JPH0419935B2 - - Google Patents

Description

[Detailed Description of the Invention] This invention has abrasion resistance and a wood-like decorative surface, and prepares a resin plate with a honeycomb structure as a core material, which is then molded using a press machine. The present invention relates to a method of forming a decorative panel material as described above.

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 expands and contracts with changes in temperature, and is likely to be stretched in an expanded state due to heating when stretching onto the core material surface, which may cause tension. 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 as a result of 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 this condensation causes panel wear and tear, 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 decorative panel molding method according to the present invention provides a panel material that avoids the disadvantages of conventional panel materials and maintains good abrasion resistance on the decorative surface. By providing appropriate moisture absorption and water resistance functions, it creates a comfortable living space. Furthermore, it has a natural appearance and texture that is close to that of wood when touched, and it is heated by pressing. This eliminates the warpage and distortion of the panel that occurs during molding, as well as the occurrence of tension and wrinkles on the panel decorative surface.

Therefore, in order to effectively achieve these 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 suitable cellulose-based materials. On the other hand, the material is dried so that the moisture content is within 15o/wt to induce collapse of its fiber structure, and the processed material is impregnated with a urea resin liquid, and then the processed material is impregnated with a urea resin liquid. The processed material is dried and crushed in a temperature range of 100℃ to 250℃ to form a neutralized fine aggregate with a pH of 6 to 7.Then, this formed aggregate is mixed with vinyl chloride and other resin materials to form a film. a step of molding a wooden decorative plate in the form of a shape or a sheet, reheating the wooden decorative plate, and attaching the decorative plate to a synthetic resin plate surface having a mesh-like partition wall in the thickness direction,
This method combines the process of pressurizing and molding the surface of the attached decorative plate. or,
The following specific embodiments accompanying the gist of such a configuration and considerable design changes accompanying these embodiments are planned.

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 wooden decorative plate, 2 is a resin plate with a honeycomb-shaped reinforcing wall, and 3 is a press device, which presses the wooden decorative plate 1 heated at 100°C to 140°C through an adhesive. The plate 2 is then laminated onto the plate 2 and subjected to molding using a press device 3 at 20°C to 50°C. The compressed portion 2a and the uncompressed portion 2b according to the above are maintained in their plastic state.

That is, the plate 2 is molded by itself due to the amount of heat from the laminated decorative plates 1 and the pressure applied by the press device 3, and the decorative plate 1 has a unique aggregate described below. As a result, the plastic shape of the decorative plate 1 is ensured, and the decorative plate 1 is forced to maintain the plastic shape. Further, 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 plate 2 is ensured.

Thus, the decorative plate 1 and the plate 2 are made into a decorative panel material having a core backing material by a simple method of pressurization, adhesion, and molding, and are suitable for mass production at low cost.

The plate 2 used for such panel forming has honeycomb-shaped through holes _2n and partition walls _2o in the thickness direction, so that uniform stress can be applied in any direction, front, back, left, or right. It has a particularly strong structure as a panel core material.
Further, the honeycomb structure of the plate 2 serves to reduce the weight of the panel and to supplement the sound insulation and heat insulation functions of the through holes 2 _n in the plate 2. In addition, the honeycomb structure of the plate 2 allows the thickening of the partition wall 2 _o to absorb the heat pressing and molding by the press device 3 without crushing the through holes 2 _n . The expected functional effectiveness of the honeycomb structure was confirmed.

Next, the decorative plate 1 to be subjected to panel molding is provided by molding using the following method. Therefore, the first material to be prepared is vinyl chloride,
Thermoplastic resin materials such as ABS resin and polystyrene 1
b, mixed aggregate 1a based on wood flour, calcium carbonate powder added as necessary, hardening agent,
These include blowing agents, stabilizers, and coloring agents.

