JPH0547361B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention can be used as a surface material for wooden fixtures such as tables, counters, furniture, and sounder cases, wooden building materials such as flooring and wall materials, and car interior fixtures. Regarding the manufacturing method of the decorative material that is preferably used, a plurality of sheets of thermosetting resin-impregnated paper are laminated, heated and pressed to form a thermosetting resin-impregnated paper laminated hardening material, and then this thermosetting resin-impregnated paper laminated hardening material A flat mixture obtained by molding a mixture of a large number of small pieces of wood and a curable resin liquid into a flat plate is layered on top, and these are heated and pressed to harden and mold the flat mixture to form wood pieces.
At the same time as making a synthetic resin composite decorative material, the wood pieces
The synthetic resin composite decorative material and the thermosetting resin-impregnated paper laminated hardened material are integrated into a laminated hardened molded product, and then the laminated hardened molded product and the substrate are bonded to form a wood piece/synthetic resin. The composite decorative material is reinforced to facilitate its handling and to prevent defects in the manufacturing of the decorative material.

[Conventional technology]

Conventionally, this type of decorative material was produced by
A decorative material is known, as described in Japanese Patent No. 17049, in which a colored opaque resin tank in which small pieces of wood are dispersed is provided on a substrate. This decorative material is made by mixing small pieces of wood with an uncured paste-like resin composition and kneading it, then molding the mixture into a flat plate, heating and pressurizing it using a hot press etc. to make it a solid, and then The surface of the object is ground with a sander, etc., the small pieces of wood are exposed on the surface, a colored opaque resin layer is formed by dispersing the small pieces of wood, and then this is attached to a substrate. The resulting wood grain pattern appears effectively on the surface of the decorative board without waste, resulting in a beautiful decorative material with accentuated wood grain.

[Problem to be solved by the invention]

However, the colored opaque resin layer dispersed in small pieces of wood in this decorative material, that is, the wood piece/synthetic resin composite decorative material, has the disadvantage that it is easily broken when handled, such as when pasting it to a substrate, and it is also prone to unevenness because it is heated and molded. It was hot.

Therefore, in the present invention, reinforcing properties and heat resistance are added to the wood piece/synthetic resin composite decorative material by providing a thermosetting resin-impregnated paper laminated hardening material on the back side of the wood piece/synthetic resin composite decorative material. The purpose is to provide a method for manufacturing decorative materials.

[Means to solve the problem]

In the present invention, a plurality of sheets of paper impregnated with a thermosetting resin are laminated, this is heated and pressurized to form a hardened thermosetting resin-impregnated paper laminate, and then a large number of wood When a mixture of small pieces and a curable resin liquid is formed into a flat plate, the resulting mixture is laminated, and these are heated and pressed to harden and mold the flat mixture to form a wood piece/synthetic resin composite decorative material. At the same time, the wood piece/synthetic resin composite decorative material and the thermosetting resin-impregnated paper laminated hardening material are integrated into a laminated hardened molded product, and then the laminated hardened molded product and the substrate are bonded. It was used as a solution.

[Effect]

When heating and pressing a mixture consisting of a large number of small pieces of wood and a curable resin liquid to make a composite decorative material of wood pieces and synthetic resin, the wood pieces and It can add reinforcement, heat resistance, and smoothness to synthetic resin composite decorative materials.

〔Example〕

FIGS. 1 and 2 show an example of the method for manufacturing the decorative material of the present invention in the order of steps.

First, a thermosetting resin-impregnated paper laminated hardening material 4 is prepared.

The thermosetting resin-impregnated paper laminate cured material 4 is a prepreg laminate made by laminating a plurality of prepreg sheets whose base material is impregnated with a curable resin liquid, and is a thermosetting resin-impregnated paper laminate cured product. It is.

In addition, thermosetting resins that are in a liquid state before curing are mainly used as the curable resin liquid, such as unsaturated polyester resins, polyurethane resins, diallyl phthalate resins, epoxy resins, silicone resins, phenolic resins, and acrylic resins. .

