JPS62264944A - Method of molding wpc with irregular pattern - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a method for molding WPC having an uneven pattern.

[Conventional technology]

Wood-plastic composite material (abbreviated as WPC) is a material that takes advantage of the performance of both wood and plastic by combining them.While plastic has a beautiful but monotonous and cold feel, WPC has a good grain of wood. It is a richly expressive material that can be emphasized.

The uncured body of WPC can also be considered as a kind of sheet molding compound (SMC) or FRP molding material. Generally, in SMC molding, the usual method is to prepare the molding material and bring it to the B stage (semi-cured state) before molding, but in WPC, molding using this method is difficult for the following reasons. .

fl) In WPC, if an attempt is made to improve the shelf life of a resin impregnating solution that is impregnated into wood, a polymerization initiation catalyst with a low decomposition point cannot be used.

(2) When using a polymerization initiation catalyst with a high decomposition point, SMC
In order to bring it to the B stage state, it must be heated. At this time, monomers in the fat are likely to scatter, causing defects such as poor curing.

In addition, when WPC is directly hot-pressed using a mold with an uneven shape, the resin overflows from the end of the impregnated veneer during pressing, and insufficient pressure is applied to the curved part (the concave bone of the mold). The disadvantage is that it is not possible to form beautiful shapes up to the edges of the image area.

[Problem that the invention attempts to solve]

An object of the present invention is to eliminate the above-mentioned drawbacks and provide a manufacturing method for obtaining a WPC having a beautiful uneven pattern in which the convex portions are also sufficiently hardened.

[Means for solving problems]

The present invention uses a mold having a desired uneven shape to produce WPC.
The above object is achieved by providing a projecting edge around the entire periphery of the mold or at a required portion when molding the mold.

Providing a ridge around the entire periphery of the mold or at a certain point will prevent the resin from flowing out from the butt end when pressing the resin-impregnated veneer, store the resin in the mold, and spread it to the same amount in the concave and convex parts. pressure can be applied, and therefore the convex portions, which tend to be insufficiently hardened, can be sufficiently hardened.

The projecting edges provided around the entire periphery of the mold or at certain parts have the effect of preventing the resin from flowing out as described above, and the impregnated veneer protruding outside the projecting edges can be cut or cut as shown in Figure 4. Since it can be set to a state containing
This eliminates the need for positioning and cutting steps in the subsequent processing of the obtained decorative panel, leading to process abbreviation.

According to the manufacturing method of the present invention, a stair tread can be manufactured using a mold as shown in FIG. 1, for example. 1st
In the figure, a plurality of grooves 2 are provided in a mold 1 in parallel, and projecting edges 3 are provided at both ends in a direction perpendicular to the grooves. Second
As shown in the figures and FIG. 3, by hot pressing the impregnated veneer 4 using this mold, a cured WPC product 5 as a stair tread on which anti-slip is simultaneously molded can be obtained. It has excellent abrasion resistance and remains beautiful even if it is slightly worn.

According to the molding method of the present invention, since a mold is used, the properties of the formed WPC surface are good even without sanding and painting steps, and therefore the product can be manufactured at low cost.

In the method of the present invention, not only WPC but also veneer or plywood may be laminated and hot-pressed on this. In this case, unevenness is less likely to be formed on the back side than in the case of only WPC, or it is not formed, and the substrate No adhesion failure occurs when pasting on.

〔Example〕

Examples of the present invention are given below, but the present invention is not limited thereto.

Example 1 A resin-impregnated veneer (0.611 mm thick) was placed in the mold shown in Figure 1.
Non-resin impregnated veneer (
1** Thickness), laminated plywood (3 Dragon Thickness) via urea resin adhesive, layered a rubber sheet on top, and applied a pressure of 10 to 25cm.
kg/c+ll, hot pressed at 110 to 150°C for 3 to 20 minutes to obtain a plate having an uneven surface. This was adhered to a board for treads with an adhesive (urea, urethane, phenol, etc.), and after cutting, a hardened WPC veneer was pasted around the periphery to form a tread board for stairs.

Example 2 A resin-impregnated veneer, a nonwoven fabric coated with and impregnated with adhesive, plywood coated with adhesive (3Ryatsu), release paper, and a rubber sheet were laminated in the mold shown in FIG. After hot-pressing molding under the following conditions, stair treads were made in the same manner. This product has a good walking feel, and the aesthetic appearance of WPC is not impaired even after the abrasion test.

Example 3 A desired sheet was obtained in the same manner as in Example 1 except that the plywood was removed and hot pressing was performed.

Example 4 A desired sheet was obtained in the same manner as in Example 1 except that the plywood and unimpregnated veneer were removed and hot pressing was performed.

Example 5 A desired sheet was obtained in the same manner as in Example 2 except that the plywood was removed and hot pressing was performed.

[Effects of the Invention] As explained above, by applying the method of the present invention when manufacturing WPC having an uneven pattern, the convex portions are also sufficiently hardened, and a beautiful WPC having wear resistance can be obtained.

Further, since the sheet can be cut or slit by the ridge provided around the mold, positioning and cutting steps during processing are unnecessary, and the process can also be omitted.

[Brief explanation of drawings]

Fig. 1 is a plan view of an example of a mold used in the present invention, Fig. 2 is a cross-sectional view showing the state of the resin-impregnated veneer before heat pressing, and Fig. 3 is a cross-sectional view showing the state of the resin-impregnated veneer in the heat-pressed state. FIG. 4 is a sectional view showing the WPC in a state where a cut is made by the ridge of the mold. 1... Mold 2... Groove 3... Edge 4... Resin-impregnated veneer 5... WPC cured product 6... Cut

Claims (1)

[Claims] WPC (wood, plastic composite material) with uneven pattern
WPC having an uneven pattern, which is characterized by hot pressing a resin-impregnated veneer using a mold having a desired uneven shape and having protrusions on the entire periphery or at required parts. molding method.