JPH0419934B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION This invention provides a decorative panel with various characteristics as a wood material on the decorative surface, uses a foamed synthetic resin material as a core material, and can be mass-produced using a press machine. This relates to the disclosure of the method.

Conventional panel materials having a resin decorative surface generally consist of a decorative film made of vinyl chloride stretched onto a core material surface and bonded.

However, in such a method, the PVC film itself that is stretched expands and contracts with temperature changes, and is likely to be stretched in an expanded and contracted state due to heating when stretching onto the core material surface, which may cause the stretching. Subsequent cooling shrinkage causes the panel to warp or become distorted, or the decorative surface of the panel to tighten.

Furthermore, since the PVC film that is stretched does not generally have good compatibility with adhesives, it often peels off from the core material surface due to expansion and contraction of the stretched film due to temperature changes.

Furthermore, since the PVC film that is applied has almost no hygroscopicity, sweating tends to occur on the core material surface and the film surface, and wear and tear of the panel due to this dew condensation is a problem, and the contact surface The material has an artificial feel to the touch, and there is no natural absorption of sweat on the contact surface, making it unsatisfactory as a panel material for living spaces.

The method for forming a decorative panel according to the present invention is directed to forming a panel material that avoids the disadvantages of conventional panel materials, and maintains good abrasion resistance on the decorative surface. , creates a comfortable living space by providing appropriate moisture absorption and water resistance functions, and also provides a natural appearance and texture close to that of wood, as well as heat molding using a press. This eliminates the warpage and distortion of the panel associated with this process, as well as the occurrence of tightening and wrinkling on the panel decorative surface.

Therefore, in order to achieve effective effects on the various properties, the method for forming a decorative panel according to the present invention particularly applies the gist of its structure to crushed chips, pulp, rice husks, and other appropriate cellulosic materials. The material is dried so that the water content is within 15o/wt to induce collapse of the fiber structure, and the processed material is impregnated with a urea resin solution, and then the processed material is impregnated with a urea resin liquid. The material is dried and crushed in a temperature range of 100℃ to 250℃ to form a neutralized finely hardened aggregate with a pH of 6 to 7.Then, this formed aggregate is mixed with vinyl chloride or other resin material to form a film. The process of forming a wooden decorative plate in the form of a shape or a sheet, reheating the wood decorative plate in a temperature range of 100°C to 140°C, loading it onto a foamed synthetic resin core board, and then molding the loaded decorative plate. This is a combination of the process of pressurizing and molding from the top of the board and the process of rolling. In addition, the following specific examples accompanying the gist of such a configuration,
Considerable design changes are planned for these embodiments.

An example of a typical method for forming a decorative panel according to the present invention will be described below with reference to the accompanying drawings.
1 is a wood decorative plate, 2 is a foamed synthetic resin core board, 3 is
indicates a press equipment, which is usually 100℃~
The core board 2 is made by laminating the wooden decorative plate 1 heated at 140°C on the core board 2 via an adhesive, and stamping it with a press device 3 at 20°C to 50°C.
In response to the plastic mold formed by the press device 3 and the plastic mold formed by the decorative plate 1, the compressed portion 2a and the expanded portion 2b according to the pressing mold are maintained in their plastic state.

That is, the core plate 2 is molded by itself due to the heat of the laminated decorative plates 1 and the pressure of the press device 3, and the decorative plate 1 is made of a specific aggregate described below. As a result, the decorative plate 1 was molded reliably, and the decorative plate 1 was forced to maintain its plastic shape. or,
This forced maintenance of the plastic state is further strengthened in that the decorative plate 1 is easily adapted to the adhesive and the adhesion to the core material 2 is ensured.

In this way, the decorative plate 1 and the core material 2 are simply pressurized,
It is made into a decorative panel material having a backing core material by adhesion and molding methods, and is suitable for mass production at low cost.

The decorative plate 1 used for such panel molding was particularly provided using the following distinctive method. First, the materials to be prepared are a thermoplastic resin material 1b such as vinyl chloride, ABS resin, and polystyrene, and a mixed aggregate 1a based on wood flour.
and calcium carbonate powder added as necessary,
These include curing agents, foaming agents, stabilizers, and coloring agents.

The aggregate 1a that is then used is one that has been neutralized using the following method. That is, cellulose-based materials such as crushed wood chips, pulp materials, or rice husks are prepared, and pre-processed by drying, especially heating drying, so that the moisture content of the material is within 15 o/wt. This is what was done. As the moisture content in the material decreases to within 15o/wt, the drying process rapidly induces destruction of the constituent fiber structure of the material, resulting in coarse bundles of cellulose or crushed chips in the form of lumps. The composition of the cellulose in wood, pulp material, and rice husk is certainly destroyed, and the cellulose is in a disorganized state.

By applying an emulsion-type urea-based resin adhesive to the material that has dried and whose structure has disintegrated, and leaving it for 20 to 30 minutes,
This urea-based resin adhesive liquid is sufficiently impregnated into the material, and usually has a pH value of about 5.

