JPH0238044A - Reinforced decorative material keeping woody feeling - Google Patents

Abstract

PURPOSE:To enhance hardness, to improve cracking resistance and to reduce the exudation of a reinforcing agent from a butt end by laminating an impregnated base material impregnated with the reinforcing agent between a non- impregnated base plate and decorative veneer and applying compression molding to the formed laminate. CONSTITUTION:As a base material to be impregnated, a wooden material such as veneer, a nonwoven fabric, paper, a glass fiber, an inorg. material such as asbestos paper and a composite material thereof can be designated. As a reinforcing agent, any one liquid at room temp., capable of being infiltrated in decorative veneer and capable of reinforcing said veneer may be used and a synthetic resin having viscosity of 500cps or less is designated. The base material impregnated with this reinforcing agent is laminated to at least one surface of a base plate and non-impregnated decorative veneer having a thickness of 0.2-2mm is further laminated to the impregnated base material and the whole is subjected to compression molding. At this time, an adhesive may be together used in order to enhance the adhesion of the impregnated base material and the base plate.

Description

[Detailed Description of the Invention] "Industrial Application Field" The present invention relates to a reinforced decorative material that maintains a wood texture on the surface, and is used as building materials such as walls, ceilings, columns, and floors of houses, furniture, and fittings, for example. It is something that will be done.

"Conventional technology" Decorative wood materials that are made by simply bonding unreinforced decorative veneers onto a base plate, such as a base plate, have poor hardness, ilN abrasion resistance, durability, etc. of the surface decorative veneer. Because of its poor performance, it has been difficult to use it on floors, etc., which have harsh operating environments.

Therefore, in order to provide the above performance, we created a composite of wood and synthetic resin (Wood-Plastic Combination).
C) has become popular with the development of impregnation technology. However, in the conventional WPC manufacturing method, which involves soaking a decorative veneer in a reinforcing agent and impregnating it under reduced pressure or pressure, and then layering it on an unimpregnated base plate and compression molding, the performance of the surface veneer cannot be improved. Even if the surface decoration veneer can be improved, the surface decorative veneer often exhibits the wet color of the resin, and the original color tone of natural wood is often lost or it appears as if it has been printed, making it difficult to maintain the wood feel. there were. In addition, since only the decorative veneer is reinforced, cracks are likely to occur during molding due to the difference in shrinkage rate from the base plate, and the crack resistance in repeated cold and heat tests is also poor. Furthermore, a base plate is conventionally known as a wood material having a woody texture. However, the base plate is usually made of a wood material such as a veneer, and is glued with urea/melamine resin with a thickener added, phenolic resin, or emulsion resin with a moderate viscosity, etc., and attached to both sides of the core veneer. It is applied and bonded by heat-pressure curing, and the adhesion at the interface between the surface decorative veneer and the core veneer provides strength. In this case, the resin used is sufficient for adhesion, but there is almost no penetration of the resin into the surface decorative veneer, and the mechanical strength and durability such as hardness and abrasion resistance of the surface decorative veneer itself It has little effect on improving. Therefore, the mechanical strength and durability of the surface decorative veneer itself, such as hardness and abrasion resistance, are almost the same as the surface decorative veneer before bonding, and it is easily damaged in applications with severe usage conditions such as heavy walking floors. There are problems such as lack of durability. Therefore, a surface-reinforced decorative veneer is usually used, which is a surface-reinforced decorative veneer that is forcibly impregnated with a resin, cured, and then bonded to the base plate. However, in these cases, the surface decorative veneer exhibits a wet color due to the resin, and the wood texture is significantly impaired.

The present inventors studied to solve these drawbacks, and strengthened the base plate by impregnating the base plate with a reinforcing agent, laminating an unimpregnated decorative veneer thereon, and compression molding it. We also strengthened the veneer while maintaining its wood feel.

As a result, it was found that the resulting reinforced decorative material had improved crack resistance compared to conventional materials; however, compared to the conventional manufacturing method for WPC, this method had a lower thickness of the base plate. As the amount of reinforcing agent increases, the amount of reinforcing agent impregnated increases significantly, making it difficult to manufacture at low cost.
During molding, the amount of reinforcing agent that seeped out from the end of the base plate was extremely large, reducing workability and requiring further improvements.

