JP3636009B2 - Laminate and manufacturing method thereof - Google Patents

Laminate and manufacturing method thereof Download PDF

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Publication number
JP3636009B2
JP3636009B2 JP33355199A JP33355199A JP3636009B2 JP 3636009 B2 JP3636009 B2 JP 3636009B2 JP 33355199 A JP33355199 A JP 33355199A JP 33355199 A JP33355199 A JP 33355199A JP 3636009 B2 JP3636009 B2 JP 3636009B2
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Japan
Prior art keywords
base material
resin
adhesive sheet
paper layer
adhesive
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JP2001150597A (en
Inventor
力 渡辺
宏明 碓氷
悟 小西
浩司 南
政介 塚本
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Panasonic Electric Works Co Ltd
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Matsushita Electric Works Ltd
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Description

【０００１】
【発明の属する技術分野】
本発明は、樹脂を含有する基材の表面に突き板のような表面材を積層一体化した積層板の構造及びその製造方法に関するものである。
【０００２】
【従来の技術及び発明が解決しようとする課題】
従来から、木粉入り樹脂板よりなる基材に突き板のような表面材を貼り合わせる場合、溶剤系接着剤のような接着剤で貼り合わせている。ところが、樹脂を含有した基材に直接接着剤を介して突き板のような表面材を貼ると、基材に対する接着性が特に悪くて接着強度が低いという問題がある。接着強度を高めようとすれば基材に表面処理が必要であり、工数が増えるという問題がある。
【０００３】
本発明は上記の点に鑑みてなされたものであり、接着強度を向上して基材に表面材を強固に一体化できる積層板とその製造方法を提供することを課題とするものである。
【０００４】
【課題を解決するための手段】
上記課題を解決するための本発明の積層板は、紙層４と、樹脂を含有した基材１と同質の樹脂繊維の入った紙層５の複合体の接着シート３を介して、上記樹脂を含有した基材１の表面に表面材２を積層一体化したことを特徴とする。このように基材１と表面材２との間に接着シート３を介して接着することにより、接着シート３と基材１とが強固に一体化され、基材１に対する表面材２の接着強度が向上して強固に一体化できる。
【０００５】
また基材１は木粉と樹脂とを含有した木粉入り樹脂板であることを特徴とすることも好ましい。
【０００６】
また本発明の積層板の製造方法は、紙層４と、樹脂を含有した基材１と同質の樹脂繊維の入った紙層５の複合体を接着シート３として用い、樹脂を含有した基材１を押出成形にて連続的に成形すると共に上記基材１を押出した直後の軟らかい状態で接着シート３を基材１に積層して一体化し、しかる後、接着シート３に表面材２を接着することを特徴とする。基材１を押出した直後の軟らかい状態で接着シート３を基材１に積層して一体化することにより、基材１に接着シート３を熱融着により強固に一体化できると共に基材１の製造工程で接着シート３を同時に一体化できる。これにより接着シート３を介して表面材２を強固に一体化できると共に接着シート３を介して接着するものでも容易に製造できる。また紙層４と、樹脂を含有した基材１と同質の樹脂繊維の入った紙層５の複合体を接着シート３として用いることにより、接着シート３と基材１とが強固に一体化され、基材１に対する表面材２の接着強度が向上して強固に一体化できる。
【０００７】
【発明の実施の形態】
本発明の積層板は、図１に示すように樹脂を含有した基材１の上に接着シート３を介して表面材２を一体化してある。基材１は例えば木粉入り樹脂板であるが、具体的には木粉入りポリプロピレン板である。この木粉入りポリプロピレン板の構成は例えば、木粉５０重量部、ポリプロピレン系樹脂４５重量部、マレイン酸変性ポリプロピレン６重量部である。この基材１の厚みは０．５〜２０ｍｍ程度である。表面材２は例えば、突き板であり、具体的な一例としてはナラ材で厚みが０．２５ｍｍである。
【０００８】
接着シート３は、紙層４と樹脂繊維を含む紙層５との複合体であるが、紙層４はパルプや麻を主成分とする層であり、紙層５はパルプや麻と樹脂繊維を含有する層である。この樹脂繊維は基材１が木粉入りポリプロピレンの場合、ポリプロピレン繊維である。この紙層５はパルプと樹脂繊維を含有するが樹脂繊維の量は４０〜７０重量％である。この接着シート３の密度は０．５ｇ／ｃｍ３以下である。上記樹脂繊維としてのポリプロピレン繊維は繊維長さが５ｍｍ程度で太さは２デニール程度である。この２層の紙層４，５よりなる接着シート３を製造する場合、別々に湿式抄造し、貼り合わせてから乾燥させることで一体化されるものであり、必要に応じてホットロールプレスにて補強される。この２層の紙層４，５よりなる接着シート３の具体的な製品としては、ヒートパックＭＷ３０［日本板紙（株）］、ヒートパックＭＷ５０［日本板紙（株）］、乾燥剤袋原紙［丸菱ペーパーテック（株）］等がある。また接着シート３は樹脂繊維を含む紙層５側が基材１側を向くように一体化される。
【０００９】
木粉入り樹脂板よりなる基材１を成形するとき図２に示すように押出成形機８にて押出成形することで成形されるが、押出成形した基材１は複数個のローラ９に通され、基材１が軟らかいうちに接着シート３が基材１とローラ９との間に挿入され、熱圧することで接着シート３と基材１とが一体化される。このようにすることで接着シート３の樹脂と基材１の樹脂が熱融着することで強固に一体化され、ポリプロピレンのような離型性のある樹脂でも強固に一体化される。
【００１０】
