JPH09254320A - Manufacture of composite material and decorative composite material, and composite material and composite decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a method for manufacture of a composite material capable of preventing warpage and twist from being generated to a composite material by a method wherein in a decorative composite material using wood fiberboard as a part of a base material, generation of a chip is avoided to the wood fiberboard, and dimensional variation by moisture absorption of the wood fiberboard is inhibited. SOLUTION: When a composite material is manufactured by sticking wood fiberboard to a wood base material, one side of the wood fiberboard is coated to be impregnated with a moisture setting type adhesive, the wood base material is superimposed thereon via a water base adhesive, which is cold pressed or hot pressed. The water base adhesive effectively transfers to the moisture setting type adhesive side, and setting is quickly advanced at ordinary temperature. Further, since the moisture setting type adhesive is pliable and has suitable elasticity, impact resistance of the wood fiberboard is improved.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a composite material, a decorative composite material having the composite material as a base material, and a method for producing the same.

[0002]

2. Description of the Related Art Plywood and laminated veneer
umber: LVL), particle board, medium quality fiberboard (MDF), hard board (H)
A wood fiberboard such as B) is attached to produce a composite material,
Further, a decorative composite material is manufactured by pasting a decorative material such as a veneer, pre-coated paper, synthetic paper, or pattern printing paper on the surface of the wood fiberboard of the composite material. Such a decorative composite material is widely used as a floor material or a wall material as it is or by further forming an appropriate coating film on the surface of the decorative material or further attaching another decorative sheet. There is.

[0003]

A wood fiberboard is a defibrated plant fiber or a small piece of plant fiber which is artificially integrated into a plate shape by applying an adhesive, and is lightweight and has a suitable durability. Since it has compressibility, it is widely used as a material for base materials such as floor materials and wall materials. However, since the wood fiberboard alone does not have strength as a base material for flooring materials and wall materials, it is usually used in the form of a composite material laminated with a strength member such as plywood or LVL. Further, since the surface of the wood fiberboard is porous and easily absorbs moisture as it is and lacks in design, the wood fiberboard side surface of the composite material is, as described above, a veneer, a pre-coated paper or a synthetic paper. Such a decorative material is usually attached, and a decorative composite material having such a three-layer structure is used as a floor material or a wall material.

In this type of makeup composite material currently on the market, the binding force between the plant fibers or the plant fiber small pieces composing the wood fiberboard is not always sufficient, and the manufacturing process of the composite material or the makeup composite material When an impact force is applied to the wood fiberboard, delamination of the wood fiberboard may occur. In addition, when the composite material is used as a base material such as a flooring material, when a strong impact force is applied to the surface, delamination may occur in the wood fiber board. This is supported by the fact that delamination occurs in the wood fiberboard when the caster test described below is performed on the decorative composite material. The occurrence of such delamination causes partial chipping of the wood fiberboard, and therefore must be avoided, and a wood fiberboard having high impact resistance is required.

Further, the dimensional change of wood fiberboard due to moisture is larger than that of plywood, and in a composite material in which the wood fiberboard and the plywood are bonded together, deformation such as warpage or twisting easily occurs, and heat compression during manufacture of the composite material When pressed, there is also a problem that the composite material is deformed due to dimensional changes due to changes in the water content of the wood fiberboard. When a composite material is manufactured by cold pressure, the deformation is relatively small, but a long time cold pressure is required, which causes a decrease in production efficiency. Therefore, in the manufacturing process of the composite material, there is a demand for a method for manufacturing the composite material in which the influence of dimensional change due to moisture is not exerted on the wood fiberboard.

Further, when the decorative composite material is used as a floor material or the like, moisture absorption from the back surface may cause warping or twisting of the composite material, which deteriorates the function of the floor material or the like. There is a need for cosmetic composites that are designed to have low absorption.

The present invention is directed to conventional composites and decorative composites,
Furthermore, the purpose is to eliminate the above-mentioned inconveniences of the manufacturing method, and more specifically, it is possible to bond the wood fiber board and the wood base material in a short time and at a cold pressure. Accordingly, a method of manufacturing a composite material and a decorative composite material, which can easily and cost-effectively manufacture the composite material, at the same time, imparts high impact resistance to the wood fiberboard and reduces dimensional change due to moisture. The purpose is to Another object of the present invention is to provide a composite material and a decorative composite material having a high-impact-resistant wood fiberboard whose dimensional change due to moisture is reduced as a part of a base material.

