JPH10114022A - Ligneous finishing material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a ligneous finishing material at a low cost in which marring resistance is excellent. SOLUTION: The ligneous finishing material is produced by superposing a sheet 2 being in a prepreg state containing a thermosetting resin on a baseplate 1 capable of impregnation of a resin and superposing a decorative material 3 capable of impregnation of a resin on the sheet 2 and performing thermal press to mutually bond them. After thermal press is performed for 5 minutes at 150 deg.C press temperature and 10kgf/cm<2> press pressure, tensile break strength of the sheet is >=10kgf. Thereby, marring resistance is enhanced by using the proper sheet 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

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

[0002]

2. Description of the Related Art In recent years, wood finishing materials have been rapidly increasing from the viewpoint of prevention of occurrence of ticks and the like, but there has been an increasing demand for improvement in scratch resistance of the surface. A general wooden finishing material is one in which a veneer (decorative material), which is a thin wooden plate for decorative veneer, is attached to a base plate, and is subjected to WPC processing so that the surface of the veneer is hardly damaged. Things are being developed. WPC is an abbreviation of Wood-Plastic Combination. A veneer is put into a heating / pressurizing container, and the veneer impregnated with plastic is hot-pressed onto a base plate coated with adhesive. And stuck 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 superimpose a sheet in a prepreg state containing a thermosetting resin on a base plate capable of impregnating the resin.
A wooden finishing material obtained by laminating a decorative material capable of impregnating a resin on the sheet and bonding them by hot pressing, wherein the sheet has a tensile breaking strength of 150 ° C. at a pressing temperature of 10 kgf / cm ^2. After hot pressing for 5 minutes at a pressing pressure of, the pressure was 10 kgf or more.

[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 sheet 2 containing a thermosetting resin is stuck on a base plate 1, and a decorative material 3 is stuck on the sheet 2.

As the base plate 1, a plywood, a wood fiber board, a particle board, a wafer board or the like or a composite plate thereof is preferably used, all of which are made of a material which can be impregnated with a resin.

The sheet 2 is obtained by impregnating a sheet base material 20 (see FIG. 2) made of paper, woven cloth, non-woven cloth or the like with a thermosetting resin. Examples of paper used as the sheet base include gypsum board paper, kraft paper, rayon paper, and the like, and woven fabrics include organic fiber fabrics, glass fibers, carbon fibers, inorganic whiskers, rock fibers, and inorganic fibers such as rock wool. And nonwoven fabrics such as amorphous metal fibers can be suitably used. As a non-woven fabric, glass fiber, cotton, rayon or other raw material fibers are bonded or entangled, or a sheet-like material made by a method using mechanical, chemical, heating or solvent using both, or a combination thereof. Things. As the fiber raw material, a material obtained by matting fibers cut to 3 to 50 mm by a wet papermaking or dry nonwoven fabric manufacturing method and bonding them with a binder resin is suitable for use. As a fiber raw material, glass fiber alone, glass fiber and alumina fiber, alumina silica fiber, carbon fiber, inorganic fiber such as metal fiber, aramid fiber, rayon fiber, vinylon fiber, nylon fiber,
Organic fibers such as polyester fiber, polypropylene fiber and polyethylene fiber can be used alone or in combination. It is preferable to use glass fiber alone from the viewpoint of the strength of the sheet substrate 20, ease of resin impregnation, and the like. Furthermore, the basis weight of the glass nonwoven fabric is preferably from 10 to 1000 g / m ² , more preferably from 50 to 250 g / m ² , from the viewpoint of impregnation, defoaming, sheet base strength, handling, and scratch resistance of the molded product. m ² . Basis weight 10
When the amount is less than g / m ² , scratch resistance is hardly developed, and 100
If it is more than 0 g / m ^2, it becomes difficult to impregnate the resin. These fibers have a low reinforcing effect with short fibers of 3 mm or less, whereas
With a long fiber exceeding 0 mm, it is difficult to form a uniform sheet, and as a result, an excellent reinforcing effect cannot be obtained. In addition, 3-15
From the viewpoint of strength (reinforcing property) and uniformity of the non-woven fabric, it is preferable that the short fibers having a length of 20 mm are 20 to 100% of the total fibers.
If the short fibers are less than 20%, uniformity of the nonwoven fabric cannot be achieved. Mixing short fiber cellulose pulp or the like in addition to these fiber materials may be used. When using glass fibers, the reinforcing effect can be enhanced by coating the fiber surface with a silane coupling agent.

