【発明の詳細な説明】
【産業上の利用分野】
この発明は、テーブル、カウンター、家具、音響機器ケ
ース等の木製什器や床材、壁材等の木質建材、車内装備
品などの表面材として好適に用いられる木質系複合材を
製造する方法に関し、硬化性樹脂液と充填剤とからなる
混練物を平板状とし、この上に木材小片を散布し、加熱
加圧し、さらに表面研削することにより、木材小片の分
散を均一とし、製造を容易とするようにしたものである
。
（従来の技術）
このような木質系複合材を製造する方法として、先に本
出願人が特許［６１−１６１５６４号として提案したも
のがある。この方法は、未硬化樹脂液に木材小片を混合
し、この混合物を型枠等に流して平坦に均らし、加熱加
圧して固化させ、ついで固化物の表面を研削する方法で
ある。
〔発明が解決しようとする問題点〕
しかしながら、この製法では未硬化８１Ｗｉ液に木材小
片を加えて撹拌混合しているため、樹脂液と木材小片と
の混合が均一に行われず、木材小片を樹脂中に均一に分
散させることが困難である問題があった。これは、木材
小片の寸法が３〜５０ｍと粗大であること、樹脂液と木
材小片との比重差があることなどのためである。
〔問題点を解決するための手段〕
この発明では、硬化性樹脂液に充填剤を混合した混練物
を平板状となし、この上から木材小片を散布し、ついで
加熱加圧し、表面研削することをその解決手段とした。
この発明で使用される樹脂液としては、不飽和ポリエス
テル樹脂、ポリウレタン樹脂、ジアリルフタレート樹脂
、エポキシ樹脂、シリコーン樹脂、フェノール樹脂、ア
クリル樹脂等の硬化前の状態が液状の熱硬化性樹脂の未
硬化状態の樹脂液が適している。
この樹脂液に充填剤を配合し、混練する。充填剤として
は、炭酸カルシウム、タルク、酸化チタン、シリカ、ガ
ラス粉末などが使用される。充填剤の配合けは、樹脂液
１００１准部に対して１００〜４００重量部程度とされ
る。この樹脂液と充填剤とからなる混練物は、したがっ
’ＣＢ粘度となり、大略ペースト状を呈する。この混練
物には、樹脂の硬化剤が添加され、必要に応じて着色剤
、安定剤等の添加剤を加えることができる。
ついで、第１図に示すように、この混練物を浅底の型１
内に流し込み、シリコーンローラやコテなどを用いて平
らに均し、平板状混線、物２とする。
勿論、型１を用いずに平板状としてもよい。この平板状
物の厚さは、約１〜２履、好ましくは１〜１．５ｍ＋ｍ
程度とされる
ついで、混練物２が未硬化状態にあるうちに、第２図に
示すように平板状物上に木材小片３・・・を散布する。
木材小片３には、黒タン、ブナ、ナラ、トチ、セン、タ
モ、カエデ、カバ、カシなどの広葉樹、スギ、ヒノキ、
マツ、スブルース、アガチスなどの針葉樹などの木材の
小片であって、その形状は特に限定されないが、板状、
直方体状、立方体状、粒状などの切削加工により形成さ
れた小片、またはこれらの小片を機械的衝撃、ローラ加
圧によって破砕した小片などの様々の形状のものが用い
られる。この小片２の大きさは、その形状を直方体状と
した場合、幅３〜７ ｔａｇ、長さ３〜２０ ａｍ 、
厚さ０．２〜３ｍから幅２０〜２５ｍ１＋１長さ２０〜
１０Ｇ、、厚さ０．２〜３ｍｗ＋までの偏平なものが好
ましく、円柱状であれば径５〜１００履、厚さ０．２〜
５１ｍ程度とされ、破砕片であれば幅１〜４履、長さ３
〜３０履、厚さ０．２〜３膳程度が望ましい。また、こ
の木材小片３は、樹種の異なるもの、色調の異なるもの
などが混入していてもよい。
また、木材小片３には必要に応じて寸法安定化処理を施
したものを用いることもできる。寸法安定化処理は、木
材小片を無水酢酸で処理するアセチル化処理、ポリエチ
レングリコール、ポリプロピレングリコールを含浸する
方法、液状のフェノール樹脂、不飽和ポリエステル樹脂
、エポキシ樹脂、シリコーン樹脂、ウレタン樹脂、アク
リル樹脂などの先の硬化性樹脂液と同種の樹脂を含浸、
固化させる方法などがある。また、ポリエチレングリコ
ールや液状樹脂中に有機ハロゲン系防腐剤を混入してお
き、寸法安定化処理と防腐処理とを同時に行うこともで
きる。
また、木材小片３には、その一部または全部を１種また
は２種以上の色調に着色処理を施したものを用いること
ができるが、黒ダンなどの黒色、レンガス、バトックな
どの黄色、ナラ、ブナなどの白色等木材の自然色を生か
ずこともまた好ましい。着色処理は、染料、顔料などの
色剤を水、有機溶剤などの溶剤に溶解した色剤濃度０．
１〜１０重量％程度の着色液に多数の木材小片を浸漬す
る方法などが用いられる。着色液を加温して着色液の浸
透を促し、濃色に着色することもできる。また、寸法安
定化処理の際に、種々の液状樹脂中に色剤を溶解してお
き、寸法安定化処理と同時に着色処理を行うこともでき
る。
このような木材小片３・・・の散布は、目の粗い篩など
を用いる方法や直接子′Ｃ散布する方法によって適宜行
われる。木材小片３・・・の散布ｍは、前記平板状物の
表面の約１０〜９０％、好ましくは約７０〜９０％が覆
い隠される程度とすることが望ましい。
