JPH09117903A - Wooden finishing material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a low cost wooden finishing material excellent in abrasion resistance by a method wherein a thermosetting resin-containing sheet under a prepreg state is piled on a resin impregnable supporting plate and a resin impregnable veneer is piled on the sheet so as to bond them together with a hot press. SOLUTION: A thermosetting resin-containing sheet 2 is pasted on a supporting plate 1 and a veneer 3 is pasted on the sheet 2 so as to bond them together with a hot press. In this case, as the supporting plate 1, a resin- impregnable material such as plywood, wooden fiber board, particle board or the like is used. Further, as the sheet 2, any thermosetting resin-impregnated sheet base material selected among paper, woven fabric and non-woven fabric is used. Accordingly, the thermosetting resin of the sheet 2 is infiltrated in the veneer 3 and hardens, resulting in improving the abrasion resistance of the veneer 3. Thus, a low cost wooden finishing material excellent in its abrasion resistance can be obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wood material used as a surface finishing material for floors, walls, ceilings, etc., a decorative material for columns, furniture and cabinets, an interior material for automobiles, and a surface material for various structures. Regarding finishing materials.

[0002]

2. Description of the Related Art In recent years, wood finishing materials have been rapidly increasing from the viewpoint of preventing the generation of mites, but demands for improvement in surface scratch resistance have increased. A general wood finishing material is a veneer, which is a thin wooden veneer for veneer, attached on a base plate. A WPC treatment was developed to prevent scratches on the surface of the veneer. ing. WPC
Is an abbreviation for Wood-Plastic combination.Put the veneer into a heating / pressurizing container and press the veneer impregnated with plastic to the base plate coated with an adhesive. Pasted together.

[0003]

The conventional WPC process has a disadvantage that the price is high.

[0004] Therefore, an object of the present invention is to provide a wooden finishing material which is inexpensive and has excellent scratch resistance.

[0005]

In order to achieve the above-mentioned object, the present invention is to stack a prepreg-state sheet containing a thermosetting resin on a base plate that enables resin impregnation,
A veneer plate capable of being impregnated with a resin is superposed on this sheet, and the sheets are hot-pressed and bonded to each other.

[0006]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

In the embodiment shown in FIG. 1, a base plate 1 is attached with a sheet 2 containing a thermosetting resin, and a veneer plate 3 is attached onto the sheet 2. As the base plate 1, a material capable of being impregnated with resin, for example, plywood, wood fiber board, particle board, wafer board, or a composite board thereof is preferably used. The sheet 2 is obtained by impregnating a sheet base material 20 (see FIG. 2) of paper, woven fabric, or non-woven fabric with a thermosetting resin. The thermosetting resin is any one or a mixture of two or more of a phenol resin, an epoxy resin, a urethane resin and a urea resin. Sheet base material 20
As the paper, gypsum board paper, kraft paper, rayon paper and the like can be preferably used. Further, as the fiber material of the non-woven fabric or the woven fabric, glass fiber, vinylon fiber, polyester fiber and the like can be preferably used. The veneer 3 that can be impregnated with resin is preferably a thin wooden plate for upholstery, and has a thickness of 1
mm or less is preferable.

FIG. 2 shows an example of a method of impregnating a storage tank of the thermosetting resin solution 10 with a woven cloth or a non-woven cloth (sheet base material 20) of paper, glass fiber, vinylon fiber, polyester fiber or the like. As the paper impregnated with the thermosetting resin, gypsum board paper, kraft paper, rayon paper and the like can be preferably used. As the woven cloth, for example, 1200
3 denier glass fibers in the vertical direction and 3 in the horizontal direction
A book / cm can be preferably used. The nonwoven fabric has a basis weight of 10 to 1000 g from the viewpoint of impregnating property, defoaming property, sheet base material strength, handling, and scratch resistance of molded products.
/ M ² more preferably 50 to 250 g / m ² , using a glass non-woven fabric in which short fibers having a short fiber length and long fibers having a length of 10 mm or more (50 mm or less) are mixed, and the thermosetting resin solution 10 has a solid content of 128 g / m ^2. The sheet 2 can be obtained by applying at a ratio of m ² . When the basis weight of the glass nonwoven fabric used as the sheet base material 20 is less than 10 g / m ² , scratch resistance is difficult to develop, and when it is more than 1000 g / m ² , resin impregnation becomes difficult. When the length of glass fiber is 3 mm or less, the reinforcing effect is low. On the other hand, when the fiber length exceeds 50 mm,
It is difficult to form a uniform sheet, and as a result, an excellent reinforcing effect cannot be obtained. Further, it is preferable that the short fibers are 20 to 100% from the viewpoint of strength (reinforcing property) and uniformity of the nonwoven fabric. If the short fibers are less than 20%, uniformity of the nonwoven fabric cannot be achieved. In addition to these fiber materials, short fiber cellulose pulp or the like may be mixed. When glass fiber is used, the reinforcing effect can be enhanced by coating the fiber surface with a silane coupling agent. The non-woven fabric as the sheet base material 20 is a method in which raw material fibers such as glass fiber, cotton and rayon are bonded or entangled, or both are used mechanically, chemically, thermally or with a solvent, or they are used. It is formed into a sheet by the combination of. As the fiber raw material, those obtained by matting fibers cut into 3 to 50 mm by wet papermaking or a dry non-woven fabric manufacturing method and binding them with a binder resin can be preferably used.