[0008]

According to the present invention, the above-mentioned problems are solved by combining adhesives used for bonding a wood fiber board and a wood base material, and for bonding a wood fiber board and a decorative material. Achieved by proper selection. That is, the first invention is basically a method for producing a composite material by laminating a wood fiber board and a wood base material, wherein at least one surface of the wood fiber board is coated and impregnated with a moisture-curable adhesive. Then, after the adhesive is hardened or in an uncured state, the wood base materials are superposed on each other via an aqueous adhesive such as an emulsion type, and cold-pressed or hot-pressed.

In the present invention, the wood fiber board means wood chips or wood fibers mixed with an adhesive and heat-pressed, and includes fiber boards such as MDF and HB, particle boards and the like. The wood base material includes plywood, LVL and the like.

According to the present invention, the moisture-curing adhesive applied and impregnated on the wood fiberboard penetrates and impregnates the interior of the wood fiberboard to reinforce the wood fiberboard. Is improved. This is because the moisture-curable adhesive is soft and has appropriate elasticity. In addition, since an adhesive layer made of a moisture-curable adhesive is formed on the surface of the wood fiberboard, the penetration of water into the wood fiberboard is suppressed. As a result, the dimensional change of the wood fiberboard due to the change of the water content is reduced, and it is possible to avoid warping or twisting of the obtained composite material.

A wood base material is attached to the moisture-curable adhesive layer of the wood fiber board with an aqueous adhesive. When pasting, apply a water-based adhesive on the moisture-curing adhesive that has been applied and impregnated on one side of the wood fiberboard after it has hardened, or uncured it, overlay the wood base material on it, and apply cold pressure. Alternatively, it may be a method of hot pressing, one surface of the wood fiber board is coated and impregnated with a moisture-curable adhesive, and an aqueous adhesive is applied to one surface of the wood base material, and then the adhesive applied to the wood fiber board is cured. After or in an uncured state, the adhesive application surface of the wood fiber board and the adhesive application surface of the wood base material may be overlapped and cold-pressed or hot-pressed.

In the former case, when the water-based adhesive is applied on the cured or uncured state,
Moisture-curing adhesives should have low molecular weight and low viscosity, because low-molecular weight, low-viscosity adhesives easily penetrate into wood fiberboard and do not form an adhesive layer and are overcoated with an aqueous adhesive. It depends on why you can. In the latter case, if the adhesive layer after curing is thickly formed on the wood fiberboard, the adhesiveness of the water-based adhesive applied to one surface of the wood base material deteriorates, so it is desirable to bond in an uncured state. . At that time, it is desirable that the moisture-curable adhesive has a relatively high molecular weight and a high viscosity.

In the method of the present invention, the moisture-curing adhesive and the water-based adhesive, which are applied and impregnated on the wood fiberboard side, are brought into contact with each other at the time of bonding, so that the water-curing adhesive is water-bonded. The moisture contained in the agent migrates, and the moisture-curable adhesive cures rapidly. Therefore, as compared with the case of pasting with only a water-based adhesive such as a conventional urea resin or a water-based emulsion resin, it is easier to press in a short time and cure at room temperature. In addition to suppressing the impregnation of water into the wood fiber board as described above, since the bonding is performed by cold pressure, it is possible to avoid warping or twisting of the bonded composite boards. When pasting
When it is desired to accelerate the penetration of the moisture-curable resin into the wood fiberboard, hot pressing may be used, and in that case, the pressing can be performed for a shorter time.

The wood base material may be attached to the wood fiber board as a step continuous with the step of applying the moisture-curable adhesive to the wood fiber board. The wood fiber board thus prepared may be manufactured in another step, and the wood fiber board may be attached by a water-based adhesive in a subsequent step using the wood fiber board.

