JP4748958B2 - Manufacturing method of base material for decorative plate - Google Patents

Description

The present invention, such as a house building, particularly relates to the production how suitable decorative plate substrate for use as a flooring material.

  Conventionally, as a flooring material for a building such as a house, a thin wooden veneer or wood pattern printing paper is pasted on the surface of a wooden base plate such as plywood, and a clear paint or a color clear paint is applied to the surface. The formed wood veneer is used.

  On the other hand, in recent years, it has become difficult to obtain high-quality timber as a raw material for the above-mentioned wooden baseboard due to depletion of resources and preservation of the global environment. Therefore, recently, afforestation has been actively promoted for the regeneration of timber resources, and attempts have been made to use the obtained afforestation tree as a wooden base plate. In addition, the use of unused wood that has not been used due to unstable quality has been attempted.

  However, when afforestation trees are used as a wooden base plate, the afforestation trees have a drawback that their material is soft and easily damaged because of their rapid growth. When the above-mentioned planted tree is used as a wooden base plate to form the above-mentioned wooden decorative board, the surface of the wooden decorative board is damaged such as a dent or a crack due to an impact or dropping of an object or sliding of a caster base ring. There is a problem that it is easy to occur and the appearance is greatly impaired.

  In addition, when unused wood is used for a wooden base plate, in addition to the above-mentioned problem that scratches are likely to occur, the surface color is often dark, and the surface color of each wooden base plate varies. There is a problem that the surface color is not uniform and there is a difference in color density in one plate. For this reason, the obtained wood decorative board has an unnatural darkness on the surface of the wooden decorative board through a decorative layer made of a thin wooden decorative veneer or a wood pattern printing paper with the color tone of the wooden decorative board attached to the wooden decorative board. There was a problem that it appeared as variations in colors and shades, and the cosmetic properties were remarkably impaired.

  On the other hand, with respect to such a problem, for example, as in the invention described in Patent Document 1, a harder reinforcing layer than the wooden base plate is provided between the wooden decorative veneer and the wooden pattern printing paper to provide scratch resistance. A method for improving surface physical properties such as the above has been proposed.

  However, in this method, the thin wood fiberboard must be precisely cut off to form a thin wood fiberboard, so that the productivity is poor, and deformation such as warping is easily caused by expansion and contraction due to moisture absorption and desorption. In addition, since many wood fiber boards have dark colors, there is a problem that the obtained wood decorative board also becomes dark.

In addition, when using a resin-impregnated sheet impregnated with a thermosetting resin, such as the resin-impregnated paper base described in Patent Document 2, warpage occurs during production due to shrinkage of the thermosetting resin during hot pressing. There is a drawback that it is easy.
Japanese Patent Laid-Open No. 11-227106 JP 2000-302900 A

  The present invention has been made in view of such problems, and even if soft wood such as the above-mentioned plantation trees and unused wood is used as a wood substrate, a decorative board substrate having excellent surface scratch resistance is obtained with high productivity. It aims at providing the manufacturing method of the base material for decorative boards which can be manufactured.

  Moreover, even if dark wood or wood with uneven shading is used for the wood substrate, a decorative board base material that can stably display a natural and good-colored wood grain pattern on the surface with high productivity. It aims at providing the manufacturing method of the base material for decorative boards which can be manufactured.

  In order to achieve the above object, an object of the present invention is to integrate a porous sheet impregnated with a hot melt resin on the surface of a substrate as a wooden base plate. Specifically, the following solutions were taken.

That is, in the invention described in claim 1, a porous sheet material is integrated on a substrate made of a wooden substrate or a volcanic glassy multilayer board, and a wooden decorative veneer or a wooden pattern print is formed on the porous sheet material. As a method for producing a decorative board substrate on which a decorative board is formed by sticking paper, a thermoplastic resin having a Vicat softening point of 35 ° C or higher and a melting point of 70 ° C to 180 ° C on the surface of the substrate , Alternatively, a hot melt resin melt composed of a moisture curable urethane resin is applied at a coating amount of 120 to 250 g / m ² and a porous sheet material is placed on the surface of the hot melt resin coating layer. By pressurizing the porous sheet material, a part of the hot melt resin melt is impregnated into the porous sheet material to form a reinforcing layer by impregnation of the hot melt resin, and the hot melt resin The remainder of the resin melt is used for bonding the porous sheet material and the substrate to integrate the porous sheet material and the substrate.

