JP5426480B2 - Long fiber board and manufacturing method thereof - Google Patents
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Description
本発明は、長繊維板とその製造方法に関するものである。 The present invention relates to a long fiber board and a manufacturing method thereof.
ドアパネル、引戸、間仕切り開閉壁等の建具に用いられるフラッシュパネルは、LVLやパーティクルボードで作製された枠材で枠組みをした後、これを面材で両側から挟んで構成される。 A flash panel used in a fitting such as a door panel, a sliding door, and a partition opening / closing wall is configured by forming a frame with a frame material made of LVL or particle board and sandwiching the frame from both sides with a face material.
面材には素板、合板、繊維板等の木質材料を用いることができるが、平滑で表面性の良い中密度繊維板(MDF)に数十μmの薄いPET製の化粧シートを酢酸ビニル等の水性エマルジョン接着剤で貼り合わせた化粧面材が意匠性の点から広く用いられている。 Wood materials such as base plate, plywood, and fiber board can be used for the face material, but a thin PET-made decorative sheet of several tens of μm is placed on a smooth and good medium density fiber board (MDF) with vinyl acetate, etc. A decorative face material bonded with an aqueous emulsion adhesive is widely used from the viewpoint of design.
しかしながら、MDFは含水率が変化したときの寸法変化が大きい。そのため、湿度の異なる2室をMDFの化粧面材を用いた建具で仕切った場合、両面のMDFの含水率の違いにより寸法に差が生じ、建具に反りが発生する。その結果、建具が枠につかえて開閉しづらくなる不具合や、枠と建具との間に隙間が生じる不具合等が生じる。 However, MDF has a large dimensional change when the moisture content changes. Therefore, when two rooms having different humidity are partitioned by a joinery using a MDF decorative face material, a difference in dimensions occurs due to a difference in moisture content between the MDFs on both sides, and warping occurs in the joinery. As a result, there arises a problem that it becomes difficult for the joinery to be held by the frame and a gap is generated between the frame and the joinery.
そのため、防湿性の高いシートを両面に貼ることでMDFの含水率変化を抑制しようとする方策もなされているが、シートのコストが高いという問題や、一般に用いられる酢酸ビニル等の水性エマルジョン接着剤で貼ることが難しいという問題が生じる。 For this reason, measures have been taken to suppress changes in the moisture content of MDF by sticking a highly moisture-proof sheet on both sides, but the problem of high sheet costs and commonly used aqueous emulsion adhesives such as vinyl acetate The problem arises that it is difficult to stick with.
一方、ケナフやジュート等の植物長繊維を原材料とした長繊維板が知られている(特許文献1、2参照)。長繊維板は、含水率変化したときの寸法安定性に特に優れていることから、これを建具の面材として用いることで面材の寸法変化が抑制され、反りが生じにくい建具とすることができる。 On the other hand, long fiber boards made from plant long fibers such as kenaf and jute are known (see Patent Documents 1 and 2). Since the long fiber board is particularly excellent in dimensional stability when the moisture content changes, the dimensional change of the face material is suppressed by using this as a face material of the joinery, and it is assumed that the joinery is less likely to warp. it can.
しかしながら、長繊維板は原材料の長繊維が長くて太いためにボード表面の凹凸が大きく、これを基材にして化粧シートを貼ると凹凸が化粧シート表面に現われてしまうために、意匠性が損なわれてしまう。 However, the long fiber board has long and thick raw fibers, so that the board surface has large irregularities. When a decorative sheet is pasted using this as a base material, the irregularities appear on the decorative sheet surface, so the design is impaired. It will be.
本発明は、以上の通りの事情に鑑みてなされたものであり、表面が平滑であり、化粧面材の基材に用いた場合に意匠性を損なうことのない長繊維板とその製造方法を提供することを課題としている。 The present invention has been made in view of the circumstances as described above, and provides a long fiber board having a smooth surface and a design method that does not impair designability when used as a base material for a decorative face material, and a method for producing the same. The issue is to provide.
本発明の長繊維板は、長繊維板を成型した後、成型時よりも高温かつ高圧の条件で熱圧処理して得られたものであることを特徴とする。 The long fiber board of the present invention is obtained by molding a long fiber board and then subjecting it to a hot-pressure treatment under conditions of higher temperature and higher pressure than at the time of molding.
