JP4533945B2 - Impregnated base paper for flooring and impregnated paper for flooring - Google Patents
Impregnated base paper for flooring and impregnated paper for flooring Download PDFInfo
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- JP4533945B2 JP4533945B2 JP2008194794A JP2008194794A JP4533945B2 JP 4533945 B2 JP4533945 B2 JP 4533945B2 JP 2008194794 A JP2008194794 A JP 2008194794A JP 2008194794 A JP2008194794 A JP 2008194794A JP 4533945 B2 JP4533945 B2 JP 4533945B2
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- base paper
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- 238000009408 flooring Methods 0.000 title claims description 66
- 239000010410 layer Substances 0.000 claims description 71
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 71
- 229920005989 resin Polymers 0.000 claims description 70
- 239000011347 resin Substances 0.000 claims description 70
- 229920001187 thermosetting polymer Polymers 0.000 claims description 56
- 239000000463 material Substances 0.000 claims description 25
- 238000012360 testing method Methods 0.000 claims description 23
- 239000002994 raw material Substances 0.000 claims description 21
- 238000010521 absorption reaction Methods 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 20
- 239000007788 liquid Substances 0.000 claims description 14
- 229920001131 Pulp (paper) Polymers 0.000 claims description 12
- 239000002344 surface layer Substances 0.000 claims description 12
- 238000010998 test method Methods 0.000 claims description 10
- 230000035515 penetration Effects 0.000 claims description 7
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical group OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 6
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 claims description 4
- 230000001070 adhesive effect Effects 0.000 claims description 4
- 239000002390 adhesive tape Substances 0.000 claims description 4
- 239000000123 paper Substances 0.000 description 217
- 238000005470 impregnation Methods 0.000 description 30
- 239000011120 plywood Substances 0.000 description 21
- 239000011229 interlayer Substances 0.000 description 18
- 239000003623 enhancer Substances 0.000 description 17
- -1 methylol group Chemical group 0.000 description 13
- 239000002655 kraft paper Substances 0.000 description 12
- 238000011156 evaluation Methods 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- 229920000298 Cellophane Polymers 0.000 description 8
- 239000003795 chemical substances by application Substances 0.000 description 8
- 230000007423 decrease Effects 0.000 description 8
- 239000002245 particle Substances 0.000 description 8
- 230000035699 permeability Effects 0.000 description 8
- 239000000126 substance Substances 0.000 description 8
- 230000032798 delamination Effects 0.000 description 7
- 239000000835 fiber Substances 0.000 description 7
- 238000002156 mixing Methods 0.000 description 7
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 6
- 229920000877 Melamine resin Polymers 0.000 description 6
- 235000014113 dietary fatty acids Nutrition 0.000 description 6
- 239000000194 fatty acid Substances 0.000 description 6
- 229930195729 fatty acid Natural products 0.000 description 6
- 239000012779 reinforcing material Substances 0.000 description 6
- 239000011122 softwood Substances 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000004640 Melamine resin Substances 0.000 description 3
- 229920002472 Starch Polymers 0.000 description 3
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 3
- 238000009835 boiling Methods 0.000 description 3
- 239000004202 carbamide Substances 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 150000004665 fatty acids Chemical class 0.000 description 3
- 239000011121 hardwood Substances 0.000 description 3
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 3
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 3
- 239000002736 nonionic surfactant Substances 0.000 description 3
- 239000013054 paper strength agent Substances 0.000 description 3
- 239000010893 paper waste Substances 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 235000019698 starch Nutrition 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000000057 synthetic resin Substances 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- BRLQWZUYTZBJKN-UHFFFAOYSA-N Epichlorohydrin Chemical compound ClCC1CO1 BRLQWZUYTZBJKN-UHFFFAOYSA-N 0.000 description 2
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 2
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 2
- 229920002522 Wood fibre Polymers 0.000 description 2
- 239000003945 anionic surfactant Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 229920001400 block copolymer Polymers 0.000 description 2
- 239000003093 cationic surfactant Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- NNPPMTNAJDCUHE-UHFFFAOYSA-N isobutane Chemical compound CC(C)C NNPPMTNAJDCUHE-UHFFFAOYSA-N 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 239000004005 microsphere Substances 0.000 description 2
- 239000011087 paperboard Substances 0.000 description 2
- 229920002401 polyacrylamide Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 239000013055 pulp slurry Substances 0.000 description 2
- 238000013441 quality evaluation Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000008107 starch Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 239000002025 wood fiber Substances 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- OMDQUFIYNPYJFM-XKDAHURESA-N (2r,3r,4s,5r,6s)-2-(hydroxymethyl)-6-[[(2r,3s,4r,5s,6r)-4,5,6-trihydroxy-3-[(2s,3s,4s,5s,6r)-3,4,5-trihydroxy-6-(hydroxymethyl)oxan-2-yl]oxyoxan-2-yl]methoxy]oxane-3,4,5-triol Chemical compound O[C@@H]1[C@@H](O)[C@@H](O)[C@@H](CO)O[C@@H]1OC[C@@H]1[C@@H](O[C@H]2[C@H]([C@@H](O)[C@H](O)[C@@H](CO)O2)O)[C@H](O)[C@H](O)[C@H](O)O1 OMDQUFIYNPYJFM-XKDAHURESA-N 0.000 description 1
- QGLWBTPVKHMVHM-KTKRTIGZSA-N (z)-octadec-9-en-1-amine Chemical compound CCCCCCCC\C=C/CCCCCCCCN QGLWBTPVKHMVHM-KTKRTIGZSA-N 0.000 description 1
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- WGVGLSURTKMQQC-UHFFFAOYSA-N 3-aminopropyl-ethyl-dimethylazanium Chemical compound CC[N+](C)(C)CCCN WGVGLSURTKMQQC-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 101150029544 Crem gene Proteins 0.000 description 1
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 description 1
- 229920000926 Galactomannan Polymers 0.000 description 1
- 240000000797 Hibiscus cannabinus Species 0.000 description 1
- JVTAAEKCZFNVCJ-UHFFFAOYSA-M Lactate Chemical compound CC(O)C([O-])=O JVTAAEKCZFNVCJ-UHFFFAOYSA-M 0.000 description 1
- 239000004166 Lanolin Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 229920002873 Polyethylenimine Polymers 0.000 description 1
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 description 1
- 101100230601 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) HBT1 gene Proteins 0.000 description 1
- VBIIFPGSPJYLRR-UHFFFAOYSA-M Stearyltrimethylammonium chloride Chemical compound [Cl-].CCCCCCCCCCCCCCCCCC[N+](C)(C)C VBIIFPGSPJYLRR-UHFFFAOYSA-M 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 125000005396 acrylic acid ester group Chemical group 0.000 description 1
- 229920006243 acrylic copolymer Polymers 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 150000003973 alkyl amines Chemical class 0.000 description 1
- 150000004996 alkyl benzenes Chemical class 0.000 description 1
- 150000005215 alkyl ethers Chemical class 0.000 description 1
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 1
- OYTKINVCDFNREN-UHFFFAOYSA-N amifampridine Chemical compound NC1=CC=NC=C1N OYTKINVCDFNREN-UHFFFAOYSA-N 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 238000010009 beating Methods 0.000 description 1
- YSJGOMATDFSEED-UHFFFAOYSA-M behentrimonium chloride Chemical compound [Cl-].CCCCCCCCCCCCCCCCCCCCCC[N+](C)(C)C YSJGOMATDFSEED-UHFFFAOYSA-M 0.000 description 1
- 239000004067 bulking agent Substances 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 229920006319 cationized starch Polymers 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- SWWQNNDPJXYCNJ-UHFFFAOYSA-N didodecylazanium;chloride Chemical compound Cl.CCCCCCCCCCCCNCCCCCCCCCCCC SWWQNNDPJXYCNJ-UHFFFAOYSA-N 0.000 description 1
- QZIVCPPRKFXYKE-UHFFFAOYSA-N diethylamino octadecanoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)ON(CC)CC QZIVCPPRKFXYKE-UHFFFAOYSA-N 0.000 description 1
- REZZEXDLIUJMMS-UHFFFAOYSA-M dimethyldioctadecylammonium chloride Chemical compound [Cl-].CCCCCCCCCCCCCCCCCC[N+](C)(C)CCCCCCCCCCCCCCCCCC REZZEXDLIUJMMS-UHFFFAOYSA-M 0.000 description 1
- 239000004664 distearyldimethylammonium chloride (DHTDMAC) Substances 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- VAIUNGBQMLPPDL-UHFFFAOYSA-N ethanamine;2-hydroxypropanoic acid Chemical compound CC[NH3+].CC(O)C([O-])=O VAIUNGBQMLPPDL-UHFFFAOYSA-N 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 229920001002 functional polymer Polymers 0.000 description 1
- 150000008282 halocarbons Chemical class 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000010409 ironing Methods 0.000 description 1
- 239000001282 iso-butane Substances 0.000 description 1
- 229940039717 lanolin Drugs 0.000 description 1
- 235000019388 lanolin Nutrition 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- UIUXUFNYAYAMOE-UHFFFAOYSA-N methylsilane Chemical compound [SiH3]C UIUXUFNYAYAMOE-UHFFFAOYSA-N 0.000 description 1
- PSZYNBSKGUBXEH-UHFFFAOYSA-M naphthalene-1-sulfonate Chemical compound C1=CC=C2C(S(=O)(=O)[O-])=CC=CC2=C1 PSZYNBSKGUBXEH-UHFFFAOYSA-M 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 239000001254 oxidized starch Substances 0.000 description 1
- 235000013808 oxidized starch Nutrition 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- CTYRPMDGLDAWRQ-UHFFFAOYSA-N phenyl hydrogen sulfate Chemical class OS(=O)(=O)OC1=CC=CC=C1 CTYRPMDGLDAWRQ-UHFFFAOYSA-N 0.000 description 1
- 229920000768 polyamine Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920002503 polyoxyethylene-polyoxypropylene Polymers 0.000 description 1
- 229920001451 polypropylene glycol Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 150000003242 quaternary ammonium salts Chemical class 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- 239000010902 straw Substances 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Paper (AREA)
- Floor Finish (AREA)
Description
本発明は、床材を構成する合板の補強材として用いられる床材用含浸原紙及び床材用含浸紙に関する。 The present invention relates to an impregnated base paper for flooring used as a reinforcing material for plywood constituting the flooring and an impregnated paper for flooring.
