JPH11100795A - Resin-impregnated paper substrate, its production and board material for building using resin-impregnated paper substrate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain both a resin-impregnated paper substrate, capable of improving the dimensional stability and producible at a low cost and a board material for building using the resin-impregnated paper substrate and to provide a method for producing the resin-impregnated paper substrate. SOLUTION: This resin-impregnated paper substrate 10 is formed by impregnating a paper material 1 recycled from a waste paper with a resin and curing the resin. Starch on the right side and back side of the paper material 1 recycled from the waste paper is removed and the resultant paper material 1 freed of the starch is then impregnated with the resin to uniformize the impregnated resin. The resin is further dried to smooth the surface and cure the resin when producing the resin-impregnated paper substrate 10.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-impregnated paper base material, a method for producing the resin-impregnated paper base material, and a building board using the resin-impregnated paper base material.

[0002]

2. Description of the Related Art As shown in FIG. 11, an MDF board (medium-density fiberboard) b is laminated on a surface of a plywood substrate a and a surface of the MDF board b is formed on the surface of the MDF board b. It is formed by laminating veneers c and integrating them.

[0003]

The MDF board b interposed between the substrate a and the surface veneer c is excellent in caster resistance, stocking resistance, crack resistance, etc. There are problems such as poor dimensional stability and cost. In order to solve this problem, use of a resin-impregnated paper base material obtained by impregnating a paper material with a resin such as a thermosetting resin and curing the same as a material replacing the MDF board b has been studied. When such a resin-impregnated paper substrate is used,
Although the dimensional stability can be improved as compared with the one using the MDF board b, there is a problem in cost. In other words, there is a problem that the cost is high because specially-impregnated paper is used as the paper material to be impregnated with the resin.

SUMMARY OF THE INVENTION The present invention has been made in view of the above description, and provides a resin-impregnated paper substrate, a method for manufacturing the resin-impregnated paper substrate, and a resin-impregnated paper that can improve dimensional stability and reduce cost. It is an object to provide an architectural plate using a base material.

[0005]

According to a first aspect of the present invention, there is provided a resin-impregnated paper substrate in which a recycled paper is impregnated with a resin and cured. . Since it is a resin-impregnated paper base material obtained by impregnating a paper material with a resin and curing, the dimensional stability of the building material can be improved when used for a building material. In addition, since a recycled paper is used as the paper, the cost can be reduced.

According to a second aspect of the present invention, there is provided a method for producing a resin-impregnated paper base material, comprising the steps of: removing starch on the front and back surfaces of a paper material obtained by recycling used paper; and impregnating the paper material with the starch removed with a resin. It is characterized by comprising a resin impregnating step, a homogenizing step for equalizing the impregnated resin, a drying step for removing moisture, and a resin curing step for curing the resin by smoothing the surface layer. Removing the starch from recycled paper, impregnating the paper with resin, homogenizing the impregnated resin, drying and curing the resin to form a resin-impregnated paper substrate successively and sequentially. Can be. By using recycled paper material, a resin-impregnated paper substrate can be manufactured at low cost. Even if recycled paper is used, the resin can be smoothly impregnated by removing the starch on the front and back surfaces of the paper, even if recycled paper is used. And the resin is hardly impregnated).

According to a third aspect of the present invention, in the method for manufacturing a resin-impregnated paper substrate according to the second aspect, the starch removing step is performed by sanding the front and back surfaces of the paper material with a brush such as a nylon brush or a stainless steel brush. It is characterized in that starch on the back surface is removed. By easily sanding the front and back surfaces of the paper material with a brush such as a nylon brush or a stainless steel brush, the starch on the front and back surfaces can be easily removed, and the impregnation property of the resin can be improved.

According to a fourth aspect of the present invention, in the method for manufacturing a resin-impregnated paper substrate according to the second aspect, the starch removing step comprises removing the starch on the front and back surfaces of the paper by dipping the paper in hot water. It is characterized by. By dipping the paper material in hot water, the starch can be removed so as to be dissolved, and the impregnation property of the resin can be improved. In the method for producing a resin-impregnated paper substrate according to claim 5 of the present invention, in claim 2, the resin impregnation step is performed by dipping the paper material into an impregnation tank, and the paper material is dipped into the impregnation tank. At this time, the paper material is inserted in a substantially vertical direction to prevent air from adhering.
The resin can be easily impregnated simply by dipping the paper material into the impregnation tank. At this time, since the paper material is put into the resin in the impregnation tank in a substantially vertical direction, it is possible to prevent air from adhering and prevent the resin impregnation from becoming uneven.

