JP3596342B2

JP3596342B2 - Door with moisture proof performance

Info

Publication number: JP3596342B2
Application number: JP8275799A
Authority: JP
Inventors: 利之渡辺
Original assignee: Nippon Paper Industries Co Ltd
Current assignee: Nippon Paper Industries Co Ltd
Priority date: 1999-03-26
Filing date: 1999-03-26
Publication date: 2004-12-02
Anticipated expiration: 2019-03-26
Also published as: JP2000274150A

Description

【０００１】
【発明の属する技術分野】
本発明は、住宅の内部に使用される、ドア、折戸などの建具、玄関収納、収納ユニット、家具などに使われる扉であって、施工後の経時変化による反り、ねじれに強く、下地木質基材のダクの発生を抑え、平滑な化粧面を有する品質の安定した扉を安価に安定供給するためのものである。
【０００２】
【従来の技術】
従来、住宅の内部の建具、扉などに使用される木質系化粧材は、合板、ＭＤＦ、パ−ティクルボ−ド、ＬＶＬ、等の木質系基材の表面、または、表裏面の両方に化粧シ−トを貼着するか、該、基材の全面を化粧シ−トでラッピングして覆ってしまうか、のいずれかであった。化粧シ−トとしては２３〜３０ｇ／ｍ^２の薄葉紙または強化紙の表面に木目印刷した、いわゆる、プリント紙が多く使われており、薄葉紙または強化紙の片方または双方を複層貼り合わせて、いわゆるダブリングシ−トとしたものも一部に使われていた。
【０００３】
通常、ラミネ−タ−装置を用いて貼着する場合が多く、この場合、化粧紙の裏面側に接着剤を比較的高速で塗布し、続いてプレスロ−ル、または、平板プレスで化粧シ−トを熱圧または冷圧で木質基材表面に圧着するのが一般的であった。
【０００４】
また、建具、扉が経時変化で吸放湿して、扉が反ったり、ネジレたり、アバレが発生したりするのを防止するため、一般的には、扉を構成する縦框、横框、鏡板等の扉構成部材の表面または裏面、または、表裏面の両方に、合成樹脂シ−ト、または、合成樹脂シ−トと紙質材料の複合からなる防湿材等を貼着するか、または、防湿材で扉構成部材の全面を覆ってしまうか、また、乾燥すると防湿皮膜を形成する防湿塗料を塗布するか、あるいは、金属、または、無機質からなる防湿材を複合させるかなどして、扉構成部材に種々の工夫がなされてきた。
【０００５】
【発明が解決しようとする課題】
ドア、扉などの建具の表面に用いられる化粧シ−トとして、２３ｇ／ｍ^２または３０ｇ／ｍ^２程度の薄葉紙を貼着した場合、化粧シ−トが薄く、従って、シ−ト自体に腰がなく、シ−ト裏面に塗布された接着剤中の水分を吸収して、裏面側が伸長し、シ−トがカ−ルして、非常に貼りづらい結果となる。このため、貼着する装置として、ラミネ−タ−が使用できないので、手作業で貼るしかなく、生産効率が著しく低下し、非経済的であった。
【０００６】
また、特に下地がパ−ティクルボ−ド、ＭＤＦ、等の木質基材の場合、下地基材が接着剤中の水分を吸収して、表面の繊維がケバ立って、その上の化粧シ−ト表面にブツブツ状のいわゆるダクが発生し、外観上、触感上問題となり、商品価値を著しく損なうものとなっていた。
【０００７】
このブツブツ状のダクの発生を軽減させるために、薄葉紙または強化紙を複合させたダブリングシ−トが使われる場合もあるが、紙層が厚くなる分だけダクの発生を軽減できるものの不十分であり、ただのダブリングシ−トでは透湿度が薄葉紙等と変わらず、防湿性能に乏しく、また、以下に述べるように、扉の防湿効果による反り防止、および、ラミネ−タ−で貼着する際のシ−トのカ−ル防止効果は残念ながらない。
【０００８】
すなわち、反り防止のため、防湿性能を付与するためには、扉を構成する縦框、横框、鏡板等の扉構成部材の基材表面または裏面、または、表裏面の両方に、いわゆる防湿シ−ト、または、防湿シ−トと他材料とを複合させた防湿材を、貼着するか、または、ラッピング加工で覆ってしまうなどの方法が従来から、行われているが、例えば塩ビシ−ト等の合成樹脂シ−ト単層の防湿シ−トでは、合成樹脂シ−ト専用の高価な接着剤が必要とされ、コスト高についていた。
【０００９】
この場合、扉構成部材の両面に同一の樹脂シ−トを貼ればよいが、片面貼りであると樹脂シ−トそのものの膨張収縮によって、防湿性能以前の問題として、基材そのものに、反りが発生する。また、防湿層単層の防湿シ−トのみでは、扉構成部材のダクは避けられない。また、合成樹脂フィルム等の防湿層の両面または片面に紙層等が複合されたものも以前から使われているが、この場合、合成樹脂フィルム等防湿層と基材との間に紙層があるので、ダクは軽減されるが完璧ではない。