The invention described in claim 2 is characterized in that, in the invention described in claim 1, an inorganic pigment is mixed in the hot melt resin .

The invention according to claim 3 is the invention according to claim 1 or 2 , wherein the hot melt resin of the hot melt resin coating layer is coated with a porous sheet material by coating the hot melt resin on the surface of the substrate. When placed, it is in a molten state.

The invention described in claim 4 is the invention according to any one of claims 1 to 3, and wherein said porous sheet material is paper having a basis weight of ^20g / ^{m 2 ~100g} / m 2 To do .

According to the invention according to claim 1, the porous sheet material is integrated on the substrate made of the wooden substrate or the volcanic glassy multilayer board, and the wooden decorative veneer or the wooden pattern printing paper is formed on the porous sheet material. As a method for producing a decorative board substrate on which a decorative board is formed by sticking, a thermoplastic resin having a Vicat softening point of 35 ° C. or higher and a melting point of 70 ° C. to 180 ° C. or moisture curing on the surface of the substrate A hot melt resin melt composed of a urethane type resin is applied at a coating amount of 120 to 250 g / m ² , and a porous sheet material is placed on the surface of the hot melt resin coating layer. The sheet material is pressurized to impregnate a part of the melt of the resin in the porous sheet material to form a reinforcing layer by impregnation of the hot melt resin, and the remainder of the melt of the hot melt resin is porous Sheet material and substrate By combining the porous sheet material and the substrate together with the substrate, a soft material such as afforestation trees and unused wood can be used for the above substrate as a wooden base plate. A board substrate can be produced with high productivity.

Moreover, since the hot-melt resin is a thermoplastic resin having a Vicat softening point of 35 ° C. or higher and a melting point of 70 ° C. to 180 ° C. or a moisture-curable urethane resin, a decorative board for floor heating devices such as heating floors and hot carpets is used. Even if it is applied to a substrate for use, a problem due to softening does not occur, and a decorative plate substrate excellent in water resistance and hot water resistance can be obtained (by JAS2 immersion peeling test). And when melting | fusing point becomes less than 70 degreeC, it will become easy to peel in the said immersion peeling test, and when it exceeds 180 degreeC, productivity will worsen.

According to the invention of claim 2, in the invention of claim 1, the hot melt resin is mixed with an inorganic pigment that enhances the concealability. In addition to the effect of the invention of claim 1, the color and shading variation of the wooden substrate does not appear on the surface through the decorative layer in addition to the effect of the invention of claim 1, and a natural and good color wood grain pattern is obtained. A base material for a decorative board that can stably appear on the surface can be produced with high productivity .

According to the invention of claim 3 , in the invention of claim 1 or 2 , when the hot melt resin of the hot melt resin coating layer is applied to the surface of the substrate and the porous sheet material is placed In addition to the effect of the invention of claim 1 or 2 , the porous sheet material placed thereon can be bonded well, and cold pressure can be achieved without using a hot-press roll. Even in the roll, the hot melt resin can be satisfactorily impregnated into the porous sheet material, and the production efficiency is good.

According to the invention of claim 4, in the invention of claims 1 to 3, because of the use of paper having a basis weight of ^20g / ^{m 2 ~100g} / m 2 in the porous sheet material, the invention of claim 1 to 3 In addition to the effect, a reinforced layer satisfactorily impregnated with a hot melt resin can be formed with good productivity .

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1 (a) to 1 (c) show a hot-melt resin coating layer in which a melted hot-melt resin 4a is applied to the surface of a substrate by a known hot-melt resin coating device 2 equipped with a heated roll coater 1. After the porous sheet material 5 is placed on the surface of 4b, the porous sheet material 5 is pressed with a pressure roll 6 to impregnate the porous sheet material 5 with the melt of the hot melt resin 4b. It is the schematic which shows the process of integrating the porous sheet material 5 and the board | substrate 3 with it.