基材１に接着シート３を一体化した後、接着シート３を介して突き板のような表面材２が一体化されるが、このとき酢酸ビニル樹脂エマルジョン接着剤や水性ビニルウレタン接着剤のような接着剤を介して接着される。この表面材２を接着剤で接着するときの熱圧プレス条件は例えば、温度が１１０〜１３０℃、圧力が５９００００〜７８００００Ｐａ（６〜８Ｋｇｆ／ｃｍ２）、時間３０〜１２０秒の条件で行う。接着剤の塗布量は５０〜１２０ｇ／ｍ２である。このように表面材２を貼ることで溶剤系の接着剤を使わずに水系の接着剤にて効率よく短時間で接着が可能になる。また接着シート３を介して表面材２を接着するとき、接着シート３の表面材２への接着側は密度が０．５ｇ／ｃｍ３以下であり、接着剤が接着シート３に十分に浸透し、表面材２の目開きを防止できると共に接着性を向上できる。
【００１１】
また上記のような構成とした本発明の積層板と従来の構造の積層板の性能を比較した場合、表１の通りとなり、本発明のものの性能が優れていることがわかる。
【００１２】
【表１】

Figure 0003636009
【００１３】
＊従来例の突き板原紙とは厚み３０〜８０μｍ程度（目付２０〜５０ｇ／ｍ２程度）で突き板に接着して補強するための強化紙であり、主原料はパルプ、麻などである。
【００１４】
なお、樹脂繊維を含有する紙の樹脂繊維の含有率を４０〜７０重量％とした理由は次の理由からである。１０重量％刻みで接着力を評価したとき、３０重量％以下の場合、紙と木粉入り樹脂板との間の接着力は目標の６９００００Ｐａ（７Ｋｇｆ／ｃｍ２）以下であった（合板の平面引っ張り強度は６９００００Ｐａ以上である）。このため樹脂繊維の含有率を４０重量％以上とした。また樹脂繊維含有率の上限を７０重量％にしたのは７０重量％以上では紙が抄造できないためである。また樹脂繊維１００％なら商品として存在するが、紙でなく不織布になる。不織布でも木粉入り樹脂板のような基材１と熱融着により接着するが、熱融着時に樹脂繊維が密状態となり、突き板のような表面材２を接着するための接着剤がしみ込まなくなって接着できない。
【００１５】
【発明の効果】
本発明の積層板は、紙層と、樹脂を含有した基材と同質の樹脂繊維の入った紙層の複合体の接着シートを介して、上記樹脂を含有した基材の表面に表面材を積層一体化したので、基材と表面材との間に接着シートを介して接着するとき接着シートと基材とが強固に一体化され、基材に対する表面材の接着強度が向上して強固に一体化できるものである。
【００１６】
また本発明の積層板の製造方法は、樹脂を含有した基材を押出成形にて連続的に成形すると共に上記基材を押出した直後の軟らかい状態で接着シートを基材に積層して一体化し、しかる後、接着シートに表面材を接着するので、基材を押出した直後の軟らかい状態で接着シートを基材に積層して一体化することにより、基材に接着シートを熱融着により強固に一体化できると共に基材の製造工程で接着シートを同時に一体化できるものであって、接着シートを介して表面材を強固に一体化できると共に接着シートを介して接着するものでも容易に製造できるものである。また紙層と、樹脂を含有した基材と同質の樹脂繊維の入った紙層の複合体を接着シートとして用いているので、基材と表面材との間に接着シートを介して接着するとき接着シートと基材とが強固に一体化され、基材に対する表面材の接着強度が向上して強固に一体化できるものである。
【図面の簡単な説明】
【図１】 本発明の実施の形態の積層板の構造を示す断面図である。
【図２】 同上の製造工程を説明する説明図である。
【符号の説明】
１ 基材
２ 表面材
３ 接着シート
４ 紙層
５ 紙層 [0001]
BACKGROUND OF THE INVENTION
The present invention relates to a structure of a laminated board obtained by laminating and integrating a surface material such as a veneer on the surface of a substrate containing a resin, and a method for manufacturing the same.
[0002]
[Prior art and problems to be solved by the invention]
Conventionally, when a surface material such as a veneer is bonded to a base material made of a resin plate containing wood powder, it is bonded with an adhesive such as a solvent-based adhesive. However, when a surface material such as a veneer is pasted directly on a base material containing a resin via an adhesive, there is a problem that the adhesive strength to the base material is particularly bad and the adhesive strength is low. If it is going to raise adhesive strength, surface treatment is required for a base material, and there exists a problem that a man-hour increases.
[0003]
This invention is made | formed in view of said point, and makes it a subject to provide the laminated board which can improve a bonding strength, and can integrate a surface material on a base material firmly, and its manufacturing method.
[0004]
[Means for Solving the Problems]