【００１０】
また、貼着または被覆する際、接着剤が塗布された側の紙層に接着剤の水分が吸収され、紙層が伸長し、カ−ルの原因となる。ラミネ−タ−で貼着する際、このカ−ルが原因で貼りづらく、また、不良率も増大して、製品品質が低下し、コスト高にもつき、市場競争力の著しく劣るものとなっていた。すなわち、扉構成部材に貼着または、被覆される化粧シ−トのカ−ル、扉構成部材表面のダク、扉構成部材を組み立てて完成した扉本体の吸放湿による反り、ネジレ、アバレ等が問題となっていた。
【００１１】
【課題を解決するための手段】
上記課題を解決するために、本発明者等が鋭意研究した結果、下記の発明に到達した。すなわち、透湿度の異なる外側シ−ト層の間に中間防湿層を挿入した３層からなる防湿シ−トを透湿度の低い側を基材側にして、扉構成部材の表面に貼着、または、被覆、すなわちラッピングするとよい。
【００１２】
この場合、ラミネ−タ−を用いての貼着または、ラッピングマシンや真空プレスを用いてのラッピング加工を行う際、防湿シ−トの透湿度が低い側に接着剤が塗布されるので、従来から問題となっていたように、接着剤中の水分がシ−ト層すなわち紙層に吸水されることにより、その面が伸長し、そのことによって防湿シ−トがカ−ルするということがなく、安定して製造ができる。また、透湿度が低いので、接着剤の塗布量を通常の場合よりも低く抑えられるので、扉構成部材の木繊維のケバ立ちが軽減され、且つ防湿シ−トが３層にもなっているので、木繊維の多少のケバ立ちは目立ちにくく、従ってダクの発生が完璧に防止できる。
【００１３】
そして、これらの部材を扉の縦框、上框、下框、中框、鏡板等の構成部材とし、これらを組み合わせることによって、防湿性能を有する扉で、施工後の反りに強く、しかもダクの発生のない品質の安定した製品が、化粧シ−ト貼着または、ラッピング加工時の化粧シ−トのカ−ルが発生することなく、安定して生産可能で、しかも安価に市場に提供できるものである。
【００１４】
防湿シ−トを木質基材に接着する際の加工方法として、ラミネ−タ−、コ−ルドプレス、ホットプレスなどによって扉構成部材の基材表面に１面づつ貼着しても実用上、じゅうぶんな防湿性能が付与できるが、ラッピングマシンや真空プレスを用いて扉構成部材の全面をラッピングすなわち被覆する方が、防湿シ−トが扉構成部材の角部分で切れ目なく連続して、且つ全面すっぽりと被覆できるので、より完全な防湿性能が可能となる。
【００１５】
さらに以下詳述する。防湿シ−トの透湿度の低い側を基材側にして貼着または被覆、すなわちラッピングすれば、接着剤中の水分による木質基材の繊維のケバ立ちが抑制される。すなわち、貼着または被覆する場合、防湿シ−トの透湿度の低い方の外側シ−ト層に接着剤を塗布すると、透湿度の高い側の外側シ−ト層に接着剤を塗布するのと比較して、接着剤がシ−ト層へ浸透するのが抑制され、従って、微量塗布が可能となり、木質基材側への接着剤中の水分の持ち込み量が抑えられ、従って、木質基材の繊維のケバ立ちが抑制され、ダクの発生が防止できる。
【００１６】
反対に透湿度が高い側に塗布すると、接着剤が付きすぎて、微量塗布が難しくなり、接着剤中の水分の基材表面への持ち込み量が多くなって、基材表面の木質繊維が膨潤し、ケバ立って、表面が凹凸状態となり、防湿シ−トの表面上にブツブツ状のダクが発生する。
【００１７】
また、防湿シ−トの中間層に防湿層があるので、防湿機能が付与され、扉そのものの反りが防止できる。
【００１８】
また、３層からなる防湿シ−トの透湿度の低い側に接着剤が塗布されるので、外側シ−ト層への接着剤中の水分の取り込み量が抑制されるので、その層の伸長はかなり抑えられ、片面のみ伸長するために発生する防湿シ−トのカ−ルが抑制される。
【００１９】
また、防湿シ−トの外側２層は、例えば紙質材料からなっている場合は、木質基材への接着剤として通常の木材用接着剤が使用可能となるので、製造が容易になるばかりでなく、製造コストも安価につく。また、表面化粧材料としては、表面に木目印刷されたプリント紙、コ−ト紙、塩ビシ−トまたは、木質単板などが用いられる。いずれの場合も、防湿シ−トの外側２層が紙層であれば、木材用接着剤が使用できるので、製造が比較的簡単であり、コストも安価について、より良いが、本発明はこれに限定するものでなく、紙層以外であっても専用の接着剤を選定する事によって解決でき、紙層以外でも木材用接着剤が使用可能な材料を選定することもできる。
【００２０】
また、防湿シ−トの他方すなわち基材と反対側は透湿度の高いシ−ト層または紙層からなるが、この理由は表面の意匠として、例えばプリント紙、木質単板などで木材用接着剤を使用する場合、透湿度が高い方が接着剤の塗布量に制限がなく、製造が容易であり安定生産が可能となるためである。