  FIG. 2 shows a decorative board base material 7 in which the porous sheet material 5 and the substrate 3 are integrated by impregnating the porous sheet material 5 with the melt of the hot melt resin 4b.

  Hereinafter, these components of the present invention will be described in detail.

(substrate)
As the substrate 3, a wood substrate such as plywood, LVL, laminated wood, wood fiber board, or the like can be suitably used. Moreover, although it is not a wooden board | substrate, a volcanic glassy multilayer board (brand name Dylite, Daiken Kogyo Co., Ltd.) is applicable to a board | substrate.

  In particular, application to a wooden substrate 3 formed using a relatively soft wood having a specific gravity of about 0.45 to 0.65, for example, afforestation trees such as unused wood, softwood, poplar, and acacia is desirable.

(Hot melt resin)
As the hot melt resin 4a, a thermoplastic resin hot melt resin or a reactive hot melt resin can be used. As the thermoplastic resin-based hot melt resin, for example, ethylene vinyl acetate copolymer resin, ethylene acrylate resin, maleic anhydride-modified polyethylene resin, maleic anhydride-modified polypropylene resin and the like can be used.

  Further, as the reactive hot melt resin, a moisture curable urethane resin can be suitably used.

(Hot-melt resin softening point, melting point)
The thermoplastic hot-melt resin desirably has a Vicat softening point of 35 ° C. or higher and a melting point of 70 ° C. or higher and 180 ° C. or lower. Use of a Vicat softening point of less than 35 ° C. for a decorative sheet for floor heating is not preferable because it causes softening and decreases the adhesive strength and surface hardness, thereby easily causing peeling and scratches.

  On the other hand, when the melting point is less than 70 ° C., the warm water resistance is lowered, and in the JAS2 immersion peeling test and the like, it is easy to peel off. On the other hand, if the melting point exceeds 180 ° C., it will not melt unless it is at a high temperature, so the productivity will be poor and the production cost will be high.

  On the other hand, when a reactive hot melt resin such as a moisture-curing urethane resin is used for floor heating as described above, the problem is that softening occurs and peeling and scratches occur due to a decrease in adhesive strength and surface hardness. There is no problem of reduction in hot water resistance. Usually, a melting point of 60 ° C. to 80 ° C. can be used.

(Additive to hot melt resin)
When unused wood is used for the substrate 3, there are many problems that the surface is dark, the surface color varies widely from one sheet to another, the surface color is not uniform, and there is a difference in light and shade. In order to solve this problem and not impair the design of the decorative surface, it is desirable to mix an inorganic pigment in the hot melt resin 4a. As such inorganic pigments, white pigments such as titanium oxide, calcium carbonate, and talc can be suitably used, and light color pigments obtained by adding a small amount of a color pigment such as Benkara to these white pigments can also be used. Moreover, inorganic powder which improves hardness, such as a silica powder, can also be added.

  Such inorganic pigments and the like can be added in an amount of about 10 to 30 parts by weight with respect to 100 parts by weight of the hot melt resin. When the addition amount is less than 10 parts by weight, the effect of concealing the dark color and the color variation on the surface of the substrate 3 is insufficient, and when it exceeds 30 parts by weight, the adhesion between the substrate 3 and the porous sheet material 5 is insufficient. Since it falls, it is not preferable.

(Porous sheet material)
As the porous sheet material 5, it is possible to use a paper having a basis weight of ^20g / ^{m 2 ~100g} / m 2 suitably. Easily broken at the time of manufacturing the basis weight of the paper is less than 20 g / m ² is used, also can not form a sufficient reinforcing layer is not preferable, also exceeds 100 g / m ^2, the resin together uneconomical Since impregnation is insufficient and it becomes difficult to obtain a desired reinforcing layer, it is not preferable. As the porous sheet material 5, a wood fiber sheet or a nonwoven fabric having a thickness of 0.3 mm to 1.5 mm can be used in addition to the above paper.

(Application and application amount of hot melt resin to the substrate)
As shown in FIG. 1 (a), a melted hot melt resin 4 a is applied to the surface of the substrate 3 by a known hot melt resin coating apparatus 2 equipped with a heated roll coater 1. The heating temperature of the roll coater 1 needs to be higher than the melting point of the hot melt resin 4a to be used, and is usually set to be 15 ° C. or higher higher than the melting point of the hot melt resin 4a.