本発明の長繊維板の製造方法は、長繊維板を成型する工程と、この長繊維板を成型時よりも高温かつ高圧の条件で熱圧処理する工程とを含むことを特徴とする。 The method for producing a long fiber board of the present invention includes a step of molding the long fiber plate, and a step of subjecting the long fiber plate to a hot-pressure treatment under conditions of higher temperature and higher pressure than those at the time of molding.
この長繊維板の製造方法において、温度300〜350℃、圧力300〜400N/mmの条件で熱圧処理することが好ましい。 In this method for producing a long fiber board, it is preferable to perform hot-pressure treatment under conditions of a temperature of 300 to 350 ° C. and a pressure of 300 to 400 N / mm.
この長繊維板の製造方法において、長繊維板を成型した後、長繊維板の含水率を5〜10%として熱圧処理することが好ましい。 In this method for producing a long fiber board, it is preferable that after the long fiber board is molded, the water content of the long fiber board is set to 5 to 10% and subjected to hot-pressure treatment.
この長繊維板の製造方法において、長繊維板を成型した後、予め長繊維板に樹脂を塗布しておき、この樹脂を塗布した長繊維板を熱圧処理することが好ましい。 In this method for producing a long fiber plate, it is preferable that after the long fiber plate is molded, a resin is applied to the long fiber plate in advance, and the long fiber plate to which this resin has been applied is subjected to heat-pressure treatment.
本発明の長繊維板とその製造方法によれば、成型後の熱圧処理により表面が平滑になるため、これを化粧面材の基材に用いたときに凹凸が化粧シート表面に現われることを抑制することができ、意匠性を損なうことがない。 According to the long fiber board of the present invention and the method for producing the same, the surface becomes smooth by the hot-press treatment after molding, so that unevenness appears on the surface of the decorative sheet when this is used as the base material of the decorative face material. It can be suppressed and the designability is not impaired.
以下に、本発明を詳細に説明する。 The present invention is described in detail below.
本発明において、長繊維板は、天然の長繊維を原材料としてこれを樹脂で接着して板状に成型したものである。 In the present invention, the long fiber board is formed by bonding natural long fibers as raw materials and bonding them with resin to form a plate.
長繊維としては、例えば、ケナフ、ジュート、ヘンプ、ラミー、リネン等の天然の長繊維を用いることができる。これらの長繊維はヘミセルロースを多く含有し、成型後の熱圧処理時にこのヘミセルロースが変性し表面に現われることで、熱圧処理後の長繊維板の表面平滑性や耐水性が向上する。この点からも、本発明では、上記したような非木材の天然の長繊維を用いることが好ましい。 For example, natural long fibers such as kenaf, jute, hemp, ramie, and linen can be used as the long fibers. These long fibers contain a large amount of hemicellulose, and the hemicellulose is denatured and appears on the surface during the hot-press treatment after molding, thereby improving the surface smoothness and water resistance of the long-fiber plate after the hot-press treatment. Also from this point, in the present invention, it is preferable to use non-wood natural long fibers as described above.
長繊維は、長さが10〜200mm程度のものを用いることが好ましく、このような長繊維を用いることで寸法安定性の良い長繊維板を得ることができる。 It is preferable to use a long fiber having a length of about 10 to 200 mm. By using such a long fiber, a long fiber plate having good dimensional stability can be obtained.
この長繊維を用いて長繊維板を製造する際には、まず、長繊維を解繊し不織布状にしたものに樹脂を供給する。樹脂の供給方法としては、特に限定されないが、例えば、不織布に水溶性樹脂を含浸させる湿式の方法や、不織布の成型時に樹脂繊維や樹脂粉末を混綿しておく乾式の方法等を用いることができる。 When a long fiber plate is manufactured using these long fibers, first, a resin is supplied to the long fibers that have been defibrated and formed into a nonwoven fabric. The method for supplying the resin is not particularly limited. For example, a wet method in which a nonwoven fabric is impregnated with a water-soluble resin, a dry method in which resin fibers or resin powders are mixed during molding of the nonwoven fabric, and the like can be used. .