At this time, the impregnation of the wood fiber board with the moisture-curable adhesive may be performed only on the surface to which the wood base material is first attached, or may be applied on both surfaces. In the latter case, in addition to improving the impact resistance on both sides of the wood fiberboard, the penetration of water into the wood fiberboard is reliably suppressed when the wood base material is attached. In addition to the advantage that high dimensional stability can be obtained, there is an advantage that the work of applying the moisture-curable adhesive to the adhesive surface can be omitted at the time of attaching the decorative material, and the attaching work can be simplified.

As the moisture-curable adhesive used in the present invention, an adhesive such as urethane resin or epoxy resin can be used, and urethane resin is most preferable because it has appropriate elasticity. As the water-based adhesive, a modified vinyl acetate resin-based adhesive, a urea resin adhesive (including a room temperature curable type), a styrene-butadiene rubber (SBR) -based adhesive, a urea resin-based adhesive, or a mixture thereof, or An adhesive such as a water-based vinyl urethane-based adhesive can be used, and when a urethane resin is used as the moisture-curable adhesive, a water-based vinyl urethane-based adhesive is preferable from the viewpoint of adhesiveness with the urethane resin. Of course, the water-based adhesive may be an emulsion type adhesive. Modified vinyl acetate resin is also preferable because it does not contain formaldehyde. In the case of a resin containing formaldehyde, the produced composite material may release harmful formaldehyde, which is not preferable. The amount of water-based adhesive applied is
It may be about 10 to ²⁰ g / scale ² .

The amount of the moisture-curable adhesive applied is preferably such that the central portion of the wood fiber board is impregnated and impregnated with it. An impregnation of about 1 mm to 1.5 mm is sufficient.

In a second aspect of the present invention, the surface of the composite wood fiberboard side produced by the method of the first aspect of the invention is coated and impregnated with a moisture-curable adhesive, if necessary, in the same manner as above. ,
In the method for producing a decorative composite material, a decorative material is attached to the surface of the moisture-curable adhesive via an appropriate second adhesive.

The decorative material may be any as long as it is excellent in design and functionality, and may be an ordinary veneer, pre-coated sheet, pattern printing paper, synthetic paper, vinyl chloride sheet or the like.

The moisture-curable adhesive used may be the same as the moisture-curable adhesive in the first invention, and the coating amount may be the same. If a wood fiberboard is coated and impregnated with a moisture-curable adhesive on both sides in advance, the application of the moisture-curable adhesive here is not required.

The second adhesive used for attaching the decorative material is optional and may be a solvent type adhesive such as a urethane resin adhesive or the same water-based adhesive as described above. When the water-based adhesive is used, the same effect as the moisture-curable adhesive and the water-based adhesive described in the first invention can be achieved. Further, the solvent-based adhesive is particularly effective when a synthetic paper or a vinyl chloride sheet is used as a decorative material, and a stable adhesive force is obtained.

The mode of attachment may be the same as in the case of the first aspect of the invention, and the moisture-curable adhesive applied and impregnated on the surface of the wood fiberboard may be cured or uncured on the surface thereof. It is also possible to apply a water-based adhesive which is the adhesive of 2 or another adhesive, and superimpose the decorative material on the adhesive, and apply cold pressure or heat pressure to the surface of the wood fiberboard. The above-mentioned wood fiber board, after applying a water-based adhesive or another adhesive as a second adhesive to one surface of the decorative material, and after the adhesive applied to the surface of the wood fiber board is cured or uncured The adhesive application surface of 1 and the adhesive application surface of the cosmetic may be superposed and cold-pressed or hot-pressed. Even in this case, the application of the decorative material to the wood fiber board may be performed as a step continuous with the step of applying the moisture-curable adhesive to the wood fiber board. The wood fiber board thus prepared may be manufactured in a separate step, and the decorative material may be attached by the second adhesive in a subsequent step using the manufactured wood fiber board.

When a solvent type adhesive is used as the second adhesive, it is desirable to take a drying step after applying the adhesive for the purpose of removing the solvent in the adhesive. In the decorative composite material produced by the method of the second invention, the resin layer in which the moisture-curing adhesive is applied and impregnated is formed on both surfaces of the wood fiber board, which further improves the water absorption capacity of the wood fiber board. Lower. As a result, even when a decorative composite material is used as a floor material or the like, the dimensional change of the wood fiberboard due to moisture is reduced, and warpage and twist are suppressed.

