JPH0433270B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is suitable for use in wooden fixtures such as tables, counters, furniture, audio equipment cases, wooden building materials such as flooring and wall materials, and car interior fixtures. Regarding the method of manufacturing a wood-based surface material, a kneaded material consisting of a curable resin liquid and a filler is made into a flat plate, and 10 to 90% of the surface area of the kneaded material is covered with the surface of this flat kneaded material. By scattering small pieces of wood, applying heat and pressure, and then grinding the surface, the wood pieces are uniformly dispersed and manufactured easily.

[Conventional technology]

As a method for manufacturing such a wood-based surface material, there is a method previously proposed by the present applicant in Japanese Patent Application No. 161564/1983. This method involves mixing small pieces of wood with an uncured resin liquid, pouring this mixture into a mold or the like, leveling it out, heating and pressurizing it to solidify it, and then grinding the surface of the solidified product.

[Problem that the invention seeks to solve]

However, in this manufacturing method, small pieces of wood are added to the uncured resin liquid and mixed by stirring, so the resin liquid and the small pieces of wood are not mixed uniformly, making it difficult to uniformly disperse the small pieces of wood in the resin. There was a problem. This is because the size of the wood pieces is large, ranging from 3 to 50 mm, and there is a difference in specific gravity between the resin liquid and the wood pieces.

[Means for solving problems]

In this invention, a kneaded product of a curable resin liquid mixed with a filler is formed into a flat plate, and small pieces of wood are sprinkled on top of this so that 10 to 90% of the surface area of the flat kneaded product is covered, and then heated. The solution was to apply pressure and grind the surface.

The resin liquid used in this invention includes uncured thermosetting resins that are in a liquid state before curing, such as unsaturated polyester resins, polyurethane resins, diallyl phthalate resins, epoxy resins, silicone resins, phenolic resins, and acrylic resins. State resin liquid is suitable.

A filler is added to this resin liquid and kneaded. As fillers, calcium carbonate, talc, titanium oxide, silica, glass powder, etc. are used. The blending amount of filler is 100 to 100 parts by weight of resin liquid.
It is said to be around 400 parts by weight. The kneaded product consisting of the resin liquid and the filler therefore has a high viscosity and is approximately paste-like. A curing agent for the resin is added to this kneaded material, and additives such as a coloring agent and a stabilizer can be added as necessary.

Next, as shown in FIG. 1, this kneaded material is poured into a shallow-bottomed mold 1 and leveled using a silicone roller, a trowel, etc. to form a flat plate-shaped kneaded material 2. Of course, it is also possible to form a flat plate without using the mold 1.
The thickness of this flat plate-like material is about 1 to 2 mm, preferably about 1 to 1.5 mm.Next, while the kneaded material 2 is in an uncured state,
As shown in FIG. 2, small pieces of wood 3 are scattered on a flat object. The small pieces of wood 3 are small pieces of wood such as hardwoods such as black tongue, beech, oak, horse chestnut, Japanese ash, maple, birch, and oak, and softwoods such as cedar, cypress, pine, spruce, and agathis,
The shape is not particularly limited, but various shapes may be used, such as small pieces formed by cutting such as a plate, rectangular parallelepiped, cube, or granule, or small pieces crushed by mechanical impact or roller pressure. shape is used. The size of this small piece 3 ranges from 3 to 7 mm in width, 3 to 20 mm in length, and 0.2 to 3 mm in thickness to 20 to 25 mm in width and 25 to 25 mm in length when its shape is a rectangular parallelepiped.
A flat one with a diameter of 20 to 100 mm and a thickness of 0.2 to 3 mm is preferable, and a cylindrical shape with a diameter of 5 to 100 mm and a thickness of 0.2 to 3 mm is preferable.
The diameter is about 5 mm, and if it is a crushed piece, it is desirable that the width is 1 to 4 mm, the length is 3 to 30 mm, and the thickness is about 0.2 to 3 mm. Further, the wood pieces 3 may contain pieces of different resins, different colors, etc. Also,
The small pieces of wood 3 may be subjected to dimensional stabilization treatment if necessary. Dimensional stabilization treatments include acetylation treatment in which small pieces of wood are treated with acetic anhydride, impregnation with polyethylene glycol or polypropylene glycol, liquid phenolic resin, unsaturated polyester resin, epoxy resin, silicone resin, urethane resin, acrylic resin, etc. There is a method of impregnating and solidifying the same type of resin as the curable resin liquid mentioned above. Alternatively, the dimensional stabilization treatment and the preservative treatment can be performed simultaneously by mixing an organic halogen preservative into the polyethylene glycol or liquid resin.

Further, the small piece of wood 3 may be partially or entirely colored in one or more different tones, such as black, such as black dun,
It is also preferable to make use of the natural color of the wood, such as the yellow of brick and paddocks, and the white of oak and beech. For the coloring treatment, a method is used in which a large number of small pieces of wood are immersed in a coloring solution in which a coloring agent such as a dye or pigment is dissolved in a solvent such as water or an organic solvent, and the concentration of the coloring agent is approximately 0.1 to 10% by weight. It is also possible to heat the coloring liquid to promote penetration of the coloring liquid, thereby producing a deep color. Further, during the dimensional stabilization treatment, a coloring agent can be dissolved in various liquid resins, and the coloring treatment can be performed simultaneously with the dimensional stabilization treatment.