樹脂としては、成型後の熱圧処理時における高温下でも変形しないものであれば特に限定されないが、例えば、尿素樹脂、メラミン樹脂、フェノール樹脂、ウレタン樹脂等の熱硬化性樹脂が好ましく用いられる。 The resin is not particularly limited as long as it does not deform even at a high temperature during the hot-press treatment after molding. For example, a thermosetting resin such as urea resin, melamine resin, phenol resin, and urethane resin is preferably used.
そして本発明においては、長繊維板を成型する工程と、この長繊維板を成型時よりも高温かつ高圧の条件で熱圧処理する工程とを経て長繊維板が製造される。 And in this invention, a long fiber board is manufactured through the process of shape | molding a long fiber board, and the process of heat-pressing this long fiber board on the conditions of a high temperature and high pressure rather than the time of shaping | molding.
まず、長繊維板を成型する工程では、例えば、樹脂を供給した長繊維の不織布を熱盤等を用いてプレスすることにより行うことができる。加熱および加圧の条件は、用いる樹脂の種類や得ようとする長繊維板の密度等によっても異なるが、例えば、温度140〜200℃、圧力1〜3MPaで行うことができる。 First, in the step of molding the long fiber plate, for example, it can be performed by pressing a non-woven fabric of long fibers supplied with resin using a hot platen or the like. The heating and pressurizing conditions vary depending on the type of resin used and the density of the long fiber plate to be obtained, but can be performed, for example, at a temperature of 140 to 200 ° C. and a pressure of 1 to 3 MPa.
この成型時において、過剰に高い温度条件で成型すると硬化不良が発生し、また過剰に高い圧力で成型すると部分的に樹脂のシミが発生したりする場合がある。これに対して本発明では、一旦適切な熱圧条件で長繊維板を成型した後、加熱ロール等を用いて成型時よりも高温かつ高圧の条件で熱圧処理を行う。そのため、硬化不良や樹脂のシミの発生を抑制しつつ長繊維板の表面を平滑にすることができる。 At the time of molding, curing may occur if molding is performed at an excessively high temperature condition, and if the molding is performed at an excessively high pressure, a resin stain may be partially generated. On the other hand, in the present invention, a long fiber board is once molded under an appropriate hot-pressure condition, and then subjected to a hot-pressure treatment using a heating roll or the like at a higher temperature and a higher pressure than during molding. Therefore, the surface of the long fiber board can be smoothed while suppressing the occurrence of poor curing and resin stains.
この成型後に熱圧処理する工程において、温度条件としては、成型時よりも高温であることが必要であり、好ましくは300〜350℃である。温度が低過ぎると熱圧処理による平滑化が不十分となる場合があり、温度が高過ぎると長繊維板が炭化してしまう場合がある。 In the step of performing the hot-press treatment after the molding, the temperature condition needs to be higher than that at the time of molding, and is preferably 300 to 350 ° C. If the temperature is too low, smoothing by hot pressing may be insufficient, and if the temperature is too high, the long fiber board may be carbonized.
次に、圧力条件としては、成型時よりも高圧であることが必要であり、好ましくは300〜400N/mmである。圧力が低過ぎると熱圧処理による平滑化が不十分となる場合があり、圧力が高過ぎると圧縮破壊やそれに伴う反りが発生する場合がある。 Next, as a pressure condition, it is necessary that the pressure is higher than that at the time of molding, and preferably 300 to 400 N / mm. If the pressure is too low, smoothing by the hot-pressure treatment may be insufficient, and if the pressure is too high, compression fracture and warping associated therewith may occur.
そして本発明では、長繊維板を成型した後、長繊維板の含水率を5〜10%として熱圧処理することが好ましい。長繊維板の含水率をこの範囲内とすることにより、熱圧処理後の長繊維板の表面の平滑性を向上させることができる。 And in this invention, after shape | molding a long fiber board, it is preferable to heat-process by making the moisture content of a long fiber board into 5 to 10%. By setting the moisture content of the long fiber board to be in this range, the smoothness of the surface of the long fiber board after the hot pressing treatment can be improved.