As the thermosetting resin to be impregnated into the sheet substrate 20, a resin having necessary properties as a surface material is selected. For example, a phenol resin obtained by a reaction between phenols and aldehydes, Resin obtained by adding a curing agent to an oligomer having an acidic epoxy group, thermosetting ethylene-vinyl acetate copolymer, unsaturated polyester resin, urea resin, melamine resin, urethane resin, urea resin, DAP resin, unsaturated Examples thereof include polyester resins. These resins are used alone or as a mixture of two or more, and are mainly combined with the fiber material by impregnation. The resin solution to be impregnated may be any of an aqueous solution, a solvent varnish, an emulsion, and the like, or may be a method of spraying solid resin powder. Among them, it is preferable to use those dissolved or dispersed in water, alcohol, or the like from the viewpoint of cost and safety. When an alcohol is used, MeOH is suitable because it has a low fluff and is easy to dry. Furthermore, various fillers such as lead stearate, dibutyltin dilaurate, carbon black, calcium carbonate, titanium white, mica, glass spheres, aluminum hydroxide, antimony oxide, tri (2,3 dibromopropyl) phosphate, and fat A heat stabilizer, a reinforcing agent, a flame retardant, an antistatic agent and the like are used by blending with an aromatic sulfonate, a higher alcoholic ester and the like. 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 if it is more than 80%, the impregnation becomes difficult due to an increase in viscosity.

The thermosetting resin is added to the sheet base 20 in a solid content of 50 to 500 g / m ² , preferably 150 to 350 g.
/ M ² . If it is less than 50 g / m ^2, it is difficult to develop sufficient scratch resistance, and if it is less than 500 g / m ² , it takes a long time to cure and there is a problem in appearance such as protruding from an end. In the impregnation method, for example, as shown in FIG. 2, the sheet base material 20 is dipped into the thermosetting resin solution 10 with a roller, and then dried under a certain condition to obtain the prepreg sheet 2.

As the sheet 2, a sheet substrate 20 made of any one of paper, woven fabric and non-woven fabric, which is impregnated with a thermosetting resin, is not used alone. A sheet obtained by laminating a woven fabric on a sheet impregnated with a thermosetting resin can also be used as the sheet 2.
For example, the use of a glass nonwoven fabric impregnated with an uncured phenolic resin and bonded with a woven fabric greatly improves the overall strength and dimensional stability.

The thermosetting resin to be impregnated into the sheet base material 20 is preferably in a state of being cured in the latter half of the impregnation, and the sheet 2 is in a prepreg state. When the materials 3 are overlapped and hot-pressed, they are firmly bonded to each other. The prepreg is the half of the reinforced plastic made by admixing the fiber reinforcing material and the thermosetting resin, and other thermoplastic resins, coloring agents, curing catalysts, etc., as needed, before the completion of the curing, leaving the ability of adhesiveness and moldability. It is a molding material in a cured state, and a preferable gel time is 30 seconds to 800 seconds at a set temperature of 150 ° C.

As a drying condition for setting the thermosetting resin impregnated in the sheet base material 20 to the cured state in the latter half of the impregnation, the finished solvent content of the sheet 2 is reduced to 3 to 15% by weight, more preferably 5 to 10% by weight. When the content is less than 3% by weight, poor adhesion to the decorative material 3 and the base plate 1 is caused. When the content is not less than 15% by weight, blocking between sheets is caused. Table 1 shows the relationship between the drying time and the temperature. ○ in the table
The ready-made prepreg sheet can be used.
Is not preferable for use, and x indicates that it cannot be used.

[0015]

[Table 1]

As shown in Table 1, a sheet 2 in a preferable semi-cured state 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 sheet 2 (JIS K 705)
4), the sheet 2 in the semi-cured state was
It has been found that it is necessary for the impregnated resin to be 10 kgf or more in a state where the impregnated resin is cured by hot pressing at 10 ° C. for 5 minutes under conditions of 10 kgf / cm ² for sufficient scratch resistance. If the tensile strength is less than 10 kgf, the scratch resistance is poor.

The decorative material 3 can suitably be a thin wooden plate for decorative upholstery or paper on which a pattern or the like has been printed or processed in advance, and the thickness thereof is preferably 1 mm or less. The material of the decorative material 3 is selected so as to be able to be impregnated with a resin.