``Problem to be solved by the invention'' The present invention provides a reinforced decorative material that maintains the wood feel of decorative veneer, has high hardness, good crack resistance, and has less reinforcing agent seeping out from the end of the wood. It's about doing.

"Means for Solving the Problem" In the present invention, an impregnated base material impregnated with a reinforcing agent is laminated between an unimpregnated base plate and a decorative veneer, and compression molding is performed to prevent the reinforcing agent from seeping out from the impregnated base material. By infiltrating the back side of the decorative veneer and hardening it without letting it seep into the surface of the decorative veneer, the decorative veneer is strengthened without damaging the wood texture, and the above problem has been solved. Ta.

The base materials for the impregnated base material used in the present invention include veneer, sawn board, bedboard, wood materials such as tickleboard and fiberboard, nonwoven fabric, paper such as P paper, glass wool, and glass cloth. , glass fibers such as glass 4-79-,
Further examples include inorganic materials such as cloth, carbon fiber, asbestos-coated gum, and composite materials thereof. The thickness of the base material can be 0.31 or more, and can be appropriately selected depending on the type and shape of the impregnated base material, preferably 0.3 to 5.0.
mx, preferably 0.3 to 2.0 mm.

If the thickness is less than 0.3 mm, the impregnation of the reinforcing agent will be small and the impregnation of the decorative veneer will be insufficient, and if it exceeds 5.0 mm, a large amount of the reinforcing agent must be impregnated, making it uneconomical. Not.

The reinforcing agent used in the present invention may be any reinforcing agent as long as it is liquid at room temperature, can be impregnated into a decorative veneer, and can strengthen the veneer, and preferably has a viscosity of 500 cps or less. Examples of such reinforcing agents include alkyd resins,
Synthetic resins commonly used for reinforced decorative materials include epoxy resins, polybutadiene resins, urethane resins, unsaturated polyester resins, vinyl ester resins, diallyl phthalate resins, area resins, and melamine resins. You can choose from them as appropriate.

Reactive monomers can also be used as reinforcing agents,
Such reactive monomers include vinyl monomers (meth)
Examples include acrylic acid hetamine (meth)acrylate monomers. Further, an initiator or accelerator may be added for the purpose of promoting the reaction.

Known methods such as dipping, vacuum impregnation, pressure impregnation, and vacuum pressure impregnation can be used to impregnate the base material with the above-mentioned reinforcing agent, but in order to efficiently perform the impregnation in a short time, The vacuum pressure impregnation method is preferable. The amount of such reinforcing agent impregnated varies depending on the type and shape of the base material, but it is appropriate to be 30 to 2000 parts by weight, preferably 4 parts by weight, of the reinforcing agent per 100 parts by weight of the base material.
It is 0 to 1000 parts by weight. If the impregnated lid is less than 30 parts by weight, there is a tendency that sufficient hardness and wear resistance cannot be obtained due to insufficient penetration of the reinforcing agent from the wood material into the decorative veneer during molding. If the amount is more than 2,000 parts by weight, the reinforcing agent often oozes out onto the surface of the decorative veneer, significantly impairing the wood feel of the decorative veneer.

The impregnated base material can be made of wood materials such as veneer, sawn board, bedboard, particle board, phynodate, etc., inorganic materials such as light calcium board, cement hoard, or composite materials thereof with a thickness of 0.2 myt or more. laminated on at least one side of a base plate consisting of 0.2 to 2
Laminated positive decorative veneers and compression molded.

In this case, the decorative veneer that can be used is a beautiful wood veneer used for the surface layer, and may be rotary veneer or sliced veneer, and the material type is not particularly limited, such as red pine, rainbow pine, larch. Domestic coniferous trees such as Japanese pine, Spanish mackerel, cedar, hemlock, fir, Japanese cypress, Japanese cypress, and imported coniferous trees such as agathis, Canadian spruce, loblolly pine, Japanese hemlock, Douglas fir, and radiata pine may also be used. , Itaya maple, Macanpa chrysanthemum, camphor tree, zelkova, Japanese cypress, Japanese white oak, Japanese cypress, Japanese alder, beech, Japanese oak, sea urchin, as well as domestically produced broad-leaved trees such as walnut, ebony, lauan,
Lawans such as mahogany ramin and yellow meranthi, and hardwoods such as rosewood may also be used. The thickness of such a plate is 0.2 to 2 mm, preferably 0.4 to 1.0 mm. If the board thickness is less than 0.2 m, the reinforcing agent will seep out and the wood texture will be impaired. If the thickness is more than 2.01, the reinforcing agent will not penetrate sufficiently and sufficient hardness and wear resistance will not be obtained. Further, the decorative veneer may be subjected to consolidation treatment for the purpose of improving impregnability and increasing hardness.