従来、例えば特許文献１に示されるように、床材等の建築用化粧板は、一般に化粧シートと、接着剤層と、合板とを具備して構成されている。特に、複合フローリング床材では合板としてベニヤ合板が用いられることが多いが、その補強材として、ＭＤＦ（中密度積層板）が用いられている。しかし、補強材としてＭＤＦが用いられると合板単体から構成される床材と比べて、コストが高くなるだけでなく、水分を吸収して膨らんでしまい、床面に波打ちが生じ易い、すなわち表面性が悪くなるという問題がある。そこで、補強材として、ＭＤＦの他に、例えば特許文献１に示されるように樹脂含浸紙硬化層（クラフト紙）を設けることが提案されている。この樹脂含浸紙硬化層は、原紙にフェノール系樹脂等の硬化樹脂を含浸塗工することにより、床材の耐衝撃性を維持すると共に、床材の表面に形成される凹凸を被覆し、波打ちが形成されないようにしている。 Conventionally, for example, as shown in Patent Document 1, a decorative board for flooring or the like is generally configured to include a decorative sheet, an adhesive layer, and a plywood. In particular, veneer plywood is often used as the plywood in composite flooring flooring, but MDF (medium density laminated board) is used as the reinforcing material. However, when MDF is used as a reinforcing material, the cost is not only higher than a floor material composed of a single plywood, but it absorbs moisture and swells, and the floor surface is likely to be wavy. There is a problem of getting worse. Thus, it has been proposed to provide a resin impregnated paper cured layer (kraft paper) as a reinforcing material in addition to MDF, as shown in Patent Document 1, for example. This resin-impregnated paper cured layer impregnates the base paper with a cured resin such as a phenolic resin, thereby maintaining the impact resistance of the flooring and covering the irregularities formed on the surface of the flooring. Is not formed.
また、昨今の木材需要量の増大により、ベニヤの価格が高騰し、ベニヤ合板が入手しにくくなってきている。従って、製造コストを抑えるために、比較的安価な中国製のベニヤ合板が用いられるようになってきている。しかしながら、中国製のベニヤ合板は軟質で、耐衝撃性が低く、表面性も悪い。このため、従来の厚さが０．３ｍｍ程度のクラフト紙では床材としての耐衝撃性を確保できず、また床材の表面に形成される凹凸も被覆できないという問題があり、床材用含浸紙に適した原紙が要求されるようになってきた。 Moreover, with the recent increase in demand for wood, the price of veneer has soared, making it difficult to obtain veneer plywood. Therefore, in order to reduce the manufacturing cost, relatively inexpensive Chinese-made veneer plywood has been used. However, Chinese-made veneer plywood is soft, has low impact resistance, and has poor surface properties. For this reason, conventional kraft paper with a thickness of about 0.3 mm cannot secure impact resistance as a flooring material, and also cannot cover unevenness formed on the surface of the flooring material. A base paper suitable for paper has been demanded.
また、補強材として厚さが０．３ｍｍ程度のクラフト紙が用いられた床材にＶカット加工が施されると、ベニヤ合板そのものが見えてしまい、床材の見栄えが悪くなるという問題もあった。そこで、厚さが約０．３ｍｍのクラフト紙を２枚貼合する方法が用いられているが、クラフト紙の貼合面での剥離強度の低下や、加工工程が多くなるという問題がある。 In addition, when V-cut processing is applied to a flooring material using kraft paper with a thickness of about 0.3 mm as a reinforcing material, the veneer plywood itself can be seen, resulting in a poor appearance of the flooring material. It was. Thus, a method of laminating two kraft papers having a thickness of about 0.3 mm is used, but there is a problem that the peel strength is lowered on the kraft paper laminating surface and the number of processing steps is increased.
さらにまた、従来のクラフト紙は樹脂等の含浸性が悪かったため、床材として使用するために必要な耐衝撃性を得ることが難しいという問題もあった。そこで、含浸性を向上させるために原料パルプのフリーネスを高くする、抄紙工程におけるプレス線圧、カレンダー線圧を低くする等の手段があるが、いずれの手段もパルプ繊維同士の絡み合いを弱くする、又は少なくするものであり、その結果、繊維間強度の低下を招き、床材用含浸原紙あるいは床材用含浸紙としての層間強度を確保できず、耐衝撃性を確保することが難しいという問題を生じる。 Furthermore, conventional kraft paper has a problem that it is difficult to obtain the impact resistance necessary for use as a flooring material because of its poor impregnation with resin or the like. Therefore, there are means such as increasing the freeness of the raw material pulp to improve the impregnation property, lowering the press linear pressure in the paper making process, the calendar linear pressure, etc., but any means weakens the entanglement between the pulp fibers, As a result, the inter-fiber strength is lowered, the interlaminar strength as impregnated base paper for flooring or impregnated paper for flooring cannot be ensured, and it is difficult to ensure impact resistance. Arise.
なお、このほか、床材の補強材として、特許文献２に示されるプレプレッグを作ったり、特許文献３に示される合成樹脂液を塗布した繊維質シートを用いることが提案されているが、これらの技術によっても上記のような問題を解決することはできなかった。 In addition, as a reinforcing material for flooring, it has been proposed to use a prepreg shown in Patent Document 2 or a fibrous sheet coated with a synthetic resin solution shown in Patent Document 3, but these Even the technology could not solve the above problems.
本発明は、上述したような実情に鑑みてなされたもので、その目的とするところは、合板として、表面性が悪く、軟質なベニヤ合板が使用された場合であっても、層間強度が高く、耐衝撃性があり、また床材の表面に形成される凹凸を被覆することができる床材用含浸原紙及び床材用含浸紙を提供することにある。 The present invention has been made in view of the above-described circumstances, and the object of the present invention is that the interlaminar strength is high even when a soft veneer plywood is used as the plywood, which has poor surface properties. Another object of the present invention is to provide an impregnated base paper for flooring and an impregnated paper for flooring that are impact resistant and can cover the unevenness formed on the surface of the flooring.
本発明の上記目的は、少なくとも表層、及び裏層の２層を有する多層抄きの床材用含浸原紙において、該床材用含浸原紙の各層を構成する原料パルプには、機械パルプを１０〜２０質量％配合し、ＮＢＫＰを８０〜９０質量％配合し、また、前記原料パルプは、ＪＩＳ−Ｐ８１２１（１９９５）に記載の「紙及び板紙−パルプのろ水度試験方法−カナダ標準ろ水度試験方法」に準拠して測定したフリーネスを５５０〜７５０ｃｃに調整し、紙厚が４００〜５００μｍであり、ＪＩＳ−Ｐ８１１８（１９９８）に記載の「紙及び板紙−厚さ及び密度の試験方法」に準拠して測定した密度が０．３〜０．６ｇ／ｃｍ３であり、ＪＩＳ−Ｐ８１４１（２００４）に記載の「紙及び板紙−吸水度試験方法−クレム法」に準拠して測定したクレム吸水度が８０〜９７ｍｍであり、また、Ｊ．ＴＡＰＰＩ Ｎｏ．４１（２０００）に記載の「紙及び板紙−はつ油度試験方法−キット法」に準拠して測定した吸油度が１．３〜１．８秒であり、少なくとも−ＣＨ２ＯＨ基（メチロール基）を有する水系熱硬化性樹脂を含浸塗工することを特徴とする床材用含浸原紙を提供することによって達成することができる。 The above object of the present invention is to provide a multi-layered floor material impregnated base paper having at least two layers, a surface layer and a back layer. 20 wt% blended, NBKP blended 80-90 wt%, and the raw material pulp described in JIS-P8121 (1995) “Paper and board-pulp freeness test method—Canadian standard freeness The freeness measured according to “Test method” is adjusted to 550 to 750 cc, the paper thickness is 400 to 500 μm, and “Paper and paperboard—Test method of thickness and density” described in JIS-P8118 (1998). The density measured according to the standard is 0.3 to 0.6 g / cm 3 , and the water absorption by Klem is measured according to “Paper and paperboard—Water absorption test method—Klem method” described in JIS-P8141 (2004). Every time Is 80 to 97 mm, and J. TAPPI No. 41 (2000), the oil absorbency measured in accordance with “Paper and paperboard—oil repellency test method—kit method” is 1.3 to 1.8 seconds, and at least —CH 2 OH group (methylol) This can be achieved by providing an impregnated base paper for flooring characterized by impregnating and applying an aqueous thermosetting resin having a base.
また、本発明の上記目的は前記床材用含浸原紙に含浸液浸透促進剤が添加されていることを特徴とする床材用含浸原紙を提供することによって、効果的に達成される。
The above-mentioned object of the present invention can be effectively achieved by providing an impregnating base paper for flooring, wherein an impregnating liquid penetration accelerator is added to the impregnating base paper for flooring.
また、本発明の上記目的は、前記床材用含浸原紙に水系熱硬化性樹脂を含浸塗工して床材用含浸紙を形成し、ＪＩＳ−Ｚ０２３７（２０００）に記載の「粘着テープ・粘着シート試験方法−引張り強さ」に準拠して測定した層間強度が、縦：３５０Ｎ／１５ｍｍ以上、横：２００Ｎ／１５ｍｍ以上であることを特徴とする床材用含浸紙を提供することによって達成される。 Further, the above object of the present invention is to form a floor material impregnated paper by impregnating and applying a water-based thermosetting resin to the floor material impregnated base paper , as described in JIS-Z0237 (2000). It is achieved by providing an impregnated paper for flooring characterized in that the interlayer strength measured in accordance with “Sheet Test Method—Tensile Strength” is longitudinal: 350 N / 15 mm or more and lateral: 200 N / 15 mm or more. The
さらにまた、本発明の上記目的は、紙厚が５５０〜７５０μｍであることを特徴とする床材用含浸紙を提供することによって、より効果的に達成される。 Furthermore, the above object of the present invention can be achieved more effectively by providing an impregnated paper for flooring characterized in that the paper thickness is 550 to 750 μm.
本発明に係る床材用含浸原紙によれば、少なくとも表層、及び裏層の２層を有する多層抄きとし、クレム吸水度を８０〜１１３ｍｍとし、また吸油度を０．５〜２．２秒としたので、水系熱硬化性樹脂の含浸性を所望の範囲とすることができ、作業効率、製造コスト、操業性のバランスの優れたものとすることができる。 According to the impregnated base paper for flooring according to the present invention, it is a multi-layer paper having at least two layers of a surface layer and a back layer, the water absorption of Klem is 80 to 113 mm, and the oil absorption is 0.5 to 2.2 seconds. Therefore, the impregnation property of the water-based thermosetting resin can be within a desired range, and the work efficiency, production cost, and operability can be excellently balanced.