The coating amount of the hot melt resin 4a is 2 to 250 g / ^{m 2} approximately 120 ^g / m. Some of them are used for bonding the substrate 3 and the porous sheet material 5, and others are used for impregnation of the porous sheet material 5. If it is less than 120 g / m ^{2, the} amount of impregnation of the hot melt resin 4a into the porous sheet material 5 may be insufficient, and if it exceeds 250 g / m ² , it becomes excessive and uneconomical.

(Placement of porous sheet material on hot melt resin coating layer)
As shown in FIG. 1B, the porous sheet material 5 is preferably placed while the hot melt resin coating layer 4b applied to the substrate 3 is in a molten state. Thereby, the adhesiveness between the hot melt resin 4a and the porous sheet material 5 is improved, and the porous sheet material 5 is smoothly impregnated with the hot melt resin 4a by pressurization in the next step. The porous sheet material 5 can be placed after the hot melt resin 4a applied to the substrate 3 is solidified. In this case, the next step is performed by heating and pressing, and the hot melt resin 4a. Needs to be remelted to impregnate the porous sheet material 5 with the hot melt resin 4a.

(Pressurization)
As shown in FIG. 1C, pressurization may be performed at normal temperature with a cooling roll or cold press, or may be performed with heat and pressure with a heating roll or hot press. When pressurizing while the hot melt resin 4a applied to the substrate 3 is in a molten state, the pressurization may be performed at room temperature or may be performed under heat.

For example, when pressurizing with a cooling roll, it can carry out by passing between the upper and lower rolls set to the space | interval of the dimension about 0.5 mm-1.0 mm smaller than the thickness of the board | substrate 3. Moreover, when pressurizing with a cold press, it is good to pressurize at 5 kg / m < ² > or less for 10 seconds or less. Even if pressure is applied over that pressure or time, the productivity only deteriorates.

  Also, when the hot melt resin 4a is applied and then the coating layer 4b is cured, when the melted hot melt resin 4a has low fluidity or high viscosity, or when the porous sheet material 5 is hot. When the melt resin 4a is sufficiently impregnated, it can be heated and pressurized by a hot press roll, a hot press or the like. The heating condition may be a temperature equal to or higher than the melting point of the hot melt resin 4a to be used, and is usually performed at a temperature of about 80 ° C to 120 ° C.

  Next, specific examples will be described.

Example 1
An ethylene vinyl acetate hot melt resin having a melting point of 80 ° C. and a Vicat softening point of 39 ° C. is heated to 100 ° C. on the surface of a 5-ply plywood wood substrate made of South Sea wood with a total dry specific gravity of 0.6 and a thickness of 12 mm. thermal with a hot-melt resin coating device provided with a roll coater and coated at a rate of 120 g / m ^2, the applied hot-melt resin having a basis weight of 23 g / m ² on the coated surface within in a molten state thin paper (Porous sheet material) is placed, then passed between cooling pressure rolls with a roll interval of 11.5 mm, and then left at room temperature for 24 hours. A part of the applied hot melt resin is thin paper (porous sheet) Material) was impregnated and cured, and the thin paper (porous sheet material) and the wood substrate were bonded to obtain a base material for a decorative sheet for flooring according to Example 1.

The decorative board base material thus obtained was measured for Brinell hardness based on JISZ2101, and found to be 1.3 kgf / mm ² . Moreover, when the Brunel hardness was similarly measured about the said wooden board | substrate of a blank, it was 1.0 kgf / mm < ² >, and the hardness of the base material for decorative boards of Example 1 was improving significantly compared with the blank wooden board | substrate. .

