JPH0237288B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing reinforced decorative boards suitable for building materials such as flooring materials, wall materials, ceiling materials, surface materials for various types of furniture, and other decorative materials. The present invention relates to a method for producing a reinforced decorative board in which synthetic resin injection treated veneers made by injecting and hardening a synthetic resin liquid are arranged and fixed in an arbitrary pattern on a substrate.

Conventionally, synthetic resin injection treated wood boards, which are made by injecting synthetic resin liquid into thin wood boards and curing them, are generally known as WPC.
(Wood plastic combination), it improves the strength, abrasion resistance, dimensional stability, stain resistance, etc. of wood materials, and uses injected resin to increase the transparency of wood boards and create deep wood grain patterns. It is known as an exposed material and is often used as a decorative surface material for architectural materials such as floorboards.

However, although the above-mentioned synthetic resin injection-treated wooden boards have the above-mentioned advantages, the whole board becomes hard after the injected resin has hardened, so it can be cut with a cutter or the like like a natural wood veneer. When trying to form a decorative piece in the shape of , it has the disadvantage that it is prone to cracking and chipping, resulting in poor yields, and therefore it has been difficult to use it as a surface decorative material for parquet-like or checkerboard-like decorative boards.

On the other hand, as a method for forming parquet or checkerboard-like decorative boards using such synthetic resin injection-treated wood boards, the thin wood boards are cut into decorative pieces of a predetermined shape in advance, and synthetic resin liquid is injected into them. However, it is extremely difficult to immerse the small decorative pieces in the resin solution and inject the resin without them overlapping each other, and it is also difficult to immerse the small decorative pieces in the resin solution and inject the resin into them. Even when curing under pressure, small uncured decorative pieces must be arranged and pressurized, which is very difficult and expensive.

In addition, the synthetic resin injection treated wood board is injected in the form of a thin plate in order to shorten the synthetic resin injection time and prevent uneven injection, and this is used by pasting it on the surface of the base material. However, when used in thin sheets like this, just as the strength of wood boards has anisotropy depending on the fiber direction, synthetic resin injection treated thin sheets also show a property of being weak against external forces in the direction perpendicular to the fiber direction. In particular, when cutting into small size pieces such as parquet-like decorative boards, WPC
The veneer becomes prone to cracking along the fiber direction,
Furthermore, even after bonding to the substrate, if a board material with cushioning properties, such as a foamed synthetic resin board, or a relatively soft material, such as softwood or soft fiberboard, is used as the board, the surface side There was a problem in that each decorative piece easily cracked due to the impact force, and the decorative board deteriorated significantly.

In order to eliminate such drawbacks, the present invention has been developed by polymerizing and bonding a resin-injected veneer to a thin plate made of a wood veneer or a laminated veneer so that its fiber direction is perpendicular to the fiber direction of the surface of the thin plate. The present invention provides a method for manufacturing a reinforced decorative board, characterized in that the decorative pieces are then cut into a plurality of decorative pieces and the resulting decorative pieces are arranged and fixed on a substrate.

To explain the drawings showing the embodiment, a resin-injected veneer 1 is obtained by injecting a synthetic resin liquid into a thin wood veneer with a thickness of about 1 mm, such as a sliced veneer or a rotary veneer.

The method for injecting resin liquid into thin wood veneers is as follows:
Methods such as pressurized injection, reduced pressure injection, or reduced pressure pressurized injection are adopted.

Injection synthetic resin liquids include condensed synthetic resin liquids,
It may be an addition polymerization type synthetic resin, an aqueous solution type, or a solvent type synthetic resin liquid.

In addition, appropriate solvents, plasticizers, curing agents, colorants such as pigments and dyes, and other additives may be mixed into such synthetic resin liquid.

The resin-injected veneer 1 thus obtained is placed on a thin plate 2 with a thickness of 5 mm or less made of wood alone or a composite veneer laminated material such as LVL, so that the fiber direction is the thin plate 2.
The decorative base material 3 is obtained by adhering them together in a manner perpendicular to the fiber direction on the surface. This adhesive means
After injecting a resin liquid into a thin wood veneer, it may be immediately superimposed on the thin board 2 and bonded together as the injected resin liquid hardens, or the resin injected veneer 1 may be heat-cured in advance. They may be cured by irradiation, electron beams, microwaves, etc., and then bonded together using a suitable adhesive.

Next, this decorative base material 3 is divided into two or several parts using an appropriate cutting tool such as a circular saw, a guillotine, etc., and the synthetic resin injection treated veneer piece 1a is integrally superposed on the thin plate piece 2a. Obtain cosmetic piece 4.