The laminated board of the present invention for solving the above-mentioned problems is obtained by using the resin sheet 4 and the composite adhesive sheet 3 of the paper layer 5 containing resin fibers of the same quality as the base material 1 containing the resin. The surface material 2 is laminated and integrated on the surface of the base material 1 containing the material . In this way , the adhesive sheet 3 and the base material 1 are firmly integrated by bonding between the base material 1 and the surface material 2 via the adhesive sheet 3, and the adhesive strength of the surface material 2 to the base material 1. Can be integrated firmly.
[0005]
Moreover, it is also preferable that the base material 1 is a resin plate containing wood powder containing wood powder and resin.
[0006]
Moreover, the manufacturing method of the laminated board of this invention uses the composite of the paper layer 4 and the paper layer 5 containing the resin fiber of the same quality as the base material 1 containing resin as the adhesive sheet 3, and the base material containing resin 1 is continuously formed by extrusion molding, and the adhesive sheet 3 is laminated and integrated with the base material 1 in a soft state immediately after the base material 1 is extruded, and then the surface material 2 is bonded to the adhesive sheet 3. It is characterized by doing. By laminating and integrating the adhesive sheet 3 with the base material 1 in a soft state immediately after the base material 1 is extruded, the adhesive sheet 3 can be firmly integrated with the base material 1 by heat fusion and the base material 1 The adhesive sheet 3 can be integrated simultaneously in the manufacturing process. As a result, the surface material 2 can be firmly integrated through the adhesive sheet 3 and can be easily manufactured even if it is bonded through the adhesive sheet 3. Moreover, the adhesive sheet 3 and the base material 1 are firmly integrated by using the composite of the paper layer 4 and the paper layer 5 containing the resin fiber of the same quality as the base material 1 containing the resin as the adhesive sheet 3. The adhesion strength of the surface material 2 to the base material 1 is improved and can be firmly integrated.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
In the laminate of the present invention, as shown in FIG. 1, a surface material 2 is integrated on a base material 1 containing a resin via an adhesive sheet 3. The base material 1 is, for example, a resin plate containing wood powder, and specifically, a polypropylene plate containing wood powder. The structure of this wood powder-containing polypropylene plate is, for example, 50 parts by weight of wood powder, 45 parts by weight of polypropylene resin, and 6 parts by weight of maleic acid-modified polypropylene. The substrate 1 has a thickness of about 0.5 to 20 mm. The surface material 2 is, for example, a veneer and, as a specific example, is a oak material and has a thickness of 0.25 mm.