【００２１】
【発明の効果】
透湿度の異なる外側シ−ト層の間に中間防湿層を挿入した３層構造の防湿シ−トを、透湿度の低い側を基材側にして、扉構成部材の表面に貼着または被覆してなる木質基材を扉などの建具の縦框、上框、下框、中框、鏡板などの扉構成部材とすることによって、ドア、扉等に防湿機能が付与され、従って、施工後の吸放湿による扉の反り、ネジレ、アバレが防止でき、また、透湿度が低い側に接着剤を塗布するので、基材表面の木繊維のケバ立ちが抑制され、従って、ダクの発生しない平滑な表面性を有する品質の安定したドア、扉が可能となる。
【００２２】
また、ラミネ−タ−またはラッピングマシン、真空プレスで基材に防湿シ−トを貼着または被覆する際に、接着剤中の水分によって、防湿シ−トの接着剤を塗布した側のみが著しく伸長し、防湿シ−トがカ−ル状態となることも防止できる。従って、不良率の少ない、品質の安定した製品が安価に且つ容易に製造可能となる。
【００２３】
【発明の実施の形態】
３層からなる防湿シ−トの外側２層は互いに透湿度が異なるシ−ト層である。透湿度が高い方のシ−ト層は坪量約２３〜１００ｇ／ｍ^２の薄葉紙、再生紙、クラフト紙、等のいわゆる紙層、または、不織布、普通セロハン等が用いられる。
【００２４】
透湿度が低い方のシ−ト層は薄葉紙等の原紙に樹脂、塗料、顔料等をコ−ティングした軽量コ−ト紙、微塗工紙、キャストコ−ト紙などの、いわゆるコ−ト紙、または、防湿セロハン等が用いられる。
【００２５】
また、防湿シ−トの中間層を構成する中間防湿層としては、ポリエチレン、ポリプロピレン、塩ビ、ナイロン等の合成樹脂フィルムで厚み２０〜４０ミクロン程度のもの、アルミニウム箔、スチ−ル箔、ステンレス箔等の金属箔で厚みが１０〜１５ミクン程度のもの、ポリエチレン、ポリプロピレン等を主原料としたフィルム法による合成紙、ガラス繊維を用いた無機質シ−トなどが用いられる。
【００２６】
この中で、中間防湿層としては合成樹脂フィルムが防湿性能が安定しており、入手も容易であり、中間防湿材料として適している。なかでも厚さ２０〜４０ミクロンのポリエチレンフィルムが防湿性能、ラッピング適性、価格面などから見て最も望ましい。また、防湿シ−トの外側シ−ト層は紙層であると、木材用接着剤が使用可能であり生産が容易である。また、透湿度が異なる外側シ−ト層の透湿度の低い方のシ−ト層は透湿度３００ｇ／ｍ^２２４ｈｒ以下の紙層が最も望ましい。
【００２７】
その理由は透湿度が３００ｇ／ｍ^２２４ｈｒ以上では防湿シ−トのカ−ルや下地基材のケバ立ちが発生し易い。
【００２８】
また、透湿度の高い方のシ−ト層は透湿度７００ｇ／ｍ^２２４ｈｒ以上の紙層が望ましい。その理由は表面化粧材としてプリント紙、木質単板などを貼着または被覆する場合、その方が安定して接着加工できるので、安定した生産が可能となる。
【００２９】
また、中間防湿層が厚み２０〜４０ミクロンのポリエチレンフィルムが望ましい。その理由はポリエチレンフィルムは安価であるばかりでなく熱を加えると軟化するので被覆すなわちラッピングする際、下地基材によくなじんで、加工し易い。
【００３０】
以上の３層からなる防湿シ−トは、その片側に透湿度が低いシ−ト層、反対側には透湿度の高いシ−ト層を積層し、酢酸ビニル、アクリル、ユリア、フェノ−ル、エポキシ、エチレン酢ビ系等の接着剤を用いて塗布量１０〜５０ｇ／ｍ^２で貼り合わせるか、または、熱溶着等の方法で積層接着し、３層構成の防湿シ−トとする。外側２層が普通セロハンまたは防湿セロハンの場合は温度１２０℃、圧力１ｋｇ／ｃｍ^２の条件で比較的容易に積層可能である。
【００３１】
下地木質基材としては、ＭＤＦ、パ−ティクルボ−ド、ＯＳＢ、ハ−ドボ−ド等が用いられる。下地木質基材への貼着方法は、下地木質基材の片面または両面にホットプレスまたは、コ−ルドプレスにて、熱圧または冷圧する方法以外にラミネ−タ−を利用して貼着する方法がある。基材側が例えばコ−ト紙など紙層の場合でも防湿セロハンの場合でも、この時の接着剤は酢酸ビニル、ユリア、メラミン、合成ラテックス系、エチレン酢ビ系、ウレタン系等、木材用接着剤を使用するとよい。
【００３２】
３層構成の防湿シ−トを巻きロ−ル状にしておいて、これを巻き戻しつつ、その透湿度の低い側に貼着用の接着剤を３０〜７０ｇ／ｍ^２の塗布量を目安として塗布し、つづいてラミネ−タ−の圧締ロ−ルにて、熱圧または冷圧する。
【００３３】
以上のほか、木質基材の周囲をくるみ込むようにして被覆する、いわゆる、ラッピング方式もある。ラッピングの方法は、まず、ラミネ−タ−方式で基材の表面に防湿シ−トを平貼りし、続いて傾斜角度が順次変わるラッピングロ−ルで、基材の側面、裏面折り返し部の順で順次シ−トを曲げながら圧締していくものである。さらに、このほかに、真空プレスでラッピングする方法もある。これは基材の上に防湿シ−トをかぶせ、その上から耐熱ゴムの薄シ−トをかぶせ、さらに基材の下側から、エア−を抜いて、基材と防湿シ−トの間の気圧を下げ、大気圧の圧力で防湿シ−トを基材へ密着させて、ラッピングするものである。
