JPH03216333A - Manufacture for decorative plate material - Google Patents

Abstract

PURPOSE:To constitute the above manufacturing method so that the plate possesses sufficient deep appearance, by a method wherein an insertion material comprised of paper or nonwoven cloth is put on a fiber base into which a curing resin solution is impregnated, ligneous small pieces are spread over the insertion material, then they are heated, pressurized and unified. CONSTITUTION:Uncured liquid epoxy resin is impregnated into, for example, glass fiber nonwoven cloth having weighing of 50g/m<2> at a resin impregnation ratio of 80%, five sheets of which are laminated by piling up and made into a prepreg sheet laminated matter 1. A matter colored in white is used for liquid epoxy resin. A sheet of Awa hand-made Japanese paper having the weighing of the 50g/m<2> which is colored in blue is put on the surface of the prepreg sheet laminated matter 1 as an insertion material 2. Splinters of spruce are spread uniformly over the same, on the surface of which mold releasing polypropylene film is put, unified by heating and pressurizing for 60 minutes at pressure of 1.5Mpa and temperature of 130 deg.C and a decorative plate material is obtained.

Description

[Detailed Description of the Invention] : Industrial Application Field] This invention relates to a method for manufacturing decorative board materials using small pieces of wood as decorative materials. A decorative pattern layer made of small wood particles is given a sense of depth by placing small pieces of wood on the intervening strips and applying heat and pressure.

I. Prior art] A fiber base material such as a glass fiber non-woven fabric is impregnated with a curable resin liquid such as Epoquine resin to form a prepreg, and small pieces of wood such as crushed wood pieces are sprinkled on top of the prepreg. A method has been proposed in which a decorative plate material is obtained by heating and pressurizing the materials into one piece using a pressurizer (Japanese Patent Application No. 62-310024).

The decorative board material obtained in this way is buried in the substrate in an uncompressed state due to the cushioning effect of the large number of small wooden pieces or the fiber base material, and a portion of it is slightly exposed on the surface. It has become.

For this reason, it is necessary to finish the surface by grinding the surface to make it smooth and then forming a transparent coating.

In addition, because the small pieces of wood were buried shallowly, the pattern lacked a sense of depth, and the texture as a decorative pattern was not necessarily sufficient.

[Problem to be solved by the invention]

Therefore, an object of the present invention is to provide a method for manufacturing a decorative board material that can form a wooden decorative pattern with sufficient depth.

Means for Solving the Two Problems] In order to solve these problems, an interpolation material made of paper or non-woven fabric was placed on a fiber substrate impregnated with a curable resin liquid, and small pieces of wood were sprinkled on the interposer material. Later, a method was adopted to integrate them by heating and pressurizing them.

[For production]

Together with the interpolation material or the fiber base material, it exhibits a cushioning effect, and the wood particles are buried deeper, giving a sense of depth.

This invention will be explained in detail below.

First, a fiber base material used in this invention is prepared. This fiber base material may be a cloth made of synthetic fibers such as glass fiber, polyamide, acrylic, or polyester, or a nonwoven fabric or woven fabric made of glass paper, acrylic fiber, vinylon fiber, etc., with a thickness of 0.03 to 0.5 mm. It is preferable to use a material of about
A material that forms a laminate with a basis weight of about 100 to 300 g/m' is used.

This fiber base material is impregnated with a curable resin liquid.

This curable resin liquid is mainly a curable resin that is in a pre-cured state or a liquid state, such as Evoquin resin, unsaturated polyester resin, allyl phthalate resin, polyurethane resin, /licon resin, phenol resin, acrylic resin, etc. used. The viscosity of this curable resin before curing is not particularly limited, and if the viscosity is high, a reactive diluent,
It is desirable to dilute with a solvent or the like. Then, appropriate additives such as fillers and colorants are added thereto as necessary. The fillers here include carunium carbonate,
Talc, titanium oxide, lyca, glass powder, etc. are used, and the blending amount is 50 to 100 parts by weight of resin liquid.
It is said to be about 200 parts by weight.

In addition, the coloring agent is preferably a dye or pigment with a black, white, or brown color tone, or may be any other color tone, and the amount added is not particularly limited.