[0008]
The adhesive sheet 3 is a composite of a paper layer 4 and a paper layer 5 containing resin fibers. The paper layer 4 is a layer mainly composed of pulp and hemp, and the paper layer 5 is pulp, hemp and resin fibers. It is a layer containing. This resin fiber is a polypropylene fiber when the base material 1 is polypropylene containing wood flour. The paper layer 5 contains pulp and resin fibers, but the amount of resin fibers is 40 to 70% by weight. The density of the adhesive sheet 3 is 0.5 g / cm 3 or less. The polypropylene fiber as the resin fiber has a fiber length of about 5 mm and a thickness of about 2 denier. When the adhesive sheet 3 composed of the two paper layers 4 and 5 is manufactured, it is integrated by wet papermaking, bonding and drying, and if necessary, by hot roll press Reinforced. Specific products of the adhesive sheet 3 composed of the two paper layers 4 and 5 include heat pack MW30 [Nippon Paperboard Co., Ltd.], heat pack MW50 [Nippon Paperboard Co., Ltd.], desiccant bag base paper [Maru Ryo Paper Tech Co., Ltd.]. The adhesive sheet 3 is integrated so that the paper layer 5 side including the resin fibers faces the base material 1 side .
[0009]
When the base material 1 made of a wood powder- containing resin plate is formed, the base material 1 is formed by extrusion using an extruder 8 as shown in FIG. The adhesive sheet 3 is inserted between the base material 1 and the roller 9 while the base material 1 is soft, and the adhesive sheet 3 and the base material 1 are integrated by hot pressing. By doing in this way, the resin of the adhesive sheet 3 and the resin of the base material 1 are firmly integrated by heat-sealing, and even a resin having releasability such as polypropylene is firmly integrated.
[0010]
After the adhesive sheet 3 is integrated with the base material 1, the surface material 2 such as a veneer is integrated through the adhesive sheet 3, but at this time, like a vinyl acetate resin emulsion adhesive or an aqueous vinyl urethane adhesive It is bonded through a proper adhesive. The hot press conditions for bonding the surface material 2 with an adhesive are, for example, a temperature of 110 to 130 ° C., a pressure of 590000 to 780000 Pa (6 to 8 kgf / cm 2 ), and a time of 30 to 120 seconds. The application amount of the adhesive is 50 to 120 g / m 2 . By sticking the surface material 2 in this manner, it becomes possible to bond efficiently with a water-based adhesive in a short time without using a solvent-based adhesive. Further, when the surface material 2 is bonded through the adhesive sheet 3, the density of the adhesive sheet 3 on the side to be bonded to the surface material 2 is 0.5 g / cm 3 or less, and the adhesive sufficiently penetrates the adhesive sheet 3. Moreover, the opening of the surface material 2 can be prevented and the adhesiveness can be improved.
[0011]
Further, when the performances of the laminate of the present invention configured as described above and the laminate of the conventional structure are compared, it is as shown in Table 1 and it can be seen that the performance of the present invention is superior.
[0012]
[Table 1]
Figure 0003636009
[0013]
* The conventional veneer base paper is a reinforced paper for adhering and reinforcing the veneer with a thickness of about 30 to 80 μm (approx. 20 to 50 g / m 2 ), and the main raw materials are pulp, hemp and the like.
