JP3103817B2 - Building material and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building material having a decorative layer formed on the surface of a wooden material and a method for producing the same.

[0002]

2. Description of the Related Art Wood materials, especially wood, are used as wall materials, floor boards, ceiling boards, stair steps, stair side plates, shelves, counters, door materials, frame materials, opening members, construction materials and the like. The surface of the board, such as solid wood, laminated wood, plywood, particle board, etc., is subjected to optional painting or pattern printing, or a decorative material such as decorative paper, veneer, etc. is pasted through an adhesive to form a decorative layer. Is used.

[0003] Further, in order to protect the decorative layer and improve the wear resistance of the surface, a coating layer containing a wear-resistant material has been formed on the surface of the decorative layer.

[0004] On the other hand, it has been conventionally proposed to heat and compress wood materials to consolidate them. The consolidation by heating and compressing a wooden material according to a conventional method is performed in a state where the wooden material is in a wet state or is humidified in a steam atmosphere so that the wooden material has a high moisture content.

[0005] In this method, consolidation by heating and compression is carried out at a high water content, that is, in a state where a large amount of water is present in the wood, so that water is used as a plasticizer, especially hemicellulose, lignin and the like in the main components of wood. Act largely as a plasticizer on the non-crystalline components of
The temperature is reduced to about ℃, and the plasticity of the wood material is increased.

[0006]

However, wood materials used as substrates for building materials generally have insufficient surface strength, and particularly have low impact resistance. Even when formed on the surface of the decorative layer, scratches and sliding scratches were prevented, but scratches such as dents and surface cracks due to impact were liable to occur.

On the other hand, in the consolidation treatment of the wooden material according to the conventional method, since the wooden material is heated and compressed in a state of high water content, the high steam pressure of the water present inside the wooden material reduces the consolidation during decompression. It acts as a force for restoring the compacted state, and it is difficult to maintain the compacted state in combination with the springback phenomenon due to the pressure release. In particular, in the case of a wood material having a low specific gravity, puncturing (delamination) may occur due to release of the high steam pressure instantaneously.

In order to prevent the release of high steam pressure, it is conceivable to perform cooling in a pressed state, but the productivity is extremely low and the cost is greatly increased.

Further, according to the above-mentioned conventional technique, even if the compacted state can be maintained, the whole wood material having a high moisture content is compacted, so that the wood material has a high specific gravity. Would.

[0010]

SUMMARY OF THE INVENTION The present invention has been made with a view to overcoming the problems of the prior art described above. With a consolidated material having a hard layer having a base material, a decorative layer is formed on at least the surface thereof,
An architectural material characterized in that an abrasion-resistant paint layer is formed without hiding the decorative layer.

The architectural material according to the present invention is a wooden material that has been preliminarily lumbered and that has been adjusted to have a water content below the fiber saturation point before or after lumbering, and is heat-compressed to be compacted on both sides. A decorative layer is formed on at least the surface of a consolidation material having a hard layer as a base material, and a wear-resistant paint layer is formed without hiding the decorative layer.

Further, the method for manufacturing a building material according to the present invention is characterized in that a preformed lumber having a water content adjusted to a fiber saturation point or lower before or after lumber is sandwiched between hot plates, Heat compression at a temperature equal to or lower than the softening point temperature of cellulose as a crystalline component and equal to or higher than the softening point temperature in the adjusted water content of the non-crystalline component,
Thereafter, by decompressing and cooling, a consolidated material having a consolidated hard layer on both front and back surfaces of the wood material is obtained, a decorative layer is formed on at least the surface of the compacted material, and a wear-resistant paint layer is further formed. Is formed without hiding the decorative layer.

As the wood material used as the substrate of the building material of the present invention, a solid wood material, a solid sawn wood material, or a processed material such as a laminated material, a veneer laminated material, a plywood, a particle board, a fiber board, or the like is used. As these wood materials, both softwood materials and hardwood materials can be used, and particularly soft materials and low specific gravity materials are suitably used.

These wood materials are dried before or after sawing to adjust the water content below the fiber saturation point. The water content below the fiber saturation point referred to herein is preferably 35%
The following moisture content is meant.

The wood material whose moisture content has been adjusted to be below the fiber saturation point is inserted between hot plates of a hot press apparatus provided with a thickness regulating jig generally called a distance bar for regulating the distance between the upper and lower hot plates. You.

As the jig for regulating the thickness between the hot plates, a jig having a thickness of 80 to 95%, more preferably 82 to 92% of the thickness of the wooden material is used. In other words, the thickness regulating jig is attached so that the compression ratio of the wooden material is 5 to 20%, more preferably 8 to 18%.

