JP3017598B2 - Manufacturing method of decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative board in which a wooden veneer is bonded and integrated on a wooden substrate, and at the same time, a synthetic resin liquid is rapidly impregnated and cured in the wooden veneer. is there.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a decorative board obtained by laminating a synthetic resin-impregnated veneer on a wooden board and integrating the same, for example, as described in Japanese Utility Model Publication No. 60-28610, Wood veneer is integrally laminated on the board,
After bonding, apply and impregnate a synthetic resin liquid on the veneer,
There are known a method of curing, a method of impregnating a wooden veneer with a synthetic resin liquid and curing it to form a decorative veneer, and bonding and integrating the decorative veneer on a wooden substrate.

[0003]

However, according to the former method, the replacement of the air inside the veneer with the synthetic resin liquid is not successful due to the viscosity and the like simply by applying the synthetic resin liquid on the wood veneer. As a result, the synthetic resin liquid could not be sufficiently impregnated into the interior of the veneer, and the surface layer seemed to be treated at first glance, but the interior was not sufficiently impregnated. In the latter method, a problem arises in terms of strength, and in the latter method, a synthetic resin liquid is once injected into a veneer veneer, subjected to a curing treatment, and then adhered to a wooden substrate, The interior of the veneer can be sufficiently impregnated, but the workability is poor and it takes a long time to produce,
There was a problem that it was not suitable for mass production.

On the other hand, in order to improve the productivity, an adhesive and a synthetic resin liquid are sequentially applied on a wooden substrate, and then the wooden veneers are overlapped and subjected to a heat and pressure treatment. A method of bonding and integrating the wood veneer and the wood substrate simultaneously with the impregnation of the resin has been developed. However, there is a possibility that the hardening of the synthetic resin liquid may progress by the time of hot pressing after the preparation of the synthetic resin liquid. In addition, there is a case where the synthetic resin liquid is impregnated on the wooden substrate side at the time of hot pressing, or the synthetic resin liquid impregnated on the wood veneer flows out of the wood veneer due to its good fluidity. There is a problem that the impregnation amount is reduced due to a situation, and desired strength and cosmetic properties cannot be obtained. An object of the present invention is to provide a method of manufacturing a decorative board that can completely solve such a problem.

[0005]

The conditions required to achieve the above object are that the wood veneer is sufficiently impregnated with the synthetic resin solution and that the impregnated synthetic resin solution flows out of the wood veneer. It is to cure without doing. Accordingly, in the method for manufacturing a decorative board of the present invention, first, an adhesive is applied onto a wooden substrate, and then the adhesive is formed into a film by heating or other means. The film formation means a state in which a film-like layer is formed by polymerization, drying or the like, but has an adhesive property.
Next, on the film forming adhesive layer, a wood unit is applied through a coating layer of an addition polymerization type synthetic resin liquid having a viscosity of 200 to 30,000 cps and a viscosity at a hot press temperature of 100 cps or less. Laminate the boards, reduce the resin viscosity by heating and pressurizing in the range of 100-140 ° C, impregnate the wood veneer with the synthetic resin liquid, harden it, glue the wood veneer on the wood substrate, It is characterized by being integrated.

In the above method, an addition polymerization type synthetic resin solution may be applied to the surface of the veneer as described in claim 2. Further, as described in claim 3, It is desirable that the kick-off temperature of the initiator added to the addition polymerization type synthetic resin liquid is 100 ° C. or less.

[0007]

[Function] Since an adhesive layer formed on a wooden substrate is provided, a single wood plate is laminated on the adhesive layer via a synthetic resin liquid having an appropriate coating thickness and subjected to a heat and pressure treatment. Is prevented by the adhesive film-forming layer from being absorbed by the wood substrate, and penetrates intensively toward the wood veneer. At this time, the viscosity of the synthetic resin liquid is reduced by heating, the flowability is increased, and the impregnated wood veneer is easily impregnated. Hardens without spilling from

[0008]

Next, an embodiment of the present invention will be described in detail. Referring to FIG. 1, first, an adhesive is applied to the entire upper surface of a wood substrate 1 such as a plywood, a particle board, or a hard board having an appropriate thickness. The adhesive is formed into a film by an appropriate means such as heating to form a film-forming adhesive layer 2 having a thickness of 30 μ or more.

As a method of forming an adhesive, vinyl acetate,
In the case of an aqueous emulsion adhesive such as a vinyl acetate-acrylic copolymer, after application onto the wooden substrate 1, moisture in the adhesive is removed by heating or other means, and the emulsion is destroyed to promote polymerization. And the adhesive layer 2 formed into a film. In the case of a solvent-based adhesive such as diallyl phthalate (DAP) or polyester, for example, a polyester-based adhesive forms a film-forming adhesive layer 2 by partially performing a copolymerization reaction between a resin and styrene. In the case of a non-solvent type adhesive such as epoxy, the film-forming adhesive layer 2 is formed by semi-curing. It is necessary to use an adhesive that does not dissolve in the synthetic resin liquid 3 applied on the film-forming adhesive layer 2 as such an adhesive.