木材小片３・・・の散布後、このものを加熱加圧するこ
とになるが、これに先立ら散布後の平板状混練物２を、
温度１５〜３０’Ｃ１時間３〜４時間の条件で静冒し、
硬化性樹脂の硬化を進めて、混練物２の粘度を高め、取
扱いを容易とし、混練物２中の気泡を除去することもで
きる。
加熱加圧は、周知のホットプレスなどの加熱加圧手段を
用いて行われ、散布された木材小片３・・・上に離型フ
ィルム、当板を置き、圧力０．５〜１．５８Ｐａ 、温
度１００〜１３０℃、時間２〜５分程度の条件で行われ
る。この加熱加圧により、平板状混練物上に散布された
木材小片３・・・がこの混練物２に圧入するとともに混
練物２が硬化し、各々の木材小片３・・・の大部分が混
練物２中に埋没した状態の固化物が得られる。
ついで、この固化物の表面を種々の研削手段により研削
して樹脂固化物と埋設木材小片との表面を面一とし、木
材小片を表面に露出させれば、第３図におよび第４図に
示すような目的とする木質系複合材４が得られる。
このような製法によれば、平板状混練物２上に木材小片
３・・・を散布しているので、混練物２上に均一に木材
小片３・・・を配することができ、木材小片３・・・の
均一分散が可能となる。特に、木材小片３・・・を散布
するものであることから、目視によって散布具合を調節
でき、容易に木材小片３・・・の均一分散を計ることが
できる。さらに、散布であるので、木材小片３・・・が
平板状混練物２の中に深く沈むことがなく、その表面に
集中して小片３・・・を配することができ、木材小片３
・・・の吊を少なくしても、表面の美しい好適には薄板
状の木質系複合材４を得ることができる。なお、この複
合材の形状は、平板状が好適に形成されるが、これに限
らず、加熱加圧時の型面の形状を変更することにより、
２次元状ないし３次元状の曲面を有する形状の複合材を
形成することもできる。
このようにして得られた木質系複合材４は、好ましくは
合板、パーヂクルボート等の木質系堰板または、繊維強
化合成樹脂等の樹脂系基板と接着ｆｔａ層して各種の製
品に使用される。また、この木質系複合材４は研削処理
により木材小片３・・・の一部または大部分が露出して
いるので、これの表面にポリエステル樹脂、ポリウレタ
ン樹脂等の塗料による塗装を施して塗膜を形成しておく
ことが特に望ましい。
〔実施例〕
不飽和ポリエステル樹脂未硬化液１００重石部に炭酸カ
ルシウム３００重量部と黄色顔料１重量部を配合し、混
練して型１に流し込み、ローうで均して厚さ１．５麿の
平板状混練物２とした。
一方、ブナ、ナラなどを幅１０〜２０厘、長さ１０〜２
０ｊｗ、厚さ１〜１．５履の大きさの小片に切新し、こ
れを乾燥したのち不飽和ポリエステル樹脂未硬化液中に
浸漬し、樹脂液を含浸し、常温で放置して半硬化状態と
した木材小片３・・・を平板状混練物２上に手で散布し
た。散布量は混練物２の全表面の８５〜９０％が隠れる
ように均一に配置した。これを室温で３時間静置したの
ち、ホットプレスにて圧力１８Ｐａ 、 温度１００℃
、時間５分加熱加圧で固化物とした。このものをサンダ
ー掛けして固化物とした。このものをサンダー掛けして
研削し、厚さ約１．５ｍｇ＋の木質系複合材を得た。
〔発明の効果〕
以上説明したように、この発明の木質複合材の製法は、
硬化性樹脂液に充填剤を配合した混練物を平板状となし
、この上に木材小片を散布し、ついで加熱加圧しさらに
表面研削するものであるので、木材小片の分散の均一化
を容易に計ることができ、かつ目視によりその分散ｍを
調節できる。
また、木材小片の混練物への沈み込みが少なく、表面に
集中させることができ、木材小片の使用量を削減できる
などの効果を得ることができる。[Detailed Description of the Invention] [Field of Industrial Application] This invention can be used as a surface material for wooden fixtures such as tables, counters, furniture, audio equipment cases, wooden building materials such as flooring and wall materials, and car interior fixtures. Regarding the method of manufacturing a wood-based composite material that is preferably used, a kneaded material consisting of a curable resin liquid and a filler is made into a flat plate, small pieces of wood are sprinkled on this, heated and pressurized, and the surface is ground. , the wood chips are uniformly