If the compression ratio of the wooden material is less than 5%, the compaction on both the front and back surfaces becomes insufficient, and the strength required for the hard layer cannot be obtained. Conversely, the compression ratio of wood is 20
%, The front and back surfaces are sufficiently densified to obtain the required strength as a hard layer, but the overall specific gravity is increased, resulting in an increase in weight. Is not preferable because the yield decreases and the cost increases.

The compression ratio can be arbitrarily selected within the above range according to the type of wood used, the specific gravity of the timber itself, the surface hardness to be obtained, and the like. Set the control jig.

The wood material inserted between the upper and lower hot plates of the hot press device to which the thickness regulating jig is attached is heated and compressed by hot pressing, and is compacted on both front and back sides to form a hard layer.

The hot pressing is performed by setting the hot pressing temperature to a temperature equal to or lower than the softening point of cellulose, which is a crystalline component of wood, and equal to or higher than the softening point of the non-crystalline component in the adjusted water content. Will be

The pressing time and pressing pressure are arbitrarily set according to the specific gravity, softness, etc. of the wood material itself.
Since the required compression ratio is obtained by using the thickness regulating jig at the time of pressing, the pressing time is 3 to 15 minutes, and the pressing pressure is 5 to 25.
It is preferably set to kg / cm ² .

The wood material heated and compressed between the upper and lower hot plates of the hot press device gradually undergoes thermal softening and consolidation due to the pressing force from the front and back surfaces directly in contact with the hot plate toward the center. Since the water content is adjusted to a low water content below the fiber saturation point, heat transfer is relatively slow, and only the front and back portions of the wood material are compacted. As described above, the temperature of the wood material itself does not increase as a whole even at the time of hot pressing, so that the wood material is easily cooled by the subsequent pressure release. In addition, fibrous cellulose remains in the wood structure without thermal softening, and the hemicellulose and lignin softened and melted at the time of hot pressing act as an adhesive to the cellulose. The springback of the wood material due to the pressure is minimized, and a compacted hard layer is formed on both front and back surfaces.

The hardness of the consolidated hard layer is determined according to JIS Z
4.5k in the method of wood hardness test according to -2007
It is preferably at least gf / mm ² . 3. Hard layer
If it is less than 5 kgf / mm ² , the impact resistance of the surface is insufficient and the surface is apt to be damaged, and the bending strength of the material itself is not improved due to insufficient consolidation, and the hydrophobic property is not improved. In addition, the swelling rate and the water absorption rate cannot be reduced, so that dimensional stabilization cannot be achieved.

Using the thus obtained consolidation material having a hard layer on both the front and back surfaces as a base material, a decorative layer is formed on at least the surface thereof. The decorative layer is subjected to a base treatment such as a sealing treatment or a sealer treatment, if necessary, on the base material surface, and thereafter, for example, is subjected to coloring painting or pattern printing, or a decorative veneer, decorative paper, or the like via an adhesive. It is formed by sticking a decorative material such as a decorative synthetic resin sheet.

In the surface hard layer of the substrate, fine grooves can be formed on the surface by wire brushing, sanding or the like, if necessary. Since the fine grooves increase the surface area of the hard layer and also exert an anchoring effect thereby,
The adhesive force of the decorative material provided on the surface of the hard layer is improved.

On the surface of the decorative layer, an abrasion-resistant coating layer is further formed without hiding the decorative layer. The abrasion-resistant coating film layer has a particle diameter as a friction-resistant material in a synthetic resin paint such as a transparent or translucent amino alkyd resin paint, urethane resin paint, acrylic resin paint, polyester resin paint, etc. 30-200μ alumina,
Apply a mixture of mineral particles such as silicon carbide,
It is formed by drying. Mineral particles mixed in the paint are scattered throughout the coating layer, either partially exposed on the surface of the abrasion-resistant coating layer to be formed or buried inside the coating layer. doing.

[0027]

The softening point of cellulose, which is a crystalline component in wood, is 200 to 250 ° C. regardless of the water content of the wood.
However, the softening points of the non-crystalline components hemicellulose and lignin greatly change depending on the moisture content of the wood material, and the softening points of the hemicellulose and lignin in a completely dry state are about 180 ° C. and about 150 ° C., respectively. ° C, but at a water content of 35%, which is the fiber saturation point of the wood material, the softening point temperature drops to around 60 ° C. That is, unlike cellulose which is substantially non-plastic, hemicellulose and lignin are plasticized by the moisture contained in the wood material acting as a plasticizer even at a fiber saturation point or lower.

