JPH04284234A - Composite panel - Google Patents

Abstract

PURPOSE:To manufacture a woody composite panel of superior dimension stability, resistance to wear and resistance to scratching to be used for a wall material, a floor covering material and the like. CONSTITUTION:A woody composite panel is manufactured by integrally bonding a woody plate 4 on one face or both faces of a three-layer structure composite material composed of reinforcing fiber 2, a surface layer composed mainly of inorganic powder and thermosetting resin and a core layer 6 composed mainly of an inorganic light aggregate 3, inorganic powder and thermosetting resin.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wood composite panel that is used for wall materials, flooring materials, etc. and has excellent dimensional stability, fire resistance, and scratch resistance.

0002

[Prior Art] In general, wood materials are materials with excellent workability and interpersonal feel, but they have the disadvantage that the material expands and contracts significantly due to water absorption and moisture absorption, and is prone to warping, violent cracking, etc. due to long-term use. . Therefore, in the prior art, measures such as lining, resin impregnation, and painting have been taken to eliminate these drawbacks, but these are not perfect in practical terms, and new improvements are being sought.

0003

SUMMARY OF THE INVENTION It is an object of the present invention to solve these drawbacks of wood materials and to provide a composite panel with excellent dimensional stability, fire resistance, and scratch resistance.

0004

[Means for Solving the Problems] In order to solve the above-mentioned problems, the present invention has been researched and has developed a surface layer mainly composed of reinforcing fibers, an inorganic powder, and a thermosetting resin, an inorganic lightweight aggregate, and an inorganic material. It has been demonstrated that a wood composite panel with excellent dimensional stability can be obtained by bonding and integrating wood boards on one or both sides of a three-layer composite material consisting of powder and a core layer mainly composed of thermosetting resin. This is what I found.

The present invention will be explained in detail below with reference to the drawings. In the drawings, 1 is a mixture of inorganic powder and thermosetting resin, 2 is a reinforcing fiber, 3 is an inorganic lightweight aggregate, and 4 is a wood material. It is composed of a surface layer 5 and a core layer 6. Moreover, as the inorganic powder 1 according to the present invention,
Inorganic powders commonly used as thermosetting resin fillers, such as calcium carbonate, silica sand, alumina, mica, glass powder, glass balloons, fly ash, and sea sand, can be used individually or in combination. However, fly ash is particularly desirable in order to bring the machinability of the resulting material closer to that of wood materials and to obtain the necessary physical properties. Further, the thermosetting resin may be a general-purpose one such as phenol resin, urea resin, melamine resin, epoxy resin, or unsaturated polyester resin. The amount of thermosetting resin added varies depending on the type of inorganic powder and resin used, and also differs between the surface layer and the core layer, so it should be set depending on each case, but it should be determined based on the required performance. From the viewpoint of economy, it is desirable that the thermosetting resin be in the range of 10 to 50 parts per 100 parts by weight of the inorganic powder. Further, additives such as a water repellent and a lubricant can be added to the mixture 1 as required.

Next, as for reinforcing fibers 2, there are inorganic fibers such as glass fiber, rock wool, carbon fiber, and metal fiber, and organic fibers such as nylon fiber, polyester fiber, vinylon fiber, and aramid fiber. From the viewpoint of molding operations, converged strand-like fibers are preferred. Furthermore,
As the inorganic lightweight aggregate 3, pumice, volcanic rubble, perlite, and expanded shale are used. The wood material 4 is a plate-shaped body such as various types of veneer or plywood, and the thickness of the wood board is not particularly limited, but it is preferable that the thickness is in the range of 0.2 mm to 5 mm to maintain the feel of wood and to maintain the dimensions. This is desirable from the viewpoint of stability effects.