[0014]
The reason why the resin fiber content of the resin fiber is 40 to 70% by weight is as follows. When the adhesive strength was evaluated in increments of 10% by weight, when it was 30% by weight or less, the adhesive force between the paper and the resin plate containing wood flour was not more than the target 690000 Pa (7 Kgf / cm 2 ) (the plane of the plywood). The tensile strength is 690000 Pa or more). Therefore, the resin fiber content is set to 40% by weight or more. The upper limit of the resin fiber content is set to 70% by weight because paper cannot be made at 70% by weight or more. If it is 100% resin fiber, it exists as a product, but it becomes a non-woven fabric instead of paper. Even non-woven fabrics are bonded to the base material 1 such as a resin plate containing wood powder by heat fusion, but the resin fibers are in a dense state at the time of heat fusion, and an adhesive for adhering the surface material 2 such as a veneer is infiltrated. Can't be glued.
[0015]
【The invention's effect】
The laminate of the present invention has a paper layer and a surface material on the surface of the resin-containing substrate through an adhesive sheet of a composite of a paper layer containing resin fibers of the same quality as the resin-containing substrate. Since the lamination is integrated, the adhesive sheet and the base material are firmly integrated when the base material and the surface material are bonded via the adhesive sheet, and the adhesive strength of the surface material to the base material is improved and strengthened. It can be integrated.
[0016]
Also, the method for producing a laminate of the present invention comprises continuously forming a base material containing a resin by extrusion molding and laminating the adhesive sheet on the base material in a soft state immediately after extruding the base material. After that, since the surface material is bonded to the adhesive sheet, the adhesive sheet is laminated and integrated with the base material in a soft state immediately after the base material is extruded, so that the adhesive sheet is firmly bonded to the base material by heat fusion. In addition, the adhesive sheet can be integrated at the same time in the manufacturing process of the base material, and the surface material can be firmly integrated via the adhesive sheet and can be easily manufactured even if it is bonded via the adhesive sheet. Is. Also, since a composite of a paper layer and a paper layer containing resin fibers of the same quality as the resin-containing base material is used as an adhesive sheet, when bonding between the base material and the surface material via an adhesive sheet The adhesive sheet and the base material are firmly integrated, and the adhesive strength of the surface material to the base material is improved and can be firmly integrated.
[Brief description of the drawings]
1 is a cross sectional view showing the structure of a laminate according to the embodiment of the present invention.
FIG. 2 is an explanatory diagram for explaining the manufacturing process of the above.
[Explanation of symbols]
1 Base material 2 Surface material 3 Adhesive sheet 4 Paper layer 5 Paper layer

Claims (3)

紙層と、樹脂を含有した基材と同質の樹脂繊維の入った紙層の複合体の接着シートを介して、上記樹脂を含有した基材の表面に表面材を積層一体化したことを特徴とする積層板。 The surface material is laminated and integrated on the surface of the base material containing the resin through the adhesive sheet of the composite material of the paper layer and the paper layer containing the same quality resin fiber as the base material containing the resin. Laminated board. 基材は木粉と樹脂とを含有した木粉入り樹脂板であることを特徴とする請求項１に記載の積層板。The laminated board according to claim 1, wherein the base material is a resin board containing wood powder containing wood powder and resin . 紙層と、樹脂を含有した基材と同質の樹脂繊維の入った紙層の複合体を接着シートとして用い、樹脂を含有した基材を押出成形にて連続的に成形すると共に上記基材を押出した直後の軟らかい状態で接着シートを基材に積層して一体化し、しかる後、接着シートに表面材を接着することを特徴とする積層板の製造方法。A composite of a paper layer and a paper layer containing resin fibers of the same quality as the resin-containing base material is used as an adhesive sheet, and the resin-containing base material is continuously formed by extrusion and the base material A method for producing a laminated board, comprising: laminating and integrating an adhesive sheet on a base material in a soft state immediately after extrusion, and then bonding a surface material to the adhesive sheet.
JP33355199A 1999-11-25 1999-11-25 Laminate and manufacturing method thereof Expired - Fee Related JP3636009B2 (en)

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