The work of impregnating the base material with these curable resin liquids is as follows:
Specifically, for example, a fiber base material is immersed in a constant temperature bath filled with an uncured product of the above-mentioned curable resin liquid and heated to room temperature or about 20 to 30°C, and then heated at a speed of 5 to 30°C. 10
A method of continuously impregnating the fiber base material by moving the fiber base material at a rate of about m/min, or a method of continuously impregnating the fiber base material by moving the fiber base material in the resin liquid
This may also be done by leaving it standing for about 3 minutes. In either case, the impregnation rate of this resin liquid is approximately 70 to 90% (
It is desirable to determine the above-mentioned immersion conditions so that the weight ratio is approximately the same. In addition, at this time, if multiple fiber base materials are dipped at the same time, or if this dipping operation is performed continuously as described above, continuous impregnation can be achieved in a short time.
Work efficiency is significantly improved.

Next, the fiber base material impregnated with the curable resin liquid is dried, and then dried at a temperature of 90 to 100° C. for about 5 to 10 minutes in the dark to produce a Bripreg plate.

Next, a plurality of sheets, preferably about 3 to 5 sheets, of the prepreg sheets obtained in this manner are laminated to form a prepreg laminate, and as shown in FIG. 1, on the surface of this prepreg laminate, An interposition material 2 made of paper or nonwoven fabric is placed. This intermediate material 2 has a weight of 20 to 30
0 g/m2, preferably around 50 to 100 g/m',
Japanese paper or glass fiber with a thickness of about 0.05 to 0.1 mm,
Non-woven fabrics made of synthetic fibers are used. Weighing 50
Two or more sheets may be laminated as long as the weight is within the range of ~300 g/m2. Further, the interposer material 2 is preferably dyed in various tones, and Japanese paper with a watermark pattern is particularly preferable because it provides a cushioning effect and a design effect. Further, the interposer 2 can be impregnated with the same curable resin liquid as the curable resin liquid with which the burry pregun laminate 1 is impregnated. Of course, this impregnation with the curable resin liquid is not necessarily necessary, and the curable resin liquid from the Bripreg sheet laminate 1 permeates during heating and pressurization, resulting in a substantially impregnated state.

Then, a large number of small pieces of wood 3... are scattered on this interpolation material 2. The wood pieces 2 include small pieces of hardwood such as black tongue, beech, oak, horse chestnut, Japanese ash, maple, birch oak, and softwood such as suki, cypress, mango, subruce, and agathis. Cut pieces of Ann and grass, cut pieces of Yuro bark, cut pieces of Nato wood bark, cut pieces of bamboo, and monofilament of synthetic fibers such as polyester fiber and acrylic fiber are used. The shape of these small pieces of wood is not particularly limited, but small pieces formed by cutting into plate, rectangular parallelepiped, cubic, and granular shapes, or small pieces crushed by mechanical impact or roller pressure, etc. Various shapes are used. This wooden piece 3
... is a width of 3 if its shape is a rectangular parallelepiped.
~50mm, length 3~100mm, thickness 0.2~2mm
It is desirable to have a diameter of 3 to 50 mm if it is cylindrical.
s Thickness 0 2 to 2 mm, width 1 for crushed pieces
~10mm, length 3-100mm, thickness 0.2-2mm
degree or desirable. Further, the wood particles 3 may be mixed with different wood species or different colors.

Further, when using the small pieces of wood 3 or small pieces of bound wood, those subjected to dimensional stabilization treatment can be used if necessary. Dimensional stabilization treatments include acetylation treatment in which small pieces of wood are treated with acetic anhydride, polyethylene glycol,
A method of C”r FXing polypropylene glycol, a method of impregnating and solidifying the same type of resin as the above-mentioned curable resin liquid, such as liquid phenol resin, unsaturated polyester resin, epoxy resin, silicone resin, urethane resin, acrylic resin, etc. In addition, by mixing an organic halogen preservative into polyethylene glycol or liquid resin, dimensional stabilization treatment and preservative treatment can be performed at the same time. It is possible to use a product whose part or all has been colored in one or more types of tones, including black for black tan, yellow for brick and batosokuna, and white for oak and beech. It is also preferable to take advantage of the natural color of the wood.Coloring treatment is performed by dissolving colorants such as dyes and pigments in a solvent such as water or an organic solvent at a concentration of 0.
A method is used in which a large number of small pieces of wood 3 are impregnated with a coloring liquid of about 1 to 10% by weight. It is also possible to heat the coloring liquid to promote penetration of the coloring liquid, resulting in a skin-colored color. Also,
At the time of the dimensional stabilization treatment, a coloring agent may be dissolved in various liquid resins, and the coloring treatment may be performed simultaneously with the dimensional stabilization treatment.

