JP4007938B2 - Manufacturing method of cosmetic material - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative material such as a flooring material, an inner wall material, and a ceiling material. Manufacturing method About.
[0002]
[Prior art and problems to be solved by the invention]
Conventionally, decorative materials used for flooring and the like generally form fruit on joints, but for example, when directly applied to the upper surface of a heat generating mat adjusted to a temperature of 55 ° C to 65 ° C Is required to have excellent heat resistance. Further, the decorative material may be required to be thin for construction reasons, and it is usually desired that the thickness is 6 mm or less. In order to overcome such severe use conditions (thinness, heat generation, and drying), the base material of the decorative material is required to have high physical performance. Therefore, plywood, MDF, and autoclaved inorganic A plate is used as the substrate.
[0003]
However, in the above-mentioned plywood, since the thermal conductivity is low, the rise of the floor heating is bad and the floor heating efficiency is not good. Further, the plywood has poor dimensional stability in the horizontal direction against heat and water. For this reason, when used for floor heating, there is a pick-up that creates a gap in the mated real part (a condition in which the joint width has increased due to contraction of the flooring material) or a part where the real part is abutted due to the expansion of the base material. There was a problem that a phenomenon called this occurred. Furthermore, since the surface of the plywood is relatively soft, there is a problem that the decorative layer on the surface is easily damaged.
[0004]
Then, in order to improve damage resistance, the interior material for construction which uses rock wool as the main material is proposed (for example, refer to patent documents 1).
[0005]
[Patent Document 1]
JP 2000-320103 A (FIG. 1)
[0006]
However, in the interior material for building described above, rock wool is the main component, it is only reinforced by impregnating synthetic resin, and it is not easy to completely retain the impregnated synthetic resin only with rock wool. It is difficult to obtain a desired strength in the real part.
[0007]
Further, when a flooring material as a decorative material is subjected to a cutting process such as a pseudo joint or chamfering, when the surface is desired to be light-colored, if the background color is dark, the cutting part becomes conspicuous. Therefore, it has been studied to select a plywood whose surface is light or to replace the generally dark-colored South Seawood MDF with a light-colored conifer MDF. However, if the color tone of plywood or MDF is selected and used, the range in which the material can be selected becomes narrow, so that it is difficult to stably supply the material and the productivity is very poor.
[0008]
As a means to solve the problems caused by the dimensional change peculiar to wood materials, the ease of scratching due to softness, and the swelling caused by water or wax, wood veneers are placed on the front and back surfaces of autoclaved inorganic plates. There is something that is pasted and used as a flooring.
However, the inorganic plate is inherently heavy, and there is a problem in that the real part is easily chipped by a slight impact force received during transportation and construction.
[0009]
The present invention has the excellent thermal dimensional stability, water resistance and scratch resistance of the inorganic board, and has the excellent impact resistance, workability and cutting workability of the wood material, and the real part has the desired strength. Stable supply of cosmetic materials Providing a manufacturing method for cosmetics The purpose is to do.
[0010]
[Means for Solving the Problems]
Cosmetic material according to the present invention Manufacturing method In order to achieve the above purpose, A wet mat obtained by wet-making a slurry containing 35 to 70% by weight of mineral fiber and / or organic fiber, 25 to 55% by weight of inorganic powder, and 5 to 25% by weight of a binder as essential components. After impregnating the front and back surfaces of a semi-cured mat having a specific gravity of 0.3 to 0.9 obtained by performing a primary hot press with a first resin liquid having a diluted resin ratio of 10 to 60%, By applying and impregnating a second resin liquid having a concentration equal to or higher than that of the first resin liquid in the area where the part is to be formed and performing the second hot press, the specific gravity of the area where the real part is formed is A process of obtaining a base material that is 5% or more higher than the specific gravity of a region not to be formed, applying a decorative process to the surface of the base material, and forming a real part It consists of
[0011]
Moreover, the manufacturing method of the other cosmetics concerning this invention is as follows. A wet mat obtained by wet-making a slurry containing 35 to 70% by weight of mineral fiber and / or organic fiber, 25 to 55% by weight of inorganic powder, and 5 to 25% by weight of a binder as essential components. The front and back surfaces of the semi-cured mat having a specific gravity of 0.3 to 0.9 obtained by the primary hot press are impregnated with a diluted resin solution having a resin ratio of 10 to 60%, respectively, and the secondary heat Embossing is performed on at least one side of the region where the real part is formed by pressure pressing, and a base material having a specific gravity of 5% or more higher than the specific gravity of the region where the real part is not formed is obtained. The process of applying cosmetic processing to the surface and forming the real part It may consist of.
[0012]
According to the above-mentioned method for producing a decorative material, the strength of the real part is high, and it has excellent thermal dimensional stability, water resistance and scratch resistance like an inorganic board, and also has impact resistance and workability similar to a wooden material. In addition, a decorative material having cutting workability can be obtained, and in particular, a decorative material for flooring that can also be used for floor heating can be stably supplied. In addition, the use of hard fiberboard with excellent thermal conductivity has the effect of providing a cosmetic material that exhibits the excellent temperature rise characteristics (fast heating start-up) required for floor heating flooring. is there.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Cosmetic material according to the present invention Manufacturing method This embodiment is a case where the present invention is applied to flooring for floor heating, and is manufactured by the following procedure.
That is, mineral fiber, inorganic powder and binder are put into water, and additives such as water repellent, antifoaming agent and pigment are added and stirred, and then auxiliary additives such as flocculant are added. Thus, a slurry having a solid content rate of several percent is obtained. Next, a primary hot press (temperature 60 to 120 ° C., pressure 5 to 7 kg / cm) is applied to a wet mat obtained by paper making and dewatering the slurry with a long net type or round net type paper machine. ² And pressurizing time 30 to 150 seconds) to obtain a pre-semi-cure mat, and then drying with a hot-air ventilation dryer to obtain a semi-cure mat.
[0014]
Then, the semi-cured mat is impregnated with the diluted low concentration first resin liquid, and further, the high concentration second resin liquid is applied and impregnated in the region where the real part is formed. Then, after obtaining a hard fiberboard having an average specific gravity of 1.2 to 1.7 and a thickness of 2 to 6 mm by applying a secondary hot press under a higher temperature and high pressure condition than the primary hot press, A decorative sheet is attached and integrated on the surface of the hard fiberboard, and a flooring is obtained by actual processing.
[0015]
Examples of the mineral fiber include rock wool, slag wool, glass wool, glass fiber, and the like, and these are used alone or in combination. The mineral fiber is added in an amount of 35 to 70% by weight, particularly 45 to 60% by weight. This is because if the mineral fiber is less than 35% by weight, the bending strength of the obtained semi-cured mat becomes weak and handling of the semi-cured mat becomes difficult. On the other hand, when the mineral fiber exceeds 70% by weight, the amount of inorganic powder added relatively decreases, and the obtained semi-cure mat is coated and impregnated with a resin solution diluted with water. This is because the density is hardly increased even by hot pressing.
[0016]
Heat resistant organic fibers may be used as a partial substitute for the mineral fibers. This is because the use of heat-resistant organic fibers dramatically improves the Charpy impact strength, and is extremely effective in improving cracks, chipping and chipping during cutting. Here, the heat-resistant organic fiber means a fiber that does not melt even when hot-pressed at a temperature of 150 to 200 ° C., for example, nylon, tetron, polyamide, polypropylene, polyethylene terephthalate, polyurethane, various rubber fibers, and These composites or wood fibers can be mentioned.
[0017]
The addition amount of the heat resistant organic fiber is preferably 0.5 to 15% by weight of the total weight. This is because when the amount added is less than 0.5% by weight, there is almost no effect of improving the Charpy impact strength. Further, if the addition amount exceeds 15% by weight, not only a cohesive failure occurs during papermaking, but a semi-cured mat having a non-uniform density is obtained, and even if the semi-cured mat is subjected to hot press again, the specific gravity is increased. This is because the Charpy impact strength is reduced.
[0018]
The length of the heat resistant organic fiber is preferably 1.0 to 15 mm. If the length is less than 1.0 mm, there is almost no effect of improving Charpy impact strength. If the length exceeds 15 mm, a cohesion failure occurs during papermaking, and a semi-cured mat with uniform density cannot be obtained. is there.
[0019]
The thinner the heat-resistant organic fiber is, the more uniformly it can be dispersed at the time of papermaking. Therefore, a thin one is preferable in order to exert an effect in a small amount, and generally has a diameter of 500 μm or less, more preferably 30. Those having a thickness of ˜100 μm are preferred.
[0020]
Examples of the inorganic powder include shirasu foam, silica flour, glass foam, calcium carbonate, aluminum oxide, vermiculite, and the like. These may be used alone or in combination. Moreover, it is preferable to add the said inorganic powdery material in the ratio of 20 to 55 weight%. This is because when the inorganic powder is less than 20% by weight, the bending strength of the obtained semi-cured mat becomes weak and handling of the semi-cured mat becomes difficult. On the other hand, if the amount of inorganic powder exceeds 55% by weight, the amount of mineral fiber added is relatively small, and the resulting semi-cured mat is coated and impregnated with a resin solution diluted with water. However, even if it is hot-pressed again, the density is difficult to increase.
[0021]
Examples of the binder include melamine resin, phenol resin, isocyanate resin, polyvinyl alcohol, acrylic emulsion or vinyl acetate emulsion and modified products thereof, starch, corn starch, soybean flour, wheat flour, and the like. Used alone or in combination. The addition amount of the binder is preferably 5 to 25% by weight. This is because when the amount added is less than 5% by weight, the strength of the semi-cured mat is insufficient. Moreover, when the addition amount exceeds 25% by weight, the addition amount of the mineral fiber is relatively reduced, and in particular, the bending strength is weakened.
[0022]
In particular, if the binder is an isocyanate resin, polyvinyl alcohol, acrylic emulsion or vinyl acetate emulsion and modified products thereof, starch, corn starch, soybean flour, wheat flour, 60 ° C. to 120 ° C. during semi-cure by the first hot press. The bending performance of a semi-cured mat having a specific gravity of 0.3 to 0.9 can be improved and the handleability can be improved by curing with heat at 0 ° C. and curing when drying to a moisture content of 10% or less.
However, when the addition amount of polyvinyl alcohol, vinyl acetate emulsion and their modified products, starch, corn starch, soybean powder or wheat flour increases, the water resistance of the finally obtained cosmetic material deteriorates. For this reason, when using these as a binder, it is desirable to make the addition amount 5% by weight or less and use it together with other binders.
[0023]
On the other hand, for example, binders excellent in water resistance such as the melamine resin and the phenol resin are not completely cured by heat at 60 ° C. to 120 ° C. at the time of semi-curing by the first hot press, but are 150 to 250 ° C. By completely curing with a secondary hot press under high temperature and high pressure, the final decorative material exhibits excellent water resistance. However, since the above-mentioned binder having excellent water resistance is expensive, it is not desirable that the amount added exceeds 20% by weight.
[0024]
Therefore, it is desirable to use at least two types of a binder for improving the handling property of the semi-cured mat and a binder for improving the water resistance of the finally obtained cosmetic material. However, from the viewpoint of cost and water resistance, it is not preferable that the added amount of the binder exceeds a maximum of 25% by weight.
[0025]
A pre-semi-cure mat is obtained by subjecting a wet mat obtained by wet papermaking to a primary hot press. The semi-cure to improve the rigidity of the semi-cure mat, which will be described later, and improve the handling property is 3-7kg / cm pressure. ² The first hot pressing is performed at a temperature of 60 to 120 ° C. and a pressing time of about 40 seconds to 5 minutes. The press used for the primary hot press may be a single-stage or multi-stage batch press, or a continuous hot-press belt press.
[0026]
Then, the semi-cure mat having a specific gravity of 0.3 to 0.9 is obtained by drying the pre-semi-cure mat to a water content of 10% or less with a hot air dryer or the like preset at about 80 to 250 ° C.
[0027]
For the first resin liquid having a low concentration, vinyl urethane, acrylic emulsion, vinyl acetate emulsion, latex emulsion and modified products or mixtures thereof are used, and any water-soluble resin can be used. Among these, since the latex emulsion improves the bending strength of the hard fiber board, it is preferable to use it in a small amount (5 to 25% by weight) mixed with other resins. However, if the addition amount of the latex emulsion is increased, the suitability of the sander is deteriorated, so that an addition amount exceeding 25% by weight is not preferable.
Further, in order to improve the sander suitability, a hard resin (5 to 25% by weight) such as a melamine resin or a phenol resin may be added. However, if the addition amount of these resins exceeds 25% by weight, it becomes hard and brittle, which is not preferable.
[0028]
Further, the resin ratio of the first resin liquid having a low concentration is preferably adjusted to 10 to 60% by weight, particularly 15 to 40% by weight. If the resin ratio is less than 10% by weight, the effect of improving the dimensional stability and scratch resistance by the impregnated first resin liquid cannot be expected. If the resin ratio exceeds 60% by weight, the permeability of the first resin liquid is not expected. This is because remarkably decreases.
[0029]
Further, the first resin liquid diluted with water so that the resin ratio becomes 10 to 60% by weight is 300 g / m on each of the front and back surfaces of the semi-cured mat. ² As described above, it is preferable to impregnate by coating or dipping. For example, the coating amount is 200 g / m ² This is because most of the impregnated resin is removed by grinding of about 0.2 mm, and desired scratch resistance cannot be obtained. In particular, when used as a flooring material, it is generally sanded so that the surface becomes uniform before applying a decorative sheet or the like, and is ground by about 0.1 to 0.2 mm. For this reason, in order for the resin to remain sufficiently even after grinding of about 0.2 mm, 300 g / m ² Or more, preferably 400 g / m ² The application amount is required.
[0030]
The semi-cured mat exhibits a certain degree of water repellency due to the semi-curing of the adhesive. Therefore, in order to increase the permeability of the first resin liquid, the semi-cured mat is a penetrant (a kind of surfactant and the first resin diluted with water). Drugs that lower the surface tension of the liquid and increase its permeability) are added. In addition to the penetrant, an antifoaming agent or a release agent may be added as appropriate.
[0031]
In particular, when the first resin liquid diluted with water is impregnated, during the second hot press under high temperature and high pressure, burrs (water containing excess resin impregnated in the semi-cured mat at the time of pressing, 1) It is necessary to apply an amount corresponding to the thickness and specific gravity so that the resin liquid does not flow out of the semi-cure mat and is cured around the hard fiber board. For example, in the case of a semi-cured mat having a thickness of 6 mm and an average specific gravity of 0.4, the total amount of resin liquid impregnated from the front and back surfaces is 800 g / m. ² Exceeds 1,200 g / m ² Exceeds a large amount of burrs. Therefore, in the case of a semi-cured mat having a thickness of 6 mm and an average specific gravity of 0.4, resin 400 to 500 g / m on each of the front and back surfaces ² (Total amount 800-1000 g / m ² ) Is preferably applied and impregnated.
[0032]
Further, before applying and impregnating the first resin liquid, the generation of burrs may be suppressed by providing a through hole that communicates the recess or the front and back surfaces on at least one surface. These recesses or through holes also have an effect of allowing the first resin liquid diluted with water to penetrate inside.
[0033]
When the pitch between the recesses or the through-holes is larger than 2 cm, the effect of assisting infiltration is thin. For example, when recesses or through holes are provided at a pitch of 2 cm, 25/10 cm square recesses or through holes are provided in each 10 cm. In addition, when the pitch is 1 cm, approximately 100/10 cm square recesses or through holes are formed.
[0034]
The concave portion or the through hole may be provided by a batch type press with a large number of needle-like protrusions protruding from a flat plate, and it is preferable that the recess or the through hole is continuously processed by a large number of needle-like protrusions provided on the surface of the rotating roll .
[0035]
The concave portion needs to have a diameter of 3.0 mm or less, and preferably about 0.5 to 1.5 mm. When the diameter exceeds 3.0 mm, when the second hot press is performed under high temperature and high pressure conditions, uneven portions communicating with the front and back surfaces are generated and cannot be used as a flooring. However, when the concave portion has a diameter of 1.5 mm or more, it becomes difficult to completely fill the concave portion even when pressed under high temperature and high pressure conditions. For this reason, when providing the recessed part with a diameter of 1.5 mm or more, it is desirable to use only one side and to use the surface which provided the recessed part for the back surface of a flooring.
