JPH07205108A - Woody decorative laminate and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain a woody decorative laminate which can satisfy consumers in terms of quality, by coating the surface of resin impregnated veneer with a curing agent containing radical polymerization type resin layer. CONSTITUTION:Resin impregnated veneer 5 prepared by impregnating woody veneer with a resin solution not containing a curing agent is laminated on a base material l with a resin solution 3 containing the curing agent and the surface of the resin impregnated veneer 5 is coated with the resin solution 3 containing the curing agent. When a pressure is applied in a state of the resin impregnated veneer 5 held between the resin solutions 3 containing the curing agent, parts of the resin solutions 3 containing the curing agent are pressed into the resin impregnated veneer 5 from both of the surface and the rear thereof. A part of the resin solution 3 containing the curing agent, which is applied on the base material 1, is transferred also into the base material 1. Thereafter curing is effected on the basis of the principle of radical polymerization, and integration with the base material 1. Thereafter curing is accomplished. Since the surface is coated with a curing agent containing radical polymerization type resin layer, according to this constitution, adhesion between layers is good and the quality such as water resistance is excellent.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material, and more particularly to a wooden decorative material using a wood veneer of natural wood, and a simple production method thereof.

[0002]

2. Description of the Related Art Conventionally, a decorative material using natural wood is used for horizontal surface members such as tables and counters and vertical surface members such as wall materials in order to adapt to a residential environment where woody feeling is respected. Therefore, there is a demand as a product that has a greater depth than the so-called decorative board that expresses the texture of wood using printing paper and that makes the most of the properties of the material. The decorative material using this natural wood is (1) a natural wood treated by a conventional method, and a thin sliced veneer is attached to a base material such as plywood or particle board with an adhesive. And then open the surface of the veneer.
A method of coating with Burley paper is known. A method is also known in which a wood-based veneer is impregnated with an amino-based resin and is integrated with a base material by heating and pressing.

On the other hand, (2) thickness 2 obtained from wood
The so-called WPC technique of treating a flat plate of about 0 to 60 mm with PEG, MMA, etc. has been extensively researched and developed as a means for compensating for the drawbacks of wood and improving durability. This WPC technology typically uses a vacuum pressurizer. Also, as seen in phenolic resin reinforced wood, it can be used as a phenotype on wood veneer with a thickness of 0.5-2.0 mm.
A method is also known in which a resin is immersed at room temperature and atmospheric pressure.

[0004]

However, in the prior art (1) of the prior art in which the veneer is not treated with a resin, the adhesive and the resin contained in the overlay paper are not used. When trying to transfer it into the plate, it is inevitably heated (10
(0-160 ℃) and pressurization (20-80kg / cm ² ) operation not only makes the equipment large-scale, but also the water contained in the veneer loses a place to escape, and when it becomes a product, it easily causes blister. was there. Further, when the resin does not sufficiently migrate to the veneer, the quality when it is made into a product, for example, water resistance, light resistance, etc., is liable to be inferior and the user's needs are not always satisfied. . In addition, even if the veneer is treated with an amino resin, it is necessary to transfer the amino resin contained in the veneer to the base material in the same manner. In addition to the above, there is a problem that water vapor generated when the amino resin is cured and condensed loses an escape area, causes blister, and does not finish the gloss of the surface of the product uniformly.

On the other hand, in the latter (2) of the prior arts, when the resin for WPC is attempted to penetrate into the flat plate having a thickness of 20 to 60 mm, it takes several tens of minutes to several hours and a considerably reduced pressure is applied. Not only was it time consuming and consumed a large amount of resin, but it was almost impossible to completely penetrate the interior. Therefore, if a processed product is manufactured using this as a core material, the dimensional stability due to temperature and humidity tends to be poor, and even if it penetrates to a considerable inside of the flat plate, the solvent is removed and the resin for WPC is cured. However, there is a problem in that a heavy load must be transported from the work surface because a heating device is required. Further, in the phenol resin reinforced wood, a great deal of time and energy are required for the drying step, and a heating and pressing operation is required to cure the resin.

[0006] That is, the present invention makes effective use of valuable forest resources in recent years when environmental protection is sought, and obtains a wooden decorative material which can satisfy consumers in terms of quality, and facilitates this wooden decorative material. The purpose is to manufacture and reduce the work.

[0007]

Means for Solving the Problems The present invention has been studied in view of the above circumstances, and a radical-polymerizable resin liquid containing no curing agent is applied to the surface of a substrate on which the radical-polymerizable resin liquid containing a curing agent is applied. The above object is solved by placing a resin-impregnated veneer that has been impregnated, and using a wood decorative material that is pressure-integrated by coating the surface of the resin-impregnated veneer with a hardener-containing radical polymerization type resin layer. To be done.