A plywood having a thickness of 12 mm was used as the base plate 1, and a veneer veneer having a thickness of 0.3 mm was used as the decorative material 3.
0 μm, basis weight 100 consisting of mixed fibers of short fibers and long fibers
g / m ² glass nonwoven fabric was impregnated with a 40% solids aqueous dispersion phenolic resin to obtain a sheet 2 having a solid content of 200 g / m ² , and after impregnation, dried at 105 ° C. for 10 minutes to obtain a semi-cured state. . A sheet 2 in a prepreg sheet state is superimposed on a base plate 1 and a decorative material 3 is superimposed on the sheet 2 to produce a wood finishing material at a press temperature of 150 ° C., a pressure of 10 kgf / cm ² , and a press time of 5 minutes. Was set to Example 1. Further, Example 2 was made of a wood-based finish manufactured under the same conditions as in Example 1 except that the solid content at the time of resin impregnation was 300 g / m ² . Furthermore, the drying condition for making the prepreg state was 105 ° C. for 3 minutes, and the other conditions were the same as those in Example 1, and the wood-finished material was used as a comparative example.

Example 3 Base plate 1 ... 12 mm thick plywood Cosmetic material 3 ... 0.3 mm thick cypress veneer Glass non-woven fabric ... Fiber diameter 10 µm, mixed fiber of short fiber and long fiber A glass nonwoven fabric having a basis weight of 100 g / m ² is impregnated with a methanol-soluble phenol resin having a solid content of 58% to obtain a solid material having a solid content of 200 g / m ^2.
After drying at 10 ° C. for 10 minutes, a semi-cured sheet 2 was obtained. The sheet 2 is superimposed on the base plate 1, the decorative material 3 is superimposed on the sheet 2, and the pressing temperature is 150 ° C. and the pressure is 10 kgf.
/ Cm ² and a press time of 5 minutes to produce a wood finish.

Embodiment 4 Using the same base plate 1 and decorative material 3 as in Embodiment 3,
The same glass nonwoven fabric was impregnated with a methanol-soluble phenol resin having a solid content of 58% to obtain a solid content of 300 g / m ² , and was dried under the same conditions as in Example 3 to obtain a semi-cured state. The pressing conditions at the time of bonding were such that the pressing time was 10 minutes, and the other conditions were the same as in Example 3.

The above Examples 1 to 4 and Comparative Examples were subjected to a steel ball drop test according to JIS A-1408. In this test, the pit depth of the sample was measured when a No. 2 steel ball (540 g) was dropped on the sample. The sample should be supported on the entire surface of the sand.
The results are as shown in Table 2 below.

[0023]

[Table 2]

The prepreg (semi-cured) sheets used in Examples 1 to 4 and Comparative Example were sandwiched between two release papers, and subjected to a pressure of 10 kgf / cm ² at 150 ° C. for 5 minutes. The tensile strength at break of each sheet was measured. Table 3 shows the results.

[0025]

[Table 3]

It was determined from Tables 2 and 3 that the tensile rupture strength after curing of the prepreg sheet used under certain conditions also affected the scratch resistance.

[0027]

As described above, according to the present invention, a prepreg-containing sheet containing a thermosetting resin is superimposed on a base plate capable of impregnating a resin, and impregnation of the resin is performed on this sheet. A wood finishing material obtained by laminating decorative materials which can be overlapped with each other by hot pressing and adhering to each other, wherein the sheet has a tensile breaking strength of 150 ° C. at a pressing temperature of 10 kg.
10 minutes after hot pressing for 5 minutes at a pressing pressure of f / cm ²
Since it is at least kgf, the scratch resistance can be improved by using an appropriate sheet. Further, an adhesive for bonding the decorative material on the base plate is not required, and the sheet and the decorative material can be securely bonded on the base plate only by hot pressing, so that manufacturing is easy. further,
The sheet has excellent dimensional stability against changes in temperature and humidity due to the presence of the sheet, and strength is also improved.

[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 production example of a sheet.

[Explanation of symbols]

 1 Base plate 2 Sheet 3 Cosmetic material

Claims (1)

[Claims] 1. A prepreg sheet containing a thermosetting resin is superimposed on a base plate capable of impregnating a resin, and a decorative material capable of impregnating the resin is superimposed on the sheet and hot-pressed. Wood finishes bonded to each other at a press temperature of 150 ° C.
A wood finishing material having a pressure of 10 kgf or more after hot pressing at a pressing pressure of 0 kgf / cm ² for 5 minutes.