In the method for producing a resin-impregnated paper substrate according to claim 6 of the present invention, in the resin impregnation step, the liquid temperature of the resin in the impregnation tank is raised to lower the viscosity of the resin. It is characterized in that the impregnation amount is increased. Thereby, the impregnation property of the resin into the paper material can be improved, the impregnation time can be shortened, and the productivity can be improved. In the method for producing a resin-impregnated paper substrate according to claim 7 of the present invention, the homogenization step according to claim 2 is characterized in that:
It is characterized in that the impregnated resin is made uniform by passing a paper material impregnated with the resin between elastic rolls such as sponge rolls and rubber rolls. The resin impregnated by pressing with the elastic roll can be made uniform, and the resin can be stably made uniform.

[0010] In a second aspect of the present invention, in the method for manufacturing a resin-impregnated paper substrate, the resin curing step is performed by hot pressing with a hot roll. By applying heat and pressure with a hot roll, curing does not proceed too much, and no adverse effects are caused when a veneer is adhered to a resin-impregnated paper substrate. The method for producing a resin-impregnated paper substrate according to claim 9 of the present invention is characterized in that, in claim 5, the resin impregnated in the paper material is a modified melamine resin.

According to a tenth aspect of the present invention, there is provided an architectural plate material wherein the resin-impregnated paper base material obtained according to the first or second aspect is laminated on a substrate such as a plywood, an MDF board or a particle board. By sticking the resin-impregnated paper base material to the substrate, it is possible to obtain an architectural plate material having good dimensional stability and low cost. An architectural plate according to claim 11 of the present invention is characterized in that, in claim 10, a resin-impregnated paper base material is laminated on the surface side of the resin-impregnated paper base material instead of sticking a surface veneer on the surface side. And

According to a twelfth aspect of the present invention, there is provided an architectural plate according to the tenth aspect, wherein an aqueous vinyl urethane adhesive is applied between the resin-impregnated paper substrate and the substrate. If the aqueous vinyl urethane adhesive is applied between the resin-impregnated paper substrate and the substrate, a porous state can be created between the substrates to improve the adhesiveness. Is bad.).

According to a thirteenth aspect of the present invention, in the tenth aspect, the surface of the resin-impregnated paper base material is sanded and a surface veneer is adhered to the surface. By sanding the surface of the resin-impregnated paper substrate to roughen the surface, it is possible to improve the adhesiveness when bonding the surface veneer with an adhesive. The building plate of claim 14 of the present invention is:
In the tenth aspect, a plurality of resin-impregnated paper substrates are laminated, and when the resin to be impregnated is a melamine resin, a modified melamine resin is applied between the plurality of resin-impregnated paper substrates. Adhesion between a plurality of resin-impregnated paper substrates can be improved.

According to a fifteenth aspect of the present invention, there is provided a building plate according to the tenth aspect, wherein a plurality of resin-impregnated paper bases are laminated, and the direction of warpage of the adjacent resin-impregnated paper bases is reversed. It is characterized by aiming. Warpage of architectural plates can be reduced. According to a sixteenth aspect of the present invention, in the tenth aspect, the thickness of the layer of the resin-impregnated paper base provided below the surface veneer is 0.8 mm or more. By setting the thickness of the resin-impregnated paper base material to 0.8 mm or more, caster resistance can be ensured.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A resin-impregnated paper base material is formed by impregnating a resin material into a recycled paper material and curing the resin. It is desirable to utilize. As an example of the components of the hybrid paper, there are used newspapers, cotton waste, and pulp. A single layer (1 ply) of the recycled paper is desirable. In the case of a plurality of layers (for example, in the case of three plies), the impregnating property decreases on the lamination surface, the intermediate layer portion is not sufficiently impregnated, and the intermediate layer is peeled off. The thickness of the paper material is required to be 0.8 mm or more in order to ensure caster resistance equal to that of the MDF board (indentation amount is 0.07 mm). 0.8m thick
Although the surface hardness is improved by increasing the amount of resin to be impregnated even if it is less than m, the secondary adhesion at the time of bonding the surface veneer is reduced and a puncture phenomenon occurs as described later. Further, the water content of the paper material is desirably 8% or less. When the water content is 15% or more, the impregnating property when the resin is impregnated decreases.