また、本発明に係る床材用含浸紙によれば、層間強度を縦：３５０Ｎ／１５ｍｍ以上、横：２００Ｎ／１５ｍｍ以上としたので、床材の合板として表面性が悪く、軟質なベニヤ合板等が用いられても、耐衝撃性があり、床材の表面の凹凸を被覆することができるようになる。特に、水系熱硬化性樹脂として、特定のメチロール基を有するものを用いると、その効果は顕著なものとなる。 In addition, according to the floor material impregnated paper according to the present invention, the interlayer strength is set to 350 N / 15 mm or more in the vertical direction and 200 N / 15 mm or more in the horizontal direction. Even if is used, it has impact resistance and can cover the unevenness of the surface of the flooring. In particular, when a water-based thermosetting resin having a specific methylol group is used, the effect becomes remarkable.
以下、本発明に係る多層抄きの床材用含浸原紙及び床材用含浸紙について、床材用含浸原紙が表層、１層の中間層、及び裏層の３層の紙層から成る場合を例に詳細に説明する。なお、本発明に係る多層抄きの床材用含浸原紙及び床材用含浸紙は、以下の実施形態に限定されるものではなく、特許請求の範囲を逸脱しない範囲内において、その構成を適宜変更できることはいうまでもない。 Hereinafter, in the case of the base paper impregnated paper for flooring and the floor material impregnated paper according to the present invention, the base paper for flooring is composed of three paper layers of a surface layer, one intermediate layer, and a back layer. An example will be described in detail. In addition, the base paper impregnated base material for flooring and the base material for floor material impregnation according to the present invention are not limited to the following embodiments, and the configuration is appropriately set within the scope of the claims. Needless to say, it can be changed.
本発明に係る床材用含浸原紙（以下、「本含浸原紙」という。）は、表層、１層の中間層、及び裏層の３層の紙層を有する。 The impregnated base paper for flooring according to the present invention (hereinafter referred to as “the main impregnated base paper”) has three paper layers: a surface layer, one intermediate layer, and a back layer.
本含浸原紙は、ＪＩＳ−Ｐ８１４１（２００４）に記載の「紙及び板紙−吸水度試験方法−クレム法」に準拠して測定した縦のクレム吸水度（以下、単に「クレム吸水度」と言う。）が８０〜１１３ｍｍであることが好ましく、より好ましくは８０〜９７ｍｍである。また、Ｊ．ＴＡＰＰＩ Ｎｏ．４１（２０００）に記載の「紙及び板紙−はつ油度試験方法−キット法」に準拠して測定した吸油度（以下、単に「吸油度」と言う。）が０．５〜２．２秒であることが好ましく、より好ましくは１．３〜１．８秒である。 The impregnated base paper is referred to as a vertical clem water absorption (hereinafter simply referred to as “Clem water absorption”) measured according to “paper and paperboard—water absorption test method—Klem method” described in JIS-P8141 (2004). ) Is preferably 80 to 113 mm, more preferably 80 to 97 mm. In addition, J.H. TAPPI No. 41 (2000), the oil absorption measured in accordance with “Paper and paperboard—oil repellency test method—kit method” (hereinafter simply referred to as “oil absorption”) is 0.5 to 2.2. It is preferable that it is second, More preferably, it is 1.3 to 1.8 second.
含浸原紙のクレム吸水度が８０ｍｍ未満であると、後述する水系熱硬化性樹脂の含浸性が低くなり、水系熱硬化性樹脂の含浸量が減ってしまう。このため、含浸原紙に水系熱硬化性樹脂を含浸塗工して形成される含浸紙は、所望とする層間強度を得ることができず、床材として使用することが困難となる。一方、クレム吸水度が１１３ｍｍを超えると、含浸原紙の水系熱硬化性樹脂の含浸性が高くなりすぎ、必要量以上の水系熱硬化性樹脂が含浸原紙に含浸されてしまうため、乾燥に時間が掛かり、作業効率が悪くなると共に、製造コストが増加する。 If the Krem water absorption of the impregnated base paper is less than 80 mm, the impregnation property of a water-based thermosetting resin, which will be described later, becomes low, and the amount of water-based thermosetting resin impregnated decreases. For this reason, the impregnated paper formed by impregnating and applying the water-based thermosetting resin to the impregnated base paper cannot obtain a desired interlayer strength and is difficult to use as a flooring. On the other hand, if the water absorption of Klem exceeds 113 mm, the impregnation of the water-based thermosetting resin of the impregnated base paper becomes too high, and more than the required amount of water-based thermosetting resin is impregnated in the impregnated base paper. As a result, the work efficiency becomes worse and the manufacturing cost increases.
また、含浸原紙の吸油度が０．５秒未満であると、水系熱硬化性樹脂の含浸性が高くなりすぎ、必要量以上の水系熱硬化性樹脂が含浸原紙に含浸されてしまうため、乾燥に時間が掛かり、作業効率が悪くなると共に、製造コストが増加する。一方、含浸原紙の吸油度が２．２秒を超えると、水系熱硬化性樹脂の含浸性が低くなり、必要量の水系熱硬化性樹脂が含浸されるまでの時間が長くなり、操業性が低下してしまう。 Further, if the impregnated base paper has an oil absorption of less than 0.5 seconds, the impregnation property of the water-based thermosetting resin becomes too high, and the impregnated base paper is impregnated with more water-based thermosetting resin than necessary. It takes a long time, resulting in poor working efficiency and increased manufacturing costs. On the other hand, if the oil absorption of the impregnated base paper exceeds 2.2 seconds, the impregnation property of the water-based thermosetting resin is lowered, and the time until the required amount of the water-based thermosetting resin is impregnated becomes longer, and the operability is improved. It will decline.
また、本含浸原紙を形成する各層の原料パルプには、加温、加圧下でチップを機械的にパルプ化したサーモメカニカルパルプ（ＴＭＰ）等の機械パルプを０〜３０質量％配合することが好ましく、より好ましくは１０〜２０質量％である。各層の機械パルプの配合率が３０質量％を超えると、含浸原紙の水系熱硬化性樹脂の含浸性が悪くなるという問題が生じてしまう。 Moreover, it is preferable to mix | blend 0-30 mass% mechanical pulps, such as thermomechanical pulp (TMP) which mechanically pulped the chip | tip with heating and pressurization, in the raw material pulp of each layer which forms this impregnating raw paper More preferably, it is 10-20 mass%. When the blending ratio of the mechanical pulp in each layer exceeds 30% by mass, there arises a problem that the impregnation property of the water-based thermosetting resin of the impregnated base paper is deteriorated.
本含浸原紙を形成する各層の原料パルプは、機械パルプが０〜３０質量％配合されていれば、その他の原料パルプとしては、広葉樹晒クラフトパルプ（ＬＢＫＰ）、針葉樹晒クラフトパルプ（ＮＢＫＰ）、広葉樹未晒クラフトパルプ（ＬＵＫＰ）、針葉樹未晒クラフトパルプ（ＮＵＫＰ）、広葉樹亜硫酸パルプ、針葉樹亜硫酸パルプ等の木材繊維を主原料として、化学的に処理されたパルプ、化学的に処理されたパルプやチップを機械的にパルプ化したグランドパルプ、木材またはチップに化学薬品を添加しながら機械的にパルプ化したケミグランドパルプ、及びチップを柔らかくなるまで蒸解した後、レファイナー等でパルプ化したセミケミカルパルプ等のバージンパルプ等を用いることができる。また、木材以外の繊維原料であるケナフ、麻、葦等の非木材繊維も用いることができる。なお、古紙からなるパルプを配合しても良いが、微細繊維が多いため、濾水性が悪くなり、生産スピードが落ち、また水系熱硬化性樹脂を含浸原紙に含浸させて形成される含浸紙の紙面の見栄えが悪化するとともに、層間強度も低下してしまう。従って、古紙パルプは特に表層及び裏層を形成する原料パルプには配合しない方が好ましく、さらには中間層を形成する原料パルプにも配合しないほうがより好ましい。 If the raw material pulp of each layer forming the impregnated base paper contains 0 to 30% by mass of mechanical pulp, other raw material pulps include hardwood bleached kraft pulp (LBKP), softwood bleached kraft pulp (NBKP), and hardwood. Untreated bleached kraft pulp (LUKP), softwood unbleached kraft pulp (NUKP), hardwood sulfite pulp, softwood sulfite pulp and other wood fibers as main raw materials, chemically treated pulp, chemically treated pulp and chips Ground pulp that has been mechanically pulped, chemi-ground pulp that has been mechanically pulped while adding chemicals to wood or chips, and semi-chemical pulp that has been digested to a softer chip and then pulped with a refiner, etc. Virgin pulp or the like can be used. In addition, non-wood fibers such as kenaf, hemp, and straw, which are fiber materials other than wood, can also be used. In addition, pulp made from waste paper may be blended, but since there are many fine fibers, drainage becomes worse, production speed decreases, and impregnated base paper impregnated with water-based thermosetting resin is impregnated. The appearance of the paper surface deteriorates and the interlayer strength also decreases. Therefore, it is preferable not to mix the waste paper pulp with the raw material pulp that forms the surface layer and the back layer, and it is more preferable not to mix it with the raw material pulp that forms the intermediate layer.
また、本含浸原紙は、同じ配合の原料パルプを用いて各層を抄造するのが好ましいが、例えば中間層の原料パルプ中に古紙を配合する等、表層、中間層、裏層と異なる配合の原料パルプを用いて抄紙しても良い。 In addition, the impregnated base paper is preferably made of each layer using raw pulp having the same composition. For example, raw paper having a composition different from that of the surface layer, intermediate layer, and back layer, such as mixing waste paper in the raw material pulp of the intermediate layer. You may make paper using pulp.