In addition, ammonia chloride or hydrochloric acid is separately added to this resin adhesive liquid as a hardening agent, and the material
Attempts were made to further adjust the pH value toward neutrality as necessary.

In this way, the material impregnated with the urea-based resin liquid and cured is subjected to heat drying at a temperature of 100°C to 250°C and crushing into powder in the next step. The moisture content is within 3-5o/wt,
While keeping the particle size as close to 0o/wt as possible,
It is made into a fine powder of about 100 to 150 mesh.

During such heat drying and crushing, the material itself
The pH value is within the range of 6 to 7, and is generally adjusted to be neutral.

The neutralization treatment of the acidic material at such a starting point is
This is largely due to the action of the urea-based resin adhesive that is interposed during the process, and is a starting point for simple heating and drying treatment of cellulose materials where no urea-based resin adhesive is planned to be added. in point material
The pH of the target material, which is made into a dry fine powder, is PH5.
is between 2 and 3, meaning that the pH value tends to be more acidic. On the other hand, by interposing a urea-based resin adhesive, the PH5 material is neutralized while gradually releasing the acetic acid contained in the material as wood acid gas as it is heated and dried. The pH of the material is adjusted to within the neutralization range of 6 to 7.

The aggregate 1a thus provided can be heat treated during processing to maximize the water content in the aggregate.
Within 13 o/wt, ideally within 3 to 5 o/wt, and even as much as possible to 0 o/wt, to eliminate any room for water vapor to occur in the subsequent resin molding with aggregate mixed in, and It prevents the wood acid contained therein from exfoliating and volatilizing to eliminate the possibility of acid gas generation, and is sufficiently neutralized to have a pH value of 6 to 7.

In the aggregate 1a thus provided, the wood acid contained in the wood powder, especially acetic acid gas, is evaporated during impregnation with a thermosetting resin agent mainly composed of urea resin and thermoforming. After being neutralized, the possibility of acid gas generation is effectively reduced compared to the aggregate used in the subsequent processing of mixing the aggregate into a resin material and molding it.

In addition, most of the water contained in the aggregate is evaporated by the heating and drying treatment performed during the molding of the aggregate 1a, and the generation of water vapor, which is considered to be a problem in resin molding using the molded aggregate, is avoided. No foaming in the molded product,
This eliminates the possibility of cavities, rough skin, etc. In addition, the removal of this water content can have a significant effect on the volatilization of wood acid contained in wood flour, and wood acid contained in wood flour usually reacts with H ₂ O groups. This effectively prevents the depletion and volatilization of the product. Therefore, in addition to erasing the wood acid produced in the heating crushing-hardening process by impregnating the thermosetting resin material and adjusting the pH to 6 to 7 by neutralization, it is possible to suppress the generation of residual wood acid gas from the aggregate. This makes it even more effective.

Effective elimination of wood acid gas in such aggregates,
Prevention of this occurrence has an extremely important meaning in subsequent resin molding. In other words, if wood acid gas is generated during resin molding, the cylinder screws, molding dies, or molding rolls of presses, extruders, and roll machines used for resin molding will be oxidized and corroded, dramatically reducing their durability. In addition, the molding efficiency was also reduced, and in particular, the problem of molding defects due to uneven extrusion pressure occurred.

In addition, unlike ordinary pure wood flour, Aggregate 1a has a hardening resin impregnated into or attached to it, so the surface resistance value is extremely reduced, making it suitable for use as an aggregate. The extrusion pressure when mixed into a resin material and molded is almost similar to that of common resins.

Furthermore, the use of such aggregate 1a improves compatibility with the mixed resin material, ensures uniform mixing of the aggregate, and eliminates as much as possible the voids that occur on the peripheral surface of the aggregate in the molded product. This makes it possible to provide molded products with the desired quality.

The calcium carbonate powder prepared next is used as needed to prevent molded products from deforming during extrusion processing, etc., and to keep the unit price of molded products low since calcium carbonate itself is particularly cheap. It is something that

In addition to these materials, stabilizers such as lead were separately prepared in an attempt to prevent deterioration in the molded product and to reduce as much as possible the frictional resistance that occurs during extrusion processing.

Furthermore, when the molded product is to be colored, a corresponding coloring agent is prepared. For example, when the molded product is made white, titanium oxide is mixed in.

The aggregate 1a thus provided is mixed into the resin material 1b at a concentration of 20 to 60 o/wt and heated to 110°C.
Heating at 170°C to produce a sheet-like foamed or non-foamed decorative plate 1, or mixed in the range of 5 to 40o/wt and heated at 110°C to 170°C to create foamed or non-foamed decorative plate 1. A film-like decorative plate 1 was produced.

Next, the core plate 2, which is the laminated core material of this decorative plate 1, is an appropriate foam such as foamed polyurethane, foamed polyethylene, foamed polystyrene, foamed polypropylene, etc., and a material suitable for molding by hot pressing was planned. It is something.

Such decorative plate 1 is subjected to reheating treatment in a temperature range of 100°C to 140°C, and is laminated on the core plate 2 via adhesive 4 to form the desired shape.
It is pressed and molded using a cooling press 3 at a temperature of 20°C to 50°C.