The process for forming a paper material from waste paper pulp will be described as follows. Waste paper (raw material) → Valper (disintegration of waste paper) → Screen (dust removal) → Flotator (deinking) → Thickener (dehydration) → Refiner (beating) → Chest (pulp storage) → Refiner → Wire part (formation of paper layer) )
→ Press part (squeezing water) → Dryer part (drying by steam) → Reel (winding) In the dryer part, use a multi-cylinder dryer or Yankee dryer. The multi-cylinder dryer is a type in which many cylinders are lined up and both sides of the paper are alternately dried little by little. The Yankee dryer is a type in which wet paper is adhered to a large cylinder having a diameter of 3 m or more, and dries to a target moisture of the paper during a half rotation (progress). In this type, since the wet paper is dried without leaving the surface of the dryer even once, one surface of the paper becomes smooth (glossy) and the dimensional stability is improved.

FIG. 1 shows an example of a process for producing a resin-impregnated paper substrate and a building plate. Fig. 1 shows the recycled paper 1
As shown in (a), it is supplied so as to be rewound from the roll, and the starch of the paper material 1 is removed in the starch removing step as shown in FIG. 1 (b). In the case of this example, by passing the paper material 1 between brushes 2 such as a stainless steel brush and a nylon brush arranged vertically, sanding of the front and back of the paper material 1 removes starch on the front and back, thereby improving the impregnating property of the resin. Can be The paper material 1 from which the starch has been removed is immersed in the resin liquid 4 in the impregnation tank 3 in the resin impregnation step as shown in FIG. At this time, the resin liquid 4 is heated so that the temperature thereof becomes, for example, about 60 ° C. The resin-impregnated paper 5 impregnated with this resin is passed between elastic rolls 6 such as sponge rolls in a homogenization step as shown in FIG. Can be At this time, water is applied before passing between the elastic rolls 6 to prevent the resin from adhering to the elastic rolls 6. Next, as shown in FIG. 1 (e), in a drying step, the resin-impregnated paper 5 is passed through a dryer 7, and drying is performed by blowing hot air from upper and lower nozzles 8 to remove moisture of the resin. Next, as shown in FIG. 1 (f), in a resin curing step, the resin-impregnated paper 5 is passed between the upper and lower heat rolls 9, and the resin is cured to form a resin-impregnated paper base material 10. The conditions for passing through the heat roll 9 are, for example, that the roll temperature is 180
The roll pressure is 5 to 10 kg / cm ² at ° C. Next, as shown in FIG. 1 (g), the resin-impregnated paper base material 10 is cut to a fixed size by a cutter 14 or the like in a fixed size cutting step. At this time, for example, it is cut into a size of 3 × 6. The resin-impregnated paper base material 10 cut to a fixed size is sent to another factory or another process, and as shown in FIG. 1 (h), is put on a substrate 11 such as plywood via an adhesive or the like in a composite pressing process. Resin impregnated paper substrate 10
Are laminated and composited by pressing with a hot press 12 to form an architectural plate material 13 such as a floor material.

The above description is an outline of an example of a process for manufacturing the resin-impregnated paper base material 10 and the building plate material 13. The details will be further described below. The types of resin as the main component of the resin include thermosetting resins such as melamine resin, phenol resin, urea resin, and epoxy resin, but from the viewpoint of curability, impregnation, handleability, compatibility with starch, and cost. Melamine resins are preferred. Although the melamine resin is most suitable as the type of the resin as the main component, there is a problem with aging, and it is desirable to add an additive. Examples of the additive include SBR resin (latex), vinyl chloride resin, EVA (ethylene vinyl acetate resin), and fluororesin, but the SBR resin is most suitable in terms of aging and cost. In addition, when the additive is added as described above, the mixing ratio of the additive to the resin as the main agent is about 20 to the main agent 80, which is optimal from the viewpoint of aging and wet heat. Further, the ratio of the solid content to the water content of the resin is preferably about 50% for the solid content of 50%. When the solid content is 60% or more, the impregnating property of the paper material 1 is reduced, and when the solid content is low, there is a problem in strength.