Further, (a) a step of impregnating a wood veneer with a radical-polymerizable resin solution containing no curing agent to obtain a resin-impregnated veneer, (b) a curing agent for the radical-polymerizable resin solution on the surface of a substrate. The step of applying the curing agent-containing radical-polymerizable resin solution containing (c), the resin-impregnated veneer is placed on the application surface, and the curing-agent-containing radical-polymerizable resin solution is placed on the surface of the resin-impregnated veneer. The above-mentioned object is solved by a manufacturing method including a step of applying, (d) placing a plastic film, applying pressure, and then removing the plastic film. Hereinafter, the present invention will be described in detail.

The wood veneer used in the present invention is made of a raw material such as taro, shioji, oak, Japanese cypress, walnut, maple, cheek, beech, rosewood, mackerel, duck, etc. by a conventional method. After boiling, cutting can be applied using a rotary racer, a slicer or the like so as to have a thickness of 0.1 to 3.0 mm. If the thickness is less than the lower limit, the handling property is poor and it is easy to break, and if it exceeds the upper limit, the penetration of the radical polymerization type resin liquid is deteriorated, which is not preferable.

As the radical polymerization type resin which is the main component of the resin liquid used for impregnation and coating, the presence of an organic peroxide such as unsaturated polyester resin, vinyl ester resin, methacrylic resin or diallyl phthalate resin. A prepolymer that polymerizes below can be applied.

The unsaturated polyester resin is a divalent alcohol such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-butylene glycol or neopentyl glycol.
And at least one dibasic acid such as maleic acid, maleic anhydride, fumaric acid, isophthalic acid, terephthalic acid, phthalic acid, phthalic anhydride, adipic acid, etc., and react by a conventional method. You can apply what you let.

Regarding the vinyl ester resin, epoxy compounds such as epi-bisglycidyl ether, novolac type glycidyl ether, brominated glycidyl ether, and the like,
What was made to react with unsaturated monobasic acid, such as acrylic acid, methacrylic acid, and crotonic acid, by a conventional method can be applied.

As the methacrylic resin, a prepolymer of methyl methacrylate or a solution of polymethyl methacrylate dissolved in a monomer of methyl methacrylate can be applied.

The resin liquid to be impregnated into the wood veneer is a radical polymerization type resin such as unsaturated polyester resin or vinyl ester resin, and a polymerizable monomer such as styrene, orthochlorostyrene, diallyl phthalate or methyl methacrylate, Also, a curing accelerator such as a cobalt complex salt may be added if necessary, and by not containing a curing agent, a large volume of resin liquid for impregnation can be stored for several months, and resin-impregnated veneer can be stored well. Becomes It is desirable to adjust the viscosity to 1.5 to 2.0 P / 25 ° C. so that the impregnated amount is 20 to 220% by weight in terms of solid content. Here, the impregnated amount indicates the impregnated weight of the resin when the weight of the wood veneer is 1. If the impregnated amount is less than the lower limit, whitening tends to occur, and physical properties such as heat resistance and dimensional stability tend to deteriorate. If it exceeds the upper limit, it is likely to cause silver eyes, and it is not good in terms of cost.

With respect to the curable agent-containing radical-polymerizable resin liquid to which a curing agent has been added, the above-mentioned polymerizable monomer and curing accelerator are added to the radical-polymerizable resin such as the unsaturated polyester resin or vinyl ester resin described above, Furthermore, a curing agent,
For example, an organic peroxide such as benzoylperoxide, methyl ethyl ketone peroxide, cyclohexanone peroxide, acetylacetone peroxide, and acetoacetic acid peroxide is added to have a viscosity of 2.0 to 3.0.
Those adjusted to P / 25 ° C can be applied. The amount of the curing agent added may be 0.8 to 2.0% by weight of the total amount of the resin liquid, and if it does not reach the lower limit, the crosslinking of the resin is insufficient and the resin-impregnated veneer and the plate-shaped substrate are bonded. And the surface properties of the wooden decorative material tend to be inferior. On the other hand, if the amount exceeds the upper limit, the viscosity of the resin liquid increases and the storage stability tends to deteriorate.

If the resin liquid used to impregnate the wood veneer is the same as the radical polymerization type resin or the polymerizable monomer used in the resin liquid applied to the surface of the substrate and the resin-impregnated veneer, the interlayer adhesion is excellent. It is convenient for managing the resin liquid.