According to the present invention, a moisture-curable resin is applied and impregnated on the back surface of the composite or decorative composite wood base material produced by the above method to form a resin layer. Also disclosed are methods of making composites and decorative composites made by the methods. By doing so, the manufactured composite composite material is less likely to absorb moisture from the back surface thereof, and dimensional changes such as warpage and twist can be further suppressed. The moisture-curable resin used here may be the same as described above, and urethane-based resin, epoxy-based resin, or the like can be used.

[0025]

The present invention will be described below with reference to examples. It was applied to Example 1 3mm moisture-curing one side of the thickness of the MDF urethane resin adhesive 10 g / scale ^2. On the other hand, 9
An acrylic modified vinyl acetate resin emulsion was applied at 10 g / square ² on one surface of a mm thick needle-leaf plywood. The MD
The adhesive-applied surface of F and the adhesive-applied surface of the softwood plywood were overlaid and pressed at room temperature for 5 minutes at a pressure of 7 kg / cm ² to produce an MDF composite board.

[0026] The Example 2 3mm moisture-curing one side of the thickness of the MDF urethane resin adhesive was coated at 15 g / scale ^2. On the other hand, it was applied to one side of a 9mm thick softwood plywood ethylene-modified vinyl acetate resin emulsion in 10 g / scale ^2. The adhesive-coated surface of the MDF and the adhesive-coated surface of the softwood plywood were overlaid and pressed at a pressure of 7 kg / cm ² for 5 minutes at room temperature to produce an MDF composite board.

Example 3 A moisture-curable urethane resin adhesive was applied to one side of a 3 mm-thick MDF at 10 g / scale ² . On the other hand, was applied to 9mm thick acrylic modified vinyl acetate resin emulsion acetaldehyde modified PVA was protective colloid to one side of softwood plywood 10 g / scale ^2.
The adhesive-coated surface of the MDF and the adhesive-coated surface of the softwood plywood were overlaid and pressed at a pressure of 7 kg / cm ² for 5 minutes at room temperature to produce an MDF composite board.

[0028] was applied to Example 4 3mm moisture-curing one side of the thickness of the MDF urethane resin adhesive 10 g / scale ^2. On the other hand, was applied to 9mm thick acrylic modified vinyl acetate resin emulsion acetaldehyde modified PVA was protective colloid to one side of softwood plywood 10 g / scale ^2.
The adhesive-coated surface of the MDF and the adhesive-coated surface of the softwood plywood are overlapped, and 120 ° C. and a pressure of 7 kg / cm ²
An MDF composite board was manufactured by hot pressing for minutes.

[Example 5] A polyether-type moisture-curable urethane resin adhesive was applied to the MDF surface of the MDF composite plate produced in Example 1 at 10 g / scale ² without curing the urethane resin adhesive. Then, an SBR + urea melamine resin adhesive was applied thereon at 9 g / square ² and a 0.3 mm thick oak veneer was thermocompression bonded. A urethane decorative coating was applied to the surface of the veneer-bonded composite plate at 7 g / square ² to produce a composite decorative plate.

Example 6 A polyester-type moisture-curable urethane resin adhesive was applied to the MDF surface of the MDF composite plate produced in Example 2 at 10 g / scale ² , without curing the urethane resin adhesive. Then, an SBR + urea melamine resin adhesive was applied thereon at a rate of 9 g / square ² , and a 0.3 mm-thick oak veneer was thermocompression bonded. A urethane decorative coating was applied to the surface of the veneer-bonded composite plate at 7 g / square ² to produce a composite decorative plate.

[Example 7] A polyether-type moisture-curable urethane resin adhesive was applied to the MDF surface of the MDF composite plate produced in Example 3 at 8 g / scale ² without curing the urethane resin adhesive. Then, an SBR + urea melamine resin adhesive was applied thereon at 9 g / square ² and a 0.3 mm thick oak veneer was thermocompression bonded. A urethane decorative coating was applied to the surface of the veneer-bonded composite plate at 7 g / square ² to produce a composite decorative plate.