Before the resin material is impregnated with the resin, the paper material 1 is passed through a brush 2 such as a nylon brush or a stainless steel brush in a starch removing step to sand the front and back surfaces of the paper material 1 and remove the starch on the front and back surfaces. It has become. As shown in FIG. 2A, the surface layer portion of the paper material 1 has a fibrous portion 15 and a starch layer 16, but the starch layer 16 is removed by sanding as described above, and as shown in FIG. A void 17 is formed in the space. By thus removing the starch, the impregnation of the resin can be improved (the starch layer reduces the impregnation of the resin).

The starch removal step is carried out by dipping in warm water instead of sanding with the brush 2 as described above. Paper material 1 in warm water (30 ° C to 100 ° C)
The starch on the front and back surfaces of the paper material 1 is removed by dipping. By dipping the paper material 1 in warm water, the starch can be removed so as to be dissolved, and the impregnation property of the resin can be improved. For example, when the untreated paper material 1 is impregnated with the resin, it takes about 10 minutes to impregnate the resin. However, when the starch is removed by dipping in hot water at about 50 ° C., the time required for the resin impregnation is taken. About 6 minutes, 80
When the starch was removed by dipping in warm water at about ° C, the time required for resin impregnation was about 3 minutes. This indicates that the impregnating property is improved when the starch is removed by dipping in hot water, and that the higher the temperature of the hot water, the more the starch can be sufficiently removed and the impregnating property can be improved.

In the resin impregnation step, the paper material 1 is placed in the impregnation tank 3.
The resin is impregnated with the resin liquid 4 in the inside. When the paper material 1 is dipped into the resin liquid 4 of the impregnation tank 3, the paper material 1 is inserted in a substantially vertical direction to prevent air from adhering. That is, as shown in FIG. 3, a plurality of guide rollers 18 are arranged to guide the feeding of the paper material 1, and when the paper material 1 is introduced so as to be immersed in the resin liquid 4, the paper material 1 is vertically moved. It is supposed to enter. If the paper material 1 is inserted diagonally, it is easy to entrain the air, and the adhesion of the air may cause impregnation of the resin. However, if the paper material 1 is inserted vertically, the adhesion of the air is prevented to impregnate the resin. Unevenness can be eliminated.

In the resin impregnation step, the temperature of the resin liquid 4 in the impregnation layer 3 is increased to lower the viscosity of the resin liquid 4 and increase the amount of impregnation. Thereby, the impregnation property of the resin into the paper material 1 can be improved, the impregnation time can be shortened, and the productivity can be improved. For example, when the liquid temperature of the resin liquid 4 is 25 ° C., the time required for the resin impregnation is about 10 minutes.
In the case of 0 ° C., it took about 7 minutes, and the impregnating property was improved by increasing the temperature of the resin liquid 4. At this time, the liquid temperature of the resin liquid 4 is
In the case of a non-aqueous (solvent type) resin, the temperature is preferably from 20C to 60C, and in the case of an aqueous resin, it is preferably from 40C to 100C.

When the paper material 1 is impregnated with the resin in the resin impregnation step, it is also preferable to add a colorant (dye) to the resin and check the amount of the resin impregnated by the color of the paper material 1. By checking the amount of resin impregnation in this way, it is easy to determine whether the amount of resin impregnation is appropriate. It is also preferable to apply a bleaching agent to the surface of the paper material 1, dry the paper material, impregnate the resin material, and put a coloring agent (dye) in the adhesive when laminating with the veneer. In this case, the state of adhesion by the adhesive can be checked.

When the paper material 1 is impregnated with a resin in the resin impregnation step, it is preferable to impregnate the paper material 1 by vacuum impregnation, vacuum pressure impregnation, pressure impregnation (air pressure, liquid pressure), suction impregnation or the like. By impregnating as described above, it is possible to impregnate even the paper material 1 having a multilayer (two or more plies). Although the multi-layer paper material 1 has a lower impregnating property on the lamination surface than the single-layer paper material and cannot be uniformly impregnated, the multi-layer paper material 1 can be evenly impregnated with the above method. The conditions for vacuum impregnation are as follows:
For example, in the case of a single-layer paper material 1, the impregnation time is 1 minute at a pressure of 10 Torr to 60 Torr, and in the case of a multi-layer paper material 1, the impregnation time is 1 minute at a pressure of 5 Torr to 30 Torr. .