【００３４】
【実施例】
次に実施例にしたがって詳しく述べる。
実施例１
厚さ２０ミクロンで、３０ｇ／ｍ^２（３００番手）の、片面にニトロセルロ−ス系防湿剤を塗布した防湿セロハンで、透湿度４５ｇ／ｍ^２２４ｈｒのものを透湿度の低い方のシ−トとした。
【００３５】
そして、透湿度の高い方のシ−トとして、３０ｇ／ｍ^２の薄葉紙を用意した。また、中間防湿層として、厚み２０ミクロンのポリプロピレンフィルムで透湿度が１３ｇ／ｍ^２２４ｈｒのものを用意した。それぞれ幅寸法は１０００ｍｍで長さ３０００ｍの巻きロ−ル状である。それらにエチレン酢ビ共重合樹脂接着剤を４０ｇ／ｍ^２塗布し、圧締温度１２０℃、圧締圧力１．８ｋｇ／ｃｍ^２で接着し、３層構成の防湿シ−トを作成した。
【００３６】
下地木質基材としては比重０．６５で厚み３０ｍｍのＭＤＦを用意した。次にこれを縦框、上框、下框、中框、鏡板などの扉構成部材のサイズに切削加工し、続いてこれに上記３層構成の防湿シ−トを透湿度の低い防湿セロハン側を木質基材側にして、ラミネ−タ−で４側面を貼着して、扉構成部材を作成した。この時の接着剤はユリア、酢酸ビニルブレンドタイプで塗布量は４８ｇ／ｍ^２、圧締圧力５．０ｋｇ／ｃｍ^２、圧締温度１１０℃であった。
【００３７】
さらにこの上に厚み０．３ｍｍのオ−ク単板をユリアメラミン系接着剤を９０ｇ／ｍ^２ロ−ル塗布し、温度１２５℃、圧力８．０ｋｇ／ｃｍ^２、圧締時間２分の条件で接着した。この材料をドアの各構成部材、すなわち、上下框、縦框、中框、鏡板等の材料寸法に切断加工し、さらに木ダボを用いて、組み立て加工し、ウレタン樹脂塗料で塗装仕上げし、厚み３０ｍｍ、幅８００ｍｍ、高さ２０００ｍｍの框組ドアを作製した。
【００３８】
実施例２
透湿度の低い方のシ−ト層として、坪量７３ｇ／ｍ^２のコ−ト紙、透湿度の高い方のシ−ト層として坪量７３ｇ／ｍ^２のクラフト紙を用意した。また、中間防湿層として、厚さ３０ミクロンのポリエチレンフィルムを用意した。これら３層をポリエチレンフィルムを中間層として熱融着ラミネ−タ−方式で融着温度１３０℃で張り合わせし、３層構造の防湿シ−トを作製した。
【００３９】
下地基材としては厚み２５ｍｍのＬＶＬの両面に厚み５ｍｍのＭＤＦを張り合わせた総厚み３５ｍｍの複合基材を用意した。これをドアの縦框、上框、下框、中框、鏡板などの扉構成部材の厚み、幅、長さ寸法に切削加工し、次にこれら構成部材の６面全面に上記防湿シ−トをラッピングマシンを用いてシ−トの切れ目なく連続して被覆した。
【００４０】
この時、透湿度の低いコ−ト紙側を基材側にした。この時の接着剤は実施例１と同じものを使用した。次にこれら扉構成部材の表面に実施例１と同じく厚さ０．３ｍｍのオ−ク単板を貼着した。この時の接着剤並びに接着条件は実施例１と同じとした。続いて、これらの扉構成部材を木ダボを用いて組み立て加工し、ウレタン樹脂塗料で塗装仕上げし、厚み３０ｍｍ、幅８００ｍｍ、高さ２０００ｍｍの框組ドアを作製した。
【００４１】
実施例３
フラッシュ構造の木質扉基材を用意し、実施例２と同じ３層構造の防湿シ−トを用いてコ−ト紙側を基材側にして、真空プレスにてフラッシュ扉全面を真空貼りした。続いて、この上に木目柄の塩ビ化粧シ−トをコ−ルドプレスにて冷圧し、実施例１、２と同サイズのフラッシュ扉を作製した。
【図面の簡単な説明】
【図１】本発明の扉の１例を示す正面図。
【図２】本発明の扉構成部材の断面図。
【図３】本発明の扉構成部材の他の例を示す断面図。
【図４】本発明の３層構造からなる防湿シ−ト。
【図５】本発明の扉構成部材の断面詳細図。
【符号の説明】
１扉
２扉構成部材
２ａ縦框
２ｂ上框
２ｃ下框
２ｄ鏡板
２ｅ中框
３防湿シ−ト
４木質基材
５透湿度の高い方のシ−ト層
６透湿度の低い方のシ−ト層
７中間防湿層[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to doors used for interiors of houses, such as doors, folding doors and other fittings, entrance storage, storage units, furniture and the like. The purpose of this is to suppress the generation of ducks in the material and to supply a stable door of a stable quality with a smooth decorative surface at a low cost.