また、各層の原料パルプは、ＪＩＳ−Ｐ８１２１（１９９５）に記載の「紙及び板紙−パルプのろ水度試験方法−カナダ標準ろ水度試験方法」に準拠して測定したフリーネス（以下、単に「フリーネス」と言う。）を５５０〜７５０ｃｃに調整することが好ましく、より好ましくは６００〜７５０ｃｃである。各層の原料パルプのフリーネスが７５０ｃｃを超えると含浸原紙の水系熱硬化性樹脂の含浸量が多くなるため、使用する水系熱硬化性樹脂の量が増え、コストが増加してしまうほか、水系熱硬化性樹脂の含浸量が多くなるために乾燥に時間がかかり、操業性も低下する。また、繊維間結合力も低下し、層間強度が低くなるため、このような含浸原紙が床材として使用されると、層間剥離が発生したり、耐衝撃性が低下する等の問題が生じる。一方、各層の原料パルプのフリーネスが５５０ｃｃ未満であると、繊維間結合力は増し、層間強度は高まるものの、含浸原紙の水系熱硬化性樹脂の含浸性が著しく低下してしまうため、やはり本発明の所望とする層間強度を得ることが困難となり、耐衝撃性が低下してしまう。 In addition, the raw material pulp of each layer was measured according to JIS-P8121 (1995) "Paper and paperboard-Pulp freeness test method-Canadian standard freeness test method". "Freeness") is preferably adjusted to 550 to 750 cc, more preferably 600 to 750 cc. If the freeness of the raw pulp in each layer exceeds 750 cc, the amount of water-based thermosetting resin impregnated in the impregnated base paper will increase, increasing the amount of water-based thermosetting resin used, increasing costs, and water-based thermosetting. Since the amount of the impregnated resin increases, drying takes time and the operability also decreases. In addition, since the fiber-to-fiber bonding force is reduced and the interlayer strength is lowered, when such an impregnated base paper is used as a flooring, problems such as delamination and a reduction in impact resistance occur. On the other hand, if the freeness of the raw material pulp of each layer is less than 550 cc, the fiber-to-fiber bond strength increases and the interlayer strength increases, but the impregnation property of the water-based thermosetting resin of the impregnated base paper is significantly reduced. It is difficult to obtain the desired interlayer strength, and the impact resistance is lowered.
また、含浸原紙を構成する少なくとも１層の原料パルプ中に、湿潤紙力増強剤及び／又は乾燥紙力増強剤を添加することが好ましい。これにより、水系熱硬化性樹脂の含浸塗工時における本含浸原紙の加工適性を向上させることができると共に、本含浸原紙に水系熱硬化性樹脂を含浸塗工して形成される床材用含浸紙の層間強度をより高くすることができる。なお、湿潤紙力増強剤が配合されない場合、含浸原紙に水系熱硬化性樹脂を含浸塗工する際に紙切れが発生する等、加工適性が低下する場合がある。また、乾燥紙力増強剤が配合されない場合、含浸原紙に水系熱硬化性樹脂を含浸塗工して形成される床材用含浸紙の層間強度が低下してしまうため、このような含浸紙を床材用として用いることが難しくなる。従って、湿潤紙力増強剤及び乾燥紙力増強剤を本含浸原始を構成する全層の原料パルプ中に添加することが好ましい。 In addition, it is preferable to add a wet paper strength enhancer and / or a dry paper strength enhancer to at least one layer of raw pulp constituting the impregnated base paper. As a result, the processability of the impregnated base paper during the impregnation coating of the water-based thermosetting resin can be improved, and the floor material impregnation formed by impregnating the water-based thermosetting resin with the water-based thermosetting resin. The interlayer strength of the paper can be further increased. In the case where the wet paper strength enhancer is not blended, the suitability for processing may be lowered, for example, paper breakage may occur when the water-based thermosetting resin is impregnated and applied to the impregnated base paper. Further, when a dry paper strength enhancer is not blended, the interlayer strength of the floor material impregnated paper formed by impregnating and applying the water-based thermosetting resin to the impregnated base paper is lowered. It becomes difficult to use for flooring. Therefore, it is preferable to add a wet paper strength enhancer and a dry paper strength enhancer to the raw pulp of all layers constituting the impregnation raw material.
このような湿潤紙力増強剤としては、例えばポリアミドポリアミン・エピクロロヒドリン系，メラミン・ホルマリン系，尿素・ホルマリン系樹脂等を用いることができる。また、乾燥紙力増強剤としては、アニオン性、カチオン性、または両性のポリアクリルアミド、ポリビニルアルコール、カチオン化澱粉、植物性ガラクトマンナン等を用いることができる。しかしながら、本含浸紙に用いられる湿潤紙力増強剤、乾燥紙力増強剤はこれらに限定されるものではない。 As such a wet paper strength enhancer, for example, polyamide polyamine / epichlorohydrin type, melamine / formalin type, urea / formalin type resin and the like can be used. As the dry paper strength enhancer, anionic, cationic or amphoteric polyacrylamide, polyvinyl alcohol, cationized starch, vegetable galactomannan, or the like can be used. However, the wet paper strength enhancer and the dry paper strength enhancer used for the impregnated paper are not limited to these.
また、上記の紙力増強剤を添加することにより、含浸原紙の水系熱硬化性樹脂の含浸性が低下してしまうため、紙力増強剤を添加する層を形成する原料パルプに含浸液浸透促進剤を添加することが好ましい。この含浸液浸透促進剤としては、アニオン性界面活性剤、カチオン性界面活性剤、ノニオン性界面活性剤を用いることができ、またこれらの１種又は２種以上を併用してもよい。 In addition, the addition of the paper strength enhancer decreases the impregnation of the water-based thermosetting resin of the impregnated base paper, so that the penetration of the impregnating liquid into the raw pulp that forms the layer to which the strength enhancer is added is promoted. It is preferable to add an agent. As the impregnating liquid permeation accelerator, an anionic surfactant, a cationic surfactant, or a nonionic surfactant can be used, or one or more of these may be used in combination.
アニオン性界面活性剤としては、アルキルベンゼンスルホン酸の金属塩、アルキル硫酸エステル塩、ポリオキシアルキレンアリール硫酸エステル塩、アルキルナフタレンスルホン酸塩、ナフタレンスルホン酸塩ホルマリン縮合物、モノ置換又はジ置換スルホコハク酸エステル塩等が挙げられる。 Anionic surfactants include alkylbenzene sulfonic acid metal salts, alkyl sulfate esters, polyoxyalkylene aryl sulfate esters, alkyl naphthalene sulfonates, naphthalene sulfonate formalin condensates, mono-substituted or di-substituted sulfosuccinates. Examples include salts.
カチオン性界面活性剤としては、第４級アンモニウム塩型（塩化ステアリルトリメチルアンモニウム、塩化ベヘニルトリメチルアンモニウム、塩化ジステアリルジメチルアンモニウム、エチル硫酸ラノリン脂肪酸アミノプロピルエチルジメチルアンモニウム等）、アミン塩型（ステアリン酸ジエチルアミノエチルアミド乳酸塩、ジラウリルアミン塩酸塩、オレイルアミン乳酸塩等）等が挙げられる。 Cationic surfactants include quaternary ammonium salt types (stearyl trimethyl ammonium chloride, behenyl trimethyl ammonium chloride, distearyl dimethyl ammonium chloride, ethyl lanolin sulfate fatty acid aminopropylethyl dimethyl ammonium, etc.), amine salt types (diethylamino stearate). Ethyl amide lactate, dilaurylamine hydrochloride, oleylamine lactate, etc.).
また、ノニオン性界面活性剤としては、ポリオキシアルキレンソルビトール脂肪酸エステル、ポリオキシアルキレンソルビタン脂肪酸エステル、ポリオキシアルキレンアルキルエーテル、ポリオキシアルキレン脂肪酸エステル、ポリオキシエチレンポリオキシプロピレンブロック共重合体、エチレンジアミンポリオキシエチレンポリオキシプロピレンブロック共重合体、ポリオキシアルキレンアルキルアミン、ポリオキシアルキレン脂肪酸アミド等が挙げられる。 Nonionic surfactants include polyoxyalkylene sorbitol fatty acid ester, polyoxyalkylene sorbitan fatty acid ester, polyoxyalkylene alkyl ether, polyoxyalkylene fatty acid ester, polyoxyethylene polyoxypropylene block copolymer, ethylenediamine polyoxy Examples include ethylene polyoxypropylene block copolymers, polyoxyalkylene alkylamines, polyoxyalkylene fatty acid amides, and the like.
これらの含浸液浸透促進剤の中でもノニオン性界面活性剤が好ましく、特にポリエチレングリコールを含まない多価アルコール、多価フェノール化合物のプロピレンオキサイド付加体を含有することが好ましい。さらに、ＤＦ６３００（星光ＰＭＣ株式会社製）の、脂肪酸系でシリコーンを含まない液状の自己乳化型の界面活性剤が用いられると、より好ましい。 Among these impregnating liquid permeation accelerators, nonionic surfactants are preferred, and it is particularly preferred to contain a polyhydric alcohol not containing polyethylene glycol and a propylene oxide adduct of a polyhydric phenol compound. Further, it is more preferable to use a liquid self-emulsifying surfactant of DF6300 (manufactured by Seiko PMC Co., Ltd.) which is a fatty acid type and does not contain silicone.
また、この含浸液浸透促進剤の添加量は０．０１〜０．５質量％が好ましく、０．０５〜０．２５質量％がより好ましい。 Moreover, 0.01-0.5 mass% is preferable, and, as for the addition amount of this impregnation liquid penetration accelerator, 0.05-0.25 mass% is more preferable.
含浸液浸透促進剤の添加量が０．０１質量％未満であると、サイズ性を十分に消去することができないため、樹脂浸透性が悪く、含浸紙の生産性が低下してしまう。一方、添加量が０．５質量％を超えるとサイズ性の消去は十分にできるが、紙力増強剤、染料等の薬品の定着を阻害するとともに、パルプ繊維同士の水素結合も阻害する傾向にあり、含浸原紙の層間強度が低下する問題が発生する。また、樹脂含浸後の含浸紙の剥離強度も低下するおそれがある。 If the addition amount of the impregnating liquid penetration accelerator is less than 0.01% by mass, the size cannot be sufficiently erased, so that the resin permeability is poor and the productivity of the impregnated paper is lowered. On the other hand, if the added amount exceeds 0.5% by mass, the sizing property can be sufficiently erased, but it tends to inhibit fixing of chemicals such as paper strength enhancers and dyes and also inhibit hydrogen bonding between pulp fibers. There arises a problem that the interlayer strength of the impregnated base paper is lowered. In addition, the peel strength of the impregnated paper after impregnation with the resin may be reduced.
なお、含浸原紙に水系熱硬化性樹脂の含浸性を付与するために、含浸液浸透促進剤剤の他に吸液剤や嵩高剤等の薬品を添加する事も可能である。しかしながら、原料パルプの叩解の度合いや、パルプの配合率によっては含浸液浸透促進剤剤等の薬品を添加する必要がないので、この場合には添加しなくても良い。 In addition, in order to give the impregnating base paper the impregnation property of the water-based thermosetting resin, it is also possible to add chemicals such as a liquid absorbing agent and a bulking agent in addition to the impregnating liquid penetration accelerator agent. However, it is not necessary to add chemicals such as an impregnating liquid penetration accelerator depending on the degree of beating of the raw pulp and the blending ratio of the pulp.