The scattering of the wood particles 3 is carried out as appropriate by using a coarse sieve or by directly scattering them by hand. The amount of wood particles 3 to be sprinkled is approximately 10 to 90%, preferably approximately 30 to 90%, of the surface of the Bribregunt laminate 1.
It is preferable to set it to about 60% or to the extent that it is covered.

After spraying the wood chips 3, the laminate will be heated and pressurized, or the laminate after being sprayed will be heated to a temperature of 15 to 3.
Allow to stand at 0°C for about 3 to 4 hours to advance the curing of the curable resin, increase the withering of the impregnated resin liquid, make it easier to handle, and remove air bubbles in the impregnated resin liquid. You can also do it.

The heating and pressing is performed using a heating and pressing means such as a well-known Honto Breath, and a release film and a backing plate are placed on the scattered wood chips 3, and a pressure of 1 to 2 MPa and a temperature of 130 to 200 psi are applied.
The test is carried out at 1500C for about 10 to 60 minutes.

By this heating and pressurization, as shown in Fig. 2, a plurality of brifligunds and interposers 2 are fixed and integrated, and a small piece of wood 3 placed on the top surface of the interposers 2 is fixed. At the same time as the prepregs are pushed inward, the impregnated resin hardens, creating a smooth surface with each wooden piece 3 deeply embedded in the integrated laminated material of the interpolation material and the prepreg sheet. A decorative board material 5 is obtained.

The surface of the decorative board material 5 thus obtained is lightly ground as necessary, and unsaturated polyester resin paint is applied to the decorative board material 5.
A transparent coating film with a thickness of 50 to 500 μm can be provided by applying a urethane resin paint or the like.

According to this method of manufacturing decorative board materials, by using the interpolation material, a buffering effect is obtained by the two materials, the interpolation material and the fiber base material, and the burial of the wood particles can be carried out more smoothly and deeply. As a result, a pattern rich in depth can be obtained. In addition, when heated and pressurized, it also functions as an intervening material or a nonwoven material, and the air bubbles contained in the fiber base material are well expelled to the outside, so that no hoist remains on the decorative board material.

Furthermore, if a colored material or a material with a watermark pattern is used as the gap material, a pattern with a new color pattern can be obtained, making it possible to enrich the tesine.

(Example) A glass fiber nonwoven fabric with a weight of 50 g/m' was impregnated with an uncured liquid epoxy resin to a resin impregnation rate of 80% (weight ratio), and five sheets were laminated to form a prebregunt laminate. The liquid epoxy resin used was colored white.

A sheet of Awa handmade washi paper (with Unryu watermark pattern) with a weight of 50 g/mt, colored blue, was placed on the surface of this Buri Preg sheet laminate as an intervening material, and on top of this A polypropylene film for mold release was placed on the surface of the crushed pieces, and a pressure of 1. 5 MPa, temperature 130'C,
They were heated and pressurized for 60 minutes to be integrated, and a decorative board material was obtained.

The surface of the obtained decorative board material was smooth, and the crushed beech pieces were completely buried. It also looks like crushed beech pieces floating on the blue background.
On the blue background, I could see a faint pattern based on the Japanese paper's Unryu pattern.

〔Effect of the invention〕

As explained above, the method for manufacturing decorative board materials of the present invention involves placing an interpolation material made of paper or nonwoven fabric on a fiber substrate impregnated with a curable resin solution, and then scattering small pieces of wood on the interposer material. Since these are integrated by heating and pressurizing, the resulting decorative board material is in a state where the small wood pieces are completely buried in the base consisting of the resin-impregnated fiber base material and the interpolation material, and the surface is smooth and smooth. The result will be something that is both unique and rich in depth. In addition, the interposer material also functions as a cushioning material when heated and pressurized, thereby preventing the generation of voids such as air bubbles. Furthermore, if a colored material is used as an interpolation material, various designs can be added to the surface pattern of the decorative board material.

[Brief explanation of drawings]

FIGS. 1 and 2 are schematic sectional views showing an example of the manufacturing method of the present invention in the order of steps. 1. Buri Pregunt laminate, 2. 3. Small piece of wood, 5. Decorative board material. Intermediate material,

Claims (1)

[Claims] It is characterized by placing an interpolation material made of paper or nonwoven fabric on a fiber base material impregnated with a curable resin liquid, scattering small pieces of wood on the interposer material, and then heating and pressurizing them to integrate them. How to make decorative board materials.