JP2017511266A - 複合ボード及びパネル - Google Patents
複合ボード及びパネル Download PDFInfo
- Publication number
- JP2017511266A JP2017511266A JP2016558320A JP2016558320A JP2017511266A JP 2017511266 A JP2017511266 A JP 2017511266A JP 2016558320 A JP2016558320 A JP 2016558320A JP 2016558320 A JP2016558320 A JP 2016558320A JP 2017511266 A JP2017511266 A JP 2017511266A
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- Prior art keywords
- layer
- core
- particles
- thermoplastic
- surface layer
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Abstract
Description
このカテゴリーのフローリングは、例えば、メラミン・ホルムアルデヒド(MF)樹脂、ユリア・ホルムアルデヒド(UF)樹脂、又はフェノール・ホルムアルデヒド(PH)樹脂が主に木質繊維と混合された後、分離コア又は表面層が形成され得るように加熱及び加圧下で硬化されることを特徴としている。
全てのラミネートフロアの多くは木質デザインを有している。このようなラミネートフロアは、6−12mmの繊維ボードからなるコアと、0.2mm厚さの上側装飾表面ラミネート層と、0.1−0.2mm厚さの下側釣合層と、を有している。装飾及び摩耗性は、一般に、紙に含浸させたメラミン・ホルムアルデヒドからなる上下の2つの別々の層(装飾層、及び摩耗層)により得られる。装飾層は印刷紙であり、摩耗層は、小さい酸化アルミニウム粒子からなる透明なオーバーレイ紙である。コアは、通常、木質繊維と、MF樹脂とUF樹脂の混合体とからなる高密度繊維ボード(HDF)である。装飾紙とオーバーレイ紙は、熱間−熱間製法により、高温圧力下(170℃、40bar)でHDFに直接ラミネートされる。熱間−熱間プレスは、一般に、プレステーブルが開放温度と本質的に同一の閉鎖温度(例えば、約10℃内)を有するプレス法を指す。熱間−熱間プレスは非常にコスト効率が良い。なぜならば、プレステーブルを冷却する必要がなく、冷却は高温で硬化する熱硬化ベース表面の直接的なラミネート工程においてのみ利用され得るからである。このような表面は、コアの水分から蒸気を吸収可能な熱硬化性樹脂と100℃を超える高いプレス温度において形成された表面層とからなる比較的厚いコア材料コアにラミネートされる。
近年、新しい種類の「ペーパーフリー」フロアが開発されている。このフロアは、実質的に均一な繊維混合粉体と、バインダと、耐摩耗性粒子とからなる頑丈な表面を有し、以下でWFF(木質繊維フロア)と称する。
このカテゴリーのフローリングは、例えばポリ塩化ビニル(PVC)、ポリプロピレン(PP)又はポリエチレン(PE)等の熱可塑性材料を、鉱物繊維又は木質繊維と混合させることを特徴としている。最終プレスは、例えばラミネート製造時に通常用いられるよりも低い圧力下で、熱間−冷間プレス方法を用いてなされる。温度は略同様であって、約140−160℃である。熱可塑性材料は高温で融解し、硬化は起こらない。したがって、プレステーブル又はベルトを、熱可塑性層が流動性ペーストから固体層へと変換するように、100℃未満に冷却する必要がある。圧力下において加熱及び冷却することにより、別々の熱可塑性層が、ともに融合又はラミネートされ得る。
一般にLVTフローリングと呼ばれる高級ビニルタイルは、鉱物充填剤や着色顔料及び可塑剤に混合された、一般にビニルと呼ばれるPCV等の熱可塑性材料からなる積層製品として構成されるのが一般的である。LVTフロアの多くは木質デザインを有する厚板サイズであるため、LVTという名称は幾分誤解を招きやすい。LVTフロアは、ビニルでないプラスチック材料からも構成され得る。LVTは、流動的な態様で係止システムにより設置され得る高品質な弾性フロアに対する通称となっている。