The work of impregnating base materials with these curable resin liquids can be carried out by, for example, preparing a constant temperature layer filled with the uncured curable resin liquid, and immersing each base material in it. do by doing. The dipped base material is moved at a speed of about 5 to 10 m/min for continuous impregnation. Next, each base material impregnated with the resin liquid was taken out from the constant temperature layer, and
Drying is performed at a temperature of 90 to 100°C for approximately 5 to 10 minutes to create a prepreg sheet. and,
These prepreg sheets are laminated and heated and pressurized.Prior to this, they are allowed to stand at a temperature of 15 to 30°C for about 3 to 4 minutes to advance the curing of the curable resin and the impregnating resin liquid. It increases the viscosity, makes handling easier, and can also remove air bubbles in the impregnated resin liquid. The heating and pressing is performed using a well-known heating and pressing means such as a hot press, and the pressure is 10 to 20 MPa.
It is carried out at a temperature of 130 to 150°C and for about 10 to 20 minutes. By this heating and pressurization, the plurality of prepreg sheets are fixed and integrated, the impregnated resin is cured, and a thermosetting resin-impregnated paper laminated cured material 4 is obtained.
Here, the thickness of this thermosetting resin-impregnated paper laminated hardened material 4 is preferably about 0.3 to 2 mm, and if it is less than 0.3 mm, it will be too thin, and later it will be simultaneously applied to the wood piece/synthetic resin composite decorative board 1. When pasted, no reinforcing effect can be obtained, and if it is thicker than 2 mm, it may cause warping.

On the other hand, a mixture of resin composition 2 and wood chips 3 is prepared. First, an uncured paste resin composition 2, which is a curable resin liquid, is prepared.

For this resin, a thermosetting resin is used in the same manner as that used for forming the thermosetting resin-impregnated paper laminated hardening material 4, and additives such as fillers and colorants are added as necessary to this resin. is added and used. Fillers used here include calcium carbonate, talc, titanium oxide, silica, and glass powder.
The blending amount is 100 to 100 parts by weight of resin liquid.
It is said to be around 400 parts by weight. Further, the colorant is preferably a dye, pigment, or the like having a yellow, brown, or tan color similar to the color of the wood piece 3, but other colors may be used. The amount added may be within a normal range and is not particularly limited.

The small pieces of wood 3 used include small pieces of wood such as hardwoods such as black tongue, beech, oak, horse chestnut, Japanese ash, ash, maple, birch, and oak, and softwoods such as cedar, cypress, pine, spruce, and agathis. The shape is not particularly limited. Further, the size of the small piece of wood 3 is, when the shape is a rectangular parallelepiped, width 3 to 7 mm, preferably 5 to 6 mm, length 3 to 20 mm, preferably 12 to 20 mm.
mm, thickness 0.2-3 mm, preferably 0.2-1 mm, width 20-25 mm, length 20-100 mm, preferably 30
~60mm, thickness 0.2~3mm, preferably 0.2~1mm flat is desirable, and if it is cylindrical, diameter 5
~100mm and a thickness of about 0.2~5mm, and if it is a crushed piece, the width is 1~4mm and the length is 3~30mm, preferably 5~
30 mm and a thickness of 0.2 to 3 mm, preferably about 0.2 to 1 mm. Further, the wood pieces 3 may include wood pieces of different species, wood pieces of different colors, etc. In addition, the small pieces of wood 3 may be dimensionally stabilized if necessary, or organic halogen preservatives may be mixed into polyethylene glycol or liquid resin to stabilize the dimensions. Treatment and preservative treatment can also be carried out at the same time. Further, the wood pieces 3 may be partially or entirely colored in various tones such as black or brown, but it is also preferable to take advantage of the natural color of the wood. For the coloring treatment, a method is used in which a large number of small pieces of wood are immersed in a coloring liquid 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 may be dissolved in various liquid resins, and the coloring treatment may be performed simultaneously with the dimensional stabilization treatment.

Then, a large number of small wood pieces 3 are added to the resin composition 2.
After mixing and kneading, this mixture is molded into a flat plate to obtain a flat mixture.

Next, this plate-shaped mixture is laminated on the thermosetting resin-impregnated paper laminated hardening material 4, and heated and pressed using a hot press or the like to harden and mold the plate-shaped mixture into a wood piece/synthetic resin composite decorative material. At the same time, this wood piece/synthetic resin composite decorative material 1 and a thermosetting resin-impregnated paper laminated hardened material 4 are integrated to form a laminated hardened molded product 5. The molding conditions for this laminated cured molded product 5, that is, the conditions for heating and pressing, are preferably about 1 to 3 MPa in pressure, 130 to 150° C., and about 10 to 60 minutes.

Here, the total exposed area of the small wood pieces 3 occupying the surface area of the wood piece/synthetic resin composite decorative material 1 is 10
~90%, preferably about 70~90%, and the thickness of this wood piece/synthetic resin composite decorative material 1 is 1~2%.
mm, preferably about 1 to 1.5 mm.

Next, the thus obtained cured laminated product 5 and a separately prepared thermosetting resin-impregnated paper laminated cured material 6 for balance are mixed together with a substrate 7 interposed therebetween to form the thermosetting resin of the cured laminated product 5. Impregnated paper laminated hardening material 4
are laminated so as to be in contact with the substrate 7, adhesive layers 8, 8 are provided between each, and the adhesive layers 8, 8 are bonded under heat and pressure to obtain the intended decorative material 9.