dispersed to facilitate manufacturing. (Prior Art) As a method for manufacturing such a wood-based composite material, there is a method previously proposed by the present applicant as Patent No. 61-161564. This method involves mixing small pieces of wood with an uncured resin liquid, pouring this mixture into a mold or the like, leveling it out, heating and pressurizing it to solidify it, and then grinding the surface of the solidified product. [Problems to be solved by the invention] However, in this manufacturing method, small pieces of wood are added to the uncured 81Wi liquid and mixed by stirring, so the resin liquid and the small pieces of wood are not mixed uniformly, and the small pieces of wood are mixed with the resin. There was a problem in that it was difficult to uniformly disperse the powder. This is because the size of the wood pieces is large, ranging from 3 to 50 m, and there is a difference in specific gravity between the resin liquid and the wood pieces. [Means for solving the problem] In the present invention, a kneaded mixture of a curable resin liquid and a filler is made into a flat plate shape, small pieces of wood are sprinkled on top of the kneaded product, and then the plate is heated and pressurized, and the surface is ground. was the solution. The resin liquid used in this invention includes uncured thermosetting resins that are in a liquid state before curing, such as unsaturated polyester resins, polyurethane resins, diallyl phthalate resins, epoxy resins, silicone resins, phenolic resins, and acrylic resins. State resin liquid is suitable. A filler is added to this resin liquid and kneaded. As fillers, calcium carbonate, talc, titanium oxide, silica, glass powder, etc. are used. The filler is added in an amount of about 100 to 400 parts by weight per 1001 parts of the resin liquid. The kneaded product consisting of the resin liquid and filler therefore has a 'CB viscosity and is approximately paste-like. A curing agent for the resin is added to this kneaded material, and additives such as a coloring agent and a stabilizer can be added as necessary. Next, as shown in Figure 1, this kneaded material was placed in a shallow mold 1.