The resin-impregnated paper 5 in which the paper material 1 is impregnated with the resin as described above is passed between elastic rolls 6 such as sponge rolls and rubber rolls in a homogenization step to uniformize the applied resin. At this time, the hardness of the elastic roll 6 is 5 ° in rubber hardness.
４０40 °. If the hardness of the roll is high or if the roll is an iron roll, the coating resin cannot be made uniform. That is, in the case of the iron roll 19, the resin accumulates in the portion indicated by the symbol A in FIG. 4B (the portion indicated by oblique lines), and the resin cannot be made uniform. However, in the case of the elastic roll 6, FIG. As shown in FIG. In FIG. 4, reference numeral 25 denotes a roll shaft.

The drying process includes hot air drying, vacuum drying (conditions are, for example, 60 ° C. at 10 Torr), high frequency drying, natural drying (indoor drying), sky drying (outdoor drying), electric drying, and Combination of the above drying (for example,
Induction drying after natural drying). In the resin curing step, the resin of the resin-impregnated paper 5 is cured in a heat and pressure step. Means for curing in the hot-pressing step include hot air, a hot roll, ultraviolet light or infrared light, and high frequency.

It is desirable that the hot-pressing step of the resin curing step is a hot-rolling step. In the case of the hot plate process, the curing of the resin proceeds excessively, and the surface becomes too hard, so that when a veneer as a surface material is adhered, the adhesiveness with the veneer deteriorates. If the surface is too hard, the moisture of the veneer cannot be transferred to the paper material 1 at the time of bonding with the veneer, and there is no place for the moisture to escape, causing cracks in the veneer (puncture phenomenon). Fig. 5
As shown in (a), the resin-impregnated paper 5 is pressed by a hot plate 20 from above and below, and the hot plate press extrudes the resin in the middle layer of the paper material 1 to the surface layer over time. As a result, as shown in FIGS.
Becomes dense (the cross-hatched portion indicated by the symbol B), and moisture cannot move to the paper material 1 side when adhering to the veneer. In the case of the heat roll process (a multi-cylinder process in which a number of upper and lower heat rolls 9 are arranged in the traveling direction).
This is performed as shown in FIG. 6 (a), and the resin is repeatedly applied to the paper material 1 in order to repeat the pressurization → opening pressure → pressurization → opening pressure and to perform linear pressurization.
Are uniformly dispersed in the surface layer portion and the middle layer portion. That is, FIG.
(B) As shown in (c), the resin of the surface layer portion and the middle layer portion of the paper material 1 are uniformly dispersed (hatched portion indicated by reference C), and the resin layer of the surface layer portion is dense as in the hot plate process. Therefore, moisture can be transferred to the paper material 1 at the time of bonding to the veneer. In addition, since the pressure is applied to a certain extent when hot-pressed by the heat roll 9, the peel strength and the like are improved. Paper material 1 if pressure is not applied during resin curing
In the middle layer portion, the peel strength decreases. That is, in the case of hot-air curing, although curing is performed, the peel strength is weakened. By applying pressure, a state in which the resin is sufficiently cured even in the middle layer of the paper material 1 can be created.

It is also preferable that the resin-impregnated paper substrate 10 is formed by integrally laminating a plurality of sheets. That is, a plurality of resin-impregnated papers 5 dried in the drying step may be laminated, and a plurality of the resin-impregnated paper bases 10 may be integrally formed by applying heat and pressure in the resin curing step to form the resin-impregnated paper substrate 10. . In the composite pressing step, the resin-impregnated paper base material 10 is laminated on the substrate 11 via an adhesive or the like, the surface veneer 23 is laminated on the front side of the resin-impregnated paper base material 10, and the hot press 12 By doing so, an architectural plate 13 such as a floor shown in FIG. 7 is formed. Plywood, MD as substrate 11
There are an F board, a particle board, an OSB (a kind of wafer board, an oriented standard board) and the like. By sticking the resin-impregnated paper base material 10 on the substrate 11 in this way, it is possible to obtain the architectural plate material 13 having good dimensional stability and low cost. Instead of adhering the surface veneer 23 to the front side of the resin-impregnated paper substrate 10, another resin-impregnated paper substrate 10 may be laminated to form a surface layer.