また、長繊維板を成型した後、予め長繊維板に樹脂を塗布しておき、この樹脂を塗布した長繊維板を熱圧処理することが好ましい。これにより、熱圧処理後の耐水性を向上させることができ、熱圧処理後の平滑性が吸湿後も安定的に持続することから、長繊維板の表面の平滑性をさらに向上させることができる。このとき用いる樹脂としては、耐水性の高い樹脂が好ましい。具体的には、例えば、尿素樹脂、メラミン樹脂、フェノール樹脂、ウレタン樹脂等の熱硬化性樹脂を用いることができる。これらは、例えば水性エマルジョンとして供給することができる。 In addition, after the long fiber plate is molded, it is preferable to apply a resin to the long fiber plate in advance, and to heat-treat the long fiber plate to which this resin has been applied. Thereby, the water resistance after the hot-pressure treatment can be improved, and the smoothness after the hot-pressure treatment is stably maintained even after moisture absorption, so that the smoothness of the surface of the long fiber board can be further improved. it can. As resin used at this time, resin with high water resistance is preferable. Specifically, for example, thermosetting resins such as urea resin, melamine resin, phenol resin, and urethane resin can be used. These can be supplied, for example, as an aqueous emulsion.
成型後の熱圧処理を行う装置は、特に限定されないが、必要とする熱圧条件やメンテナンスの簡便性の観点から、誘電発熱式の加熱ロールを用いた高圧カレンダー機等を用いることが好ましい。 Although the apparatus which performs the heat-pressure process after shaping | molding is not specifically limited, It is preferable to use the high-pressure calender machine etc. which used the heating roll of a dielectric heating type from a viewpoint of the required heat pressure conditions and the simplicity of a maintenance.
以上のようにして得られる長繊維板は、表面が平滑であり、表面に化粧シートを貼ることで建具等の化粧面材の基材として用いることができる。この基材を用いた化粧面材は、意匠性が良く反りの発生も少ない建具とすることができる。 The long fiber board obtained as described above has a smooth surface, and can be used as a base material for decorative face materials such as joinery by applying a decorative sheet to the surface. A decorative face material using this base material can be used as a fitting having good design and less warping.
以下に、実施例により本発明をさらに詳しく説明するが、本発明はこれらの実施例に何ら限定されるものではない。
<実施例1>
目付け1000g/m2のケナフ長繊維による不織布に、フェノール樹脂を固形分で20質量%供給した。これを200℃、2.0MPa、3.5分間の条件で熱圧成型し、2.0mmのボードとした後、#240の研磨布で表面をサンディングして厚み1.5mm、密度700kg/cm2の長繊維板を得た。
EXAMPLES Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.
<Example 1>
Phenol resin was supplied in a solid content of 20% by mass to a nonwoven fabric of kenaf long fibers with a basis weight of 1000 g / m 2 . This was hot-press molded under the conditions of 200 ° C., 2.0 MPa, and 3.5 minutes to form a 2.0 mm board, and then the surface was sanded with a # 240 polishing cloth to obtain a thickness of 1.5 mm and a density of 700 kg / cm. Two long fiberboards were obtained.
この長繊維板を気乾状態で養生して含水率が約5%となるように調湿した。その後、高圧カレンダー機を用いて、温度300℃、圧力(線圧)300N/mm、送り速度5m/minの条件で熱圧処理を行い、長繊維板を製造した。
<実施例2>
実施例1において、高圧カレンダー機の温度を350℃とし、それ以外は実施例1と同様にして長繊維板を製造した。
<実施例3>
実施例2において、成型後の長繊維板を調湿した後、その片面に固形分50質量%の水性ポリウレタン樹脂(DIC株式会社製)を100g/m2塗布し、その後高圧カレンダー機による熱圧処理を行った。それ以外は実施例2と同様にして長繊維板を製造した。
<実施例4>
実施例2において、長繊維板を気乾状態で養生して含水率約10%となるように調湿し、その後高圧カレンダー機による熱圧処理を行った。それ以外は実施例2と同様にして長繊維板を製造した。
<実施例5>
実施例2において、高圧カレンダー機の圧力を400N/mmとし、それ以外は実施例2と同様にして長繊維板を製造した。
<比較例1>
厚み2.5mm、密度700kg/cm2の針葉樹系MDF(N&E社製)を用いた。
<比較例2>
実施例1において、長繊維板を成型後、気乾状態で養生して含水率約5%となるように調湿し、その後高圧カレンダー機による熱圧処理を行わず、それ以外は実施例1と同様にして長繊維板を製造した。
<比較例3>
実施例1において、高圧カレンダー機による圧力を200N/mmとし、加熱しないで加圧処理を行った。それ以外は実施例1と同様にして長繊維板を製造した。
<比較例4>
実施例1において、高圧カレンダー機による圧力を300N/mmとし、加熱しないで加圧処理を行った。それ以外は実施例1と同様にして長繊維板を製造した。
<比較例5>
実施例1において、高圧カレンダー機による圧力を600N/mmとし、加熱しないで加圧処理を行った。それ以外は実施例1と同様にして長繊維板を製造した。
<比較例6>