As the sheet 2, any one of paper, woven cloth and non-woven cloth as a sheet base material 20 impregnated with a thermosetting resin is not used alone, but a plurality of sheets may be used, for example. It is also possible to use, as the sheet 2, a product obtained by impregnating a thermosetting resin with a woven fabric and bonding the woven fabric.
For example, if the uncured phenolic resin is impregnated into paper and a woven fabric is bonded to the paper, the overall strength and dimensional stability are dramatically improved.

It is desirable that the thermosetting resin with which the sheet base material 20 is impregnated is in a cured state in the latter half of the impregnation, the sheet 2 is in a prepreg state, and this is superposed on the base plate 1 and projected onto the sheet 2 in this prepreg state. By stacking the plates 3 and heat-pressing them, they are firmly bonded to each other. A prepreg is a half-strength pre-curing material that retains the adhesive and moldability capabilities of a reinforced plastic made by admixing a fiber reinforcement and a thermosetting resin, and if necessary, a thermoplastic resin, a coloring agent, a curing catalyst, etc. It is a molding material in a cured state, and the preferable gel time is 30 to 800 seconds at 150 ° C.

The thermosetting resin to be impregnated into the sheet base material 20 using the fiber raw material contains the fiber to fiber ratio of 100% or more,
It is preferably about 200 to 300%. Sheet base material 2
As the thermosetting resin to be impregnated into 0, a resin having the required properties as a surface material is selected, for example, a phenol resin obtained by the reaction of phenols and aldehydes, or a terminal having a reactive epoxy group. Epoxy resins, urea resins and urethane resins obtained by adding a curing agent to the oligomer can be preferably used. These resins are singly or in a mixture of a plurality, and are mainly impregnated to form a composite with a fiber material. The resin solution to be impregnated may be an aqueous solution, a solvent varnish, an emulsion, or the like, or may be a method in which a solid resin powder is sprayed. Among these, it is preferable to use one dissolved or dispersed in water, alcohol or the like from the viewpoint of cost and safety. In addition to these various fillers,
For example, lead stearate, dibutyltin dilaurate, carbon black, calcium carbonate, titanium white, mica, glass spheres, aluminum hydroxide, antimony oxide,
Tri (2,3 dipromopropyl) phosphate, an aliphatic sulfonate, a higher alcohol salt ester, etc., a heat stabilizer, a reinforcing agent, a flame retardant, an antistatic agent, etc. are mixed and used. Further, as a catalyst necessary for the production of a phenol resin, alkylamine, ammonia, sodium hydroxide, barium hydroxide and the like are preferable. In particular, alkylamine and ammonia have larger molecular weights than the other two, and have low hydration properties in terms of molecular structure, so that the water resistance after bonding is remarkably improved. At this time, the phenol resin is preferably dissolved or dispersed in water so as to have a solid content of 20 to 80% from the viewpoint of easy impregnation. If the solid content is less than 20%, it becomes difficult to impregnate the required amount, and 8
If it exceeds 0%, impregnation becomes difficult due to an increase in viscosity.

The thermosetting resin with which the sheet base material 20 is impregnated has a solid content of 50 to 500 g / m ^2, preferably 150 to 3
It is preferably 50 g / m ² . 50g
If it is less than / m ^2, it is difficult to develop sufficient scratch resistance and 500 g
If it is not less than / m ² , it takes a long time to cure and there is a problem in appearance such as protrusion from the end.

As a drying condition for making the thermosetting resin impregnated in the sheet base material 20 into a cured state in the latter half of the impregnation, the moisture content of the finished sheet 2 is 5 to 15% by weight, further 8 to 10% by weight. %, Preferably 5% by weight
If it is less than 15%, adhesion failure with the veneer 3 or the base plate 1 may occur, and
If it is not less than% by weight, the sheets are blocked from each other. A preferred semi-cured sheet can be obtained at a temperature of 80 to 120 ° C. and a drying time of 2.5 to 30 minutes.