また、含浸原紙の嵩を出すため、すなわち含浸原紙の紙厚を大きくするために、熱発泡性粒子を原料パルプ中に混合することもできる。本含浸原紙に用いることができる熱発泡性粒子としては、アクリル系コポリマーを主成分とする熱可塑性合成樹脂で構成された微細粒子外殻内に低沸点溶剤を封入したものである。なお、この熱発泡性粒子は、平均粒径が５〜１５μｍで、７５〜１３０℃の加熱により膨張を開始するものが好ましい。外殻を構成する熱可塑性合成樹脂としては、例えば塩化ビニリデン、アクリロニトリル、アクリル酸エステル、メタクリル酸エステル等の共重合体等を挙げることができる。また、外殻内に封入される低沸点溶剤としては、例えば、イソブタン、ペンタン、石油エーテル、ヘキサン、低沸点ハロゲン化炭化水素、メチルシラン等を挙げることができる。 Further, in order to increase the bulk of the impregnated base paper, that is, in order to increase the paper thickness of the impregnated base paper, the thermally foamable particles can be mixed into the raw pulp. The thermally foamable particles that can be used in the impregnated base paper are those in which a low-boiling solvent is enclosed in a fine particle outer shell composed of a thermoplastic synthetic resin mainly composed of an acrylic copolymer. The thermally foamable particles preferably have an average particle diameter of 5 to 15 μm and start to expand upon heating at 75 to 130 ° C. Examples of the thermoplastic synthetic resin constituting the outer shell include copolymers such as vinylidene chloride, acrylonitrile, acrylic acid ester, and methacrylic acid ester. Examples of the low boiling point solvent enclosed in the outer shell include isobutane, pentane, petroleum ether, hexane, low boiling point halogenated hydrocarbon, and methylsilane.
このような熱発泡性粒子としては、例えば、松本油脂製薬株式会社製造の「マツモトマイクロスフェアＦ−２０シリーズ」、「同Ｆ−３０シリーズ」、「同Ｆ−３６シリーズ」、「同Ｆ−４６シリーズ」や、日本フィライト株式会社販売の「エクスパンセルＷＵ」、「同ＤＵ」などを使用することができるが、含浸原紙に使用する熱発泡性樹脂はこれらに限定されるものではない。 Examples of such thermally expandable particles include “Matsumoto Microsphere F-20 Series”, “F-30 Series”, “F-36 Series”, and “F-46” manufactured by Matsumoto Yushi Seiyaku Co., Ltd. "Expancel WU" and "Same DU" sold by Nippon Philite Co., Ltd. can be used, but the thermally foamable resin used for the impregnated base paper is not limited to these.
また、熱発泡性粒子は自己定着しないため、あらかじめ定着剤を混合して用いることが好ましい。この定着剤としては、ポリアクリルアミド系紙力剤、ポリアミドエピクロロヒドリン系紙力剤、ポリエチレンイミン系紙力剤、澱粉，酸化澱粉，カルボキシメチル化澱粉等の澱粉類、植物ガム、ポリビニルアルコール、カルボキシメチルセルロース等、公知の種々のものを用いることができる。 In addition, since the thermally foamable particles do not self-fix, it is preferable to use a mixture of a fixing agent in advance. As this fixing agent, polyacrylamide type paper strength agent, polyamide epichlorohydrin type paper strength agent, polyethyleneimine type paper strength agent, starches such as starch, oxidized starch, carboxymethylated starch, plant gum, polyvinyl alcohol, Various known materials such as carboxymethyl cellulose can be used.
なお、この他、含浸原紙を構成する各層の原料パルプに添加される薬品の添加量、種類等については、原料の種類等に応じて、適宜調整することができる。 In addition, the addition amount, type, and the like of the chemical added to the raw material pulp of each layer constituting the impregnated base paper can be appropriately adjusted according to the type of raw material.
上述した原料パルプは、公知の抄紙工程、例えばワイヤーパート、プレスパート、ドライヤーパート、サイズプレス、カレンダーパートなどを経て、表層、中間層、及び裏層の３層の紙層を有する本含浸原紙を形成する。なお、本含浸原紙の抄紙方法については、特に限定されるものではないので、酸性抄紙法、中性抄紙法、アルカリ性抄紙法のいずれであっても良い。また、抄紙機も特に限定されるものではないので、例えば長網抄紙機、ツインワイヤー抄紙機、円網抄紙機、円網短網コンビネーション抄紙機等の公知の種々の抄紙機を使用することができる。 The raw pulp described above is subjected to a known papermaking process, for example, a wire part, a press part, a dryer part, a size press, a calender part, etc., and then the impregnated base paper having three paper layers of a surface layer, an intermediate layer, and a back layer. Form. The paper making method of the impregnated base paper is not particularly limited, and any of an acidic paper making method, a neutral paper making method, and an alkaline paper making method may be used. Also, since the paper machine is not particularly limited, for example, various known paper machines such as a long net paper machine, a twin wire paper machine, a circular net paper machine, and a short net combination machine can be used. it can.
このように形成された本含浸原紙は、ＪＩＳ−Ｐ８１１８（１９９８）に記載の「紙及び板紙−厚さ及び密度の試験方法」に準拠して測定した密度（以下、単に「密度」という）が０．３〜０．６ｇ／ｃｍ３、好ましくは０．３５〜０．５５ｇ／ｃｍ３、より好ましくは０．３５〜０．５ｇ／ｃｍ３に調整されている。このように本含浸原紙の密度を調整することによって、含浸原紙の水系熱硬化性樹脂の含浸性（含浸量）を調整することができる。なお、本含浸原紙の密度が０．３ｇ／ｃｍ３未満であると、含浸原紙の水系熱硬化性樹脂の含浸性は向上するが、必要量以上の水系熱硬化性樹脂が含浸原紙に含浸されてしまうため、乾燥に時間が掛かり、作業効率が悪くなるとともに、製造コストが高くなる。一方、本含浸原紙の密度が０．６ｇ／ｃｍ３を超えると、水系熱硬化性樹脂の含浸性が低下し、含浸原紙に含浸塗工される水系熱硬化性樹脂の量が減少するため、本発明の所望とする層間強度を得ることが困難となり、耐衝撃性が低下するため、本含浸原紙を床材として用いることができなくなる。 The thus-impregnated base paper formed in this manner has a density (hereinafter simply referred to as “density”) measured in accordance with “Paper and paperboard—Test method for thickness and density” described in JIS-P8118 (1998). It is adjusted to 0.3 to 0.6 g / cm 3 , preferably 0.35 to 0.55 g / cm 3 , more preferably 0.35 to 0.5 g / cm 3 . By adjusting the density of the impregnated base paper as described above, the impregnation property (impregnation amount) of the water-based thermosetting resin of the impregnated base paper can be adjusted. When the density of the impregnated base paper is less than 0.3 g / cm 3 , the impregnating property of the water-based thermosetting resin of the impregnating base paper is improved, but the impregnated base paper is impregnated with more than the required amount of the water-based thermosetting resin. Therefore, drying takes time, work efficiency is deteriorated, and manufacturing cost is increased. On the other hand, if the density of the impregnated base paper exceeds 0.6 g / cm 3 , the impregnation property of the water-based thermosetting resin is reduced, and the amount of the water-based thermosetting resin impregnated and applied to the impregnated base paper is reduced. Since it becomes difficult to obtain the desired interlayer strength of the present invention and the impact resistance is lowered, the impregnated base paper cannot be used as a flooring.
また、本含浸原紙の坪量は１７０〜２００ｇ／ｍ２、好ましくは１８０〜１９５ｇ／ｍ２、より好ましくは１８０〜１９０ｇ／ｍ２である。本含浸原紙の坪量をこのような範囲とすることにより、水系熱硬化性樹脂の含浸量を後述する範囲にすることができる。すなわち、本含浸原紙の坪量が１７０ｇ／ｍ２未満であると、所望の厚みを確保することができなくなるため、耐衝撃性が低下してしまう傾向にある。一方、本含浸原紙の坪量が２００ｇ／ｍ２を超えると、含浸原紙に対する水系熱硬化性樹脂の含浸量の割合が低下するため、本発明の所望とする層間強度を得ることが困難となり、耐衝撃性が低下するため、本含浸原紙を床材として用いることが難しくなる。 The basis weight of the impregnated base paper is 170 to 200 g / m 2 , preferably 180 to 195 g / m 2 , and more preferably 180 to 190 g / m 2 . By setting the basis weight of the impregnated base paper in such a range, the impregnation amount of the water-based thermosetting resin can be set in a range described later. That is, when the basis weight of the impregnated base paper is less than 170 g / m 2 , a desired thickness cannot be ensured, and impact resistance tends to decrease. On the other hand, when the basis weight of the impregnated base paper exceeds 200 g / m 2 , the ratio of the impregnated amount of the water-based thermosetting resin with respect to the impregnated base paper is reduced, so that it is difficult to obtain the desired interlayer strength of the present invention. Since the impact resistance is lowered, it becomes difficult to use the impregnated base paper as a flooring.
以上、本含浸原紙について、表層、中間層、及び裏層の３層の紙層から成る場合について説明したが、本発明は必ずしもこのような床材用含浸原紙に限らず、含浸原紙が多層抄き構造で形成されていれば、この他、例えば、表層及び裏層の２層の紙層から成る含浸原紙であっても良く、さらには含浸原紙の中間層を２層以上で構成し、４層以上の紙層で構成しても良い。すなわち、複数層の中間層を有する床材用含浸原紙においては、中間層も含めた全ての層に水系熱硬化性樹脂を含浸塗工することができる構造になっていれば良い。 As described above, the present impregnated base paper has been described with respect to the case where the front layer, the intermediate layer, and the back layer are composed of three paper layers. In addition to this, for example, it may be an impregnated base paper composed of two paper layers, a front layer and a back layer, and further, an intermediate layer of the impregnated base paper is composed of two or more layers, and 4 You may comprise the paper layer more than a layer. That is, the floor material impregnated base paper having a plurality of intermediate layers only needs to have a structure in which all layers including the intermediate layer can be impregnated with the water-based thermosetting resin.
上述した本含浸原紙に水系熱硬化性樹脂を含浸塗工して、本発明に係る床材用含浸紙（以下、「本含浸紙」と言う。）が形成される。すなわち、本含浸紙は、本含浸原紙を構成する全層に、水系熱硬化性樹脂である含浸液を含浸塗工することによって形成される。 The above-described impregnated base paper is impregnated and coated with a water-based thermosetting resin to form an impregnated paper for flooring according to the present invention (hereinafter referred to as “the impregnated paper”). That is, the impregnated paper is formed by impregnating and applying an impregnating liquid, which is a water-based thermosetting resin, to all layers constituting the impregnated base paper.