The scattering of such small pieces of wood 3 is carried out as appropriate by using a coarse sieve or by directly scattering them by hand. The amount of the small pieces of wood 3... is 10 to 90% of the surface area of the flat object, preferably
It is estimated that 70-90% is covered.

After scattering the wood chips 3..., this will be heated and pressurized, but prior to this, the plate-shaped kneaded material 2 after scattering is left standing at a temperature of 15 to 30 ° C. for 3 to 4 hours, After curing the curable resin, kneaded material 2
It is also possible to increase the viscosity of the kneaded material 2, make it easier to handle, and remove air bubbles in the kneaded material 2.

The heating and pressing is performed using a well-known heating and pressing means such as a hot press, and the scattered wood pieces 3...
Place a release film and a backing plate on top, and apply a pressure of 0.5~
It is carried out under the conditions of 1.5 MPa, temperature of 100 to 130°C, and time of about 2 to 5 minutes. By this heating and pressurization, the wood pieces 3 scattered on the flat plate-shaped kneaded material 2...
As the kneaded material 2 is press-fitted into the kneaded material 2, the kneaded material 2 hardens, and a solidified material is obtained in which most of the individual wood pieces 3 are buried in the kneaded material 2.

Next, the surface of this solidified material is ground by various grinding means to make the surfaces of the solidified resin material and the buried wood pieces flush, and the wood pieces are exposed on the surface, as shown in FIGS. 3 and 4. The desired wooden surface material 4 as shown is obtained.

According to such a manufacturing method, since the small wood pieces 3 are scattered on the flat plate-shaped kneaded material 2, the small wood pieces 3 can be uniformly distributed on the kneaded material 2, and the small wood pieces 3 can be uniformly distributed. Dispersion becomes possible. In particular, since the small pieces of wood 3 are to be scattered, the degree of scattering can be adjusted by visual inspection, and the uniform dispersion of the small pieces of wood 3 can be easily measured. Furthermore, since it is a scattering method, the small pieces of wood 3 do not sink deeply into the flat kneaded material 2, and the small pieces 3 can be concentrated on the surface, reducing the amount of the small pieces of wood 3. However, it is possible to obtain a preferably thin plate-like wood-based surface material 4 with a beautiful surface. Note that the shape of this surface material is preferably formed into a flat plate shape, but it is not limited to this, and by changing the shape of the mold surface during heating and pressing, it can have a two-dimensional or three-dimensional curved surface. It is also possible to form composites of shapes.

The wood surface material 4 thus obtained is preferably adhesively laminated with a wood substrate such as plywood or particle port, or a resin substrate such as fiber-reinforced synthetic resin, and used for various products. In addition, since some or most of the small pieces of wood 3 are exposed in the wood surface material 4 due to the grinding process, the surface of this material is coated with a paint such as polyester resin or polyurethane resin to form a coating film. It is especially desirable to keep it.

〔Example〕

300 parts by weight of calcium carbonate and 1 part by weight of yellow pigment are mixed with 100 parts by weight of uncured unsaturated polyester resin liquid, kneaded, poured into mold 1, and smoothed with a roller to form a flat plate-shaped kneaded product 2 with a thickness of 1.5 mm. And so.

On the other hand, beech, oak, etc. are 10~20mm wide and 10~20mm long.
Cut into small pieces of 20 mm and 1 to 1.5 mm thick.
After drying, the wood pieces 3 were immersed in an uncured unsaturated polyester resin liquid, impregnated with the resin liquid, and allowed to stand at room temperature to be in a semi-hardened state.The wood pieces 3 were then scattered by hand onto the flat kneaded material 2. The amount of spraying was uniformly distributed so that 85 to 90% of the entire surface of the kneaded material 2 was covered. After this was left to stand at room temperature for 3 hours, it was heated and pressed in a hot press at a pressure of 1 MPa and a temperature of 100° C. for 5 minutes to form a solidified product. This material was sanded to form a solidified product. Grind this thing with a sander,
A wood-based surface material with a thickness of approximately 1.5 mm was obtained.

〔Effect of the invention〕

As explained above, the method for producing a wood surface material of the present invention involves forming a kneaded product containing a filler into a curable resin liquid into a flat plate, and then covering the kneaded product with 10 to 90% of the surface area of the flat plate-shaped kneaded product. Since the small pieces of wood are scattered so as to be hidden, then heated and pressurized, and the surface is ground, it is possible to easily measure the uniformity of the distribution of the small pieces of wood, and to adjust the amount of dispersion by visual inspection. In addition, the small pieces of wood are less likely to sink into the kneaded material and can be concentrated on the surface, resulting in the effect that the amount of small pieces of wood used can be reduced.

[Brief explanation of drawings]

1 to 3 are schematic cross-sectional views showing the steps of an example of the manufacturing method of the present invention, and FIG. 4 is a plan view showing a wood-based surface material obtained by the manufacturing method of the present invention. 1... Mold, 2... Flat kneaded material, 3... Small pieces of wood, 4... Wooden surface material.

Claims (1)

[Scope of Claims] 1 A kneaded product of a curable resin liquid mixed with a filler is formed into a flat plate, and 10 to 90% of the surface area of this surface is covered and hidden on the surface of this flat kneaded product. A method for producing a surface material, which comprises scattering small pieces of wood, heating and pressurizing the material to solidify the material, and then grinding the surface of the solidified material. 2. Claim 1, characterized in that after the small pieces of wood are scattered, they are allowed to stand still and then heated and pressurized.
Manufacturing method of the surface material described in section.