[Example 8] A polyether-type moisture-curable urethane resin adhesive was applied to the MDF surface of the MDF composite plate produced in Example 1 at a rate of 10 g / scale ² without curing the urethane resin adhesive. to, thereon the acryl-modified vinyl acetate resin emulsion + urea resin adhesive 4g / scale ²
Then, 30 g / m ² of precoated paper was applied as a decorative sheet and heat-bonded. A urethane decorative paint was applied to the decorative sheet side of the decorative sheet-attached composite plate at 3 g / square ² to produce a composite decorative plate.

[Example 9] A polyether-type moisture-curable urethane resin adhesive was applied to the MDF surface of the MDF composite plate produced in Example 1 at 10 g / scale ² to cure the urethane resin adhesive. Instead, the SBR + urea melamine resin adhesive was applied thereon at 9 g / square ² and the oak veneer having a thickness of 0.3 mm was thermocompression bonded. Urethane paint is applied to the surface of this veneer composite plate at a rate of 7 g / scale ² , and a polyester type moisture-curing urethane resin is applied at a rate of 5 g /
A scale ² was applied to manufacture a composite decorative board.

[Example 10] The MDF produced in Example 1
A polyether type moisture-curable urethane resin adhesive is applied to the surface of the MDF of the composite board at 10 g / scale ² , and the urethane resin adhesive is not cured, and an acrylic modified vinyl acetate resin emulsion + urea resin is applied thereon. 4 g of adhesive
Was applied at scale ² was thermally pressed wearing precoated paper 30 g / m ² as a cosmetic sheet. The surface of the composite sheet with the decorative sheet applied was coated with urethane paint at a rate of 3 g / scale ² , and then the surface of the softwood plywood was coated with a moisture-curable urethane resin of the ether type at a rate of 4 g / scale ² to produce a composite decorative board. .

[Example 11] MDF manufactured in Example 4
A polyether type moisture-curable urethane resin adhesive is applied to the surface of the MDF of the composite board at 10 g / scale ² , and the urethane resin adhesive is not cured, and an acrylic modified vinyl acetate resin emulsion + urea resin is applied on top of it. 4 g of adhesive
Was applied at scale ² was thermally pressed wearing precoated paper 30 g / m ² as a cosmetic sheet. The surface of the composite sheet with the decorative sheet applied was coated with urethane paint at a rate of 3 g / scale ² , and then the surface of the softwood plywood was coated with a moisture-curable urethane resin of the ether type at a rate of 4 g / scale ² to produce a composite decorative board. .

[0036] and Comparative Example 1 3mm of MDF and 9mm thick thickness softwood plywood, acrylic modified vinyl acetate resin emulsion 10 g / scale ² was applied to the bonded surface, 7 kg / cm
^A MDF composite board was manufactured by pressing at a pressure of ² for 30 minutes. An SBR + urea melamine resin adhesive was applied to the surface of the MDF of this MDF composite board at 9 g / scale ² and a 0.3 mm thick oak veneer was hot-press bonded. A urethane decorative coating was applied to the surface of the veneer-bonded composite plate at 7 g / square ² to produce a composite decorative plate.

[0037] and Comparative Example 2 3mm of MDF and 9mm thick thickness softwood plywood, acrylic modified vinyl acetate resin emulsion 10 g / scale ² was applied to the bonded surface, 7 kg / cm
^A MDF composite board was manufactured by pressing at a pressure of ² for 30 minutes. Acrylic-modified vinyl acetate resin emulsion + urea resin adhesive on the MDF surface of this MDF composite board 4 g / square ²
And a 30 g / m ² precoated paper was adhered as a decorative sheet. The decorative sheet bonded urethane paint precoated paper surface side of the composite plate was coated with 3 g / scale ² to produce a composite veneer.

For each of them, a caster test, a plane tensile test and a warp amount were measured. Table 1 shows the results. The caster test is 2
After applying a load of 5 kg and reciprocating the test piece 3000 times at a distance of 100 mm in that state, visually observing the presence or absence of peeling of the decorative veneer, coating film, etc., and using a dial gauge, The maximum dent is measured to 1/100 mm, and at this time, the test piece makes one revolution in about 17 reciprocations and returns to the original position.

The plane tensile test conforms to JAS (special plywood), and one side is 20 m on the surface of the test piece.
A metal plate having a square m-shaped bonding surface was bonded using a cyanoacrylate-based adhesive, and a cut having a depth reaching a wood fiberboard such as MDF was attached to the periphery, and then a plane tensile test was performed.