The dimensions and shape of the decorative piece 4 are set according to the desired arrangement and pattern, such as a small checkerboard, a large checkerboard, a parquet pattern, etc.

The thus obtained decorative pieces 4, 4... have a synthetic resin injection-treated veneer piece 1a and a thin plate piece 2a on their surfaces.
Regardless of the direction of the wood fibers in the decorative piece,
Because they are always polymerized in an orthogonal relationship, their dimensional stability is significantly improved, and their strength anisotropy against external forces is also improved. For example, like a foamed synthetic resin board, Even if it is attached to the surface of a substrate made of a soft material such as a substrate with cushioning properties, softwood material, or soft fiberboard, the synthetic resin injection treated veneer piece 1a on the surface layer will be affected by impact force etc. No cracks or cracks will occur.

Moreover, unlike the case where the synthetic resin injection treated veneer 1 is cut alone, the decorative pieces 4, 4, . In addition to eliminating anisotropy, the soft thin plate 2 reduces impact resistance during cutting, allowing the resin-injected veneer to be cut without chipping or cracking, improving yield.
When chamfering is performed, the thin plate piece 2a on the back side prevents tearing of the synthetic resin injected veneer piece 1a on the front side due to the same effect, and also provides an appropriate thickness, making chamfering easy and beautiful. It is something that can be done.

Furthermore, when forming the decorative base material 3 that is the base of the cosmetic piece, for example, when curing the injected resin liquid and adhering to the thin plate 2 at the same time by heating and pressing, the fiber direction of the thin plate 2 may be changed. When pressed in the same direction as the fiber direction of the synthetic resin injection treated veneer 1, the proportion of the injected resin liquid flowing out into the hollow parts such as conduits of the thin plate 2 increases, but as in the present invention,
When polymerizing with the fiber directions of the two perpendicular to each other, the rate of outflow of the injected resin liquid is reduced, and a decrease in transparency of the synthetic resin injection treated veneer 1 and occurrence of uneven injection can be prevented, and the cosmetic properties are also good. It is something that can be formed in a state.

Next, after chamfering 5 the four edges of the resin-injected veneer piece 1a of the decorative piece 4 thus obtained, if necessary, two or more decorative pieces 4 are attached to a substrate having an appropriate thickness depending on the purpose, especially Thickness 2.7~15mm
They are arranged in a desired pattern on a substrate 6 such as plywood, particle board, MDF, etc., and are attached to the substrate 6 using an adhesive.

Note that the adhesive should be applied to the top surface of the substrate 6 or the decorative piece 4.
It can be applied to either bottom surface.

Next, specific examples of the present invention will be shown.

Example 1 A spruce veneer with a thickness of 1.0 mm was cut to 310 mm using a guillotine.
After cutting into rectangular plates of 1,550 mm in size, the plates were placed in a vacuum pot, evacuated to a vacuum level of 10 mmHg, and left for 30 minutes. Next, a synthetic resin prepared by adding 40% by weight of styrene monomer and 1% of BPO as a curing agent to an unsaturated polyester resin was placed in the vacuum pot, and the mixture was allowed to stand still for an additional 30 minutes.

The resin-injected spruce veneer was taken out of the vacuum pot and hot-pressed to 135 mm.
When the injected resin was cured by applying heat and pressure at 3 Kg/cm ² for 10 minutes at ℃, a beautiful resin-injected spruce veneer was obtained.

Next, this resin-injected veneer is attached to 2.7 mm thick lauan plywood of the same size and shape via a urea-vinyl acetate resin adhesive so that the fiber direction is perpendicular to the fiber direction of the surface veneer of the lauan plywood. A decorative base material was obtained by polymerizing and pasting as described above, and this decorative base material was cut using an inclined circular saw to obtain a plurality of rectangular and square decorative pieces as shown in FIG.

When the periphery of the upper end of this decorative piece was chamfered, no chips or cracks occurred because the resin-injected veneer piece was integrated with the lauan plywood.

Next, a plurality of such decorative pieces were arranged end-to-end in a parquet pattern to have a size of 1 x 1, and were pasted onto 12 mm thick lauan plywood using urea resin adhesive. 5 pieces of reinforced decorative board 7 were obtained.

