JPH10114024A - Ligneous finishing material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a ligneous finishing material at 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 a superposing decorative material 3 capable of impregnation of a resin on the sheet 2 and performing thermal press to mutually bond them. The sheet 2 consists of glass nonwoven fabric which is constituted of an individual glass fiber or of fiber mixed with other fiber and impregnated with a thermosetting resin.

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 wood finishing material obtained by superimposing a decorative material capable of impregnating a resin on the sheet and bonding them by hot pressing, wherein the sheet is made of glass fiber alone or a fiber mixed with other fibers. A glass nonwoven fabric impregnated with a thermosetting resin.

[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 material that can be impregnated with a resin, for example, a plywood, a wood fiber board, a particle board, a 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) made of a glass nonwoven fabric with a thermosetting resin. The nonwoven fabric used as the sheet base material 20 may be made of a glass fiber alone, or a raw material fiber such as a mixed fiber of glass fiber and cotton or rayon, bonded or entangled, or mechanically, chemically, thermally or solvently using both. , Or a sheet made by a combination thereof. 3-50 as a fiber raw material
A fiber obtained by matting fibers cut into mm by a wet papermaking or dry nonwoven fabric manufacturing method and bonded with a binder resin is suitable for use. As a fiber raw material, glass fiber alone, or glass fiber and alumina fiber, alumina silica fiber, carbon fiber, inorganic fiber such as metal fiber,
Organic fibers such as aramid fiber, rayon fiber, vinylon fiber, nylon fiber, polyester fiber, polypropylene fiber and polyethylene fiber can be used alone or in combination. It is preferable to use glass fiber alone in view of the strength of the sheet substrate, 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 , and more preferably from 50 to 1000, from the viewpoints of resin impregnation, defoaming, sheet base strength, handling, and scratch resistance of the molded product. It is 250 g / m ² . When the basis weight is less than 10 g / m ² , scratch resistance is hardly exhibited, and when the basis weight is more than 1000 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, while it is difficult to form a uniform sheet with long fibers exceeding 50 mm, and as a result, excellent reinforcing effects cannot be obtained. In addition, it is preferable that the short fiber having a length of 3 to 15 mm accounts for 20 to 100% of all the fibers in view 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. 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 to be 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. When a phenol resin is selected as the thermosetting resin, alkylamine, ammonia, sodium hydroxide, barium hydroxide, and the like are preferable as a catalyst required for producing the resin. 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.

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.
Impregnate so as to obtain 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 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 made of a glass nonwoven fabric as a base material and impregnated with a thermosetting resin is not used alone. It can also be used. For example, if an uncured phenolic resin is impregnated into a glass nonwoven fabric and paper is bonded thereto, the overall strength and dimensional stability are dramatically improved.

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 mixing the fiber reinforcing agent and the thermosetting resin, and other thermoplastic resins, coloring agents, curing catalysts, etc., as necessary, before the completion of curing, while maintaining the 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 the thermosetting resin to be impregnated into the sheet base material 20 to be in a cured state in the latter half of the impregnation, the finished sheet is made to have a solvent content of 3 to 15% by weight, more preferably 5 to 10% by weight. It is preferable that when the content is less than 3% by weight, poor adhesion to the decorative material 3 and the base plate 1 is caused, and 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 preferable semi-cured sheet can be obtained at a temperature of 80 to 120 ° C. and a drying time of 2.5 to 30 minutes.

[0017] The tensile strength of the prepreg sheet is preferably 10 kgf or more in order to exhibit 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 decorative material 3 is a thin wooden board for decorative upholstery or paper on which a pattern or the like has been printed or processed in advance, and has a thickness of preferably 1 mm or less.

Example 1 Base plate 1 ... 12 mm thick plywood Decorative material 3 ... 0.3 mm thick oak veneer Glass non-woven fabric ... Fiber diameter 10 µm, mixed fiber of short fiber and long fiber A glass fiber with a basis weight of 100 g / m ² alone Thermosetting resin: water-dispersed phenol resin with a solid content of 40% Solid content at the time of resin impregnation: 200 g / m ^{2 A} phenol resin is added to the above glass nonwoven fabric (Solid content: 200 g / m ² ) was dried at 105 ° C. for 10 minutes to obtain a sheet 2 in a semi-cured state. And the base plate 1
The sheet 2 is superimposed on the sheet 2. The decorative material 3 is superimposed on the sheet 2, and the pressing temperature is 150 ° C. and the pressure is 1
A wood finish was produced at 0 kgf / cm ² and a press time of 5 minutes.

Example 2 A glass nonwoven fabric was impregnated with a water-dispersed phenol resin having a solid content of 40% so that the solid content of the water-dispersed phenol resin was 300 g / m ² , and then dried to obtain a sheet 2. . Other conditions were the same as in Example 1 to produce a wood finish.

Example 3 Base plate 1 ... 12 mm thick plywood Decorative 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.

Example 4 Example 3 was performed using the same base plate 1 and decorative material 3 as in Example 3.
The same glass nonwoven fabric was impregnated with a methanol-soluble phenolic resin having a solid content of 58% to obtain a solid content of 300 g / m ² , and dried under the same conditions as in Example 1 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.

Comparative Example Sheet 2 was obtained by impregnating kraft paper with the same phenolic resin as in Example 1. Other conditions were the same as in Example 1 to produce a wood finish.

With respect to Examples 1 to 4 and Comparative Example,
A steel ball drop test was performed according to JIS A-1408. This is to measure the depth of the depression of the sample when the No. 2 steel ball is dropped on the sample. (1) Steel ball: No. 2 hard ball (540 g) (2) Drop height: 0.75 m (3) Sample support method: whole surface support on sand The results are shown in Table 2.

[0025]

[Table 2]

[0026]

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. Because the decorative materials that can be used are overlapped and hot pressed and adhered to each other, the sheet is made by impregnating a thermosetting resin into a glass nonwoven fabric composed of glass fibers alone or fibers mixed with other fibers. In addition, the thermosetting resin of the sheet is impregnated into the decorative material and hardened, thereby improving the scratch resistance of the decorative material. 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. Furthermore, the presence of the sheet provides excellent dimensional stability against changes in temperature and humidity, and improves strength. Further, by using the glass nonwoven fabric, the strength of the sheet is further improved, the impregnation property of the resin is improved, and the production of the sheet in the prepreg state is facilitated.

[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

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29L 31:00

Claims (4)

[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. A wood finish, wherein the sheet is a glass nonwoven fabric made of glass fiber alone or a fiber mixed with other fibers, and a thermosetting resin impregnated with the sheet. Wood. 2. The glass nonwoven fabric has a basis weight of 10 to 10.
Wood finishing material according to claim 1, wherein it is a 1000 g / m ^2. 3. The glass nonwoven fabric has a fiber length of 3 to 3.
The wood finishing material according to claim 1, comprising a mixed fiber of 15 mm short fiber and 10 to 50 mm long fiber. 4. The glass nonwoven fabric according to claim 1, wherein the short fibers have a length of from 20 to 10.
4. The wood finishing material according to claim 3, wherein the wood finishing material has a ratio of 0%.