Furthermore, an adhesive may be used in combination to improve the adhesion between the impregnated base material and the base plate. Adhesives 1d that can be used can be appropriately selected from aqueous vinyl urethane, phenol, resorcinol, urethane, urea-melamine, epoxy and the like.

Compression molding for producing the reinforced cosmetic material of the present invention can be performed using known molding methods such as flat press, roll press, belt press, etc., and may be performed by cold pressure or hot pressure. In order to perform this molding efficiently in a short time, hot pressure molding is desirable. The molding conditions at that time vary depending on the combination of reinforcing agent, decorative veneer, impregnated base material, and base plate used, and the pressing temperature is 20°C (room temperature) to 150°C, and the pressing pressure is contact pressure to 30 kg/crn2. The pressing time ranges from 5 minutes to 3 days, but can be roughly divided into two categories, particularly regarding pressure conditions.

One type has tracheids and when using a decorative hardwood veneer with a dense tissue, 4 kg/cTL to 10 kg/cIrL is preferable. In the case of a decorative veneer, a contact pressure of ~5 kg/crfL2 is preferable. Moreover, in order to further reduce the degree of leaching, it is possible to use an impregnated base material impregnated with a reinforcing agent which is then dried with hot air to form a B-stage.

In the above method, the decorative veneer is strengthened by the reinforcing agent seeping out from the impregnated base material during compression molding and penetrating into the back surface and hardening. At this time, appropriate molding conditions are appropriately selected so that the reinforcing agent does not ooze out onto the surface of the decorative veneer, so as not to change the feel of the surface of the decorative veneer after reinforcement. Substantially,
Due to the additive effect with the reinforced impregnated base material, sufficient hardness and abrasion resistance can be obtained without impregnating the decorative veneer with a reinforcing agent to the extent that it discolors. Furthermore, according to this method, the impregnation lid of the reinforcing agent is not affected by the thickness of the base plate, so even if a thick base plate is used, the amount of impregnation will strengthen the decorative veneer and the impregnated base material. Therefore, the amount of reinforcing agent leached from the impregnated base material during molding is also very small. From the above, the method described above has better workability than the method of impregnating the base plate with a reinforcing agent and can provide a reinforced decorative material that maintains the wood texture at a lower cost.

"Example" The present invention will be explained below by giving examples.

Example 1 A length of 20 CrI was placed in an impregnation container equipped with a pressure reduction device and a pressure device.
Six beech veneers with a width of L1 of 10 cm and a thickness of 1.0 MIK were inserted. Next, a reinforcing agent with a viscosity of 30 cps (at 25°C) was added to a vinyl ester resin (Dainippon Ink Chemical Co., Ltd. product, DICRY) in a weight ratio of 60:40:1. was placed in an impregnation container and the beech veneer was completely immersed.

Next, operate the pressure reducing device to reduce the pressure inside the impregnation container to 40 degrees.
The pressure was reduced to maHg and maintained for 30 minutes. Next, after returning to normal pressure, the pressure device was operated to increase the pressure to 10 kg 7 cm 2 and maintain it for 30 minutes. Return to normal pressure again, take out the beech veneer, and apply a water-based vinyl urethane adhesive (Dainippon Ink & Chemicals Co., Ltd., Dick Zand V-255:
Weight ratio of 7 de M-3 = 9:1, approximately 10,000 ep8
) was coated on an unimpregnated base plate having a length of 20α, a width of 1oα, and a thickness of 9 layers. Further, on top of this, there is no impregnation and the thickness is 0.
Laminated 8 mm cypress decorative veneer and press using a flat plate press cuff 2, press temperature 130℃, press time 1
By hot-pressing molding under conditions of 3 minutes, a cypress-reinforced decorative material that maintained a woody feel was obtained. This reinforced decorative material had excellent hardness, abrasion resistance, crack resistance, and appearance, and the content of the reinforcing agent was not much different from that in the conventional method for producing hPC (Comparative Example 3). Furthermore, the amount of reinforcing agent that oozed out from the beech veneer during molding was not so great as to cause flaking, and workability was also good. About this reinforced decorative material Hardness, abrasion resistance,
Table 1 shows the results of measuring crack resistance, appearance, amount of reinforcing agent impregnated, and workability.