このように形成された本含浸紙は、ＪＩＳ−Ｚ０２３７（２０００）に記載の「粘着テープ・粘着シート試験方法−引張り強さ」に準拠して測定した層間強度（以下、単に「層間強度」と言う。）が、縦：３５０Ｎ／１５ｍｍ以上、横：２００Ｎ／１５ｍｍ以上となるように調整する。含浸紙の縦の層間強度が３５０Ｎ／１５ｍｍ未満、横の層間強度が２００Ｎ／１５ｍｍ未満であると、層間剥離が発生し易くなり、耐衝撃性が低下するため、本含浸紙を床材として使用できなくなる。 The impregnated paper formed in this manner has an interlaminar strength (hereinafter simply referred to as “interlaminar strength”) measured according to “Adhesive tape / adhesive sheet test method—tensile strength” described in JIS-Z0237 (2000). Is adjusted so that the length is 350 N / 15 mm or more and the width is 200 N / 15 mm or more. If the longitudinal interlayer strength of the impregnated paper is less than 350 N / 15 mm and the lateral interlayer strength is less than 200 N / 15 mm, delamination tends to occur and impact resistance decreases, so this impregnated paper is used as a flooring. become unable.
本含浸原紙に含浸塗工される水系熱硬化性樹脂は、少なくとも−ＣＨ２ＯＨ基（メチロール基）を有するものである。このように少なくとも−ＣＨ２ＯＨ基を有する水系熱硬化性樹脂を本含浸原紙に含浸塗工することにより、本含浸紙を床材用コア紙とすることができる。すなわち、合板として、表面性が悪く、軟質なベニヤ合板が使用された場合であっても、床材用コア紙として本含浸紙を用いると、床材の表面に形成される凹凸を被覆することができるようになる。 The water-based thermosetting resin impregnated and coated on the impregnated base paper has at least a —CH 2 OH group (methylol group). Thus, the impregnated paper can be used as the core paper for flooring by impregnating and applying the water-based thermosetting resin having at least —CH 2 OH group to the impregnated base paper. That is, even if soft plywood is used as plywood, even if soft plywood is used, if this impregnated paper is used as the core paper for flooring, the unevenness formed on the surface of the flooring will be covered. Will be able to.
このような少なくとも−ＣＨ２ＯＨ基を有する水系熱硬化性樹脂としては、メラミン、フェノール、ユリア、ＤＡＰ、エポキシ樹脂等を挙げることができ、これらの中でも水系熱硬化性樹脂として好適であるのは、メラミン、フェノール、ユリアである。これらの中でも特にメラミン樹脂を用いると、硬度が高く、耐衝撃性の高い含浸紙とすることができるので、より好ましい。 Examples of the water-based thermosetting resin having at least a —CH 2 OH group include melamine, phenol, urea, DAP, and epoxy resin. Among these, water-based thermosetting resins are preferable. , Melamine, phenol and urea. Among these, it is more preferable to use a melamine resin, because it can provide an impregnated paper having high hardness and high impact resistance.
また、本含浸紙における水系熱硬化性樹脂の含浸量は、含浸原紙全層の坪量に対して、３７〜７１％、好ましくは４０〜６０％である。なお、水系熱硬化性樹脂の含浸量が３７％未満であると、本発明の所望とする層間強度を得ることができず、層間剥離を起こしやすくなるため、含浸紙を床材として使用することが困難となる。一方、水系熱硬化性樹脂の含浸量が７１％を超えると、必要量以上の水系熱硬化性樹脂が含浸されているため、乾燥に時間が掛かり、作業効率が悪くなるほか、製造コストも高くなるという問題が生じる。 Moreover, the impregnation amount of the water-based thermosetting resin in the impregnated paper is 37 to 71%, preferably 40 to 60% with respect to the basis weight of the entire impregnated base paper. If the impregnation amount of the water-based thermosetting resin is less than 37%, the desired interlaminar strength of the present invention cannot be obtained, and delamination tends to occur. Therefore, impregnated paper should be used as a flooring material. It becomes difficult. On the other hand, when the impregnation amount of the water-based thermosetting resin exceeds 71%, since the water-based thermosetting resin is impregnated more than the necessary amount, drying takes time, work efficiency is deteriorated, and the manufacturing cost is high. Problem arises.
このように特定の−ＣＨ２ＯＨ基を有する水系熱硬化性樹脂を本含浸原紙に含浸塗工させて形成された本含浸原紙は、樹脂浸透性が５〜１３秒であることが好ましく、より好ましくは６〜１１秒である。本含浸原紙の樹脂浸透性が５秒未満であると、水系熱硬化性樹脂の含浸性が高くなりすぎ、必要量以上の水系熱硬化性樹脂が含浸されてしまうため、乾燥に時間が掛かり、作業効率が悪くなると共に、製造コストが増加する。一方、樹脂浸透性が１３秒を越えると、水系熱硬化性樹脂の含浸性が低くなり、必要量の水系熱硬化性樹脂が含浸されるまでの時間が長くなり、操業性が低下してしまう。 Thus, the impregnated base paper formed by impregnating and applying the water-based thermosetting resin having a specific —CH 2 OH group to the impregnated base paper preferably has a resin permeability of 5 to 13 seconds. Preferably, it is 6 to 11 seconds. If the resin permeability of the impregnated base paper is less than 5 seconds, the impregnation property of the water-based thermosetting resin becomes too high and the water-based thermosetting resin more than the necessary amount is impregnated. As the work efficiency deteriorates, the manufacturing cost increases. On the other hand, when the resin permeability exceeds 13 seconds, the impregnation property of the water-based thermosetting resin becomes low, the time until the required amount of the water-based thermosetting resin is impregnated becomes long, and the operability is lowered. .
また、本含浸紙の紙厚は５５０〜７５０μｍの範囲内であることが好ましい。これにより、本含浸紙を、合板として、表面性が悪く、軟質なベニヤ合板が使用された場合であっても、層間強度が高く、耐衝撃性があり、また床材の表面に形成される凹凸を被覆することができる床材用含浸紙とすることができる。なお、本含浸紙の紙厚を５５０〜７５０μｍの範囲とするには、本含浸原紙の紙厚は、水系熱硬化性樹脂の含浸塗工後に膨れが発生することから、４００〜５００μｍであることが好ましい。 The paper thickness of the impregnated paper is preferably in the range of 550 to 750 μm. As a result, even if this impregnated paper is used as a plywood, the surface property is poor and a soft veneer plywood is used, the interlayer strength is high, it has impact resistance, and is formed on the surface of the flooring. It can be set as the impregnated paper for flooring which can coat | cover an unevenness | corrugation. In order to set the paper thickness of the impregnated paper in the range of 550 to 750 μm, the paper thickness of the impregnated base paper is 400 to 500 μm because swelling occurs after the water-based thermosetting resin is impregnated. Is preferred.
本含浸紙の紙厚が５５０μｍ未満であると、合板として、例えば軟質で表面性の悪いベニヤ合板を用いた際、耐衝撃性が低くなると共に、床材の表面に形成される凹凸を被覆できなくなるので、本含浸紙を床材として使用することが困難となる。また、Ｖカット加工を施すことによりベニヤ合板が見えてしまうようになり、床材として見た目が悪くなり、品質が低下するという問題も生じる。 When the paper thickness of the impregnated paper is less than 550 μm, for example, when a veneer plywood that is soft and has poor surface properties is used as the plywood, impact resistance is lowered and unevenness formed on the surface of the flooring can be covered. Therefore, it becomes difficult to use the impregnated paper as a flooring. In addition, the veneer plywood can be seen by applying the V-cut process, which causes a problem that the appearance as a flooring material is deteriorated and the quality is deteriorated.
一方、本含浸紙の紙厚が７５０μｍを超えると、床材としての加工適性が低下する。また、含浸紙の紙厚を７５０μｍより大きくするには、含浸原紙の紙厚を大きくする必要があるが、含浸原紙の紙厚が大きすぎると、水系熱硬化性樹脂の含浸塗工時、水系熱硬化性樹脂が含浸原紙に浸透するまでの時間が長くなり、操業性が低下すると共に、使用する水系熱硬化性樹脂の量も多くなるため、製造コストが増加する。さらにまた、層間剥離が発生しやすくなり、耐衝撃性が低下するという問題も生じる。 On the other hand, when the paper thickness of the impregnated paper exceeds 750 μm, processability as a flooring material is lowered. Further, in order to make the paper thickness of the impregnated paper larger than 750 μm, it is necessary to increase the paper thickness of the impregnated base paper. However, if the paper thickness of the impregnated base paper is too large, the water-based thermosetting resin is impregnated during the impregnation coating. The time until the thermosetting resin penetrates into the impregnated base paper becomes longer, the operability is lowered, and the amount of the water-based thermosetting resin to be used is increased, so that the production cost is increased. Furthermore, delamination is likely to occur, resulting in a problem that impact resistance is reduced.
以上に詳述したような本含浸原紙を用い、本含浸紙を形成することにより、合板として、表面性が悪く、軟質なベニヤ合板が使用された場合であっても、層間強度が高く、耐衝撃性があり、また床材の表面に形成される凹凸を被覆することができるという床材用含浸原紙及び床材用含浸紙を提供するという本発明の課題を解決することができるのである。 By using this impregnated base paper as described in detail above and forming this impregnated paper, even when a soft veneer plywood with poor surface properties is used as a plywood, the interlayer strength is high and the It is possible to solve the problem of the present invention of providing an impregnated base paper for flooring and an impregnated paper for flooring that have impact properties and can cover unevenness formed on the surface of the flooring.
本発明に係る床材用含浸紙の効果を確認するため、以下のような各種の試料を作製し、これらの各試料に対する品質を評価する試験を行った。なお、本実施例において、配合、濃度等を示す数値は、固形分又は有効成分の質量基準の数値である。また、本実施例で示すパルプ・薬品等は一例にすぎないので、本発明はこれらの実施例によって制限を受けるものではなく、適宜選択可能であることはいうまでもない。 In order to confirm the effect of the impregnated paper for flooring according to the present invention, the following various samples were prepared, and a test for evaluating the quality of each sample was performed. In addition, in a present Example, the numerical value which shows a mixing | blending, a density | concentration, etc. is a numerical value of the solid content or the mass reference | standard of an active ingredient. Moreover, since the pulp, chemical | medical agent, etc. which are shown in a present Example are only examples, it cannot be overemphasized that this invention is not restrict | limited by these Examples, and can be selected suitably.