[0002]
[Prior art]
Conventionally, wood-based decorative materials used for fittings, doors, and the like inside a house include decorative materials on the surface of a wood-based base material such as plywood, MDF, particle board, LVL, or both front and back surfaces. Either the sheet was adhered or the entire surface of the substrate was wrapped and covered with a decorative sheet. As a decorative sheet, a so-called printed paper is often used, in which the surface of thin paper or reinforced paper of 23 to 30 g / m ² is grain-grained, and one or both of the thin paper and reinforced paper are laminated in multiple layers. What was called a doubling sheet was also used in part.
[0003]
Usually, a laminator is often used to apply the adhesive. In this case, the adhesive is applied to the back side of the decorative paper at a relatively high speed, and then the decorative sheet is pressed by a press roll or a flat plate press. In general, heat or cold pressure was applied to the surface of the wooden substrate by pressure.
[0004]
In addition, fittings and doors absorb and release moisture over time to prevent the door from warping, twisting, and abrasion.In general, vertical frames, horizontal frames, A synthetic resin sheet or a moisture-proof material made of a composite of a synthetic resin sheet and a paper material is attached to the front or back surface of the door component such as a head plate, or both of the front and back surfaces, or By covering the entire surface of the door component with a moisture-proof material, applying a moisture-proof paint that forms a moisture-proof film when dried, or combining a metal or inorganic moisture-proof material, Various contrivances have been made to the constituent members.
[0005]
[Problems to be solved by the invention]
When a thin sheet of about 23 g / m ² or 30 g / m ² is stuck as a decorative sheet used on the surface of a fitting such as a door or a door, the decorative sheet is thin, and accordingly, the sheet itself has a waist. Absorbing the moisture in the adhesive applied to the back surface of the sheet, the back surface is stretched, and the sheet is curled, which results in a very difficult adhesion. For this reason, since a laminator cannot be used as a sticking device, the sticking must be done by hand, and the production efficiency is remarkably reduced, which is uneconomical.
[0006]
In particular, when the base is a wood base such as particle board, MDF, etc., the base base absorbs the moisture in the adhesive, and the fibers on the surface become fluffy, and the decorative sheet thereon is used. A so-called "duck" was formed on the surface, which was a problem in appearance and tactile sensation, and significantly impaired commercial value.
[0007]
A doubling sheet in which thin paper or reinforced paper is combined may be used in order to reduce the occurrence of the lumpy ducks, but the occurrence of the ducks can be reduced by the thickness of the paper layer, but it is insufficient. However, a doubling sheet does not have the same moisture permeability as thin paper, and has poor moisture proof performance. Further, as described below, the door is prevented from warping due to the moisture proof effect, and a sheet when affixed with a laminator. -Unfortunately, there is no curl prevention effect.
[0008]
That is, in order to provide a moisture-proof performance for preventing warpage, a so-called moisture-proof seal is provided on both the front and back surfaces of the base material of the door components such as the vertical frame, the horizontal frame, and the end plate, or both the front and rear surfaces. Conventionally, a method of sticking or covering a moisture-proof material in which a moisture-proof sheet and another material are combined with each other by a wrapping process is used. In the case of a single-layer moisture-proof sheet such as a synthetic resin sheet, an expensive adhesive dedicated to the synthetic resin sheet is required, resulting in an increase in cost.
[0009]
In this case, the same resin sheet may be stuck on both sides of the door constituent member. However, if the sheet is stuck on one side, the base sheet itself may be warped as a problem before moisture proof performance due to expansion and contraction of the resin sheet itself. appear. Further, with only a single moisture-proof sheet, it is inevitable that the door constituting member becomes dull. In addition, a composite in which a paper layer or the like is compounded on both sides or one side of a moisture-proof layer such as a synthetic resin film has also been used for a long time. In this case, a paper layer is provided between the moisture-proof layer such as a synthetic resin film and the substrate. Because there are, ducks are reduced, but not perfect.
[0010]
In addition, when the adhesive is applied or covered, the moisture of the adhesive is absorbed by the paper layer on the side where the adhesive is applied, and the paper layer is elongated, causing curling. When sticking with a laminator, it is difficult to stick due to this curl, the defect rate also increases, the product quality decreases, the cost increases, and the market competitiveness becomes extremely poor. I was That is, the curl of the decorative sheet to be adhered to or covered by the door component, the duck on the surface of the door component, the door body completed by assembling the door component, warping due to moisture absorption and release, twisting, ablation, etc. Was a problem.