木材粒子と混合された熱可塑性材料からなる木材プラスチック複合材(WPC)パネルは、数種の業界において長年にわたって押出セクションや射出成形に使用されている。近年、厚板サイズのWPC床パネルが、主にデッキとしてアウトドアに使用されるものとして開発されている。PVC又はPP等の熱可塑性材料が、おがくず又は木片状の木材に、木材粒子重量(wt)において約50%乃至80%で混合されている。室外で使用されることが意図されている製品は、50wt%以下の木材粒子からなり得る。室内で使用されることが意図されている製品における木材含有量は70wt%を超えてもよい。加工方法は、LVT床を製造するための方法と同様である。第1段階において木質繊維粒子とプラスチック粒子が加熱及び加圧下で互いに混合されてプラスチックタブレットにされ、次いで押出機に供給される2段階工程が利用され得る。繊維やプラスチック細粒を、押出中に直接混合してもよい。或いは、混合プラスチックタブレットをベルト上に散布して、上述のように加熱及び冷却部を備えた連続二重ベルトプレスにおいてWPCシートにプレスしてもよい。装飾性は、木材/プラスチック混合体に含まれる顔料によって主に得られる。また、WPCパネルは、印刷、塗装又は箔打ちされてもよい。
熱可塑性材料と熱硬化性材料とを組み合わせることも可能である。熱可塑性LVT層が、例えばHDFコアやWPCコアに接着され得る。
以下において、設置された床パネルの目に見える表面を「前側又は上側」と称し、床パネルの逆側であって下地床に面する側を「後側又は下側」と称する。
上述の床の特性やコスト構造を改良することを目的とする産業により開発された一般技術について以下に説明する。本発明の実施形態によるボード及びパネルを作製するために、これらの方法は本発明の好適な実施形態と部分的又は全体的に様々に組み合わせられ得る。
・紛体形状の木材粒子と紛体形状の熱可塑性粒子とからなる乾燥混合物を含むマット形状層を形成し、プレス後にシートが形成されるように、前記マット形状層を圧力下において加熱及び冷却することによりコアを提供する工程と、
・木材粒子と熱硬化性樹脂とからなる混合紛体を含む表面層を前記コア上に設ける工程と、
・紛体ベースの前記表面層を熱間−熱間プレス操作において前記コアにラミネートして建物用パネルを形成する工程であって、前記表面層の前記木材粒子と前記コアの前記木材粒子とが硬化した熱硬化性樹脂によって互いに結合される工程と、を備えている。
・熱硬化性樹脂からなる表面層の水分移動を管理可能とするために、WPPコア材料の水分移動を従来のWPCボードに比較して大幅に増大させた。これは、木質繊維と熱可塑性紛体との乾燥混合物をベースとするコアであって、プレス後に、高い湿潤状態においてコアに水分が浸透可能となるが乾燥状態において水分が蒸発可能となるような材料特性を有するコアによって達成された。
・好適には、熱硬化性樹脂と木質繊維とからなる紛体ベースの表面層のプレス中及び室温への冷却中の水分移動及び収縮を減少させるとともに、例えば紛体層に熱可塑性粒子を含ませることによって層の可撓性を増大させた。紛体形状の熱硬化性樹脂と紛体形状の熱可塑性粒子は、これらが両方のタイプのプラスチックに結合する木質繊維に混合された場合に、結合可能となるであろう。
・WPPコアは、表面層が当該コアに熱間−熱間加工において直接ラミネートされ得るように構成されている。紛体形状の小さい木材粒子と紛体形状の熱可塑性粒子との乾燥混合物からコアを形成することにより、これらが加熱により互いにプレスされるときにマトリクス材が形成される。マトリクス材は、多量のフリーな被覆されていない繊維をコアの表面部分に有しており、これは、熱硬化性樹脂からなる表面層の熱可塑性材料からなるコアに対する強力な結合を提供するように利用され得る。
Claims (33)
- 建物用パネル(1)を製造する方法であって、
・紛体形状の木材粒子(20)と紛体形状の熱可塑性粒子(21a)とからなる乾燥混合物(25)を含むマット形状層を形成し、プレス後にシートが形成されるように、前記マット形状層を圧力下において加熱及び冷却することによりコア(5)を提供する工程と、
・木材粒子(20)と熱硬化性樹脂とからなる混合紛体を含む表面層(4)を前記コア(5)上に設ける工程と、
・紛体ベースの前記表面層(4)を熱間−熱間プレス操作において前記コア(5)にラミネートして建物用パネル(1)を形成する工程であって、前記表面層(4)の前記木材粒子(20)と前記コア(5)の前記木材粒子(20)とが硬化した熱硬化性樹脂によって互いに結合される工程と、
を備えた方法。 - 前記表面層(4)は熱可塑性材料(21)を含む、