When the resin-impregnated paper substrate 10 is pasted on the substrate 11, it is preferable that an aqueous vinyl urethane-based adhesive is applied as an adhesive between the resin-impregnated paper substrate 10 and the substrate 11. When the aqueous vinyl urethane-based adhesive is applied between the resin-impregnated paper base material 10 and the substrate 11, a porous state can be formed between the resin-impregnated paper base material 10 and the substrate 11 to improve the adhesiveness. Poor adhesion.). When the surface veneer 23 is adhered to the surface of the resin-impregnated paper substrate 10, it is preferable to sand the surface of the resin-impregnated paper substrate 10 and affix the surface veneer 23 to the surface. By sanding the surface of the resin-impregnated paper base material 10 to roughen the surface, the adhesiveness can be improved when the surface veneer 23 is bonded with an adhesive.

When a plurality of resin-impregnated paper substrates 10 are laminated and integrated, it is preferable to apply a modified melamine resin between the plurality of resin-impregnated paper substrates 10 and integrate them.
That is, when laminating the resin-impregnated paper 5 which is impregnated with the resin and dried, the modified melamine resin is applied between the resin-impregnated papers 5. When only the melamine resin is used as the resin to be applied, the resin is mixed into the paper material 1 due to the low molecular weight, and the resin is mixed as shown in FIG.
Although an adhesive layer cannot be formed as in (a), a modified melamine resin (in the present example, for example, a resin obtained by adding latex to melamine resin) is applied and the molecular weight is increased to bond as shown in FIG. 8 (b). The layer 24 can be formed to increase the adhesive strength. In addition, other than the denatured melamine resin (eg, melamine resin plus latex) between resin-impregnated papers 5,
It is also preferable that a mixture of a thermosetting resin and a thermoplastic resin is applied.

When a plurality of resin-impregnated paper base materials 10 are laminated and integrated, the paper material 1 of adjacent resin-impregnated paper base materials 10 may be used.
It is also preferable that the direction of warpage is reversed. That is, the relationship between the warpage of the paper material 1 of the adjacent resin-impregnated paper base material 10 is shown in FIG.
The combination is performed so that the state shown in FIG. 9A or the state shown in FIG. In this way, the warpage of the building plate 13 can be reduced.

When the resin-impregnated paper substrate 10 is formed,
The resin to be impregnated into the paper material 1 is preferably a modified melamine resin (in this example, a resin obtained by adding a latex to a melamine resin, for example). In the case of melamine resin, the resin layer is scattered throughout the paper material 1 due to its low molecular weight, but a modified melamine resin (for example, a melamine resin to which latex is added)
In this case, as shown in FIG. 10, a layer D having a low molecular weight such as a melamine layer and a layer E having a high molecular weight such as a latex layer are formed on the surface of the paper material 1 to prevent aging. . The resin to be impregnated into the paper material 1 is a denatured melamine resin (for example, melamine resin plus latex).
Alternatively, a mixture of a thermosetting resin and a thermoplastic resin may be used.

The paper material 1 may contain a soft resin (paraffin wax) in an amount of 0.2 to 5% to prevent swelling of the fibrous material of the paper material 1 or to prevent deterioration.

[0034]

According to the first aspect of the present invention, a recycled paper is impregnated with a resin and cured to form a resin-impregnated paper base material. The dimensional stability can be improved, and the cost can be reduced because the recycled paper is used as the paper.

The second aspect of the present invention is as follows. A starch removal step of removing starch on the front and back surfaces of recycled paper, a resin impregnation step of impregnating the paper with the starch removed with a resin, a homogenization step of equalizing the impregnated resin, and removing water. Drying process, and a resin curing process of curing the resin by smoothing the surface layer, so that the starch of the paper material obtained by recycling the used paper is removed, the resin material is impregnated with the paper material, and the impregnated resin is homogenized. By drying and curing the resin, the resin-impregnated paper base can be formed successively and continuously, and the resin-impregnated paper base can be manufactured at low cost by using recycled paper. You can do it. Furthermore, even if a recycled paper is used, the starch can be smoothly impregnated with the resin by removing the starch on the front and back surfaces of the paper.