Comparative Example 1 Six base plates similar to those in Example 1 were placed in an impregnating container equipped with a pressure reducing device and a pressurizing device. Next, the reinforcing agent prepared in Example 1 was placed in an impregnation container to completely impregnate the base plate, and the impregnation treatment was carried out under the same conditions as in Example 1.

The unimpregnated decorative cypress veneer used in Example 1 was laminated on the surface of the obtained treated base plate, and a press pressure cuff was applied using a flat plate press.
9/cyn2. Press temperature 130C, press time 13
A decorative cypress veneer that maintains the wood feel was obtained by hot-pressing forming under conditions of 100%. This reinforced decorative board has the same level of hardness, abrasion resistance, crack resistance, and appearance as the reinforced decorative material of Example 1, but the amount of reinforcing agent impregnated increases and the end of the base plate oozes out during molding. Since the amount of reinforcing agent was extremely large, the cost was higher and the workability was poorer than in Example 1.

Table I shows the results of measuring hardness, abrasion resistance, crack resistance, appearance, reinforcing agent content, and workability for this material.
Show K.

Comparative Example 2 An unimpregnated cypress decorative veneer similar to Example 1 was attached to an unimpregnated base plate using a water-based vinyl urethane adhesive (Dainippon Ink & Chemicals).
Product Dickpond'/-255: Dickbond M-
3-9:1 weight ratio) to obtain a cypress decorative material. Although this cypress decorative material had a woody feel, its hardness and abrasion resistance were significantly inferior to those of Example IK. The measurement results are shown in Table 1.

Comparative Example 3 Six cypress decorative veneers similar to those in Example 1 were placed in an impregnating container equipped with a pressure reducing device and a pressurizing device. Next, the reinforcing agent used in Example 1 was placed in an impregnating container, the decorative veneer was completely immersed, and the impregnating treatment was carried out under the same conditions as in Example I. The obtained impregnated decorative veneer was coated with the same water-based vinyl urethane adhesive as in Example 1 (Inu Nippon Ink Kagaku Kogyo ■ product, Dick Bond V-255:
Dicksend M-3 = 9:1 weight ratio) was laminated on the base plate coated with the pressure cuff kg7' using a flat plate press.
m2. A tank-reinforced decorative material was obtained by hot-press molding at a press temperature of 130° C. and a press time of 13 minutes. This reinforced decorative material lost the woody feel of the veneer and had poor crank resistance. Table 1 shows the measurement results.

Example 2 Unsaturated polyester resin (Dainippon Ink & Chemicals @ product, Polylite C8-810): Methyl methacrylate monomer: BPO = 90: 10: 2 g
Six sheets of glass cloth having a length of 30α, a width of 12 crfL, and a thickness of 0.6 were immersed for 5 minutes in a reinforcing agent with a viscosity of 300 cps (25° C.) containing a weight ratio of L. After draining the liquid for 5 minutes, it was left in a dryer maintained at 70° C. for 10 minutes to dry. Next, apply this to an epoxy adhesive (Dainippon Ink Chemical Industry ■ product, Evicron 850).
An unimpregnated vane with a length of 3°1, a width of L2 crrts and a thickness of 12" coated with was laminated on top of the sawn timber. Furthermore, a non-impregnated birch veneer with a thickness of 0.5 mm was laminated on top of this, and a press pressure cuff of 1 kg/an was applied using a flat plate press, and a press temperature was 130°C.
A reinforced decorative material that maintained a woody feel was obtained by hot-pressing molding under conditions of a pressing time of 13 minutes. This reinforced decorative material had excellent hardness, abrasion resistance, crack resistance, and appearance. In addition, there was very little reinforcing agent seeping out of the glass cloth during molding, and workability was good. About this material Hardness,
Table 2 shows the results of measurements regarding abrasion resistance, crack resistance, appearance, amount of reinforcing agent impregnated, and workability.

