layer WJ Water jet 10 Nozzle 11 Ejection hole

Claims (4)

  A wood decorative board intermediate material having a defibrated layer on a surface where wood fibers are in a defibrated state by the impact energy of a water jet colliding at high speed. In claim 1,
The defibrating layer is in a defibrated state to such an extent that at least a part of the surface wood fibers are microfibrillated.   A wood decorative board, wherein a resin including the defibrated layer of the wood decorative board intermediate material of claim 1 or 2 is impregnated and solidified. In claim 3,
A wooden decorative board characterized in that a coating layer is provided on a surface impregnated and solidified with a resin.