According to a third aspect of the present invention, in the second aspect, in the starch removing step, the starch on the front and back surfaces is removed by sanding the front and back surfaces of the paper material with a brush such as a nylon brush or a stainless steel brush. , Nylon brush,
By easily sanding the front and back surfaces of the paper material with a brush such as a stainless steel brush, the starch on the front and back surfaces can be easily removed and the impregnation property of the resin can be improved.

According to a fourth aspect of the present invention, in the second aspect, in the starch removing step, the starch on the front and back surfaces of the paper is removed by dipping the paper in hot water. By doing so, the starch can be removed so as to be dissolved, and the impregnation property of the resin can be improved. According to a fifth aspect of the present invention, in the second aspect, the resin impregnation step is performed by dipping the paper material into the impregnation tank, so that the resin can be easily impregnated simply by dipping the paper material into the impregnation tank. In addition, it is possible to prevent the adhesion of air when the paper material is inserted into the resin in the impregnation tank in a substantially vertical direction, so that it is possible to prevent the resin impregnation from becoming uneven.

According to a sixth aspect of the present invention, in the fifth aspect, in the resin impregnation step, the amount of the resin impregnated is increased by increasing the liquid temperature of the resin in the impregnation tank and decreasing the viscosity of the resin. The present invention can improve the impregnation property of the resin into the paper material, shorten the impregnation time, and improve the productivity. According to a seventh aspect of the present invention, in the second aspect, the homogenizing step is to homogenize the resin impregnated by passing the paper impregnated with the resin between elastic rolls such as sponge rolls and rubber rolls. In this case, the resin impregnated by pressing can be made uniform, and the resin can be stably made uniform.

According to an eighth aspect of the present invention, in the second aspect of the present invention, the resin curing step is performed by applying heat and pressure by a hot roll. It does not cause any harm when sticking a veneer to the substrate. According to a tenth aspect of the present invention, an architectural plate is formed by laminating the resin-impregnated paper base material obtained according to the first or second aspect on a substrate such as a plywood, an MDF board, or a particle board. By attaching a resin-impregnated paper base material to a substrate, it is possible to obtain an architectural plate material having good dimensional stability and low cost.

The twelfth aspect of the present invention is the tenth aspect of the present invention.
In the above, since the aqueous vinyl urethane-based adhesive was applied between the resin-impregnated paper base material and the substrate, a porous state was created between them, thereby improving the adhesiveness. In the invention of claim 13 of the present invention, in claim 10, since the surface of the resin-impregnated paper base material is sanded and a surface veneer is adhered to the surface, the surface of the resin-impregnated paper base material is sanded to roughen the surface. By forming the surface, the adhesiveness can be improved when the surface veneer is bonded with an adhesive.

The fourteenth aspect of the present invention is the tenth aspect of the present invention.
In, a plurality of resin-impregnated paper substrates are laminated, and when the resin to be impregnated is a melamine resin, the modified melamine resin is applied between the plurality of resin-impregnated paper substrates, The adhesiveness between them can be improved.
According to a fifteenth aspect of the present invention, in the tenth aspect, a plurality of resin-impregnated paper base materials are laminated, and the warp directions of the paper materials of adjacent resin-impregnated paper base materials are reversed. It is possible to reduce the warpage of the sheet material.

According to a sixteenth aspect of the present invention, a tenth aspect is provided.
In the above, since the thickness of the layer of the resin-impregnated paper substrate provided below the surface veneer is 0.8 mm or more, caster resistance can be ensured.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing an example of a process for producing a resin-impregnated paper base material and a building plate material of the present invention.

FIG. 2 is an explanatory view illustrating a state in which starch is removed in a starch removing step of the above, wherein (a) shows a state before starch is removed;
(B) after removing the starch.

FIG. 3 is a schematic cross-sectional view for explaining a state of impregnating another example of the above resin.

FIGS. 4A and 4B are explanatory diagrams illustrating a state in which the resin is homogenized in the homogenization step, in which FIG. 4A illustrates a state using an elastic roll, and FIG. 4B illustrates a state using an iron roll.