Pour the mixture into the inside and smooth it using a silicone roller or a trowel to form a flat mixed wire, product 2. Of course, it is also possible to form a flat plate without using the mold 1. The thickness of this flat plate is approximately 1 to 2 m, preferably 1 to 1.5 m+m
Then, while the kneaded material 2 is in an uncured state, small pieces of wood 3 are sprinkled onto the flat material as shown in FIG. Wood pieces 3 include hardwoods such as black tongue, beech, oak, horse chestnut, Japanese ash, maple, birch, and oak, cedar, cypress,
A small piece of wood such as a coniferous tree such as pine, subluce, or agathis, and its shape is not particularly limited, but it can be plate-shaped,
Various shapes are used, such as small pieces formed by cutting such as rectangular parallelepiped, cubic, and granular shapes, or small pieces crushed by mechanical impact or roller pressure. The size of this small piece 2 is, when its shape is a rectangular parallelepiped, a width of 3 to 7 tags, a length of 3 to 20 am,
Thickness 0.2~3m, width 20~25m1+1 length 20~
10G, a flat one with a thickness of 0.2~3mw+ is preferable, and a cylindrical one with a diameter of 5~100 mm and a thickness of 0.2~3mW+ is preferable.
It is said to be about 51m long, and if it is a crushed piece, it will be 1 to 4 feet wide and 3 feet long.
~30 shoes and a thickness of 0.2 to 3 pairs are desirable. Further, the wood pieces 3 may include wood pieces of different species, wood pieces of different colors, and the like. Furthermore, the small pieces of wood 3 may be subjected to dimensional stabilization treatment if necessary. Dimensional stabilization treatments include acetylation treatment in which small pieces of wood are treated with acetic anhydride, impregnation with polyethylene glycol or polypropylene glycol, liquid phenolic resin, unsaturated polyester resin, epoxy resin, silicone resin, urethane resin, acrylic resin, etc. Impregnated with the same type of resin as the curable resin liquid at the end of the
There are ways to solidify it. Alternatively, the dimensional stabilization treatment and the preservative treatment can be performed simultaneously by mixing an organic halogen preservative into the polyethylene glycol or liquid resin. Further, the wood pieces 3 may be partially or entirely colored in one or more colors, including black such as black dun, yellow such as brick and buttock, and yellow such as brick and buttock. It is also preferable not to take advantage of the natural color of the wood, such as the white color of beech. Coloring treatment is performed by dissolving a colorant such as a dye or pigment in a solvent such as water or an organic solvent at a concentration of 0.
A method such as immersing a large number of small pieces of wood in a coloring liquid of about 1 to 10% by weight is used. It is also possible to heat the coloring liquid to promote penetration of the coloring liquid, thereby producing a deep color. Further, during the dimensional stabilization treatment, a coloring agent can be dissolved in various liquid resins, and the coloring treatment can be performed simultaneously with the dimensional stabilization treatment. The scattering of such small pieces of wood 3 is carried out as appropriate by a method using a coarse sieve or by a method of directly scattering the wood chips. The scattering m of the small pieces of wood 3 is desirably such that about 10 to 90%, preferably about 70 to 90%, of the surface of the flat object is covered. After scattering the small pieces of wood 3..., this material will be heated and pressurized, but prior to this, the plate-shaped kneaded material 2 after being spread,
Leave to stand at a temperature of 15 to 30'C for 1 hour and 3 to 4 hours,
By advancing the curing of the curable resin, the viscosity of the kneaded material 2 can be increased, handling can be facilitated, and air bubbles in the kneaded material 2 can be removed. The heating and pressing is performed using a heating and pressing means such as a well-known hot press, and a release film and a backing plate are placed on top of the scattered wood pieces 3, and a pressure of 0.5 to 1.58 Pa is applied. It is carried out at a temperature of 100 to 130°C and for a time of about 2 to 5 minutes. By this heating and pressurization, the small pieces of wood 3... scattered on the flat plate-shaped kneaded material are press-fitted into the kneaded material 2, and the kneaded material 2 is hardened, and most of the small pieces of wood 3... are kneaded. A solidified product is obtained which is buried in the material 2. Next, the surface of this solidified material is ground by various grinding means to make the surfaces of the solidified resin material and the buried wood pieces flush, and the wood pieces are exposed on the surface, as shown in FIGS. 3 and 4. The desired wood-based composite material 4 as shown is obtained. According to such a manufacturing method, since the small wood pieces 3 are scattered on the flat plate-shaped kneaded material 2, the small wood pieces 3 can be uniformly distributed on the kneaded material 2, and the small wood pieces 3... Uniform dispersion of 3... becomes possible. In particular, since the small pieces of wood 3 are to be scattered, the degree of scattering can be adjusted visually, and the uniform dispersion of the small pieces of wood 3 can be easily measured. Furthermore, since it is a scattering method, the small pieces of wood 3 do not sink deeply into the flat kneaded material 2, and the small pieces of wood 3 can be concentrated on the surface of the mixed material 2.