Next, 200 to 3 are placed on the film-forming adhesive layer 2.
A desired amount of an addition polymerization type synthetic resin liquid typified by an unsaturated polyester resin having a viscosity of 000 cps is applied to form a synthetic resin liquid layer 3, and a wood veneer 4 is laminated on the synthetic resin liquid layer 3. I do. Oak veneer, oak,
Tree species such as hippopotamus, sen, and ash, which are sufficiently dried, are not suitable for a single veneer that is too thick to allow the synthetic resin liquid to completely penetrate into the interior from the bottom side. It is generally preferable to use a material having a thickness of about 0.3 to 1.5 mm.

The thickness of the synthetic resin liquid layer 3 to be applied varies depending on the kind and thickness of the wood veneer 4, but it is generally sufficient if the amount is sufficiently impregnated in the wood veneer 4. The applied resin liquid needs to have a certain range of viscosity. That is, it is necessary that a sufficient amount is applied on the wooden substrate 1 after application without flowing, and from this point, higher viscosity is more convenient. On the other hand, it is preferable that the resin liquid has a low viscosity from the viewpoint of impregnation into the wood veneer 4, and it is more effective that the resin liquid has a high viscosity from the viewpoint of suppressing the outflow from the wood veneer 4 after the impregnation. Further, the resin liquid impregnated in the veneer veneer 4 is required to gel promptly because it flows so as to be extruded from the veneer veneer 4 by air or gasification components.

In order to satisfy these conditions, the viscosity of the resin liquid is required to be 200 cps or more. At 200 cps or less, even if the required amount is applied onto the veneer veneer 4, it cannot flow out and be retained.
On the other hand, those having a viscosity of 30,000 cps or more have a high viscosity, so that automatic coating using a roll coater or the like becomes difficult. In addition, these resin liquids are impregnated in the veneer veneer 4 in a state where the viscosity is reduced by heating, and the lower viscosity is more preferable at the time of impregnation,
Hot pressing temperature, i.e. 100 cp within 100-140 ° C
s The following is used. The pressure at this time is 5
15 kg / cm ² is required.

That is, a resin liquid having a viscosity of 100 cps or more at the time of hot pressing requires a long time to impregnate the wood veneer 4, so that the press time becomes long and the productivity is greatly reduced. If the pressing force at the time of hot pressing is low, the viscosity is reduced, so that it easily flows out to the side face, and a decorative board uniformly impregnated with the resin liquid cannot be obtained. If the pressure exceeds 15 kg / cm ² , there is a possibility that the structure of the veneer veneer 4 may be destroyed. Next, the curing reaction of the impregnated resin liquid starts, and gelation proceeds. When the gelation is started at a low temperature, it is possible to prevent the resin liquid from flowing out of the wood veneer 4. For this reason, it is desirable that the kick-off temperature of the initiator added to the resin liquid is 100 ° C. or less.

Initiators to be added to the synthetic resin solution to accelerate the curing of the synthetic resin solution include benzoyl peroxide, 2,4-dichlorobenzoyl peroxide, caprylyl peroxide, lauroyl peroxide, acetyl peroxide. Kickoff temperature of oxides etc. is 50 ℃ or more
Organic peroxides in the range of 100 ° C. are used. When an initiator having a kick-off temperature of 100 ° C. or more is added, the curing temperature of the synthetic resin liquid increases and the curing reaction slows down.
It is not preferable because it flows out of When the kick-off temperature is 50 ° C. or lower, the pot life of the synthetic resin liquid is shortened, and there is a possibility of partial curing in a supply path of a pump or the like. There is nothing that cannot be used.

Incidentally, an accelerator may be added to the synthetic resin liquid together with the initiator. As such an accelerator, a cobalt accelerator, a vanadium accelerator, a manganese accelerator, or the like can be used.

The synthetic resin liquid 3 is applied to the wood veneer 4 side, and the synthetic resin liquid 3 is superimposed on the film forming adhesive layer 2 applied on the wooden substrate 1 so that the wood veneer can be used. In this case, the operation of applying the synthetic resin liquid 3 to the wood veneer 4 can be performed in parallel with the operation of forming the film-forming adhesive layer 2 on the wooden substrate 1. It is also effective to apply the synthetic resin liquid 3 on the upper surface side of the veneer veneer 4 when the veneer veneer 4 is thick, or when the wood grain is dense and the impregnation with the resin liquid is slow.