The aggregate 1a that is then used is one that has been neutralized using the following method. In other words, cellulose-based materials such as crushed wood chips, pulp materials, or rice husks are prepared and pre-processed by drying, especially heat drying, so that the moisture content of the material becomes 15o/wt. It is. 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,
The particle size is 100 while keeping it as close to 0o/wt as possible.
It is made into a fine powder of about 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 in simple heating and drying treatments of cellulose-based materials that do not plan on adding urea-based resin adhesives, Compared to the pH5 of the starting material, the final point material, which is made into a dry fine powder,
The PH value is 2 to 3, which means that the PH value tends to be 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, evaporates during impregnation and thermoforming with the thermosetting resin material mainly composed of urea resin. 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. By starting to dissipate and volatilize,
This was effectively suppressed. 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 ensures good 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.

The decorative plate 1 is then reheated in a temperature range of 100°C to 140°C, and laminated onto the plate 2 via an adhesive 4 to form the desired shape. Pressing and shaping were performed using a cooling press device 3 at 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 aggregate 1a is not exposed on the surface of the decorative plate 1. It is designed to improve the adhesion effect of the adhesive 4 mainly on the aggregate 1a, which is made of solid wood, and to form a strong adhesive integration with the plate 2. These characteristics make it possible to create a unique heat and sound insulation structure. This makes it possible to provide a decorative panel material with an uneven pattern.

(2) Therefore, in addition to eliminating the trouble of forming the unevenness of the decorative plate, forming the unevenness of the honeycomb plate to match the unevenness, and bonding and integrating the two, the basics of the compressed part 2a and the non-compressed part 2b can be improved. The two panels have the same thermal insulation and sound insulation functions, and are designed to ensure insulation and sound insulation properties over the entire surface of the panel.

(3) The abrasion resistance of the panel surface is said to be particularly good due to the inclusion of aggregate 1a, and it is suitable for a wide range of applications such as panel materials for difficult sliding surfaces, etc., such as wall materials, floor materials, etc. 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 1 Kgu, rotation speed 70 rpm, wear wheel
cs-17Calibarase) (4) It has good water resistance and is suitable for waterproof walls, floor coverings, and other decorative materials, has some hygroscopicity, and has the insulation properties described below as well as prevents condensation. It absorbs sweat, etc. on the surface 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 molding shrinkage and no shrinkage or expansion due to temperature changes after molding, making it suitable for decorative walls, decorative flooring, or as a decorative material for fittings such as sliding doors. , exactly on the stake base, i.e.
It can be applied without expansion or contraction, and it is a good decorative panel material without causing any wrinkles or pulling on the surface of the 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, because its surface friction resistance is close to that of wood, it has been made into a panel material with an optimal surface for use as a decorative flooring material, decorative wall material, or decorative furniture material.

(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 structure, operation, and effect described above,
It has been used in a wide range of applications as a panel material that can be easily and reliably formed into a desired shape, and as a robust panel that has excellent abrasion resistance and decorative surface characteristics.

[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 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... Plate, 3
. . . press device, 4 . . . 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 warm temperature range to form neutralized fine aggregate with pH 6 to PH 7. Next, this formed aggregate is mixed with vinyl chloride or other resin material to form a film or sheet-like wood decorative plate. The process of forming, reheating the wood decorative plate, attaching the decorative plate to the surface of a synthetic resin plate having a mesh-like partition wall in the thickness direction, and applying pressure and molding from above the surface of the attached decorative plate. A method for forming a decorative panel, which is characterized by a process of forming and a process of forming a decorative panel. 2. The method for forming a wooden decorative panel according to claim 1, wherein the mesh partition wall of the plate has a honeycomb shape. 3. 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 plates. 4. A wood-like decorative panel according to claim 1, characterized in that the aggregate is mixed into a resin material in a range of 20o/wt to 60o/wt to form a sheet-like decorative plate. Molding method. 5. A wood-like decorative panel according to claim 1, characterized in that the aggregate is mixed into a resin material in a range of 5o/wt to 40o/wt to form a film-like decorative panel. Molding method. 6. The method for forming a wood-like decorative panel according to claim 1, wherein the aggregate has a particle size of 100 to 150 mesh and a water content of 5 o/wt or less.