[0011]
[Means for Solving the Problems]
The present inventors have conducted intensive studies to solve the above problems, and as a result, have reached the following invention. That is, a three-layer moisture-proof sheet in which an intermediate moisture-proof layer is inserted between outer sheet layers having different moisture-permeabilities is attached to the surface of the door constituting member, with the side having the lower moisture-permeability as the base material side, Alternatively, it may be coated, that is, wrapped.
[0012]
In this case, when performing lamination using a laminator or lapping using a lapping machine or a vacuum press, an adhesive is applied to the side of the moisture-proof sheet having a low moisture permeability. As described above, the moisture in the adhesive is absorbed by the sheet layer, that is, the paper layer, so that the surface is elongated, thereby curling the moisture-proof sheet. And stable production. Further, since the moisture permeability is low, the amount of the adhesive applied can be suppressed to be lower than that in a normal case, so that the fluffing of the wood fibers of the door constituting member is reduced, and the moisture-proof sheet has three layers. Therefore, slight fluffing of the wood fiber is less noticeable, so that the generation of ducks can be completely prevented.
[0013]
These members are used as door vertical frames, upper frames, lower frames, middle frames, end panels, etc., and by combining these components, the doors have moisture-proof performance, are resistant to warping after construction, and A product of stable quality without generation can be stably produced without causing the curling of the decorative sheet during sticking or wrapping of the decorative sheet, and can be provided to the market at low cost. Things.
[0014]
As a processing method for bonding the moisture-proof sheet to the wooden base material, even if it is applied one by one to the base material surface of the door component by a laminator, a cold press, a hot press, etc., it is practically sufficient. Although it is possible to provide excellent moisture-proof performance, it is better to wrap or cover the entire surface of the door component using a lapping machine or a vacuum press, so that the moisture-proof sheet is continuous and seamless at the corners of the door component. So that more complete moisture-proof performance can be achieved.
[0015]
Further details will be described below. By sticking or covering, that is, wrapping, the moisture-proof sheet with the side with low moisture permeability of the base material side, fluffing of the fiber of the wood base material due to moisture in the adhesive is suppressed. That is, in the case of sticking or covering, if an adhesive is applied to the outer sheet layer having the lower moisture permeability of the moisture-proof sheet, the adhesive is applied to the outer sheet layer having the higher moisture permeability. As compared with the above, the penetration of the adhesive into the sheet layer is suppressed, and therefore, a small amount of the adhesive can be applied, and the amount of moisture brought into the adhesive by the adhesive to the wood base material side can be suppressed. The fluffing of the fiber of the material is suppressed, and the occurrence of duck can be prevented.
[0016]
Conversely, if applied on the side with high moisture permeability, the adhesive will be too sticky, making it difficult to apply a small amount, and the amount of moisture in the adhesive brought into the substrate surface will increase, and the wood fibers on the substrate surface will swell. However, the surface becomes uneven, and the surface of the moisture-proof sheet becomes bumpy.
[0017]
Further, since the intermediate layer of the moisture-proof sheet has a moisture-proof layer, a moisture-proof function is provided and the door itself can be prevented from warping.
[0018]
In addition, since the adhesive is applied to the lower moisture-permeable side of the three-layer moisture-proof sheet, the amount of moisture taken in the adhesive into the outer sheet layer is suppressed, so that the elongation of the layer is reduced. Is considerably suppressed, and the curl of the moisture-proof sheet generated due to elongation on only one side is suppressed.
[0019]
Further, when the outer two layers of the moisture-proof sheet are made of, for example, a paper material, a normal wood adhesive can be used as an adhesive to the wood base material, so that the production becomes easier. And the manufacturing cost is low. Further, as the surface decorative material, printed paper, coated paper, vinyl chloride sheet, wood veneer, or the like having a wood grain printed on the surface is used. In any case, if the outer two layers of the moisture-proof sheet are paper layers, the adhesive for wood can be used, so that the manufacturing is relatively simple and the cost is low. However, the present invention is not limited to this, and it is possible to solve the problem by selecting a dedicated adhesive even for a layer other than the paper layer, and it is also possible to select a material that can use a wood adhesive other than the paper layer.
[0020]
The other side of the moisture-proof sheet, that is, the side opposite to the base material, is formed of a sheet layer or a paper layer having high moisture permeability. When an agent is used, the higher the moisture permeability, the more the amount of the adhesive applied is not limited, so that the production is easy and stable production is possible.
[0021]
【The invention's effect】
A three-layer moisture-proof sheet having an intermediate moisture-proof layer inserted between outer sheet layers having different moisture permeability, is adhered or covered on the surface of the door member, with the side having the lower moisture permeability as the base material side. By using the wooden base material made as a door component such as a vertical frame, an upper frame, a lower frame, a middle frame, and a mirror panel of a fitting such as a door, a moisture-proof function is imparted to the door, the door, etc. The door can be prevented from warping, twisting, and ablation due to moisture absorption and release, and the adhesive is applied to the side with low moisture permeability, so that the wood fiber fluffing of the base material surface is suppressed, and thus no ducks are generated. Stable doors and doors having a smooth surface and high quality can be provided.
[0022]
Also, when the moisture-proof sheet is adhered or coated on the substrate with a laminator or a wrapping machine or a vacuum press, only the side of the moisture-proof sheet to which the adhesive has been applied is markedly affected by the moisture in the adhesive. It is also possible to prevent the moisture-proof sheet from elongating and becoming curled. Therefore, a product with a low defect rate and stable quality can be easily manufactured at low cost.