Further, an ultraviolet absorber or an air blocking agent may be added to each resin liquid, and as the ultraviolet absorber, a benzotriazole type, a hydroxyaryl type compound, a benzotriazole type compound or air is used. Paraffin wax may be used as the blocking agent.

Unsaturation obtained by reacting a radical-polymerizable resin liquid or a radical-polymerizable resin liquid containing a curing agent with melamine, formaldehyde and 2-hydroxy (meth) acrylate for the purpose of improving surface properties such as hardness. It does not matter if melamine resin is added. In this case, the amount of the unsaturated melamine resin added is preferably 10 to 60 parts by weight with respect to 100 parts by weight of the radical polymerization type resin liquid, and if the addition amount is less than the lower limit, the coating hardness tends to be poor, and
If it exceeds the upper limit, the impact strength tends to deteriorate.

The base material may be plywood or particle board.
It is possible to use wood-based base materials such as glass and medium-density fiberboard, gypsum boards, inorganic base materials such as calcium silicate, or composite materials thereof.

The wooden decorative material is prepared by coating the surface of the base material with 150 to 200 g / m ^{2 of a} radical-polymerizing resin solution containing a curing agent, placing a resin-impregnated veneer, and further containing a curing agent on the resin-impregnated veneer. The radical polymerization type resin liquid is applied at 200 to 300 g / m ² and a plastic film such as vinylon or polyethylene terephthalate is arranged, and pressure is applied to spread the curing agent containing radical polymerization type resin liquid, and after curing, Obtained by removing the plastic film. As a means for applying pressure, a rubber roller or a pressure device is used, and the temperature is 20 to 5
Pressure may be applied at 0 ° C. for 2 to 60 minutes.

At this time, (a) a step of impregnating a wood veneer with a radical-polymerizable resin liquid containing no curing agent to obtain a resin-impregnated veneer, (b) a radical-polymerizable resin containing a curing agent on the surface of a substrate. Regarding the step of applying the liquid, any of them may be preceded and may be performed in parallel.

In addition, in order to make up for the lack of thickness, a plurality of wood veneers are used, and (a ') a plurality of wood veneers are impregnated with a radical-polymerizable resin liquid containing no curing agent to obtain resin-impregnated veneers. (B) applying a curing agent-containing radical polymerization type resin liquid to the surface of the base material, (c ') laminating a plurality of the resin-impregnated veneers on the application surface, and A wooden decorative material is obtained by a manufacturing method including a step of applying a radical-polymerizable resin liquid containing a curing agent on the surface of a plate, (d) placing a plastic film, applying pressure, and then removing the plastic film. It doesn't matter.

[0023]

[Function] A resin-impregnated veneer in which a wood veneer is impregnated with a resin solution containing no curing agent is laminated on a substrate with a resin solution containing a curing agent, and the surface of the resin-impregnated veneer is a resin containing a curing agent. Covered with liquid. When pressure is applied while the resin-impregnated single plate is sandwiched by the resin liquid containing the curing agent, a part of the resin liquid containing the curing agent is pressed into the resin-impregnated single plate from both front and back surfaces. Further, a part of the resin liquid containing the curing agent applied to the base material is also transferred to the base material. Then, it cures based on the principle of radical polymerization and becomes integral with the substrate.

Radical polymerization type resins such as unsaturated polyester resins and vinyl ester resins are cured at room temperature and therefore can be manufactured at low pressure (0.01 to 3 kg / cm ² ) without requiring heating. When the resin cures, no gas is generated, so no blistering occurs and the gloss is evenly finished.

A detailed description will be given below with reference to examples.

【Example】

Example 1 3 mol of phthalic anhydride, 5 mol of maleic anhydride, 6.5 mol of propylene glycol, 1.5 mol of diethylene glycol
62 parts by weight of unsaturated polyester resin having an acid value of 25, which was obtained by carrying out a dehydration reaction at 200 to 220 ° C., in 0.005 parts by weight of hydroquinone, 38 parts by weight of styrene, and 2 parts by weight of 8% cobalt octylate. A part was mixed and dissolved to obtain a resin liquid (A) composed of an unsaturated polyester resin having a viscosity of 2.0 P / 25 ° C. and a resin content of 62%. Next, the impregnation amount of the resin liquid (A) was 1 in a 0.6 mm thick oak veneer.
The resin was impregnated at 30 g / m ² to obtain a resin-impregnated single plate.
Further, a resin liquid (A ′) comprising 100 parts by weight of the resin liquid (A) and 1 part by weight of 55% methyl ethyl ketone peroxide.
Is applied to a base material consisting of a water-resistant plywood with a thickness of 6 mm in an amount of 200
It was applied so as to be g / m ^2, and a resin-impregnated single plate was placed.
After that, the resin liquid (A ') is applied to the surface of the resin-impregnated single plate so that the coating amount becomes 250 g / m ^2, and after covering with a vinylon film, the pressure becomes 0.5 kg / cm ^2. Then, it was pressure spread with a rubber roller, left at 25 ° C. for 1 hour, and then the vinylon film was removed to obtain the woody decorative material of Example 1.