[0036]
The depth of the recess is preferably half or more of the entire thickness of the semi-cure mat. However, when the surface provided with the recesses is a decorative surface, it is preferable that the diameter is 1.0 mm or less and the depth is half or less of the entire thickness of the semi-cured mat. This is because by applying a high-temperature high-pressure press in the second hot press, the recesses themselves are crushed and filled with resin, so that the recesses can hardly be distinguished on the surface.
[0037]
On the other hand, in the case of a through hole, as described above, if the hole has a diameter of 1.5 mm or more, the hole does not completely fill even when pressed under high temperature and high pressure conditions. When forming a hole, a through hole having a diameter of 1.0 mm or less is desirable.
[0038]
For the high-concentration second resin liquid to be applied and impregnated in the area where the real part is formed, a resin ratio of 40% or more added with a penetrant is used, but the resin ratio is the low-concentration first resin. It may be equal to or higher than the liquid.
[0039]
As in the first resin liquid, the vinyl resin, acrylic emulsion, vinyl acetate emulsion, latex emulsion and modified products or mixtures thereof are used for the second resin liquid, and any water-soluble resin can be used. . Examples of the application method include cleaning application using a nozzle and the like, and cleaning application using a sponge coater. A larger coating amount is preferable, but it is preferable to apply the resin liquid so that the specific gravity of the region where the real part is formed is higher by about 5 to 15% than the specific gravity of the region where the real part is not formed. This is because if it is less than 5%, a desired strength cannot be obtained in the real part, and if it exceeds 15%, the coating amount is too large, resulting in puncture or substrate destruction.
[0040]
The second hot press performed under high temperature and high pressure is a temperature of 150 to 250 ° C. and a pressure of 10 to 30 kg / cm. ² The pressing is performed under pressing conditions of about 3 to 30 minutes. At this time, 0-5kg / cm before applying high-temperature high-pressure press ² 10-30 kg / cm after performing temporary pressing for several tens of seconds to several minutes at a moderate pressure ² The occurrence of burrs can be suppressed by performing the main pressing. You may arrange | position a distance bar between two press plates so that it can adjust to desired thickness. In this case, since a long press with a uniform surface is required, a batch-type single-stage or multi-stage hot-pressure press is suitable.
[0041]
Then, a decorative sheet is attached and integrated on the surface of the hard fiberboard obtained as described above to make a decorative process, and a flooring is obtained by applying an actual process. Examples of the decorative sheet include veneer, paper, resin-impregnated paper, and olefin sheet. In addition, the decorative sheet may be coated, and examples of the coating include urethane coating and UV coating.
In addition, if the said decorative sheet is each stuck and integrated on the front and back surfaces of the hard fiberboard, it is effective in preventing the occurrence of warpage.
[0042]
In general decorative processing, groove processing and chamfering processing are performed from above the decorative sheet, and actual processing is performed. Actual processing may be performed simultaneously with the second hot press or may be performed after the second hot press.
Also, for example, when a veneer with a thickness of 0.25 mm is applied as a decorative process, the surface is sanded, colored and UV-coated, and then a round chamfering process is performed with a width of 0.5 mm using a router. The hard fiberboard can be seen from the chamfered portion. For this reason, if the pigment is added to the slurry in advance, or if the pigment or dye is added in advance to the resin liquid to be impregnated, the hard fiberboard is pre-colored in the same or similar color as the decorative sheet. A flooring with no finished finish can be obtained.
[0043]
For example, when a pigment is added to the slurry, the amount of the pigment added is preferably 1 to 10% by weight. This is because if it is less than 1% by weight, the desired coloring cannot be obtained, and if it exceeds 10% by weight, the strength is adversely affected.
Moreover, when adding a pigment to a resin liquid, it is preferable that the addition amount of a pigment is 0.5 to 5 weight%. This is because if the amount is less than 0.5% by weight, desired coloration cannot be obtained, and if it exceeds 5% by weight, it is difficult to disperse in the resin liquid.
Furthermore, when adding dye to a resin liquid, it is preferable that the addition amount of dye is 0.1 to 2 weight%. This is because if it is less than 0.1% by weight, the desired coloring cannot be obtained, and if it exceeds 2% by weight, no further effect can be obtained.