Next, an example of the means for manufacturing the panel of the present invention will be described. A thermosetting resin is blended with an inorganic powder, and the two are mixed, stirred, or kneaded. In the case of liquid resin, the solvent is evaporated and adjusted until the required fluidity is achieved, and a dry mixture 1 of inorganic powder and thermosetting resin is prepared. Next, reinforcing fibers 2 are added to this mixture 1, and a certain amount of the reinforcing fibers 2 are spread on a suitable release material to form a surface layer mat 5. At this time, especially when strand-shaped fibers are used, the mixture 1 is sprinkled on the release material without mixing the mixture 1 and the reinforcing fibers 2 in advance, and then the strand-shaped fibers are sprinkled, Furthermore, a mat in which the reinforcing fibers 2 are scattered on the mixture 1 can be formed by scattering the mixture 1 thereon again. Depending on this method, the fibers are not mechanically damaged and at the same time the degree of freedom in blending amount can be increased.

[0008] Next, inorganic lightweight aggregate 3 is blended with the mixture 1 of inorganic powder and thermosetting resin, and the mixture is spread on the surface layer mat consisting of the surface layer 5 to form a core mat consisting of the core layer 6. do. Further, a mat for the surface layer is spread thereon by the method described above, and then heated and compressed for a predetermined period of time using a hot press. The thermosetting resin is reacted and hardened by heating and compression, and the inorganic powder reduces voids, so that a three-layered composite in which reinforcing fibers and inorganic lightweight aggregate are firmly fixed is formed. The present invention is completed by bonding the wooden material 4 to one or both sides of this composite, but the method for doing so is to place the wooden material 4 on one or both sides and heat press the whole when forming the mat. They may be integrated during curing, or a wood veneer may be adhered to the cured composite using a suitable adhesive. In this way, a composite panel in which the wood materials 4 are bonded and integrated is manufactured.

[0009]

[Examples] The present invention will be explained in more detail with reference to Examples below. 74 parts by weight of fly ash with a Blaine value of 1500, 13 parts by weight of novolac type phenolic resin, 2
13 parts by weight of chopped glass fiber strands with a length of 5 mm were placed on a 1 mm thick veneer at 1.0 parts per square meter.
Spread 53 kg evenly to form a surface layer, then 50 parts by weight of volcanic debris dried and adjusted to a particle size in the range of 4 mm to 1 mm, 44.5 parts by weight of fly ash, 5 parts by weight of novolac type phenolic resin, and paraffin. 0.5 parts by weight is mixed and sprinkled on the surface layer to form a core layer. Furthermore, a surface layer is again sprinkled on top of this core layer to form a three-layered mat. The mat is inserted into a heat press and compressed for 10 minutes at a temperature of 150° C. and a maximum pressure of 15 kg/cm 2 to obtain a composite panel with a wood veneer integrally bonded to one side. The composite panel made in this way has the following properties. Thickness 13mm Specific gravity 0.80 Bending strength 150kg/cm2 Water absorption expansion coefficient
0.1% Processing rate Can be cut with a saw and fixed by nailing

0010

[Effects of the Invention] As described above, in the present invention, the inorganic composite portion absorbs water, and in addition to exhibits less expansion and contraction due to moisture absorption, the surface layer forms a three-layered layered structure reinforced with fibers. Because it is endowed with great rigidity, it suppresses dimensional changes due to water absorption and moisture absorption of the joined wooden parts, and suppresses the occurrence of warping, violent cracking, etc. even after long-term use. In addition, since the inorganic composite part contains a considerable amount of inorganic raw materials, its fire resistance is improved, and since it is harder than wood materials, the wood material bonded to the surface is given scratch resistance. . In particular, when fly ash is used as an inorganic powder, since fly ash is a relatively light powder that partially contains foamed balloon-shaped particles, it has machinability similar to that of wood materials. A composite panel with . Further, when a phenolic resin is used as the thermosetting resin, a composite panel particularly excellent in fire resistance can be obtained.

[Brief explanation of the drawing]

FIG. 1 is a front cross-sectional view showing the structure of a composite panel obtained by laminating wood materials according to the present invention.

[Explanation of symbols]

1. Mixture of inorganic powder and thermosetting resin, 2. Reinforcing fiber, 3. Inorganic lightweight aggregate, 4. Wood material, 5. Surface layer, 6. Core layer.

Claims (1)

[Claims] Claim 1: A surface layer mainly consisting of reinforcing fibers, inorganic powder, and thermosetting resin; a core layer mainly consisting of inorganic lightweight aggregate, inorganic powder, and thermosetting resin; A composite panel characterized by consisting of wood boards glued on one or both sides.