[0023]
BEST MODE FOR CARRYING OUT THE INVENTION
The two outer layers of the three-layer moisture-proof sheet are different from each other in moisture permeability. As the sheet layer having the higher moisture permeability, a so-called paper layer such as a thin paper having a basis weight of about 23 to 100 g / m ² , a recycled paper, a kraft paper, or the like, or a nonwoven fabric or a cellophane is generally used.
[0024]
The sheet layer having the lower moisture permeability is a so-called coat such as lightweight coat paper, lightly coated paper, cast coat paper, etc. obtained by coating resin, paint, pigment, etc. on base paper such as thin paper. Paper or moisture-proof cellophane is used.
[0025]
The intermediate moisture-proof layer constituting the intermediate layer of the moisture-proof sheet may be a synthetic resin film of polyethylene, polypropylene, PVC, nylon or the like having a thickness of about 20 to 40 microns, aluminum foil, steel foil, stainless steel foil. Metallic foils having a thickness of about 10 to 15 mikun, synthetic paper by a film method using polyethylene, polypropylene or the like as a main raw material, inorganic sheets using glass fibers, and the like are used.
[0026]
Among them, as the intermediate moisture-proof layer, the synthetic resin film has stable moisture-proof performance, is easily available, and is suitable as an intermediate moisture-proof material. Among them, a polyethylene film having a thickness of 20 to 40 microns is most desirable from the viewpoint of moisture-proof performance, suitability for wrapping, price and the like. Further, if the outer sheet layer of the moisture-proof sheet is a paper layer, an adhesive for wood can be used and production is easy. The sheet layer having the lower moisture permeability of the outer sheet layer having a different moisture permeability is most preferably a paper layer having a moisture permeability of 300 g / m ² 24 hr or less.
[0027]
The reason is that if the moisture permeability is 300 g / m ² 24 hr or more, the curl of the moisture-proof sheet and the fluffing of the base material are likely to occur.
[0028]
The sheet layer having the higher moisture permeability is preferably a paper layer having a moisture permeability of 700 g / m ² 24 hr or more. The reason is that when printing paper, wood veneer, or the like is adhered or covered as a surface decorative material, it can be stably bonded, so that stable production can be achieved.
[0029]
Further, a polyethylene film having an intermediate moisture-proof layer having a thickness of 20 to 40 microns is desirable. The reason is that the polyethylene film is not only inexpensive but also softens when heat is applied, so that it is well adapted to the underlying substrate and easily processed when coated or wrapped.
[0030]
The above three-layer moisture-proof sheet is formed by laminating a sheet layer having a low moisture permeability on one side and a sheet layer having a high moisture permeability on the other side, and forming vinyl acetate, acrylic, urea, and phenol. A three-layer moisture-proof sheet is formed by laminating with an adhesive such as epoxy or ethylene vinyl acetate at an application amount of 10 to 50 g / m ² , or by laminating and bonding by a method such as heat welding. When the outer two layers are ordinary cellophane or moisture-proof cellophane, they can be laminated relatively easily at a temperature of 120 ° C. and a pressure of 1 kg / cm ² .
[0031]
As the base wood base material, MDF, particle board, OSB, hard board, or the like is used. The method of sticking to the base wood substrate is a method of sticking to one or both sides of the base wood substrate using a hot press or a cold press using a laminator in addition to the method of hot or cold pressing. There is. Regardless of whether the base material side is a paper layer such as a coated paper or a moisture-proof cellophane, the adhesive at this time is an adhesive for wood such as vinyl acetate, urea, melamine, synthetic latex, ethylene vinyl acetate, urethane, etc. It is better to use
[0032]
A three-layered moisture-proof sheet is wound into a roll, and while being unwound, an adhesive to be stuck is applied on the side having a low moisture permeability with a coating amount of 30 to 70 g / m ² as a guide. It is applied, and then hot or cold pressed by a laminator pressing roll.
[0033]
In addition to the above, there is also a so-called wrapping method in which a wooden base material is covered so as to cover it. The wrapping method is as follows. First, a moisture-proof sheet is applied to the surface of the base material by a laminator method, and then the side surface of the base material and the folded back portion of the base material are sequentially changed by a wrapping roll in which the inclination angle is sequentially changed. The sheet is pressed while bending the sheet sequentially. In addition, there is a method of lapping with a vacuum press. In this method, a moisture-proof sheet is put on the base material, a thin sheet of heat-resistant rubber is put on the base material, and air is evacuated from the lower side of the base material. The wrapping is performed by lowering the atmospheric pressure and bringing the moisture-proof sheet into close contact with the substrate at atmospheric pressure.
[0034]
【Example】
Next, the embodiment will be described in detail.