Example 2 A spruce veneer injected with resin in the same manner as in the previous example was taken out of the vacuum pot, and then placed on a 2.7 mm thick lauan plywood whose upper surface was coated with urea resin adhesive so that the fiber direction was the surface of the lauan plywood. After laminating the veneers in a direction perpendicular to the fiber direction of the veneers, they are heated at 135°C and 10 kg/cm ² for 10 minutes using a hot press to cure the injected synthetic resin at the same time as adhesion, creating a beautiful spruce resin injection treatment. A plate-attached decorative base material was obtained.

This was made into two types of decorative pieces as shown in Figure 1 in the same manner as in Example 1, and these decorative pieces were arranged in a parquet pattern and placed on 12 mm thick lauan plywood using urea resin adhesive. A tile-shaped reinforced decorative board 7 of 1 shaku x 1 shaku as shown in Fig. 1 is pasted with
I got it.

Example 3 The decorative pieces obtained in Example 2 were arranged on the surface of a foamed polystyrene plate with a thickness of 7 mm in the same manner as in Example 2 in a parquet pattern and attached to the surface, and the cushioning properties of 1 shaku x 1 shaku were obtained. A reinforced decorative board having the following characteristics was obtained.

Since the substrate of the above-mentioned decorative board is expanded polystyrene, it has appropriate cushioning properties and absorbs unevenness, so it can be installed directly on concrete floor slabs, etc. Moreover, the surface of the veneer is treated with synthetic resin injection. Even though the board has such cushioning properties, it is supported by a thin piece of lauan plywood on the back side, and the fiber direction of each decorative piece is always perpendicular to each other, so there is no impact from the front side. No cracking occurred even when exposed to water, and it had excellent performance as a direct flooring material.

As described above, in the method of the present invention, a synthetic resin injection treated veneer obtained by injecting a synthetic resin liquid into a thin wood veneer is added to a thin plate made of a wood veneer or a laminated veneer so that the fiber direction of the synthetic resin injection treated plate is the same as that of the thin wood veneer. are integrally laminated and bonded perpendicular to the fiber direction on the surface to form a synthetic resin injection treated veneer decorative base material, which is then cut into predetermined dimensions to form several decorative pieces. A plurality of pieces are combined and arranged and bonded onto a substrate. In other words, the resin-injected veneer is bonded to a thin plate to create a decorative base material, which is then cut into pieces of specified dimensions, so the soft veneer or laminated veneer material cushions the impact during cutting. No corner chips or cracks will occur in the resin-injected veneer. In addition, the decorative pieces obtained by cutting are made by laminating resin-injected veneer pieces on thin plate pieces and have a suitable thickness, so they do not break when arranged into a desired pattern such as a checkerboard pattern. It can be easily and accurately constructed.

Furthermore, according to the present invention, each decorative piece is formed by integrally laminating and bonding the synthetic resin-injected veneer piece and the thin plate piece in such a way that the directions of the wood fibers on the surface are always perpendicular to each other. Dimensional stability has been significantly improved, and strength anisotropy has been improved.In addition, the soft veneer and veneer laminate material acts as a buffer material for cutting resistance, so the surface is treated with synthetic resin injection. Even when a thin veneer piece is formed, there is no risk of cracking or chipping due to impact force, etc., and a beautiful decorative surface can be maintained for a long time even after construction.

In addition, even if chamfering is performed on the decorative piece, the edge of the decorative piece will not be damaged by the cutting process because it is reinforced by the thin plate pieces, allowing for sharp chamfering. It is possible to give the decorative board a three-dimensional effect, and as mentioned above, since it is assembled after being cut into decorative pieces, unlike when it is assembled when the injected resin liquid is uncured, the synthetic resin does not seep out at the joints and is beautiful. This makes it possible to achieve a good finish and improve cosmetic properties.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention, and FIG. 1 is a diagram of its manufacturing process. DESCRIPTION OF SYMBOLS 1... Synthetic resin injection treated veneer, 1a... Veneer piece thereof, 2... Thin plate, 2a... Thin plate piece, 3... Decorative base material, 4
... Decorative piece, 5... Chamfer, 6... Substrate, 7... Reinforced decorative board.

Claims (1)

[Claims] 1 A synthetic resin injection treated veneer in which a synthetic resin liquid is injected into a thin wood veneer is turned into a thin plate made of a wood veneer or a laminated veneer so that the fiber direction of the synthetic resin injection treated veneer is perpendicular to the fiber direction of the surface of the thin plate. A synthetic resin injection-treated veneer is laminated and bonded together to form a decorative base material, which is then cut to a predetermined size to form several decorative pieces, and a plurality of these decorative pieces are combined and arranged. A method for manufacturing a reinforced decorative board, characterized in that the reinforced decorative board is bonded onto a substrate.