実施例1において、高圧カレンダー機の温度を約200℃(200℃未満)とし、それ以外は実施例1と同様にして長繊維板を製造した。
<参考例1>
実施例1において、高圧カレンダー機の温度を400℃とし、それ以外は実施例1と同様にして長繊維板を製造した。
<参考例2>
実施例1において、成型後の長繊維板を105℃の乾燥機で絶乾状態にして、これに高圧カレンダー機で熱圧処理を行った。それ以外は実施例1と同様にして長繊維板を製造した。
<参考例3>
実施例1において、長繊維板を気乾状態で養生して含水率約15%となるように調湿し、その後高圧カレンダー機による熱圧処理を行った。それ以外は実施例1と同様にして長繊維板を製造した。
This long fiber board was cured in an air-dried state and conditioned to a moisture content of about 5%. Then, using a high-pressure calender machine, a hot fiber treatment was performed under the conditions of a temperature of 300 ° C., a pressure (linear pressure) of 300 N / mm, and a feed rate of 5 m / min to produce a long fiber board.
<Example 2>
In Example 1, a continuous fiberboard was manufactured in the same manner as in Example 1 except that the temperature of the high-pressure calender machine was 350 ° C.
<Example 3>
In Example 2, after conditioning the long fiber board after molding, 100 g / m 2 of an aqueous polyurethane resin (manufactured by DIC Corporation) having a solid content of 50% by mass was applied to one side, and then heat pressure by a high-pressure calender machine Processed. Otherwise, a long fiber board was produced in the same manner as in Example 2.
<Example 4>
In Example 2, the long fiber board was cured in an air-dried state and conditioned to a moisture content of about 10%, and then subjected to hot-pressure treatment with a high-pressure calender. Otherwise, a long fiber board was produced in the same manner as in Example 2.
<Example 5>
In Example 2, a long fiber board was produced in the same manner as in Example 2 except that the pressure of the high-pressure calender was 400 N / mm.
<Comparative Example 1>
A softwood MDF (manufactured by N & E) having a thickness of 2.5 mm and a density of 700 kg / cm 2 was used.
<Comparative example 2>
In Example 1, after molding the long fiber board, it was cured in an air-dried state and conditioned so as to have a water content of about 5%. In the same manner, a long fiber board was produced.
<Comparative Example 3>
In Example 1, the pressure by the high-pressure calender was 200 N / mm, and the pressure treatment was performed without heating. Otherwise, a long fiber board was produced in the same manner as in Example 1.
<Comparative Example 4>
In Example 1, the pressure by the high-pressure calendar machine was set to 300 N / mm, and the pressure treatment was performed without heating. Otherwise, a long fiber board was produced in the same manner as in Example 1.
<Comparative Example 5>
In Example 1, the pressure by the high-pressure calender was 600 N / mm, and the pressure treatment was performed without heating. Otherwise, a long fiber board was produced in the same manner as in Example 1.
<Comparative Example 6>
In Example 1, the temperature of the high-pressure calender was set to about 200 ° C. (less than 200 ° C.), and other than that, a long fiber board was produced in the same manner as in Example 1.
<Reference Example 1>
In Example 1, a continuous fiberboard was manufactured in the same manner as in Example 1 except that the temperature of the high-pressure calender was 400 ° C.
<Reference Example 2>
In Example 1, the long fiber plate after molding was completely dried with a dryer at 105 ° C., and this was subjected to hot-pressure treatment with a high-pressure calender. Otherwise, a long fiber board was produced in the same manner as in Example 1.