Next, on the surface of the base material for decorative plate, an SBR adhesive obtained by mixing 5% by weight of melamine resin and 30% by weight of wheat flour in terms of solid content in an SBR emulsion is converted in terms of solid content by a roll coater. It was applied at a rate of 50 g / m ² , and a 0.25 mm thick oak veneer veneer was placed thereon, and heated by hot pressing for 50 seconds under a hot pressure condition of 110 ° C. and 7 kgf / cm ^2. The veneer wood veneer veneer was bonded to the decorative board substrate. Further, an acrylic polyester-based UV curable clear coating was applied to the surface at a rate of 30 g / m ^{2 in} terms of solid content and cured to obtain a decorative board according to Example 1.

The obtained wood decorative board was subjected to a ball drop impact test in which a 500 g steel ball was dropped from a height of 75 cm based on the measurement of Brinell hardness as described above and JIS A1408. As a result, the Brinell hardness was 1.4 kgf / mm ² , and the depth of depression due to falling ball impact was 0.2 mm.

On the other hand, an SBR adhesive was applied to the surface of a 5-ply plywood wood base plate (substrate) made of the same total dry specific gravity 0.6 and 12 mm thick south seawood used above, and the same thickness as above. A wood-made veneer veneer having a thickness of 0.25 mm was placed and bonded by hot pressing with a hot press for 50 seconds under hot pressure conditions of 110 ° C. and 7 kgf / cm ² . Further, an acrylic polyester ultraviolet curable clear coating was applied to the surface at a rate of 30 g / m ^{2 in} terms of solid content and cured.

The same Brinell hardness test and falling ball impact test were performed on a blank wooden base plate. As a result, the Brinell hardness was 1.0 kgf / mm ² , and the dent depth by the falling ball impact test was 0.4 mm.

(Example 2)
A hot roll coater in which a moisture-curable reactive urethane-based hot melt resin having a melting point of 60 ° C. is heated to 100 ° C. on the surface of a 5-ply plywood wood substrate made of a lauan material having a total dry specific gravity of 0.56 and a thickness of 12 mm was applied at a rate of 120 g / m ² by using a hot-melt resin coating device equipped with a 1, the applied hot-melt resin having a basis weight of 30 g / m ² on the coated surface within in a molten state thin paper (porous sheet Then, in the same manner as in Example 1, it was passed through a cooling pressure roll with a roll interval of 11.5 mm, and left at room temperature for 48 hours, and then applied to a moisture-curing reactive urethane hot melt. Part of the resin was impregnated and cured in thin paper (porous sheet material), and the thin paper and the wooden substrate were bonded together to obtain a decorative board substrate for flooring according to Example 2.

The decorative board base material thus obtained was measured for Brinell hardness based on JISZ2101, and found to be 1.2 kgf / mm ² . Moreover, when the Brinell hardness was similarly measured about the said wooden board | substrate of a blank, it was 0.9 kgf / mm < ² >, and the hardness of the base material for decorative boards of Example 2 was improving significantly compared with the blank wooden board | substrate. .

Next, on the surface of the decorative board substrate, a SBR emulsion is mixed with an SBR adhesive prepared by mixing 5% by weight of melamine-based resin and 30% by weight of wheat flour with a roll coater (not shown). It is applied at a rate of 50 g / m ^{2 in} terms of solid content, and a wooden pattern printing paper having a basis weight of 35 g / m ² is placed thereon, and hot pressing is performed for 50 seconds under a hot pressure condition of 110 ° C. and 7 kgf / cm ^2. The wood pattern printing paper was bonded to the decorative board substrate 7 by hot pressing. Then, in the same manner as in Example 1, an acrylic polyester ultraviolet curable clear coating was applied to the surface at a rate of 30 g / m ^{2 in} terms of solid content and cured to obtain a wooden decorative board according to Example 2. It was.

The obtained decorative board was subjected to the same Brinell hardness test and falling ball impact test as in Example 1. As a result, the Brinell hardness was 1.3 kgf / mm ² , and the depth of depression due to falling ball impact was 0.2 mm. The same Brinell hardness test and falling ball impact test were performed on a blank wood substrate. As a result, the Brinell hardness was 0.9 kgf / mm ² , and the depth of depression due to falling ball impact was 0.4 mm.