請求項1に記載の方法。 - 前記熱硬化性樹脂は、例えば、メラミン・ホルムアルデヒド樹脂、ユリア・ホルムアルデヒド樹脂、フェノール・ホルムアルデヒド樹脂、又はこれらの組合せからなるアミノ樹脂である、
請求項1又は2に記載の方法。 - 前記乾燥混合物(25)の前記熱可塑性粒子(21a)は、ポリ塩化ビニル(PVC)、ポリプロピレン(PP)、又はポリエチレン(PE)を含む、
請求項1乃至3に記載の方法。 - 前記乾燥混合物(25)の前記熱可塑性粒子(21a)は、約0.3mm以下の平均粒子径を有している、
請求項1乃至4のいずれか一項に記載の方法。 - 前記表面層(4)は、上下に配設された2つの層(3、2)として設けられ、これら2つの層(3、2)のうちの上側層(2)は、漂白セルロース繊維と熱硬化樹脂とを含む、
請求項1乃至5のいずれか一項に記載の方法。 - 前記コア(5)の前記木材粒子(20)を、前記コアを提供する工程に先立って、水分含有量が約2%以下になるように乾燥させる、
請求項1乃至6のいずれか一項に記載の方法。 - 前記コア(5)の前記木材粒子(20)を、前記表面層を設ける工程に先立って、1.0mm以下の平均寸法となるようにふるい分けする、
請求項1乃至7のいずれか一項に記載の方法。 - 前記コア(5)における前記木材粒子(20)の含有量は、約30−80wt%の範囲である、
請求項1乃至8のいずれか一項に記載の方法。 - 前記コア(5)は、20バール未満の圧力を用いて形成される、
請求項1乃至9のいずれか一項に記載の方法。 - 前記熱可塑性材料(21)は、前記表面層(4)の前記混合紛体に含まれているとともに熱可塑性粒子(21a)を含み、
前記熱可塑性粒子は約0.2mm以下の平均寸法を有している、
請求項2乃至10のいずれか一項に記載の方法。 - 前記表面層(4)の前記木材粒子(20)は、前記コア(5)の前記木材粒子(20)より小さい、
請求項1乃至11のいずれか一項に記載の方法。 - 前記コア(5)は、中間層(5b)と上側層(5a)とを備え、
前記中間層(5b)は、前記上側層(5)よりも多量の熱可塑性材料(21)を含む、
請求項1乃至12のいずれか一項に記載の方法。 - 前記中間層(5b)は、更に石灰岩粒子を含んでいる、
請求項13に記載の方法。 - 前記表面層(4)は、熱硬化性樹脂と、酸化アルミニウム粒子(22)等の耐摩耗性粒子と、好適には漂白セルロース繊維(20)であるセルロース繊維と、を含む透明摩耗層(2)を備えている、
請求項1乃至14のいずれか一項に記載の方法。 - 前記透明摩耗層(2)の前記熱硬化性樹脂は、例えば、メラミン・ホルムアルデヒド樹脂、ユリア・ホルムアルデヒド樹脂、フェノール・ホルムアルデヒド樹脂、又はこれらの組合せからなるアミノ樹脂である、
請求項15に記載の方法。 - コア(5)と表面層(4)とを備えた建物用パネル(1)であって、
前記コア(5)は、熱可塑性材料(21)と木材粒子(20)との混合体を含み、前記表面層(4)は、硬化した熱硬化性樹脂により互いに結合された木材粒子(20)をもつ複合材料を含み、
前記表面層(4)は、前記コア(5)に前記硬化した熱硬化性樹脂により結合されている、
建物用パネル。 - 前記熱硬化性樹脂は、例えば、メラミン・ホルムアルデヒド樹脂、ユリア・ホルムアルデヒド樹脂、フェノール・ホルムアルデヒド樹脂、又はこれらの組合せからなるアミノ樹脂である、
請求項17に記載の建物用パネル。 - 前記表面層は、熱可塑性粒子(21a)を更に含んでいる、
請求項17又は18に記載の建物用パネル。 - 前記コア(5)の前記熱可塑性材料(21)は、PVC、PP、又はPEを含む、
請求項17乃至19に記載の建物用パネル。 - 前記表面層(4)は、約0.2mm以下の寸法を有する熱可塑性粒子(21a)を含む、
請求項19及び20のいずれか一方に記載に建物用パネル。 - 前記表面層(4)の前記木材粒子(20)は、前記コア(5)の前記木材粒子(20)の平均寸法より小さい平均寸法を有している、
請求項17乃至21のいずれか一項に記載の建物用パネル。 - 前記建物用パネル(1)は床パネルである、
請求項17乃至22のいずれか一項に記載の建物用パネル。 - 一対の対向する端部が、突出ストリップ(7)を備えた機械的係止システムを有するように形成され、
前記突出ストリップ(7)は、木材粒子(20)と熱可塑性材料(21)とを含む、
請求項17乃至23のいずれか一項に記載の建物用パネル。 - コア(5)と、表面層(4)と、機械的係止システムを備えた少なくとも2つの対向する端部(1a、1b)とを有する建物用パネル(1)であって、