[0044]
Basically, if it is set lighter than the decorative sheet provided on the surface, it is possible to arbitrarily color the groove portion according to the color applied to the veneer, while the groove portion Any color can be selected for coloring. For this reason, for example, it is also possible to arrange the grooves in an accented manner by coloring the groove portions in completely different colors.
[0045]
When the specific gravity of the region forming the real part is increased only by impregnating the semi-cured mat with the first resin liquid without applying and impregnating the second resin liquid with a high concentration, embossing is performed. Processing may be performed.
That is, the distance bar may be positioned on at least one side of the region where the real part is formed, and the second hot press may be performed to form the hard fiberboard and embossing may be performed at the same time. In this case, it is preferable to perform embossing so as to be about 10 to 50% thinner than other portions. If it is less than 10%, there is almost no effect of improving the strength, and if it exceeds 50%, it causes puncture. In addition, the concave groove formed by embossing serves as a reference for forming a decorative groove or cutting, and has an advantage that positioning of the cutting tool becomes easy.
[0046]
The decorative material manufactured by the above procedure is applied not only to floor heating flooring but also to floor surfaces with a uniform surface, such as plywood ground that is abandoned on particle board grounds for joist and double floors. It is preferable. In such a case, it is possible to lay directly on the floor finishing material that is constructed in a normal state. However, even in this case, it is necessary to finish the surface as uniformly as possible, and it is desirable that the step of the floor finish is within 1 mm. The floor finish may have a floor heating configuration.
[0047]
For example, if it is a floor heating configuration, it may be laid on the upper surface of the floor heating mat via the real part of the flooring. In this case, the floor base and the floor material may be bonded and integrated with a small amount of adhesive, but it is preferable not to perform the bonding with the floor base in consideration of replacement of the upper adhesive material. Furthermore, in the case of a floor heating configuration, sticking is preferable to adhesive integration.
Moreover, you may mutually engage through the real part formed by the above-mentioned actual process instead of not performing adhesion | attachment with a floor base. Thereby, it is possible to reduce the gap generated by the temperature change during the floor heating operation.
[0048]
【Example】
Example 1
50% by weight of rock wool as mineral fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch and 7% by weight of powdered phenolic resin as a binder are put into water to obtain a slurry with a solid content of 5%. A small amount of an antifoaming agent was added thereto and stirred. The slurry was made with a long net paper machine and then dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. This wet mat has a temperature of 90 ° C. and a pressure of 7 kg / cm. ² The first hot press was performed under the pressing conditions of a pressurization time of 1 minute to obtain a pre-semi cure mat. This pre-semi-cure mat is cut into a size of an angle with a water cutter and dried with a hot air dryer adjusted to 220 ° C. to obtain a semi-cure mat with a moisture content of 5%, a thickness of 6 mm and a specific gravity of 0.45. It was.
[0049]
And the 1st resin liquid was apply | coated and impregnated with the flow coater for each of the front and back surfaces of the semi-cure mat 10 shown in FIG. 1A to form impregnated layers 11 and 12 (FIG. 1B). The first resin liquid was prepared by diluting an acrylic emulsion with water to a resin ratio of 35%, and adding 1% by weight penetrant, 0.05% by weight antifoaming agent, and 5% by weight release agent. Each is added. Further, 10 g of the second resin liquid was applied and impregnated in a region 13 having a width of 25 mm crossing the center of the back surface side that does not become a decorative surface (FIG. 1C). The second resin liquid has a higher concentration than the first resin liquid, and is obtained by diluting an acrylic emulsion with water to adjust the resin ratio to 55% and adding 1% by weight of a penetrant. .
[0050]
In the second hot-pressing press, a distance bar (not shown) having a thickness of 3.0 mm is arranged on both sides of the semi-cured mat 10, and the temperature is 190 ° C. and the pressure is 5 kg / cm. ² , After pre-pressing under press conditions for 1 minute, temperature 190 ° C, pressure 20kg / cm ² The hard fiber board having a thickness of 3.3 mm was obtained by performing the main pressing under the pressing conditions of a pressing time of 20 minutes.