<Reference Example 3>
In Example 1, the long fiber board was cured in an air-dried state and conditioned to a moisture content of about 15%, and then subjected to hot-pressure treatment with a high-pressure calendar machine. Otherwise, a long fiber board was produced in the same manner as in Example 1.
実施例1〜5、比較例1〜6、および参考例1〜3の各ボードについて、初期状態および40℃、90%RHの恒温恒湿槽に7日間放置後の表面粗さ(Ra)を測定した。その結果を表1に示す。 About each board of Examples 1-5, Comparative Examples 1-6, and Reference Examples 1-3, the surface roughness (Ra) after being left in an initial state and a constant temperature and humidity chamber of 40 ° C. and 90% RH for 7 days. It was measured. The results are shown in Table 1.
表1において、比較例1はMDFの結果であるが、化粧面材においてシート貼り可能な表面平滑性の目標値となる。 In Table 1, Comparative Example 1 is a result of MDF, but it is a target value of surface smoothness that can be pasted on a decorative face material.
比較例2は、成型後に熱圧処理をしていない長繊維板の結果であるが、MDFに比べると表面粗さが大きく、シート貼りしてもシート表面に凹凸が現われて意匠性が損なわれてしまう。 Comparative Example 2 is the result of a long fiber board that has not been hot-pressed after molding, but its surface roughness is larger than that of MDF. End up.
比較例3、4の結果から、成型後の熱圧処理において圧力を加えることで平滑性は向上していくものの、吸湿することで元に戻ることがわかる。また、比較例5では、さらに圧力を加えると平滑性は増すものの、高圧のためボードが部分的に圧縮破壊を起こしてボードがゆがんでしまったため、面材として用いることは不可能な状態となった。 From the results of Comparative Examples 3 and 4, it can be seen that, although the smoothness is improved by applying pressure in the hot-pressure treatment after molding, it returns to its original state by absorbing moisture. Further, in Comparative Example 5, although the smoothness increases when more pressure is applied, the board is partially compressed and broken due to the high pressure, and the board is distorted, so that it cannot be used as a face material. It was.
一方、実施例1、2の結果より、300℃以上の高温の状態で高圧をかけることにより初期の平滑性が向上し、吸湿後も持続させることができた。適切な温度範囲について検討を行ったところ、比較例6の結果より、温度が200℃未満であると耐水性の向上は小さくなり、参考例1の結果より、400℃付近を超えると長繊維板が炭化してしまった。 On the other hand, from the results of Examples 1 and 2, the initial smoothness was improved by applying a high pressure at a high temperature of 300 ° C. or higher, and it was possible to maintain the moisture after moisture absorption. When an appropriate temperature range was examined, from the result of Comparative Example 6, when the temperature was less than 200 ° C., the improvement in water resistance was small. From the result of Reference Example 1, when the temperature exceeded 400 ° C., the long fiber board Has carbonized.
実施例3では、樹脂を塗布した状態で熱圧処理を行うことにより耐水性が向上し、吸湿後も平滑性は低下しなかった。 In Example 3, the water resistance was improved by performing the heat and pressure treatment with the resin applied, and the smoothness did not decrease even after moisture absorption.
実施例4では、散水して含水率の高い状態で熱圧処理を行うことにより、初期の平滑性と耐水性が向上した。しかし、参考例2の結果より、含水率が低過ぎると熱圧処理をしても平滑性の向上は見られなかった。また参考例3の結果より、含水率が高過ぎても平滑性の向上は見られなかったが、これは、おそらく高圧カレンダー機のロールの熱が奪われたことによるものと考えられる。 In Example 4, the initial smoothness and water resistance were improved by spraying water and carrying out the hot-pressure treatment in a high water content state. However, from the result of Reference Example 2, when the moisture content was too low, no improvement in smoothness was observed even if the hot pressing treatment was performed. Further, from the result of Reference Example 3, even if the water content was too high, the smoothness was not improved, but this is probably due to the heat of the roll of the high-pressure calender machine being taken away.
実施例5では、高圧カレンダー機の圧力を300N/mmから400N/mmに変更したが、上記の実施例と同等の結果が得られた。 In Example 5, the pressure of the high-pressure calendar machine was changed from 300 N / mm to 400 N / mm, but the same result as in the above example was obtained.
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