The amount of warpage is measured by attaching a weight to the other end of the thread, one end of which is fixed to one end in the length direction of a 1 × 6 length test piece, and dropping the weight from the other end side of the test piece. The warp amount was measured by setting the maximum tension (maximum arrow height) (mm) between the surface of the test piece and the yarn at that time.

[0041]

[Table 1]

As can be seen from Table 1, the decorative composite materials of the examples clearly have improved dents by the caster test, peeling of MDF and the like, and values in the tensile test as compared with those of the comparative examples. . Thereby, when the composite material manufactured by the manufacturing method according to the present invention is used as a base material, it is possible to avoid chipping of the base material MDF or the like in the manufacturing process of the decorative composite material, and It can be seen that peeling does not occur in the obtained product. Furthermore, the amount of warpage in the examples is very small, and in particular, the amount of warpage in examples 8 and 9 is 0 mm,
It can be seen that the dimensional change due to the original water content of MDF when laminated with plywood is reduced.

[0043]

According to the manufacturing method of the present invention, in a decorative composite material using a wood fiberboard as a part of a base material, it is possible to avoid chipping of the wood fiberboard during the manufacturing process, and it is possible to avoid makeup. The quality of the board is improved. It is also possible to prevent delamination of the wood fiberboard when an external impact is applied to the decorative composite material. Further, dimensional change due to moisture absorption of the wood fiber board is suppressed, and warpage and twisting of the composite material are avoided.

Claims (9)

[Claims] 1. A method for producing a composite material, which comprises bonding a wood fiber board and a wood base material together, wherein at least one surface of the wood fiber board is coated and impregnated with a moisture-curable adhesive, and the adhesive is cured. After that, or in the uncured state, the wooden base materials are superposed on each other via an aqueous adhesive, and the composite material is cold-pressed or hot-pressed. 2. A method for manufacturing a composite material, which comprises bonding a wood fiber board and a wood base material together, wherein at least one surface of the wood fiber board is coated and impregnated with a moisture-curing adhesive to form one surface of the wood base material. A water-based adhesive is applied to, and after the adhesive applied to the wood fiberboard is cured or in an uncured state, the adhesive application surface of the wood fiberboard and the adhesive application surface of the wood base material are superposed, A method for manufacturing a composite material, which comprises cold pressing or hot pressing. 3. The surface of the wood fiberboard of the composite material produced by the production method according to claim 1 or 2 is coated and impregnated with a moisture-curable adhesive if necessary, and the adhesive is cured. Alternatively, in the uncured state, a decorative material is overlaid via a second adhesive and cold-pressed or hot-pressed, which is a method for producing a decorative composite material. 4. The surface of the wood fiberboard of the composite material manufactured by the manufacturing method according to claim 1 or 2 is coated and impregnated with a moisture-curable adhesive as needed, and the second surface is formed on one side of the decorative material.
After the adhesive applied to the wood fiber board is cured or uncured, the adhesive application surface of the wood fiber board and the adhesive application surface of the decorative material are overlapped and cooled. A method for producing a decorative composite material, which comprises pressing or hot pressing. 5. The method for producing a decorative composite material according to claim 3, wherein the second adhesive is a water-based adhesive. 6. A moisture-curable resin is applied and impregnated on the back surface of the wooden base material of the decorative composite material manufactured by the manufacturing method according to claim 3 or 4 to form a resin layer. A method for producing a featured composite material. 7. A composite material obtained by laminating a wood fiber board and a wood base material, wherein a moisture-curing adhesive is applied and impregnated on the wood fiber board to form an aqueous adhesive layer on the adhesive-impregnated surface. A composite material, in which a wooden base material is bonded via the interposition. 8. A composite material in which a wood base material is bonded to one surface of a wood fiber board and a decorative material is bonded to the other surface, and both surfaces of the wood fiber board are coated and impregnated with a moisture-curable adhesive. A wood base material is attached to one surface of the adhesive-impregnated surface via an aqueous adhesive layer, and a decorative material is attached to the other surface via a second adhesive layer. Cosmetic composite material characterized by. 9. The decorative composite material according to claim 8, wherein the second adhesive layer is a water-based adhesive layer.