[0051]
The front and back surfaces of the hard fiber board were sanded to obtain a hard fiber board 20 having a uniform surface thickness of 3.0 mm (FIG. 1D). As a result of visual observation of the appearance at this time, it was confirmed that the resin-reinforced surface was uniform. Further, an adhesive mixed with vinyl acetate emulsion and isocyanate was applied to the surface of the hard fiber board 20, and a cover dry veneer 21 having a thickness of 0.25 mm was attached. Then, a UV coating was applied to the surface of the birch dry veneer 21 to obtain a flooring.
[0052]
Then, as shown in FIG. 1D, the region 22 (shown by hatching) having a depth of 1.5 mm, a width of 25 mm, and a length was deleted from the decorative surface side of the reinforced and reinforced region to form a groove. Furthermore, the strip-shaped sample 23 cut out from the part located in the bottom face of the said groove | channel to width 20mm, thickness 1.7mm, and scale length was obtained. The maximum bending fracture strength and specific gravity of the three samples were measured, and the bending Young's modulus was obtained by calculation. The measurement results and calculation results are shown in FIG.
[0053]
(Example 2)
The semi-cured mat 10 (FIG. 2A) used in Example 1 was coated and impregnated with the first resin liquid under the same conditions as in Example 1 to form impregnated layers 11 and 12 (FIG. 2B). Next, a distance bar 13 (FIG. 2C) having a thickness of 1 mm and a width of 25 mm was positioned at the center portion of the semi-cured mat 10, and a 3.0 mm distance bar (not shown) was disposed on both sides thereof. And temperature 190 ℃, pressure 5kg / cm ² , After pre-pressing under press conditions for 1 minute, temperature 190 ° C, pressure 20kg / cm ² The main pressing was performed under pressing conditions of a pressing time of 20 minutes to obtain a hard fiber plate having a thickness of 3.3 mm.
[0054]
The front and back surfaces of the hard fiber board were sanded to obtain a hard fiber board 20 having a uniform surface thickness of 3.0 mm (FIG. 2D). Further, an adhesive mixed with vinyl acetate emulsion and isocyanate was applied to the surface of the hard fiber board 20, and a cover dry veneer 21 having a thickness of 0.25 mm was attached. Then, a UV coating was applied to the surface of the birch dry veneer 21 to obtain a flooring.
[0055]
Next, as shown in FIG. 2D, the region 22 from the decorative surface side to the depth of 1.5 mm of the portion that has been reinforced by pressing is deleted with a width of 25 mm, and the portion located on the bottom surface is 20 mm wide with a thickness of 1. mm. A strip-shaped sample 23 was obtained by cutting out to a length of 7 mm. The maximum bending fracture strength and specific gravity of the three samples 23 were measured, and the bending Young's modulus was calculated. The measurement results and calculation results are shown in FIG.
[0056]
(Example 3)
The semi-cured mat 10 (FIG. 3A) used in Example 1 was coated and impregnated with the first resin liquid under the same conditions as in Example 1 to form impregnated layers 11 and 12 (FIG. 3B). Next, distance bars 14 and 14 each having a thickness of 0.3 mm and a width of 25 mm were positioned on the front and back surfaces of the central portion of the semi-cured mat 10 (FIG. 3C). Further, a distance bar (not shown) having a thickness of 3.0 mm is disposed on both sides of the semi-cured mat 10, and the temperature is 190 ° C. and the pressure is 5 kg / cm. ² , After pre-pressing under press conditions for 1 minute, temperature 190 ° C, pressure 20kg / cm ² The main pressing was performed under pressing conditions of a pressing time of 20 minutes to obtain a hard fiber plate having a thickness of 3.3 mm.
[0057]
The front and back surfaces of the hard fiber board were sanded to obtain a hard fiber board 20 having a uniform surface thickness of 3.0 mm (FIG. 3D). Further, an adhesive mixed with vinyl acetate emulsion and isocyanate was applied to the surface of the hard fiber board 20, and a cover dry veneer 21 having a thickness of 0.25 mm was attached. Then, a UV coating was applied to the surface of the birch dry veneer 21 to obtain a flooring.