Example 1
Moisture-proof cellophane with a thickness of 20 microns and a thickness of 30 g / m ² (300th count) coated with a nitrocellulose-based moisture-proofing agent on one side and having a moisture permeability of 45 g / m ² 24 hr. And
[0035]
Then, as a sheet having a higher moisture permeability, a thin paper of 30 g / m ² was prepared. As the intermediate moisture-proof layer, a polypropylene film having a thickness of 20 μm and a moisture permeability of 13 g / m ² 24 hr was prepared. Each of the rolls has a width of 1000 mm and a length of 3000 m. An ethylene-vinyl acetate copolymer resin adhesive was applied to them at 40 g / m ² and bonded at a pressing temperature of 120 ° C. and a pressing pressure of 1.8 kg / cm ² to form a three-layer moisture-proof sheet.
[0036]
An MDF having a specific gravity of 0.65 and a thickness of 30 mm was prepared as a base wooden base material. Next, this is cut into the size of a door component such as a vertical frame, an upper frame, a lower frame, a middle frame, and a panel, and then the above-described three-layer moisture-proof sheet is placed on the moisture-proof cellophane side having low moisture permeability. Was made to be a wooden base material side, and four side surfaces were stuck together with a laminator to prepare a door constituent member. The adhesive at this time was a urea / vinyl acetate blend type, the coating amount was 48 g / m ² , the pressing pressure was 5.0 kg / cm ² , and the pressing temperature was 110 ° C.
[0037]
Further, a 0.3 mm-thick oak veneer was coated thereon with a urea melamine-based adhesive at a roll rate of 90 g / m ² , at a temperature of 125 ° C., a pressure of 8.0 kg / cm ² , and a pressing time of 2 minutes. Glued. This material is cut into the dimensions of the door components, that is, upper and lower frames, vertical frames, middle frames, end panels, etc., and further assembled using a wooden dowel, painted and finished with urethane resin paint, A framed door having a size of 30 mm, a width of 800 mm, and a height of 2000 mm was produced.
[0038]
Example 2
As coat layer, a basis weight of 73 g / m ² co - - sheet having a lower moisture permeability preparative paper, sheet of higher moisture permeability - were prepared kraft paper having a basis weight of 73 g / m ² as a coat layer. A polyethylene film having a thickness of 30 microns was prepared as an intermediate moisture-proof layer. These three layers were laminated at a fusion temperature of 130 ° C. using a polyethylene film as an intermediate layer by a heat fusion laminator method to produce a three-layer moisture-proof sheet.
[0039]
As a base material, a composite material having a total thickness of 35 mm was prepared by laminating a 5-mm-thick MDF on both sides of a 25-mm-thick LVL. This is cut into the thickness, width and length dimensions of the door components such as the vertical frame, the upper frame, the lower frame, the middle frame, and the end plate of the door, and then the above-mentioned moisture-proof sheet is applied to the entire six surfaces of these components. Was coated continuously using a lapping machine without any breaks in the sheet.
[0040]
At this time, the side of the coated paper having low moisture permeability was used as the base material side. At this time, the same adhesive as in Example 1 was used. Next, an oak veneer having a thickness of 0.3 mm was adhered to the surfaces of these door components in the same manner as in Example 1. The adhesive and bonding conditions at this time were the same as in Example 1. Subsequently, these door components were assembled using a wooden dowel and painted and finished with a urethane resin paint to produce a framed door having a thickness of 30 mm, a width of 800 mm, and a height of 2000 mm.
[0041]
Example 3
A wooden door base material with a flash structure was prepared, and the entire surface of the flash door was vacuum-applied by a vacuum press using the same three-layer moisture-proof sheet as in Example 2 with the coated paper side as the base material side. . Subsequently, a vinyl-grained PVC decorative sheet was cold-pressed on this with a cold press to produce flash doors of the same size as in Examples 1 and 2.
[Brief description of the drawings]
FIG. 1 is a front view showing an example of a door of the present invention.
FIG. 2 is a sectional view of a door component according to the present invention.
FIG. 3 is a cross-sectional view showing another example of the door constituting member of the present invention.
FIG. 4 is a moisture-proof sheet having a three-layer structure according to the present invention.
FIG. 5 is a detailed sectional view of a door constituting member of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Door 2 Door constituent member 2a Vertical frame 2b Upper frame 2c Lower frame 2d End plate 2e Middle frame 3 Moisture-proof sheet 4 Wood base material 5 Sheet layer with higher moisture permeability 6 Sheet with lower moisture permeability Layer 7 Middle moisture barrier

Claims

A three-layer moisture-proof sheet in which an intermediate moisture-proof layer is inserted between outer sheet layers having different moisture-permeabilities is adhered or covered using an aqueous adhesive with the side having a low moisture-permeability as the base material side. A door having moisture-proof performance, characterized in that a door made of a wooden base material is used.

2. The door having moisture-proof performance according to claim 1, wherein the entire surface of the door component is attached or covered with the moisture-proof sheet.

3. The door having moisture-proof performance according to claim 1, wherein the outer sheet layer having a different moisture permeability is a paper layer, and the intermediate moisture-proof layer is a synthetic resin film.

The outer sheet layer having a lower moisture permeability is a paper layer having a moisture permeability of 300 g / m ² 24 hr or less, and the outer sheet layer having a higher moisture permeability is a paper layer having a moisture permeability of 700 g / m ² 24 hr or more. The door having moisture-proof performance according to any one of claims 1 to 3, wherein the intermediate moisture-proof layer is a polyethylene film having a thickness of 20 to 40 microns.