(Example 3)
A 5-ply plywood wood substrate made of lauan material with a total dry specific gravity of 0.6 and a thickness of 12 mm. The surface of the wood substrate is dark and uneven in color, with a melting point of 100 ° C. and a Vicat softening point of 56 ° C. A hot roll coater heated to 125 ° C. was prepared by adding a hot melt resin composition colored by adding 10 parts by weight of titanium oxide and 1 part by weight of a yellow inorganic pigment to 100 parts by weight of an ethylene acrylate ester hot melt resin. It was applied at a rate of 120 g / m ² using a hot melt resin coating device, and a thin paper (porous sheet material) having a basis weight of 30 g / m ² was placed on the coated surface while the applied hot melt resin was in a molten state. Then, after passing between heated pressure rolls heated to 140 ° C. with a roll interval of 11.5 mm, left at room temperature for 24 hours, and a part of the applied hot melt resin 4b was thin paper ( To obtain a decorative plate substrate of flooring according to the example 3 by bonding with said thin paper and wood substrate with impregnated cured porous sheet material).

Next, the same SBR adhesive as that used in Example 1 was applied to the surface of the decorative board substrate at a rate of 50 g / m ^{2 in} terms of solid content using a roll coater as in Example 1. Then, a wooden pattern printing paper having a basis weight of 35 g / m ² is placed thereon, and hot pressed by hot pressing for 50 seconds under a hot pressure condition of 110 ° C. and 7 kgf / cm ^2. Glued the printing paper. And the acrylic polyester type ultraviolet curable clear coating was apply | coated and hardened in the ratio of 30 g / m < ² > in conversion of solid content on the surface, and the wooden decorative board which concerns on Example 3 was obtained.

The wood decorative board obtained above was subjected to a Brinell hardness test and a falling ball impact test in the same manner as in Example 1. As a result, the Brinell hardness was 1.4 kgf / mm ² , and the depth of depression due to falling ball impact was 0.2 mm. The same Brinell hardness test and falling ball impact test were performed on a blank wood substrate. As a result, the Brinell hardness was 1.0 kgf / mm ² , and the depth of depression due to falling ball impact was 0.4 mm.

  Further, the surface appearance of the obtained wooden decorative board was not affected by the surface color of the dark and uneven wooden substrate, and had a good appearance.

  INDUSTRIAL APPLICABILITY The present invention is useful for a method for manufacturing a base material for a decorative board used as a flooring material for a building such as a house, and a technique related to a decorative board using the base material.

It is the schematic which shows the process of the manufacturing method of the base material for decorative boards which concerns on embodiment of this invention. It is a side view which shows the base material for decorative boards obtained similarly.

DESCRIPTION OF SYMBOLS 1 Roll coater 2 Hot melt resin coating apparatus 3 Substrate 4a Hot melt resin 4b Hot melt resin coating layer 5 Porous sheet material 6 Pressure roll 7 Base material for decorative plate

Claims (4)

A porous sheet material is integrated on a substrate made of a wooden substrate or a volcanic glassy multilayer board, and a decorative sheet is obtained by sticking a wooden decorative veneer or a wooden pattern printing paper on the porous sheet material. A method for producing a decorative board substrate,
On the surface of the substrate, a melt of a hot melt resin made of a thermoplastic resin having a Vicat softening point of 35 ° C. or higher and a melting point of 70 ° C. to 180 ° C. or a moisture curable urethane resin is 120 to 250 g / m ² . In addition to being applied in a coating amount, a porous sheet material is placed on the surface of the hot melt resin coating layer, and then the porous sheet material is pressurized, whereby the hot melt resin is placed in the porous sheet material. A part of the melt is impregnated to form a reinforcing layer made of the hot melt resin, and the remaining part of the hot melt resin melt is used for bonding the porous sheet material and the substrate. And a method for producing a base material for a decorative board.   The manufacturing method of the base material for decorative boards of Claim 1 with which the inorganic pigment is mixed in the said hot-melt resin. The hot-melt resin coating layer of the hot-melt resin, when by applying the hot-melt resin on the surface of the substrate for placing a porous sheet material, cosmetic plate according to claim 1 or 2 in a molten state A method for producing a substrate. It said porous sheet manufacturing method of the veneer substrate according to any one of claims 1 to 3 is a paper having a basis weight of ^{20g / m 2 ~100g / m 2} .

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