As described above, the veneer veneers 4 are sequentially laminated on the wooden substrate 1 via the film forming adhesive layer 2 and the synthetic resin liquid layer 3 to which the initiator is added, and inserted into the hot press. When the wooden veneer 4 is heated and pressurized at a predetermined temperature and pressure for an appropriate period of time, the synthetic resin liquid 3 is imparted with fluidity and at the same time receives a compressing action between the wooden substrate 1 and the wooden veneer 4. An attempt is made to penetrate the opposing surfaces of the wooden substrate 1 and the wooden veneer 4.

At this time, since the film forming adhesive layer 2 is interposed between the wooden substrate 1 and the synthetic resin liquid layer 3, the synthetic resin liquid penetrates into the wooden substrate 1 side by the adhesive film forming layer 2. Therefore, the synthetic resin liquid 3 is impregnated into the wood veneer 4 from the lower surface of the wood veneer 4 directly pressed.

As described above, when the synthetic resin liquid 3 penetrates into the wood veneer 4 from the lower surface of the wood veneer 4 and rises, it is present in the cell space such as the conduit of the wood veneer 4 accordingly. The air escapes while being pushed upward, and is discharged to the outside, so that the synthetic resin liquid 3 easily impregnates the wood veneer. At this time, if the heating temperature by the hot press is lower than 100 ° C., the hardening of the synthetic resin liquid impregnated in the veneer veneer 4 is delayed, and the once impregnated resin liquid may flow out. Since styrene is present as a monomer in the liquid, it boils and acts to extrude the resin liquid, and a portion of the veneer veneer 4 is not impregnated with the synthetic resin liquid. It must be adjusted to 140 ° C.

When the thickness of the film-forming adhesive layer 2 is 30 μm or less, the film layer becomes thin, and the synthetic resin liquid 3 penetrates the film layer by the pressure of the press to the wooden substrate 1 side. In order to effectively prevent the synthetic resin liquid 3 from impregnating the wooden substrate 1 side by the film-forming adhesive layer 2, it is preferable that the thickness is formed to be 30 μm or more, since there is a possibility of infiltration. Even if the surface is rough, such as plywood, if it is formed to a thickness of about 100 μ, its prevention is ensured, and the wood veneer 4 can be more thoroughly impregnated with the synthetic resin liquid 3.

In this way, when the heat and pressure treatment by hot pressing is performed for a predetermined time, the resin liquid is given fluidity and is impregnated in the cell voids of the veneer, and the temperature is further increased in the material to act as an initiator. At the same time, the curing reaction of the impregnated synthetic resin liquid is started immediately and rapidly to be cured in the veneer veneer, and at the same time, the film forming adhesive layer 2 is activated by heating to exert an adhesive effect, and A beautiful decorative plate free from blurring or the like is obtained by bonding and integrating with the wooden substrate 1 via the film adhesive layer 2. Next, specific examples of the present invention will be described.

Example 1 Using a 12 mm-thick plywood as a substrate, an adhesive was prepared by adding 10 parts of polyvinyl alcohol and 5 parts of pigment to a DAP prepolymer using acetone as a solvent, and having a non-volatile content of 70%. Was applied by a roll coater at a rate of 110 g / m ² , and then the adhesive was applied with a hot air drier at 80 g / m ^2.
After drying at 5 ° C. for 5 minutes, the mixture was air-cooled to form a thermosetting adhesive layer having a thickness of about 60 μm. On the other hand, the thickness is 1.0mm
One side of a sen dry veneer (water content: 5%) was coated with an unsaturated polyester resin solution (viscosity 5000 cps / 25 ° C.) containing 1 part by weight of BPO as an initiator at a rate of 500 g / m ² = Then, the veneer is laminated on a substrate such that the resin layer is in contact with the film-forming adhesive layer, and a 20 μm-thick polyester film is placed on the veneer as a release film, followed by hot pressing. It was hot-pressed at 120 ° C. and 10 kg / cm ² for 5 minutes. By this heat and pressure treatment, a resin plate was impregnated into the veneer and cured, and a veneer was obtained in which the veneer was integrated with the substrate by the adhesive layer.

Example 2 Instead of applying the synthetic resin liquid to the veneer in Example 1 above, the synthetic resin liquid was applied to the film forming adhesive layer provided on the upper surface of the substrate, and the synthetic resin liquid was applied After laminating veneers,
By hot pressing under the same conditions as above by hot pressing, a resin-injected veneer veneer was obtained.