前記機械的係止システムは、垂直方向係止を行うさね部(10)及び溝部(9)と、一方の端部に設けられた係止要素(8)を有する突出ストリップ(7)及び前記係止要素(8)と協働して水平方向係止を行う他方の端部に設けられた係止溝部(14)とを備えた建物用パネルにおいて、
前記コア(5)は、3つの材料層(5a、5b、5c)を備え、
各層(5a、5b、5c)は、熱可塑性材料(21)と充填剤とを含み、
上側層(5a)及び下側層(5c)は、木材粒子からなる充填剤を含み、
中間層(5b)は、鉱物粒子(24)からなる充填剤を含む、
建物用パネル。 - 前記ストリップ(7)と前記係止要素(8)は、前記下側層(5c)に形成されている、
請求項25に記載の建物用パネル。 - 前記突出ストリップ(7)と、前記係止要素(8)と、前記係止溝部(14)は、前記下側層(5c)に形成されている、
請求項25又は26に記載の建物用パネル。 - 前記建物用パネル(1)は床パネルである、
請求項25乃至27のいずれか一項に記載の建物用パネル。 - 前記建物用パネルは、木材粒子(20)と熱硬化性樹脂とを含む表面層(4)を備えている、
請求項25乃至28のいずれか一項に記載の建物用パネル。 - 上面(11)と、下面(12)と、前記上面(11)と前記下面(12)との間に配置された中間部(13)とを備えたボード(1’)であって、
前記中間部(13)は、熱可塑性材料(21)に埋設された木材粒子(20)を含み、
前記上面(11)は、熱硬化性樹脂に結合するのに適した基本的に未加工の木材粒子(20)を含む、
ボード。 - 前記本質的に未加工の木材粒子(20)は、前記上面(11)を越えて突出している、
請求項30に記載のボード。 - 前記熱可塑性材料(21)は、ポリ塩化ビニル(PVC)、ポリプロピレン(PP)、又はポリエチレン(PE)を含む、
請求項30又は31に記載の方法。 - 前記上面(11)における前記木材粒子(20)の平均寸法は、約0.1−1.0mmである、
請求項30乃至32のいずれか一項に記載のボード。
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BR112016021957A2 (pt) | 2017-08-15 |
JP6538069B2 (ja) | 2019-07-03 |
US20210129485A1 (en) | 2021-05-06 |
US20150343739A1 (en) | 2015-12-03 |
CN106103096B (zh) | 2018-08-24 |
CL2016002334A1 (es) | 2017-03-03 |
KR102329746B1 (ko) | 2021-11-19 |
WO2015152802A1 (en) | 2015-10-08 |
US20170120558A1 (en) | 2017-05-04 |
EP3126145A1 (en) | 2017-02-08 |
MY178456A (en) | 2020-10-13 |
MX2016012477A (es) | 2017-05-04 |
CN109130438A (zh) | 2019-01-04 |
US9573343B2 (en) | 2017-02-21 |
CN109109430A (zh) | 2019-01-01 |
EP3126145B1 (en) | 2020-08-26 |
KR20160138157A (ko) | 2016-12-02 |
US20190248108A1 (en) | 2019-08-15 |
BR112016021957B1 (pt) | 2021-08-17 |
EP3126145A4 (en) | 2017-11-29 |
CN109130438B (zh) | 2021-05-07 |
US10967608B2 (en) | 2021-04-06 |
US11541630B2 (en) | 2023-01-03 |
CN106103096A (zh) | 2016-11-09 |
EP3760438A1 (en) | 2021-01-06 |
CN109109430B (zh) | 2021-05-07 |
HRP20201474T1 (hr) | 2020-12-11 |
US10307984B2 (en) | 2019-06-04 |
PL3126145T3 (pl) | 2021-01-11 |
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