本発明に係る２２種類の床材用含浸紙（これを「実施例１」ないし「実施例２２」とする）と、これらの実施例１ないし実施例２２と比較検討するために、４種類の床材用含浸紙（これを「比較例１」ないし「比較例４」とする）を、表１に示すような構成で作製した。 In order to compare and compare with 22 types of impregnated paper for flooring according to the present invention (referred to as “Example 1” to “Example 22”) and Examples 1 to 22, Impregnated paper for flooring (referred to as “Comparative Example 1” to “Comparative Example 4”) was prepared in the configuration shown in Table 1.
〔実施例１〕
以下の原料を用いて、下記の製造法に従い、表層、裏層及び両層間に位置する２層の中間層からなる４層構造の床材用含浸原紙を得た。
＜原料＞
・表層及び裏層
針葉樹晒クラフトパルプ（ＮＢＫＰ）９０質量％と、機械パルプ（ＴＭＰ）１０質量％とを配合した後に、カナディアンスタンダードフリーネス（ＣＳＦ）を５５０ｃｃに調整した原料に、薬品の定着剤として、硫酸アルミニウムを固形分で０．４質量％、湿潤紙力増強剤（星光ＰＭＣ株式会社製ＷＳ４０２４）を固形分で０．１７５質量％、乾燥紙力増強剤（星光ＰＭＣ株式会社製ＤＳ４３５６）を固形分で０．２質量％、含浸液浸透促進剤（星光ＰＭＣ株式会社製ＤＦ６３００）を固形分で０．０２質量％配合し、表層及び裏層用の原料パルプスラリーを得た。
・中間層
針葉樹晒クラフトパルプ（ＮＢＫＰ）９０質量％と、機械パルプ（ＴＭＰ）１０質量％とを配合した後に、ＣＳＦを５５０ｃｃに調整した原料に、薬品の定着剤として、硫酸アルミニウムを固形分で０．４質量％、湿潤紙力増強剤（星光ＰＭＣ株式会社製ＷＳ４０２４）を固形分で０．１７５質量％、乾燥紙力増強剤（星光ＰＭＣ株式会社製ＤＳ４３５６）を固形分で０．２質量％、含浸液浸透促進剤（星光ＰＭＣ株式会社製ＤＦ６３００）を固形分で０．０２質量％配合し、中間層用のパルプスラリーを得た。
[Example 1]
Using the following raw materials, a four-layer impregnated base material for flooring comprising a surface layer, a back layer, and two intermediate layers located between both layers was obtained according to the following production method.
<Raw material>
・ Surface and back layers After blending 90% by weight of softwood bleached kraft pulp (NBKP) and 10% by weight of mechanical pulp (TMP), the raw material with Canadian Standard Freeness (CSF) adjusted to 550cc is used as a chemical fixing agent. , 0.4% by weight of aluminum sulfate in solid content, wet paper strength enhancer (WS4024 manufactured by Seiko PMC Co., Ltd.) 0.175 mass% in solid content, dry paper strength enhancer (DS4356 manufactured by Seiko PMC Co., Ltd.) 0.2% by mass in solid content and 0.02% by mass of impregnating liquid permeation accelerator (DF6300 manufactured by Seiko PMC Co., Ltd.) in solid content were blended to obtain a raw material pulp slurry for the front and back layers.
・ Intermediate layer After blending 90% by weight of softwood bleached kraft pulp (NBKP) and 10% by weight of mechanical pulp (TMP), the raw material prepared by adjusting the CSF to 550 cc is used as a chemical fixing agent. 0.4% by mass, 0.175% by mass of wet paper strength enhancer (WS4024 manufactured by Seiko PMC Co., Ltd.) and 0.2% by mass of dry paper strength enhancer (DS4356 manufactured by Seiko PMC Co., Ltd.) %, Impregnating liquid permeation accelerator (DF6300 manufactured by Seiko PMC Co., Ltd.) was mixed in an amount of 0.02% by mass to obtain a pulp slurry for an intermediate layer.
これらの原料パルプスラリーを用い、円網抄紙機にて表層、２層の中間層、及び裏層の紙層を抄き合わせて、表層の付け量を５０ｇ／ｍ２、中間層の合計付け量を８０ｇ／ｍ２、裏層の付け量を５３ｇ／ｍ２、含浸原紙全体の坪量が１８３ｇ／ｍ２である４層抄きの床材用含浸原紙（実施例１）を得た。 Using these raw material pulp slurries, the surface layer, the two intermediate layers, and the back layer paper layer are combined with a circular paper machine, the surface layer weight is 50 g / m 2 , and the intermediate layer weight is total the 80g / m 2, 53g / m 2 Paste amount of backing layer, the basis weight of the whole impregnation base paper to obtain a 183 g / m 2 and is 4-ply flooring impregnated base paper (example 1).
このように作製した含浸原紙に、表１に示すような樹脂を、含浸原紙全層の坪量に対し、表１に示す含浸量を含浸塗工して、含浸紙を形成する。 The impregnated base paper thus prepared is impregnated with a resin as shown in Table 1 in the amount of impregnation shown in Table 1 with respect to the basis weight of the entire impregnated base paper to form an impregnated paper.
また、実施例２〜２２、及び比較例１〜４を表１に示す条件以外は実施例１と同様に含浸原紙を作製した。なお、本実施例における熱発泡性粒子としては、熱発泡性粒子（松本油脂製薬株式会社製「マツモトマイクロスフェアＦ−４６」）と、定着剤（伯東株式会社製「ハクトロンＫＣ１００」）（凝集カチオン性高分子樹脂）を用いた。 Further, impregnated base papers were produced in the same manner as in Example 1 except that Examples 2 to 22 and Comparative Examples 1 to 4 were the conditions shown in Table 1. In addition, as the thermally foamable particles in this example, thermally foamable particles (“Matsumoto Microsphere F-46” manufactured by Matsumoto Yushi Seiyaku Co., Ltd.) and a fixing agent (“Haktron KC100” manufactured by Hakuto Co., Ltd.) (aggregated cation) Functional polymer resin).
なお、表１中の「ＣＳＦ（ｃｃ）」とは、ＪＩＳ−Ｐ８１２１（１９９５）に記載の「紙及び板紙−パルプのろ水度試験方法−カナダ標準ろ水度試験方法」に準拠して測定した値である。 In addition, "CSF (cc)" in Table 1 is measured in accordance with "Paper and paperboard-Pulp freeness test method-Canadian standard freeness test method" described in JIS-P8121 (1995). It is the value.
また、「付け量（ｇ／ｍ２）」とは、各試料の層剥離を行い、各層の坪量をＪＩＳ−Ｐ８１２４に記載の「紙及び板紙−坪量測定方法」に準拠して測定した値である。 In addition, “attachment amount (g / m 2 )” refers to the delamination of each sample, and the basis weight of each layer was measured according to “paper and paperboard—basis weight measurement method” described in JIS-P8124. Value.
なお、層剥離は以下の手順で行った。まず、各試料から得た各サンプルを室温の水に約１時間浸漬する。水に浸漬した各サンプルを、角を起点として１０ｍｍΦ程度の丸棒に巻き付けた後、丸棒を転がして各サンプルをしごく。この操作を各サンプルの四隅の全ての角を起点に繰り返し、各方向からサンプルにしごきの力を加える。これにより、各サンプルの層間の一部が剥離してくるので、これを利用して、表層、中間層、及び裏層に分離して層剥離を行う。層剥離を行った後、各サンプルの各層を熱風乾燥機などで十分に乾燥し、試験に使用した。 The delamination was performed according to the following procedure. First, each sample obtained from each sample is immersed in water at room temperature for about 1 hour. Each sample immersed in water is wound around a round bar of about 10 mmΦ starting from a corner, and then the round bar is rolled to squeeze each sample. This operation is repeated starting from all four corners of each sample, and the ironing force is applied to the sample from each direction. As a result, a part of the layers of each sample is peeled off, and this is used to separate the layers into a surface layer, an intermediate layer, and a back layer. After delamination, each layer of each sample was sufficiently dried with a hot air dryer or the like and used for the test.
これらの全実施例及び比較例について品質評価を行った結果は、表２に示すとおりであった。なお、この品質評価試験は、ＪＩＳ−Ｐ８１１１に準拠して温度２３±２℃、湿度５０±２％の環境条件で行った。 Table 2 shows the results of quality evaluation for all of these Examples and Comparative Examples. This quality evaluation test was performed under environmental conditions of temperature 23 ± 2 ° C. and humidity 50 ± 2% in accordance with JIS-P8111.
なお、表２中の「坪量（ｇ／ｍ２）」とは、各試料全層、すなわち床材用含浸原紙全体の坪量で、ＪＩＳ−Ｐ８１２４（１９９８）に記載の「紙及び板紙−坪量測定方法」に準拠して測定した値である。 In addition, “basis weight (g / m 2 )” in Table 2 is the basis weight of all the layers of each sample, that is, the entire impregnated base paper for flooring, and is described in “Paper and paperboard” described in JIS-P8124 (1998). It is the value measured based on "basis weight measuring method".
「紙厚（μｍ）」とは、ＪＩＳ−Ｐ８１１８（１９９８）に記載の「紙及び板紙−厚さ及び密度の試験方法」に準拠して含浸原紙、含浸紙を測定した値である。 “Paper thickness (μm)” is a value obtained by measuring impregnated base paper and impregnated paper in accordance with “Paper and paperboard—Test method of thickness and density” described in JIS-P8118 (1998).
「密度（ｇ／ｃｍ３）」とは、ＪＩＳ−Ｐ８１２４（１９９８）に記載の「紙及び板紙−坪量測定方法」に準拠して測定した含浸原紙の坪量と、ＪＩＳ−Ｐ８１１８（１９９８）に記載の「紙及び板紙−厚さ及び密度の試験方法」に準拠して測定した含浸原紙の紙厚から算出した値である。 “Density (g / cm 3 )” means the basis weight of the impregnated base paper measured according to “Paper and paperboard—basis weight measurement method” described in JIS-P8124 (1998), and JIS-P8118 (1998). It is a value calculated from the paper thickness of the impregnated base paper measured according to “Paper and paperboard—Test method of thickness and density” described in 1.
「クレム吸水度（ｍｍ）」とは、ＪＩＳ−Ｐ８１４１（２００４）に記載の「紙及び板紙−吸水度試験方法−クレム法」に準拠して測定した含浸原紙の縦方向の吸水度の値である。 “Crem water absorbency (mm)” is the value of the water absorbency in the longitudinal direction of the impregnated base paper measured according to “paper and paperboard—water absorbency test method—Klem method” described in JIS-P8141 (2004). is there.