Example 2 50 parts by weight of the same unsaturated polyester resin as in Example 1, 50 parts by weight of unsaturated melamine resin, 5 parts by weight of styrene, and 2 parts by weight of 8% cobalt octylate were mixed and dissolved to give a viscosity of 2.2P. A resin liquid (B) of / 25 ° C was obtained. Next, the impregnation amount of the resin liquid (B) was 130
The resin was impregnated to obtain g / m ² to obtain a resin-impregnated veneer. Further, a resin solution (B ') obtained by adding 1 part by weight of methyl ethyl ketone peroxide to 100 parts by weight of the resin solution (B) was applied to a base material made of a water-resistant plywood having a thickness of 6 mm at a coating amount of 200 g / m ^2.
And a resin-impregnated single plate was placed. Then, the resin liquid (B ') is applied to the surface of the resin-impregnated veneer so that the applied amount is 250 g / m ^2, and after covering with a vinylon film, the pressure is adjusted to 0.5 kg / cm ^2. Then, it was pressure spread with a rubber roller, left at 25 ° C. for 1 hour, and the vinylon film was removed to obtain a wood decorative material of Example 2.

The test results are shown in Table 1.

[Table 1]

The test method was as follows. Pencil hardness: It was carried out based on JISK5400. Water resistance: It was carried out based on the Japan Agriculture and Forestry Standard JAS water resistance A test. Contamination: Conducted based on Japan Agriculture and Forestry Standard JAS Contamination A test. Adhesion: It was carried out based on the Japan Agricultural Standard JAS plane tensile test. Light resistance: carried out based on JISK6902.

[0029]

[Effect] In the wood decorative material obtained by the present invention, a wood veneer is impregnated with a radical-polymerizable resin solution containing no curing agent, and the resin-impregnated veneer is laminated with the base material by the radical-polymerizing resin solution containing a curing agent. Since they are integrated and the surface is coated with a curing agent-containing radical polymerization type resin layer, the adhesion of each layer is also good,
Excellent quality such as water resistance.

Further, since the resin liquid used for impregnation does not contain a curing agent, it has good storability and the resin-impregnated single plate can be stored.

In the method for producing a wood-based decorative material of the present invention, since it can be produced at a pressure of 0.01 to 3 kg / cm ^{2 at} room temperature without a heating and pressurizing operation such as hot press molding, it can be produced by heating an organic peroxide. The wood veneer does not discolor, expensive equipment is not required, and the burden on the operator is reduced.

Further, the resin liquid for impregnation and the resin liquid containing a curing agent, which substitutes for the adhesive and coats the surface of the resin-impregnated veneer, are made of the same radical polymerization resin or polymerizable monomer as the raw materials. If so, there is no waste in managing the raw materials, and each resin liquid can be effectively used.

[Brief description of drawings]

FIG. 1 is a sectional view showing the construction of a wood-based decorative material of the present invention.

[Explanation of symbols]

1 Base Material 3 Hardening Agent-Containing Radical Polymerization Resin Layer 5 Resin-Impregnated Wood Veneer Impregnated with Curing Agent-Free Radical Polymerization Resin Liquid 7 Wood Decorative Material

Claims (2)

[Claims] 1. A resin-impregnated veneer impregnated with a radical-polymerizable resin liquid containing no curing agent is placed on the surface coated with a radical-polymerizable resin liquid containing a curing agent on a substrate. A wood decorative material, the surface of which is coated with a radical-polymerizable resin layer containing a curing agent. 2. A method for producing a wood-based decorative material, which comprises the following steps (a) to (d): (A) a step of impregnating a wood veneer with a radical-polymerizable resin liquid containing no curing agent to obtain a resin-impregnated veneer; (b) a curing agent obtained by adding a curing agent to the radical-polymerizable resin liquid on the surface of a substrate. A step of applying the radical-polymerizable resin solution containing a resin, (c) placing the resin-impregnated veneer on the application surface, and applying a radical-polymerizable resin solution containing the curing agent to the surface of the resin-impregnated veneer; d) A step of placing a plastic film, applying pressure, and then removing the plastic film.