JP2749441B2 - Method of manufacturing large wood unit panel - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a woody large-sized unit panel. More particularly, the present invention relates to a method for manufacturing a high-performance and inexpensive large-sized wooden unit panel useful as a wall or a ceiling panel of a Japanese-style bathroom.

(Prior Art) Conventionally, warm and warm Japanese-style bathrooms have often been constructed. For example, as shown in FIG. 4, a bathroom wall (a) where a bathtub (a) is arranged is provided. ) And the ceiling (U) are known to be made of wood material such as cypress.

In the construction of such a Japanese-style bathroom, usually, solid wood of cypress or cypress-like coniferous wood, or composite board of cypress veneer and other board material, waterproof, antiseptic, ant-proof, mold-proof treatment, for example It was configured to be processed to a thickness of 5 to 20 mm and a width of 100 to 150 mm and then directly spliced at the site, or spliced, and then spliced while fixing to the base by needle driving or the like.

As another method, a joint panel is manufactured using solid wood of cypress or cypress-like softwood or a dimensional stabilizing material, and this is used as a room unit wall or ceiling surface material.

(Problems to be Solved by the Invention) However, in these conventional bathroom constructions, in the case of the former method of directly joining plate materials or fixing them as on-site construction by actual joining, dimensional adjustment and water supply are not possible. There are many parts left to the construction site in terms of closing, etc.
In practice, walls (a) and ceilings (c) as shown in FIG.
Furthermore, in the process of installing and installing the shower (d), mirror (e), lighting (f), etc., there is a problem that dimensions and water work are necessarily defective, and the waterproofness and durability are not sufficient. there were. In addition, in this method, it takes a long time to perform the construction, and there is a great limitation in improving the workability.

Also, in the latter conventional method of using panels, it is necessary to reduce the thickness of the panel to about 20 to 30 mm from the aspect of maintaining the strength of the panel, and if it is attempted to form a straight-grained homogeneous material,
Uneasiness remained in the stable supply of components, and inevitably increased costs.

The present invention has been made in view of the above circumstances, is excellent in performance such as water resistance, excellent in workability and easy to work, and using a homogeneous material that can be obtained relatively stably, It is an object of the present invention to provide a new method for manufacturing a large-sized wooden unit panel which can form a wall surface and a ceiling surface at low cost.

(Means for Solving the Problems) According to the present invention, there is provided a method for manufacturing a woody large-sized unit panel, comprising joining and bonding a plurality of wood veneers to an alkali-sealed inorganic substrate. I will provide a.

The method of the present invention is for producing a large-sized unit panel whose configuration can be exemplified in FIG. 1, for example. This wooden large-sized unit panel (1) is formed by joining a plurality of wooden veneers (2). This is bonded to an alkali-sealed inorganic substrate (3). In the case of this example, a joint reinforcing frame (4) for mutual joining and attachment between the frames is mounted on the back surface of the inorganic substrate (3).

For the wood veneer (2) as the surface material, for example, cypress or cypress-like softwood is used, having a thickness of 2 to 3 mm and a width of 100 mm.
It is used as about 130 mm, and about 6 to 8 pieces can be bonded to the substrate (3) per unit panel.

This veneer may be used as a veneer,
Alternatively, as shown in FIG. 1, a plurality of types of veneer members (2a) and (2b) may be laminated and used. Further, in order to improve the water resistance durability required for a bathroom panel, a water-resistant resin is required for the veneer (2).
For example, melamine resin, urethane resin, acrylic resin,
It is preferable to impregnate a polyester resin or the like to improve water resistance, dimensional stabilization, preservation, and mold resistance. Of course, this processing may be omitted depending on the required quality.

Various types can be used for the alkali-sealed inorganic substrate (3) for bonding the veneer (2), but it is preferable to use a member that is strong, inexpensive, and easily available. Can be selected.

As such an inorganic substrate (3), for example, an asbestos slate plate or a calcium silicate plate can be exemplified. A substrate having a thickness of about 3 to 5 mm and a width of about 800 to 900 mm can be used. Of course, these are not limiting.

When such an asbestos slate plate or calcium silicate plate is used, an alkali seal coating is performed on the bonding surface with the veneer (2) in order to prevent alkali contamination of wood such as the veneer (2). Further, it is preferable to apply a water-resistant coating on the back surface in order to prevent the transfer of moisture and moisture. An acrylic or urethane paint can be applied to the alkali seal. In addition, a water-resistant adhesive is used for bonding.

When the frame (4) for mounting the inorganic substrate (3) is used, it is preferable to use a lightweight and high-strength material such as a metal such as aluminum or FRP.
Or other reinforced plastics, as well as other lightweight composites. This frame (4) maintains and improves the strength of the panel (1),
This is effective in facilitating installation on the underground.

Attachment of the inorganic substrate (3) to the frame (4) can be performed by various means, such as clamping and fitting of the inorganic substrate (3) by the periphery of the frame (4), or attachment by other joining means, and further. May be formed by bonding or the like. At the time of mounting, the adhesive between the protruding plate (2) and the inorganic substrate (3) is adjusted to a predetermined size and subjected to a member mounting process.

Of course, in the panel of the present invention, the veneer (2)
The surface of the is preferably subjected to treatment for imparting stain resistance, weather resistance, and water resistance, for example, a coating thickness of 30 to 80 μm.
At about m, a weather resistant paint is applied.

Further, after bonding the veneer plate (2), a groove (5) may be dug at the joint of the veneer plate (2) to form a joint. This joint also improves the design of the surface.

(Function) The large-sized panel of the present invention adheres a wood veneer to a substrate,
In addition, since this substrate can be mounted on a frame, dimensional adjustment, water closing, and the like are good, and strength and construction workability are also excellent. For this reason, it becomes possible to easily configure the walls and ceiling of a Japanese-style bathroom having excellent water resistance and good workability.

In addition, since this panel can be compositely configured with inexpensive and easily available veneers, substrates, and the like, it is possible to configure a uniform, low-cost wall and ceiling surface.

(Example) Next, with reference to the attached drawings, a method of manufacturing a woody large-sized unit panel of the present invention will be described in detail by examples.

Example 1 As shown in FIG. 2, (a) First, as surface veneers (12a) and (12b), hinoki veneer 0.5mm (thickness) x 100mm (width) x 1800mm (length)-rice Prepare a cypress veneer 2.0 mm (thickness) x 100 mm (width) x 1800 mm (length), and bond with a water-resistant adhesive such as vinyl urethane adhesive.

Next, this plate material is impregnated with a methylolmelamine resin and an acid catalyst, and is cured by high-frequency heating and drying. The impregnation rate is 20-40%. The impregnation is performed as a reduced pressure impregnation process.

On the other hand, asbestos cement board as inorganic substrate (13), 3.
Prepare 0mm (thickness) x 800mm (width) x 1800mm (length),
An acrylic urethane-based paint having a thickness of about 60 μm is applied to each of the front and back surfaces.

Eight pieces of the adhesive protruding plates (12) are joined to the painted inorganic substrate (13) and bonded with a water-resistant adhesive.

(B) A groove (15) is formed in the joint part of the veneer veneer by digging.

Next, a weather-resistant and water-resistant paint having a coating thickness of about 50 μm is applied to the surface and the groove (15).

(C) The laminated plate of the veneer (12) and the inorganic substrate (13) coated with the surface and the groove (15) obtained by the above process is:
After adjusting by cutting etc. so as to have the predetermined dimensions,
Attach and adhere to the frame (14).

The characteristics of the woody large-sized unit panels obtained by the above steps (a), (b) and (c) were extremely excellent as follows.

<Repeated dry / wet surface test> 30 ° C, 60% RH (dry) and 40 ° C, 95% RH (humid)
A dry / wet repetitive test was repeated for 10 cycles in which each of them was held for 24 hours under the above conditions, and the warpage (central portion in the longitudinal direction) of the panel surface was evaluated. The result was only within 3mm.

As a comparison, in the case of a panel not painted on the front and back surfaces, the warpage reached a maximum of 9 mm.

Further, no mold or the like was generated in the groove in the panel of the above example.