Even if the suspension of ... is reduced, it is possible to obtain a wood-based composite material 4 with a beautiful surface, preferably in the form of a thin plate. Note that the shape of this composite material is preferably formed into a flat plate shape, but it is not limited to this, and by changing the shape of the mold surface during heating and pressing,
It is also possible to form a composite material having a two-dimensional or three-dimensional curved surface. The wood-based composite material 4 thus obtained is preferably used in various products in the form of an adhesive fta layer with a wood-based dam board such as plywood or a particle boat, or a resin-based substrate such as fiber-reinforced synthetic resin. In addition, since some or most of the small wood pieces 3 of this wood-based composite material 4 are exposed due to the grinding process, the surface of this material is coated with a paint such as polyester resin or polyurethane resin to create a coating film. It is particularly desirable to form a [Example] 300 parts by weight of calcium carbonate and 1 part by weight of yellow pigment were blended with 100 parts by weight of uncured unsaturated polyester resin liquid, kneaded, poured into mold 1, and smoothed with a rower to a thickness of 1.5 mm. A flat plate-like kneaded product 2 was obtained. On the other hand, beech, oak, etc. are 10 to 20 rin wide and 10 to 2 rin long.
Cut it into a small piece of 0jw, 1 to 1.5 shoes thick, and after drying it, immerse it in an uncured unsaturated polyester resin solution, impregnate it with the resin solution, and leave it at room temperature to semi-cure. The conditioned wood pieces 3 were spread by hand onto the flat kneaded material 2. The amount of spraying was uniformly distributed so that 85 to 90% of the entire surface of the kneaded material 2 was covered. After leaving this at room temperature for 3 hours, it was heated in a hot press at a pressure of 18 Pa and a temperature of 100°C.
It was made into a solidified product by heating and pressurizing for 5 minutes. This material was sanded to form a solidified product. This material was sanded and ground to obtain a wood-based composite material with a thickness of approximately 1.5 mg+. [Effects of the Invention] As explained above, the method for manufacturing a wood composite material of the present invention is as follows:
A kneaded mixture of curable resin liquid and filler is made into a flat plate, and small pieces of wood are sprinkled on top of this, then heated and pressed, and the surface is ground, making it easy to evenly distribute the small pieces of wood. The dispersion m can be adjusted visually. In addition, the small pieces of wood are less likely to sink into the kneaded material and can be concentrated on the surface, resulting in the effect that the amount of small pieces of wood used can be reduced.
【図面の簡単な説明】[Brief explanation of the drawing]
第１図ないし第３図は、この発明の製法の一例を工程順
に示した概略断面図、第４図はこの発明の製法によって
得られた木質系複合材を示す平面図である。
１・・・・・・型、
２・・・・・・平板状混練物、
３・・・・・・木材小片、
４・・・・・・木質系複合材。
出願人 日本楽器製造株式会社
ど
第３図
第４図1 to 3 are schematic cross-sectional views showing an example of the manufacturing method of the present invention in the order of steps, and FIG. 4 is a plan view showing a wood-based composite material obtained by the manufacturing method of the present invention. 1... Mold, 2... Flat kneaded material, 3... Small piece of wood, 4... Wood composite material. Applicant Nippon Musical Instruments Manufacturing Co., Ltd. Figure 3 Figure 4