5A and 5B show a hot plate process of the above, wherein FIG. 5A is a schematic view of a hot-pressed state, FIG. 5B is a plan view of a hot-pressed resin-impregnated paper base, and FIG. FIG.

6A and 6B show the same hot roll process, wherein FIG. 6A is a schematic view of a hot-pressed state, FIG. 6B is a plan view of a hot-pressed resin-impregnated paper base, and FIG. FIG.

FIG. 7 is a cross-sectional view showing a building plate material according to the first embodiment.

FIGS. 8A and 8B are explanatory views illustrating a state in which a plurality of resin-impregnated paper base materials are laminated on the same.

FIGS. 9A and 9B are explanatory diagrams illustrating a relationship between warpage of another example of the paper material according to the above embodiment.

FIG. 10 is an explanatory diagram illustrating a state in which the paper material of another example of the above is impregnated with a resin.

FIG. 11 is a cross-sectional view of a conventional building board.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Paper material 2 Brush 3 Impregnation tank 4 Resin liquid 5 Resin impregnated paper 6 Elastic roll 7 Dryer 8 Nozzle 9 Heat roll 10 Resin impregnated paper base material 11 Substrate 13 Building plate material 18 Guide roller 23 Surface veneer

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04F 13/16 E04F 13/16 A

Claims (16)

[Claims] 1. A resin-impregnated paper substrate obtained by impregnating a resin into a paper material obtained by recycling used paper and curing the resin. 2. A starch removing step of removing starch on the front and back surfaces of a paper material obtained by recycling waste paper, a resin impregnating step of impregnating the paper material from which starch has been removed with a resin, and a homogenizing step of homogenizing the impregnated resin. And a drying step of removing moisture, and a resin curing step of curing the resin by smoothing the surface layer portion, the method comprising the steps of: 3. The resin-impregnated paper base according to claim 2, wherein the starch removal step removes the starch on the front and back surfaces by sanding the front and back surfaces of the paper material with a brush such as a nylon brush or a stainless steel brush. The method of manufacturing the material. 4. The method for producing a resin-impregnated paper substrate according to claim 2, wherein in the starch removing step, the starch on the front and back surfaces of the paper is removed by dipping the paper into hot water. 5. The resin impregnation step is performed by dipping a paper material into an impregnation tank. When the paper material is dipped into the impregnation tank, the paper material is placed in a substantially vertical direction to prevent air from adhering. The method for producing a resin-impregnated paper substrate according to claim 2, wherein: 6. The resin-impregnated paper base according to claim 5, wherein in the resin impregnation step, the amount of resin impregnation is increased by increasing the liquid temperature of the resin in the impregnation tank and decreasing the viscosity of the resin. Manufacturing method. 7. The homogenizing step, wherein the resin impregnated is passed through a paper material impregnated with a resin between elastic rolls such as sponge rolls and rubber rolls, thereby making the resin impregnated uniform.
A method for producing the resin-impregnated paper substrate according to the above. 8. The method for producing a resin-impregnated paper substrate according to claim 2, wherein in the resin curing step, heat and pressure are applied by a hot roll. 9. The method according to claim 5, wherein the resin impregnated in the paper material is a modified melamine resin. 10. An architectural plate material comprising the resin-impregnated paper substrate obtained according to claim 1 or 2 laminated on a substrate such as a plywood, an MDF board or a particle board. 11. The architectural plate material according to claim 10, wherein a resin impregnated paper base material is laminated on the surface side of the resin impregnated paper base material instead of pasting a surface veneer. 12. The building board according to claim 10, wherein an aqueous vinyl urethane adhesive is applied between the resin-impregnated paper base and the substrate. 13. The resin-impregnated paper base material is sanded on its surface and a surface veneer is adhered to the surface.
Architectural plate material as described. 14. A plurality of resin-impregnated paper substrates are laminated, and when the resin to be impregnated is a melamine resin, a modified melamine resin is applied between the plurality of resin-impregnated paper substrates. Item 10. A building plate according to item 10. 15. The architectural plate material according to claim 10, wherein a plurality of resin-impregnated paper substrates are laminated, and the warpage directions of the paper materials of adjacent resin-impregnated paper substrates are reversed. . 16. The building board according to claim 10, wherein the thickness of the layer of the resin-impregnated paper base provided below the veneer sheet is 0.8 mm or more.