The decorative panel thus provided has the characteristic molding method and structure described above,
The following properties were observed in the molded panel material. That is, (1) Since the decorative plate 1 contains a large amount of aggregate 1a, the press-molded shape is reliably maintained during reheating and cooling molding, and the surface of the decorative plate 1 is It is designed to enhance the adhesion effect of the adhesive 4 mainly on the exposed aggregate 1a, and to achieve strong adhesive integration with the core plate 2. , it is possible to provide a decorative panel material having an uneven structure and having a sound insulating structure.

(2) Therefore, it is possible to eliminate the trouble of forming the unevenness of the decorative plate, forming the unevenness of the foamed resin agent to match the unevenness, and fitting and integrating the two, and the compression part 2a,
The basic heat insulation and sound insulation functions in the expanded portion 2b are the same, and the heat insulation properties over the entire panel,
It is designed to provide sound insulation properties.

(3) The abrasion resistance of the panel surface is said to be particularly good due to the inclusion of aggregate 1a, and it can be used as a panel material that is expected to come into contact with complicated sliding surfaces, such as wall materials, floor materials, etc. It can be used for a wide range of purposes, and its wear resistance is as follows.

Amount of wear mg/1000 rotations Decorative plate 35.9 Hard PVC 46.6 Plywood 348.2 (However, load 1Kg, rotation speed 70rpm, wear ring cs
-17Calibarase) (4) It has good water resistance and is suitable for waterproof walls, floor coverings and other decorative materials, has some hygroscopicity, has the insulation properties described below and prevents condensation, and is suitable for use on contact surfaces. It absorbs sweat, etc. from the skin and provides a good texture.

Water absorption rate (per unit area) Decorative plate 0.44 Hard PVC 0.09 Plywood 7.9 (However, 25% in JIS K7209 water absorption test method)
℃, water absorption rate for 24 hours) (5) By mixing aggregate 1a, there is no shrinkage during molding, and no shrinkage or expansion due to temperature changes after molding, so it can be used as a decorative material for decorative walls, decorative floors, sliding doors, etc. It is possible to attach the panel to the mounting base accurately, that is, without expanding or contracting, and to create a good decorative wall surface without causing any wrinkles, twitching, etc. to the surface of the decorative panel.

(6) Since the aggregate 1a is exposed on the surface, the texture is said to be similar to that of wood, and the appearance characteristics are also said to be similar to wood.
In particular, since the surface friction resistance is close to that of wood, we have promised to create a panel with an optimal surface for decorative flooring, decorative walls, or decorative furniture.

(7) Aggregate 1a is exposed on the surface, so when a coloring agent is mixed into the decorative plate itself, it is compatible with this coloring agent, and when decorative printing is applied to the surface, this The adhesion of the printing ink is ensured by using the aggregate 1a, resulting in a clear pattern,
Good color development was promised.

(8) With the addition of Aggregate 1a, it is said to have good heat insulation and sound insulation properties, and is also suitable for cutting and nailing, promising construction properties similar to those of ordinary veneer.

The method for forming a decorative panel according to the present invention has the characteristic configuration, action, and effect described above,
It has been used in a wide range of applications as a heat-insulating and sound-insulating panel that can easily and reliably form a panel material into a desired shape and has a decorative surface with excellent wear resistance.

[Brief explanation of drawings]

FIG. 1 is a laminated cross-sectional view of a panel material according to the present invention,
FIG. 2 is a sectional view showing press molding, FIG. 3 is a partially cutaway perspective view of the molded panel, and FIG. 4 is an enlarged sectional view of the decorative plate. In addition, in the figure, 1...decorative plate, 2...core board, 3...
Press device, 4... shows adhesive.

Claims (1)

[Claims] 1. For crushed chips, pulp, rice husks, and other appropriate cellulose-based materials, the water content of the material is
The processed material is dried to within 15o/wt to induce collapse of the fiber structure, and the processed material is impregnated with a urea-based resin solution, and then the processed material is heated at 100°C to 250°C. Dry and crush in a temperature range to form a neutralized finely hardened aggregate with pH 6 to PH 7, then mix this formed aggregate with vinyl chloride or other resin materials to form a film or sheet wood decorative plate. and the process of molding the wood decorative plate.
It is characterized by the steps of reheating in a temperature range of 100°C to 140°C, adding it onto a foamed synthetic resin core board, and then applying pressure and molding from the surface of the added decorative board. Method for forming wood-like decorative panels. 2. The method for forming a wood-like decorative panel according to claim 1, characterized in that an adhesive is interposed between the decorative plate and the core plate. 3. A wood-like decorative panel according to claim 1, characterized in that the aggregate is mixed in a resin material in a range of 20o/wt to 60o/wt to form a sheet-like decorative plate. Molding method. 4. A wood-like decorative panel according to claim 1, characterized in that the aggregate is mixed in a resin material in a range of 5o/wt to 40o/wt to form a film-like decorative plate. Molding method. 5. The method for forming a wood-like decorative panel according to claim 1, wherein the particle size of the aggregate is 100 to 150 mesh, and the water content is within 5 o/wt.