「吸油度（秒）」とは、Ｊ．ＴＡＰＰＩ Ｎｏ．３２−２（２０００）に記載の「紙−吸水性試験方法−第二部：滴下法」に準拠し、滴下する溶媒に軽油を用いて測定した数値である。 "Oil absorption (seconds)" TAPPI No. It is a numerical value measured using light oil as a solvent to be dropped in accordance with “Paper—Water Absorption Test Method—Part 2: Dropping Method” described in 32-2 (2000).
「樹脂浸透性（秒）」とは、上記「吸油度（秒）」と同様に、Ｊ．ＴＡＰＰＩ Ｎｏ．３２−２（２０００）に記載の「紙−吸水性試験方法−第二部：滴下法」に準拠し、滴下した溶媒に、日本カーバイト株式会社製、型番ニカレヂンＳ−２６０のメラミン樹脂を水で濃度５０％に調整したメラミン樹脂溶液を用いて測定した数値である。 “Resin permeability (seconds)” is the same as “Oil absorption (seconds)” described above. TAPPI No. In accordance with “Paper—Water Absorption Test Method—Part 2: Dropping Method” described in 32-2 (2000), water melamine resin made by Nippon Carbide Co., Ltd. It is a numerical value measured using a melamine resin solution adjusted to a concentration of 50%.
「剥離強度（ＭＰａ）」とは、ＪＩＳ−Ｐ８１３１（１９９５）に記載の「紙及び板紙−ミューレン高圧形試験機による破裂強さ試験方法に準拠して含浸原紙を測定した値を、層間剥離強度としたものである。 The “peel strength (MPa)” is a value obtained by measuring the impregnated base paper according to the burst strength test method using “Paper and paperboard-Mullen high pressure tester” described in JIS-P8131 (1995). It is what.
「樹脂浸透性（秒）」とは、水系熱硬化性樹脂の浸透性（含浸性）を評価したもので、Ｊ．ＴＡＰＰＩ Ｎｏ．４１（２０００）に記載の「紙及び板紙−はつ油度試験方法−キット法」準拠して含浸紙を測定した値である。 “Resin permeability (seconds)” is an evaluation of the permeability (impregnation) of a water-based thermosetting resin. TAPPI No. 41 (2000) is a value obtained by measuring impregnated paper in accordance with “Paper and paperboard—oil repellency test method—kit method”.
「層間強度（縦）（Ｎ／１５ｍｍ）」とは、ＪＩＳ−Ｚ０２３７（２０００）に記載の「粘着テープ・粘着シート試験方法−引張り強さ」に準拠して含浸紙を測定した縦方向の層間強度で、「層間強度（横）（Ｎ／１５ｍｍ）」とは、ＪＩＳ−Ｚ０２３７（２０００）に記載の「粘着テープ・粘着シート試験方法−引張り強さ」に準拠して含浸紙を測定した横方向の層間強度で、試験片が１５ｍｍ幅であることから、単位をＮ／１５ｍｍに変更し、測定した値である。 “Interlaminar strength (longitudinal) (N / 15 mm)” is a longitudinal interlaminar measurement of impregnated paper according to “Adhesive tape / adhesive sheet test method—tensile strength” described in JIS-Z0237 (2000). In terms of strength, “interlaminar strength (horizontal) (N / 15 mm)” refers to the width of an impregnated paper measured according to “Adhesive tape / adhesive sheet test method—tensile strength” described in JIS-Z0237 (2000). It is a value measured by changing the unit to N / 15 mm because the test piece is 15 mm wide in terms of interlayer strength in the direction.
「折曲げ」とは、含浸紙の層間強度を評価したものであり、含浸紙である各試料を９０度、１８０度に折り曲げ、ひび割れの発生状況を目視で確認して評価した。その評価基準は下記の通りとした。
○：ひび割れが発生していない。
○△：ひび割れが発生しかけている。
△：ややひび割れが発生している。
×：ひび割れが発生している。
“Bending” is an evaluation of the interlaminar strength of the impregnated paper. Each sample, which is the impregnated paper, was bent at 90 ° and 180 °, and the occurrence of cracks was visually confirmed and evaluated. The evaluation criteria were as follows.
○: No crack occurred.
○ △: Cracks are starting to occur.
Δ: Slightly cracked.
X: Cracking has occurred.
「耐セロハンテープ」とは、含浸紙の表面強度を評価するものであり、幅１５ｍｍ長さ１５０ｍｍのセロハンテープを含浸紙に縦方向に貼り付け、その上から５ｋｇの荷重を５分かけ、その後セロハンテープを引き剥がした際のセロハンテープの剥離面を観察し、評価したものである。その評価基準は下記の通りとした。
○：セロハンテープが綺麗に剥がれている。
△：含浸紙表面がやや剥ぎ取られている。
×：含浸紙表面と繊維が一緒に剥ぎ取られている。
“Cellophane tape” evaluates the surface strength of the impregnated paper. A cellophane tape having a width of 15 mm and a length of 150 mm is applied to the impregnated paper in the vertical direction, and a 5 kg load is applied for 5 minutes. The peeled surface of the cellophane tape when the cellophane tape was peeled off was observed and evaluated. The evaluation criteria were as follows.
○: The cellophane tape is peeled cleanly.
Δ: The impregnated paper surface is slightly peeled off.
X: The impregnated paper surface and the fibers are peeled off together.
「碁盤目」とは、含浸紙の層間強度を評価したものである。その評価方法は、各試料である含浸原紙に樹脂を含浸させた含浸紙の表面の流れ方向に、垂直・水平に幅２ｍｍ、深さ０．３ｍｍの升目を用い、１００枡カッターで切り込みを入れた後、含浸紙の表面にセロハンテープを貼り、その後強制的にセロハンテープを剥ぎ取った。その際に層間が剥離しなかった枡目をカウントして評価したものである。なお、表中には、「残存した枡の数／１００枡」で表している。 “Cross-cut” is an evaluation of the interlaminar strength of the impregnated paper. The evaluation method is to use a grid with a width of 2 mm and a depth of 0.3 mm vertically and horizontally in the flow direction of the surface of the impregnated paper impregnated with the impregnated base paper as each sample, and cut with a 100 mm cutter. Then, a cellophane tape was applied to the surface of the impregnated paper, and then the cellophane tape was forcibly removed. In this case, the evaluation was performed by counting the cells where the layers were not separated. In the table, it is expressed as “the number of remaining wrinkles / 100 wrinkles”.
また、「総合評価」とは、樹脂浸透性、層間強度（縦・横）、折曲げ、耐セロハンテープ、碁盤目の評価を総合的に評価したもので、その評価基準は下記の通りである。
◎：十分満足できる。
○：満足できる。
△：やや満足できる。
×：満足できない。
“Comprehensive evaluation” is a comprehensive evaluation of resin permeability, interlaminar strength (vertical / horizontal), bending, cellophane tape, and grid, and the evaluation criteria are as follows. .
A: Satisfactory.
○: Satisfied.
Δ: Slightly satisfactory
X: Not satisfied.
表２から、本発明に係る床材用含浸紙であると、層間強度が高く、耐衝撃性があり、また床材の表面に形成される凹凸を被覆することができるということが分かる。
From Table 2, it can be seen that the floor material impregnated paper according to the present invention has high interlayer strength, impact resistance, and can cover the unevenness formed on the surface of the floor material.
Claims (4)
該床材用含浸原紙の各層を構成する原料パルプには、機械パルプを１０〜２０質量％配合し、ＮＢＫＰを８０〜９０質量％配合し、
また、前記原料パルプは、ＪＩＳ−Ｐ８１２１（１９９５）に記載の「紙及び板紙−パルプのろ水度試験方法−カナダ標準ろ水度試験方法」に準拠して測定したフリーネスを５５０〜７５０ｃｃに調整し、
紙厚が４００〜５００μｍであり、
ＪＩＳ−Ｐ８１１８（１９９８）に記載の「紙及び板紙−厚さ及び密度の試験方法」に準拠して測定した密度が０．３〜０．６ｇ／ｃｍ３であり、
ＪＩＳ−Ｐ８１４１（２００４）に記載の「紙及び板紙−吸水度試験方法−クレム法」に準拠して測定したクレム吸水度が８０〜９７ｍｍであり、
また、Ｊ．ＴＡＰＰＩ Ｎｏ．４１（２０００）に記載の「紙及び板紙−はつ油度試験方法−キット法」に準拠して測定した吸油度が１．３〜１．８秒であり、
少なくとも−ＣＨ２ＯＨ基（メチロール基）を有する水系熱硬化性樹脂を含浸塗工することを特徴とする床材用含浸原紙。 In an impregnated base material for flooring of a multilayer paper having at least two layers of a surface layer and a back layer,
In the raw material pulp constituting each layer of the impregnated base paper for flooring, 10 to 20% by mass of mechanical pulp is blended, and 80 to 90% by mass of NBKP is blended,
The raw pulp is adjusted to a freeness of 550 to 750 cc according to “Paper and paperboard—Pulp freeness test method—Canadian standard freeness test method” described in JIS-P8121 (1995). And
The paper thickness is 400-500 μm ,
The density measured according to “Paper and paperboard—Test method for thickness and density” described in JIS-P8118 (1998) is 0.3 to 0.6 g / cm 3 ,
The Klem water absorption measured in accordance with “Paper and paperboard—Water absorption test method—Klem method” described in JIS-P8141 (2004) is 80 to 97 mm,
In addition, J.H. TAPPI No. 41 (2000), the oil absorption measured in accordance with “Paper and paperboard—oil repellency test method—kit method” is 1.3 to 1.8 seconds,
An impregnated base paper for flooring, which is impregnated with a water-based thermosetting resin having at least —CH 2 OH groups (methylol groups).
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| JP2008088741A (en) * | 2006-10-03 | 2008-04-17 | Sumitomo Forestry Co Ltd | Flooring and manufacturing method therefor |
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| JPS536605A (en) * | 1976-06-30 | 1978-01-21 | Matsushita Electric Works Ltd | Production of core paper for decorative board |
| JPH04364943A (en) * | 1991-06-12 | 1992-12-17 | Kohjin Co Ltd | Decorative sheet giving feeling of deep luster |
| JPH055296A (en) * | 1991-06-21 | 1993-01-14 | Oji Paper Co Ltd | Production of base paper for impregnation |
| JPH0872207A (en) * | 1994-09-06 | 1996-03-19 | Sumitomo Bakelite Co Ltd | Decorative panel |
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| JP2008088741A (en) * | 2006-10-03 | 2008-04-17 | Sumitomo Forestry Co Ltd | Flooring and manufacturing method therefor |
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