Therefore, for example, the fiber saturation point 3
In the case of a wood material adjusted to a water content of 5%, by setting the heat pressure temperature in the range of about 60 to about 200 ° C., cellulose as a crystalline component hardly softens and becomes amorphous in tissue cells. Hemicellulose and lignin as components can be heat-softened.

By heating and compressing the woody material having a low water content below the fiber saturation point at such a temperature, only the portions near the front and back of the woody material are compacted to form a hard layer.

The decorative layer and the wear-resistant coating layer are formed on the hard layer to obtain the building material of the present invention.

[0031]

FIG. 1 shows a schematic structure of a building material according to the present invention. Hard layers 2 and 2 are formed on both front and back surfaces of a wood material as a base material 1 by hardening, and a decorative layer 4 is formed on one surface thereof. The abrasion-resistant coating layer 5 is formed on the surface thereof without hiding the decorative layer 4.

As an example of the substrate 1, a thickness of 30 mm,
Agatis solid sawn timber with a width of 150 mm, a length of 100 mm and a specific gravity of about 0.5 was mixed with a low water content below the fiber saturation point (19-
After drying to 21%), it was inserted between the hot plates of a hot press equipped with a 25 mm thickness regulating jig, hot plate temperature 160 ° C., pressing pressure 10 kgf / cm ² , pressing time 15
For 30 minutes, the thickness obtained was 25 mm.
Approximately 8-10m from the front and back of compressed solid wood
a hard layer 2 having a specific gravity of 0.6 to 1.0 in a thickness range of m
No. 2 was formed, and the specific gravity of the inner central portion 3 was almost constant at the whole specific gravity (about 0.5) before the consolidation treatment. Also, the hardness of the hard layer is 4.5~16.5kgf / mm ^2, the pre-consolidation process wood hardness 2.6~3.4kgf / m
m ² was significantly improved.

[0033]

According to the present invention, the hard layer is formed by increasing the specific gravity of only the front and back sides of the wooden material without increasing the overall specific gravity, so that the bending strength, surface smoothness,
Since surface hardness etc. are improved and the balance between front and back is maintained, even if a decorative layer and a wear-resistant coating layer are formed only on one surface, warpage and twisting may occur. Absent.

The hard layer having excellent surface strength can prevent scratches such as dents and surface cracks due to impact.
The formation of the wear-resistant coating layer on the surface of the decorative layer prevents scratches and sliding scratches, so that a building plate having extremely excellent surface wear resistance can be obtained.

The hard layers on the front and back of the wood material as the base material mainly include hemicellulose, which is an amorphous component in the wood material,
Because lignin is formed by being softened and melted and then hardened to a high density after being compressed, it becomes a hydrophobic film and, together with the reduction in hydrophilicity due to compaction, reduces the swelling rate and water absorption rate Can significantly improve the dimensional stability of wood.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a schematic configuration of a building material according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Hard layer 3 Center part 4 Decorative layer 5 Abrasion resistant coating layer

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. ⁷ , DB name) B32B 21/00-21/14 B27D 5/00 E04F 13/00-13/18

Claims (5)

(57) [Claims] Claims: 1. A decorative layer is formed on at least the surface of a densified material having a hard layer densified on both sides by heating and compressing a pre-milled wooden material.
Furthermore, a building material, wherein the wear-resistant paint layer is formed without hiding the decorative layer. 2. A consolidated material having a hard layer compacted on both the front and back surfaces by heating and compressing a pre-milled wood material which has been adjusted to have a water content below the fiber saturation point before or after the lumber. A building material comprising: a base material; a decorative layer formed on at least the surface thereof; and a wear-resistant paint layer formed without hiding the decorative layer. 3. The hardness of the hard layer is 4.5 kgf / mm.
The building material according to claim 1 or 2, wherein the number is 2 or more. 4. A preliminarily lumbered wood material having a water content adjusted to a fiber saturation point or less before or after lumbering is sandwiched between hot plates, and the softening point temperature of cellulose, which is a crystalline component of the woody material. By heating and compressing at a temperature equal to or higher than the softening point temperature in the adjusted moisture content of the amorphous component and thereafter, decompressing and cooling, the hard layer compacted on both front and back surfaces of the wood material. To obtain a consolidated material having
A method for manufacturing a building material, comprising: forming a decorative layer on at least the surface of the consolidated material; and forming a wear-resistant paint layer without hiding the decorative layer. 5. The method for manufacturing a building material according to claim 4, wherein after forming fine grooves on the surface of the hard layer of the consolidated material, the decorative layer is formed via an adhesive.