<Long-term high-temperature high-humidity test> The panel was kept in an atmosphere of 60 ° C. and 95% RH for 2400 hours, but no discoloration or deterioration of the panel occurred. No alkali contamination of the hinoki wood was observed.

On the other hand, when alkali sealing was not performed, discoloration was remarkable.

Also, as in this embodiment, when a thin veneer and a relatively thick veneer are stuck and bonded to a substrate,
Even if the hinoki material on the surface is as thin as 0.5 mm or less, there is no reflection of the base,
Moreover, the surface material alone did not crack.

For this reason, it is only necessary to use a relatively expensive wooden material as a thin surface material, and an extremely inexpensive wall / ceiling panel is realized. Workability is also good.

Example 2 As shown in Fig. 3, (a) First, as surface veneers (12a) and (12b), hinoki veneer 1.0mm (thickness) x 100mm (width) x 1800mm (length)-spruce Prepare veneer 1.5mm (thickness) x 160mm (width) x 1800mm (length). In addition, calcium silicate plate,
Using 3.0mm (thickness) x 800mm (width) x 1800mm (length)
Acrylic urethane-based paint is applied to both surfaces and sealed with alkali, and the five spruce veneers (12b) are attached to the opposite side of the painted surface using a urethane-based water-resistant adhesive.

Thereafter, eight cypress protrusions (12a) are bonded to the surface of the sprue veneer (12b). Also in this case, a water-resistant adhesive is used.

(B) After the bonding is completed, a groove is dug in the joint portion of the cypress veneer (12a) to form a joint groove (15).

A weather-resistant water-resistant paint is applied to the surface of the cypress veneer (12a) and the groove (15).

At this time, it is also effective to mix a fungicide, for example, about 5% of an iodine-based fungicide in the paint.

(C) A frame (14) is adhered to the back surface of the substrate (13) in the same manner as in the first embodiment to complete a large-sized wooden unit panel.

The unit panel manufactured in this manner is the same as that of the first embodiment.
As well as having excellent characteristics,
Even if the groove (15) is formed in the seam of a), there is also an advantage that the seam of the spruce veneer (12b) is not exposed on the surface.

Therefore, in this embodiment of FIG. 3, the pattern of the spruce veneer (12b) is the same as or similar to that of the cypress veneer (12a), so that the wall or ceiling has a seamless and beautiful appearance. The surface is configured.

Also, since the thickness of the cypress veneer is 1 mm, the seam of the base spruce veneer (12b) does not appear on the surface.

(Effects of the Invention) According to the present invention, as described in detail above, 1) a large format useful as a Japanese-style bathroom wall, ceiling material, etc., which is excellent in characteristics such as water resistance and strength, has no alkali pollution, and has good workability. A wood panel is provided.

2) Since the material of this panel is easily available and an inexpensive homogeneous material can be used, low-cost construction is possible.

[Brief description of the drawings]

FIG. 1 is a perspective view illustrating a woody large-sized unit panel of the present invention. 2 and 3 are cross-sectional views illustrating the steps for manufacturing the panel of the present invention. FIG. 4 is a perspective view illustrating a Japanese-style bathroom. DESCRIPTION OF SYMBOLS 1 ... Large-sized wooden unit panel 2 ... Veneer 2a, 2b ... Veneer material 3 ... Inorganic substrate 4 ... Joint reinforcement frame 5 ... Groove 12a, 12b ... Veneer 13 ... Inorganic substrate 14 ... Frame 15 ... Groove

Claims (4)

(57) [Claims] 1. A method for manufacturing a large-sized wooden unit panel, comprising bonding a plurality of wooden veneers to an inorganic substrate which has been subjected to alkali sealing. 2. A method for manufacturing a woody large panel according to claim 1, wherein a bonding reinforcing panel is mounted on the back surface of the substrate. 3. A method for producing a woody large-sized unit panel according to claim 1, wherein the surface of the veneer and / or the backside of the substrate are subjected to weather-resistant and water-resistant coating. 4. The method according to claim 1, wherein the bonding is performed with a water-resistant adhesive.
Or (2) a method for producing a woody large-sized unit panel.