The tensile strength of the prepreg sheet is preferably a breaking strength of 10 kgf or more in order to realize sufficient scratch resistance. If it is less than 10 kgf, sufficient scratch resistance is not exhibited. The measurement of the breaking strength was performed by sandwiching the sheet 2 in the prepreg state between two release papers at 150 ° C. for 5 minutes.
The test was performed after the resin was cured by hot pressing under the condition of kgf / cm ² .

The pressing conditions for the base plate 1, prepreg sheet 2 and veneer plate 3 are preferably 130 to 180 ° C., more preferably 140 to 160 ° C. If the temperature is lower than 130 ° C, curing of the resin is insufficient and scratch resistance cannot be expressed.
This is because if the temperature is higher than 180 ° C., the curing of the resin will be too fast, the adhesion to the base plate 1 and the veneer plate 3 will be insufficient, and the base plate 1 will also have a large warp. Moreover, as the pressure, 1 to
20 kgf / cm ² is preferable, and more preferably 5 to 1
Was 5kgf / cm ^2, 1kgf / cm lower than ² and veneer 3 Enoshimi out of the resin scratch resistance is lowered due to insufficient, or the like warp of 20 kgf / cm ² larger than the base plate 1 increases Inconvenience occurs. Furthermore, the pressing time is preferably 2.5 to 20 minutes, more preferably 4 to 12.5 minutes. If it is shorter than 2.5 minutes, the curing of the resin is not sufficient and the scratch resistance is lowered, and if it is longer than 20 minutes, the resin is deteriorated and the scratch resistance is lowered, and the warp of the base plate 1 is increased.

A plywood plate having a thickness of 12 mm is used as the base plate 1, and a single veneer plate having a thickness of 0.3 mm is used as the veneer plate 3. A nonwoven fabric made of polyester fiber having a fiber length of 12 mm is used at a fiber ratio of 100%. Using sheet 2 impregnated with a cured phenolic resin, press temperature 135 ° C, pressure 10 kg / c
A wood finishing material produced at m ² and a pressing time of 10 minutes was used as Example 1, and a nonwoven fabric made of glass fiber having a fiber length of 12 mm was impregnated with a semi-cured phenol resin at a fiber ratio of 100%. The conditions are as follows: Example 2 is the same wood finishing material as in Example 1, and Example 3 is the one in which the ratio of the phenol resin to the fiber is 50%.
In Example 2, the ratio of the phenol resin to the fiber was 300.
% Was taken as Example 4 and that of the non-woven fabric in Example 4 having a glass fiber length of 3 mm was taken as Example 5. The base plate 1 and the veneer plate 3 were the same as in Examples 1 to 5, and the base plate 1 directly bonded to the veneer plate 3 with a urea-melamine adhesive was used as a comparative example. Example 1
5 to 5 and the comparative example, the scratch value of the pencil was tested based on JISK5400, and the diameter was 6.35 mm.
A test (falling ball test) for measuring the diameter of a recessed hole after dropping a ball having a weight of 150 g from a height of 3 cm 50 times was performed.
The results were as shown in Table 1 below. In the pencil scratch value, "H" is evaluated as "X", "2H" is evaluated as "△", and "3H".
Was evaluated as ○, and “4H or more” was evaluated as ◎. In the ball drop test, the diameter of the pit was 5 mm or more, x: 4 mm to less than 5 mm, ○: 3 mm to less than 4 mm, ○: less than 3 mm.

[0017]

[Table 1]

[0018]

As described above, according to the present invention, a prepreg-state sheet containing a thermosetting resin is superposed on a base plate capable of resin impregnation, and the resin is impregnated on the sheet. Since the possible veneer plates are superposed and hot pressed and bonded to each other, the thermosetting resin of the sheet impregnates and cures the veneer plate, improving the scratch resistance of the veneer plate. Further, an adhesive for adhering the veneer plate on the base plate is not required, and the sheet and the veneer plate can be reliably bonded to the base plate only by hot pressing, so that the manufacturing is easy. Furthermore, the presence of the sheet provides excellent dimensional stability against changes in temperature and humidity, and improves strength.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a preferred embodiment of the present invention.

FIG. 2 is an explanatory view showing a manufacturing example of a sheet.

[Explanation of symbols]

 1 base plate 2 sheet 3 veneer 20 sheet base material

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29K 105: 08

Claims (3)

[Claims] 1. A prepreg-state sheet containing a thermosetting resin is superposed on a base plate capable of resin impregnation, and a veneer capable of resin impregnation is superposed on the sheet and hot pressed. A wood finishing material characterized by being bonded together. 2. The wood finishing material according to claim 1, wherein the sheet is a sheet base material of paper, woven cloth or non-woven cloth impregnated with a thermosetting resin. 3. The thermosetting resin is a mixture of one or more of phenol resin, epoxy resin, urethane resin and urea resin.
Wood finishing material described in.