[0058]
Next, as shown in FIG. 3D, the region 22 from the decorative surface side to the depth of 1.5 mm is deleted with a width of 25 mm, and the portion located on the bottom is 20 mm wide, 1.7 mm thick, as shown in FIG. 3D. A strip-shaped sample 23 was obtained by cutting out with a length. The maximum bending fracture strength and specific gravity of the three samples 23 were measured, and the bending Young's modulus was calculated. The measurement results and calculation results are shown in FIG.
[0059]
(Comparative Example 1)
As shown in FIGS. 4A and 4B, except that the second resin liquid is not applied in Example 1, the rest is processed in the same manner as in Example 1 to obtain a flooring based on the hard fiberboard 20. (FIG. 4C). And while deleting the area | region 22 of depth 1.5mm, width 25mm, and length from the center part by the side of the decorative surface of the said flooring, the area | region located in the bottom face part is width 20mm, thickness 1.7mm, A strip-shaped sample 23 was obtained by cutting into a length. Then, the maximum bending fracture strength and specific gravity of the three samples 23 were measured, and the bending Young's modulus was obtained by calculation. The measurement results and calculation results are shown in FIG.
[0060]
As is clear from FIG. 5, it was found that all of Examples 1, 2, and 3 have a strength superior to that of Comparative Example 1. In particular, it was confirmed that the greater the specific gravity, the higher the strength of the real part. This is considered to be due to the fact that the adhesive surface area of the resin is increased not only through the fiber surface but also through the inorganic powder distributed between the fibers, and the resin retention is improved.
[0061]
【The invention's effect】
According to the present invention, the strength of the real part is high, and it has excellent thermal dimensional stability, water resistance and scratch resistance like an inorganic plate, and has impact resistance, workability and cutting workability similar to a wooden material. The provided decorative material, in particular, a floor decorative material that can also be used for floor heating can be stably supplied. In addition, because it uses a hard fiberboard with excellent thermal conductivity, it is a decorative material that exhibits the excellent temperature rise characteristics (fast heating start-up) required for floor heating flooring. Manufacturing method Is effective.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a manufacturing process of Example 1 according to the present invention.
FIG. 2 is a cross-sectional view showing a manufacturing process of Example 2 according to the present invention.
FIG. 3 is a cross-sectional view showing a manufacturing process of Example 3 according to the present invention.
FIG. 4 is a cross-sectional view showing a manufacturing process of Comparative Example 1 according to the present invention.
FIG. 5 is a chart showing measurement results and calculation results of examples and comparative examples according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Semi-cure mat | matte, 11, 12 ... Impregnation layer, 13, 14 ... Distance bar, 20 ... Hard fiber board, 21 ... Cosmetic sheet, 23 ... Strip-shaped sample.

Claims (2)

A wet mat obtained by wet-making a slurry containing 35 to 70% by weight of mineral fiber and / or organic fiber, 25 to 55% by weight of inorganic powder, and 5 to 25% by weight of a binder as essential components. After impregnating the front and back surfaces of a semi-cured mat having a specific gravity of 0.3 to 0.9 obtained by performing a primary hot press with a first resin liquid having a diluted resin ratio of 10 to 60%, By applying and impregnating a second resin liquid having a concentration equal to or higher than that of the first resin liquid in the area where the part is to be formed and performing the second hot press, the specific gravity of the area where the real part is formed is A method for producing a cosmetic material, comprising obtaining a base material 5% or more higher than the specific gravity of a region not to be formed, applying a decorative process to the surface of the base material, and forming a real part . A wet mat obtained by wet-making a slurry containing 35 to 70% by weight of mineral fiber and / or organic fiber, 25 to 55% by weight of inorganic powder, and 5 to 25% by weight of a binder as essential components. The front and back surfaces of the semi-cured mat having a specific gravity of 0.3 to 0.9 obtained by the primary hot press are impregnated with a diluted resin solution having a resin ratio of 10 to 60%, respectively, and the secondary heat Embossing is performed on at least one side of the region where the real part is formed by pressure pressing, and a base material having a specific gravity of 5% or more higher than the specific gravity of the region where the real part is not formed is obtained. A method for producing a cosmetic material, characterized in that a cosmetic process is applied to a surface and a real part is formed .

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