Comparative Example 4 Six hemlock logs similar to those in Example 2 were placed in an impregnation container equipped with a vacuum device +i and a pressurization device. Next, the reinforcing agent used in Example 2 was placed in an impregnating container and the lumber was completely immersed. Next, the pressure reduction device was fully operated to reduce the pressure inside the impregnation container to a degree of vacuum of 40 mmHg and maintain it for 1 hour. Next, after returning to normal pressure, the pressure device was operated to increase the pressure to 15yCg/crrL2 and maintain it for 1 hour. The pressure was returned to normal and the lumber was taken out. The birch veneer used in Example 2 was laminated on the surface of the sawn lumber, and a flat press was used to press the lumber under the conditions of a press pressure cuff of kg/cm2, a press temperature of 130, and a press time of 13 minutes. A birch-reinforced decorative material that maintains the wood feel was obtained by hot-press molding. This reinforced decorative material has the same level of hardness, abrasion resistance, crank resistance, and appearance as the reinforced decorative material of Example 2. Since the amount of reinforcing agent leached out was significantly large, the cost was higher and the workability was worse than in Example 2.

Table 2 shows the results of measuring the hardness, abrasion resistance, crack resistance, appearance, impregnated amount of reinforcing agent, and workability for this material.
Shown below.

Comparative Example 5 The unimpregnated cover decorative veneer used in Example 2 was attached to an unimpregnated base plate using a water-based vinyl urethane adhesive (Inu Nippon Ink Chemical Industry ■Product Dic?nd V-255 = Dic Bond M-
3=9:1 weight ratio) to obtain a hippo decorative material. Although this birch decorative material had a woody feel, its hardness and abrasion resistance were significantly inferior to those of Example 2.

The measurement results are shown in Table 2.

Comparative Example 6 Six pieces of birch decorative veneer used in Example 2 were placed in an impregnation container equipped with a pressure reducing device 1 and a pressurizing device. Next, the same reinforcing agent as in Example 2 was placed in an impregnating container, and the decorative veneer was completely immersed, and subjected to reduced pressure and pressure treatment under the same conditions as in Comparative Example 4. The obtained impregnated decorative veneer was similar to Example 2 in which a water-based vinyl urethane adhesive (Dainippon Ink & Chemicals Co., Ltd., Dinokugend V-255:Deitkugendo M-3 = 9 = 1 weight ratio) was applied. The vanes of were laminated on the lumber, and using a flat plate press, press pressure cuff/α2, press temperature 130℃, press time 1
A hippo-reinforced decorative material was obtained by hot-pressing molding for 3 minutes. This reinforced decorative material lost the woody feel of the veneer and had poor crack resistance. Table 2 shows the measurement results.

"Effects of the Invention" The reinforced decorative material of the present invention is obtained by laminating an impregnated base material impregnated with a reinforcing agent between an unimpregnated decorative veneer with beautiful wood grain and a base plate, and the veneer itself has It has properties such as hardness while maintaining the wood feel. In addition, this cosmetic material can reduce manufacturing costs and has good workability.

In addition, when this decorative material is applied to a house, for example, it can be used not only for walls and ceilings, but also for floors, etc., which are used in harsh environments.

In addition, this reinforced decorative material has sufficient wood texture and is extremely natural, so even residents who are sensitive to wood texture will not feel any discomfort at all.

Agent Patent Attorney Katsutoshi Takahashi

Claims (1)

[Scope of Claims] 1) An impregnated base material impregnated with a reinforcing agent is placed on at least one side of the unimpregnated base plate, and then an unimpregnated base material with a thickness of 0.2
A reinforced decorative material that maintains the wood feel and is made by laminating and compression molding ~2mm decorative veneers. 2) The base plate is made of a wood material, an inorganic material, or a composite material thereof, and the base material of the impregnated base material is a wood material, an inorganic material,
2. A reinforced cosmetic material according to claim 1, which is made of paper, cloth, glass fiber, carbon fiber, or a composite material thereof, and the reinforcing agent is a synthetic resin, a reactive monomer, or a mixture thereof. 3) The impregnated base material contains 3 parts by weight of resin curing agent per 100 parts by weight of the base material.
The reinforced cosmetic material according to claim 1, comprising 0 to 2000 parts by weight.