Example 3 In Example 1, 1 part by weight of MEKPO and 0.2 part of an 8% solution of cobalt naphthenate were added to both sides of the veneer, and 250 g / 300 cps of an unsaturated polyester resin solution having a viscosity of 300 cps was added. was applied at a rate of m ^2, veneer upper surface of the resin solution layer while laminating the veneer through the lower surface of the resin solution layer to the film-forming adhesive layer on a substrate described in example 1 After placing the release film on the hot press, apply a thin layer of metallic soap to the hot press hot plate, and then apply 110 kg
/ Cm ² for 4 minutes to obtain a resin-injected veneer-coated veneer. Observation of the veneer surface of the veneer veneer obtained by each of these examples with a microscope revealed that the resin injection rate into cell voids such as conduits reached 90% or more.

Comparative Example Using the same substrate, veneer and adhesive as in Example 1 above,
Immediately after applying the adhesive on the substrate, the veneers are laminated and integrally adhered. Thereafter, an unsaturated polyester resin solution having a viscosity of 10 cps and a viscosity of 10 cps to which 1% of BPO is added as an initiator is applied to the upper surface of the veneer. g / m ² =, and hot-pressed under the same conditions by hot pressing. In this case, a considerable amount of the resin solution flowed out during pressing, and the remaining resin solution was easily impregnated into veneers. The resin injection rate into the void was only about 50%, and the non-impregnated part appeared unevenly on the surface.

[0026]

As described above, according to the decorative board manufacturing method of the present invention, after applying an adhesive on a wooden substrate, the adhesive is formed into a film by heating or other means. The wood veneer is overlaid on the agent layer via a coating layer of an addition-polymerized synthetic resin liquid having a viscosity of 200 to 30,000 cps and having an appropriate thickness, and heated and pressurized within a temperature range of 100 to 140 ° C. It impregnates and hardens the synthetic resin liquid into the wood veneer and bonds and integrates the wood veneer onto the wood substrate.
Since the adhesive applied on the wooden substrate is formed into a film, when a single veneer is laminated and heat-pressed through a synthetic resin liquid having an appropriate coating thickness, the synthetic resin liquid The impregnation on the wooden substrate side can be reliably prevented by the film-forming adhesive layer, and a large amount of the resin solution can be impregnated in a single veneer wood.

Furthermore, the viscosity of the synthetic resin liquid decreases during heating, the fluidity increases, and the liquid is easily impregnated into the veneer, and the initiator added to the synthetic resin liquid has a kick-off temperature of 100%. ° C or lower and the heating temperature is in the range of 100 to 140 ° C, so that after the impregnation, the initiator starts the reaction and the synthetic resin liquid does not flow out of the wood veneer. It can be cured in a state of being held in a veneer, and can provide a synthetic resin-impregnated decorative board having good cosmetic properties without causing fraying or the like.

Also, in the case of a synthetic resin liquid to which a thermal decomposition type initiator having a kick-off temperature of 50 to 100 ° C. is added, the curing proceeds even after a considerable time is required from the resin preparation to the heat-pressure treatment. Therefore, it is possible to exhibit fluidity only at the time of heat and pressure.Therefore, the work of applying a film-forming adhesive layer on a wooden substrate and the work of placing a veneer of wood through an initiator-added synthetic resin liquid A series of steps of hot-press processing by a press can be continuously performed, and the productivity of a decorative board can be remarkably improved, and a resin impregnation processing unit having excellent physical properties such as hardness, strength, and cosmetic properties can be obtained. This makes it possible to efficiently and stably produce a veneered decorative board.

[Brief description of the drawings]

FIG. 1 is a simplified cross-sectional view showing a state in which a wooden veneer is laminated on a wooden substrate via a film forming adhesive layer 2 synthetic resin liquid.

[Explanation of symbols]

 Reference Signs List 1 wood substrate 2 film-forming adhesive layer 3 synthetic resin liquid layer 4 wood veneer

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-58-42406 (JP, A) JP-A-56-64805 (JP, A) JP-A-63-92403 (JP, A) JP-A 63-92403 158201 (JP, A) Jikken Sho 60-28610 (JP, Y2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B27D 5/00 B27D 1/04 B27K 3/15

Claims (3)

(57) [Claims] 1. An adhesive is applied on a wooden substrate, and the adhesive is formed into a film by heating or other means, and then has a viscosity of 200 to 30,000 cps on the film-forming adhesive layer.
Laminated wood veneers are applied via a coating layer of an addition-polymerized synthetic resin liquid of appropriate thickness, whose viscosity at the hot pressing temperature is 100 cps or less, and heated and pressurized within the range of 100 to 140 ° C. A method for producing a decorative board, which comprises lowering the viscosity, impregnating and hardening a synthetic veneer in a wood veneer, and bonding and integrating the wood veneer on a wooden substrate. 2. The method for producing a decorative board according to claim 1, wherein after addition of the wood veneer, an addition polymerization type synthetic resin solution is applied to the surface of the wood veneer. 3. The method for producing a decorative board according to claim 1, wherein the kick-off temperature of the initiator added to the addition polymerization type synthetic resin liquid is 100 ° C. or less.