In this heat-pressure bonding, urea adhesive is used for the adhesive layer 8, at a temperature of 100 to 120°C and a pressure of 0.1 to 1 MPa.
This is done by heating and pressurizing for about 1 to 3 minutes using a hot press or the like under these conditions.

The thermosetting resin-impregnated paper laminated hardening material 6 for balance used here is the same as the thermosetting resin-impregnated paper laminated hardening material 4, and its molding method is as follows. According to.

The substrate 7 is made of wood such as lauan plywood, particle board, lumber core board, solid wood, or resin such as fiber-reinforced synthetic resin board, and has a thickness of about 15 to 30 mm. Preferably.

For the decorative material 9 obtained in this way,
When heating and pressurizing a mixture consisting of a large number of wood pieces 3 and a curable resin liquid to form a wood piece/synthetic resin composite decorative material 1, by curing and molding it together with a thermosetting resin-impregnated paper laminated hardening material 4. Since it is intended to reinforce the wood piece/synthetic resin composite decorative material 1,
The desired decorative material 9 can be easily produced without any defects and with heat resistance and rigidity.

In addition, the upper surface of the laminated cured molded product 5, that is, the surface of the wood piece/synthetic resin composite decorative material 1, is ground by sanding or the like to form a polished surface, and a transparent synthetic resin film is further applied to the surface of this polished surface. It is also possible to form This transparent synthetic resin film can be formed by laminating or pressing transparent resin films, or by applying a transparent paint made of unsaturated polyester resin, polyurethane resin, diallyl phthalate resin, epoxy resin, etc. to a thickness of about 50 to 300 μm. A coating method is adopted. in this way,
When the transparent synthetic resin film is formed, the polished surface 5, which used to have a dry white appearance, becomes a wet color, improving the aesthetic appearance.

It is also possible to prevent the color pattern from fading by applying a transparent UV-shielding paint mixed with a UV-absorbing agent to the polished surface. Thickness 100~
It is coated using a well-known coating method such as a flow coater method or a spray method so that the thickness is approximately 300 μm, and the surface of the obtained transparent synthetic resin layer is air-sanded, wet-sanded, and buffed and polished to give a mirror finish. The decorative material 9 may be completed by applying a finish. in this way,
When a transparent synthetic resin layer is provided to achieve a mirror finish, this mirror resin layer plays the role of a lens, and the lens effect increases the three-dimensional appearance of the decorative material 9.

〔Effect of the invention〕

The method for manufacturing the decorative material of the present invention involves laminating a plurality of sheets of paper impregnated with a thermosetting resin, heating and pressing them to form a hardened laminated paper material impregnated with a thermosetting resin, and then placing the hardened paper laminated material impregnated with a thermosetting resin on the hardened material. Then, a mixture of a large number of small pieces of wood and a curable resin liquid is formed into a flat plate shape, and the resulting mixture is laminated, and these are heated and pressed to harden and mold the flat mixture to form pieces of wood.
At the same time as making a synthetic resin composite decorative material, the wood pieces
The synthetic resin composite decorative material and the thermosetting resin-impregnated paper laminated hardened material are integrated to form a laminate cured molded product, and then the laminated hardened molded product and the substrate are bonded. Because the thermosetting resin-impregnated paper laminated hardening material is simultaneously pasted on the back side of the wood piece/synthetic resin composite decorative material, it has a reinforcing effect, compared to when handling the wood piece/synthetic resin composite decorative material alone. It is difficult to break, and the unevenness of the wood piece/synthetic resin composite decorative material is reduced, so it is possible to provide a decorative material with improved heat resistance, rigidity, and smoothness, and a method for producing the same.

[Brief explanation of the drawing]

FIG. 1 and FIG. 2 are schematic cross-sectional views showing an example of the manufacturing method of the decorative material of the present invention in the order of steps. 1... Wood piece/synthetic resin composite decorative material, 3... Wood piece, 4... Thermosetting resin impregnated paper curing material, 5...
...Laminated cured molded product, 7...Substrate, 9...Decorative material.

Claims (1)

[Claims] 1. A plurality of sheets of thermosetting resin-impregnated paper are laminated, and this is heated and pressed to form a thermosetting resin-impregnated paper laminated hardening material, and then on this thermosetting resin-impregnated paper laminated hardening material, A mixture of a large number of wood pieces and a curable resin liquid is formed into a flat plate shape, the resulting mixture is laminated, and these are heated and pressurized to harden and mold the flat mixture to form a wood piece/synthetic resin composite makeup. At the same time, the wood piece/synthetic resin composite decorative material and the thermosetting resin-impregnated paper laminated hardened material are integrated into a laminated hardened molded product, and then the laminated hardened molded product and the substrate are bonded. A manufacturing method for decorative materials characterized by: