JPH0242041B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a reinforced decorative board that utilizes abnormal cell tissue called lumps and swellings that occur in tree trunks and large branches during the growth process of trees.

Trees such as elm and quince wood that have developed abnormal cells in their trunks and branches have lumps and swellings with complicated fiber orientations, and when cut, they are found to be different from normal wood veneers. The heather appears in a complicated manner, giving it an extremely elegant appearance.

Therefore, although some of these bulges have been used for crafts, etc., when they are cut into thin plates, the fiber direction of the bulges becomes perpendicular or nearly perpendicular to the board surface, resulting in a complicated state. As a result, it is extremely susceptible to chipping and has a weak strength, making it almost impossible to use it as a construction material.

For this reason, it may be possible to apply resin paint to the surface of the thin plate of the bulge to fill in the spaces between the fibers and strengthen it, but the thin plate of the bulge has a large number of knot holes and cracks. Not only is it difficult to completely fill and strengthen the voids with paint, but if you only finish with paint, the material will expand and contract due to changes in humidity, causing cracks, and dust will accumulate in those areas. It has the disadvantage that it accumulates and becomes dirty. or,
In the case of painting, there are problems in that there are many shrinkage spots in the paint, and it is necessary to apply multiple coats many times to form a smooth, mirror-like painted surface, which is time-consuming.

In order to eliminate such problems, the present invention has the following features:
A sheet-like material with good resin liquid permeability is pasted in advance on at least one side of the veneer veneer, and the gaps (holes) of this are filled with a filler that can be infiltrated with the resin liquid. Next, a synthetic resin liquid was injected into the knotted veneer, the sheet-like material, and the filler, and then heated and compressed to fill some of the resin liquid in the sheet-like material into the voids such as knot holes and cracks in the knotted veneer. By leaching the filler into the filler and curing the entire resin liquid in the veneer and sheet-like object, including the filler in the void, the veneer, sheet-like object, and filler are integrated and strengthened. To provide a method for manufacturing a reinforced decorative board, which can obtain a decorative board made of a veneer veneer with excellent properties.

To explain the method of the present invention in more detail, abnormal cell tissue parts called accumulations or swellings that occur in trees such as elm, quince, and walnut are cut and cut into sliced veneers, rotary veneers, sword veneers, etc. of appropriate thickness. Obtain a heathered veneer 1.

Since the running direction of the wood fibers in this wood fiber veneer 1 is completely irregular, the direction of the fibers in the wood fibers is perpendicular or nearly perpendicular to the board surface and is intricate. There are many voids 2 due to drop-outs and knotholes in the entered skin, and cracks at weak points such as the entered skin due to external force and shrinkage force during cutting and drying, and even the random cracks mentioned above. Gap area 2' due to cracks inside the thin plate due to uneven cell contraction due to the fiber direction
are occurring frequently.

Next, a sheet material 3 permeable to a synthetic resin liquid is adhered to the entire surface or a portion of one side of the heathered veneer 1 to cover the gap, thereby forming the decorative laminate main body A.

As the sheet material 3 having resin permeability, a fibrous material such as a nonwoven fabric or paper, a porous sheet material, or a wood veneer can be used.

Before injecting resin into the main body A of the decorative laminate obtained in this way, a filler that can be infiltrated with resin liquid is added to particularly large voids among the voids 2' such as knot holes in the heathered veneer 1 and the gap 2. Fill it with 4.

Such fillers 4 include organic fillers such as wood flour, walnut flour, coconut flour, and wheat flour, and inorganic fillers such as calcium carbonate, clay, titanium oxide, aluminum hydroxide, and perlite. A product made by adding an appropriate amount of an aqueous solution of glue, starch, casein, etc., or a synthetic resin such as acrylic resin, urea resin, vinyl acetate resin, or epoxy resin as a binder to the agent, and adding a coloring agent such as a dye or pigment and kneading the mixture. is used.

The filling material 4 is held inside the gap by the sheet material 3 attached to cover the gap in the heathered veneer 1, so it will not fall out from the gap 2 even during handling or injection. .

Next, a synthetic resin liquid is injected into the decorative laminate main body A by a method such as pressurized injection, reduced pressure injection, reduced pressure pressurized injection, or impregnation.

The synthetic resin liquid to be injected may be a condensation type synthetic resin liquid, an addition polymerization type synthetic resin liquid, a thermoplastic resin liquid, or a thermosetting type synthetic resin liquid.

In addition, suitable solvents, plasticizers, curing agents, coloring agents such as pigments and dyes, and other additives may be mixed into such synthetic resin liquid.

When the synthetic resin liquid is injected into the main body A of the decorative laminate A, a large amount of the resin liquid penetrates into the inside of the sheet-like object 3, and the entire sheet-like object 3 is sufficiently impregnated with the resin liquid, and the inside of the veneer veneer 1 and the filler are completely impregnated with the resin liquid. Agent 4 is also injected throughout. In this state, large gaps such as knotholes in the heathered veneer 1 are only adhered to and not filled with resin liquid.

When the decorative laminate body A into which the synthetic resin liquid has been injected is heated under pressure using an appropriate means such as a hot press, a part of the resin liquid in the sheet-like material 3 penetrates into the heathered veneer 1. The exudate is used to fill voids such as knotholes, cracks, cracks, etc. in the knotted veneer 1, the gap portions 2 and 2', the inside of the filler 4, and the gaps 2 and 2' between the filler 4 and the like.

With the synthetic resin liquid filled up to the lump veneer 1 and the filler 4 by pressing in this way, the synthetic resin liquid is cured by heating, and as a result of the hardening, the lump veneer 1 and the sheet are A reinforced decorative board in which the shaped material 3 is firmly integrated can be obtained.

Note that the sheet-like material 3 may be handled while being fixed to the veneer veneer after the resin liquid has hardened, but if it is used by adhering it to a base plate, etc., it may be removed after the resin has hardened. It is.

Next, specific examples of the present invention will be shown.

Example 1 A bump formed on the trunk of an elm tree was cut to a thickness of 1
Obtain a veneer of elm wood with a diameter of 30 mm and use a guillotine to
It was cut into a veneer of cm x 30cm. This veneer had many knot holes, cracks, cracks, and other gaps.

Next, paper is pasted on the entire back side of this heathered veneer, and a filler made of calcium carbonate mixed with vinyl acetate and an appropriate coloring agent is applied from the front side to the gaps such as knot holes and cracks. , then put it in a vacuum cooker and evacuate it to 10mmHg.
It was left in this state for 30 minutes.

Next, a synthetic resin liquid prepared by adding 40% by weight of styrene monomer and 1% of BPO as a curing agent to an unsaturated polyester resin was placed in the vacuum pot, and the mixture was allowed to stand for 30 minutes.

The resin-injected heather veneer was taken out of the vacuum pot and heated at 135°C for 30 minutes using a hot press.
By heating and pressing at Kg/cm ² for 10 minutes, the resin liquid impregnated in the backing paper is leached out, and the resin liquid is cured by filling the inside of the filler and the gaps of the heather veneer. Ta.

The thus obtained synthetic resin-injected veneer veneer has beautiful bulges in which gaps such as knotholes and cracks are strongly reinforced by filling with synthetic resin. It was an extremely strong structure with two parts fixed together.

Example 2 The elm wood veneer used in Example 1 was made into 30 cm x 30 pieces.
cm size, and partially adhere a nonwoven fabric to the knot holes and areas where the gaps due to the falling of the skin are densely packed so as to cover the gaps,
The same filler as in Example 1 was filled into the void from the side opposite to the surface to which the nonwoven fabric was attached, and then the mixture was placed in a vacuum pot and a synthetic resin liquid was injected under the same conditions as in Example 1.

The heat treated veneer veneer thus injected was taken out of the vacuum pot, placed on a plywood board with the non-woven fabric adhesive side facing up via urea adhesive, and heated at 135°C between the hot plates of a hot press at 3 kg/cm ^{2 .} By heating and compressing the nonwoven fabric for 10 minutes, the resin liquid impregnated into the nonwoven fabric is filled into the knot holes and other gaps in the knot veneer, and the resin liquid hardens and the base plate and the knots are cured. The veneers were glued together at the same time.

Next, the surface of the thus obtained decorative material pasted with the heathered veneer veneer was sanded to remove the nonwoven fabric adhered to the upper surface of the veneer veneer, and a painting finish was applied.

In the synthetic resin-injected veneer-covered decorative material obtained in this way, gaps such as knotholes and skin shedding were strongly reinforced by the resin liquid in the filler and the synthetic resin leached from the sheet material. It had beautiful lumps.

In the above embodiments, the sheet-like material was attached only to one side of the veneer veneer, but it may be attached to both the front and back sides. At this time, when pasting on both sides, if a transparent sheet material is used on at least one side, a stronger decorative material can be obtained without impairing the cosmetic properties. It is something.

As described above, in the present invention, a resin-permeable sheet-like material is adhered to the entire surface or a portion of one side of a veneer veneer having a large number of gap areas such as knotholes and cracks, and then the gap areas are covered. A filler capable of infiltrating the resin liquid is filled into the gap, and then a synthetic resin liquid is injected into the veneer veneer, the sheet-like object, and the filler, and then heated under pressure to form the inside of the sheet-like object. This method relates to a method for manufacturing a reinforced decorative board characterized in that a part of the synthetic resin liquid is leached into the gap portion of the lump veneer and inside the filler to harden the entire synthetic resin liquid. Since a sheet-like material is attached to the heathered veneer in advance, the heathered veneer, which has many weak points such as knot holes and cracks, is reinforced by the sheet-like material and may break during handling during the injection process. In addition, since the sheet-like material has good permeability to the resin liquid, it can be impregnated with a sufficient amount of resin liquid, and it is possible to eliminate gaps such as knot holes and cracks in the heather veneer during heat pressing. The resin liquid can be press-fitted and filled into the part, and in this state, the resin liquid hardens, and the bulge veneer, the sheet material, and the filler are firmly integrated through the resin, and the bulge veneer is solidified. The gap portion is completely filled with the filler and the injected resin, and as a result, it is possible to obtain a makeup that is excellent in strength and exhibits the natural and beautiful appearance of the heather.

In addition, the entire decorative board is made of synthetic resin and has uniform strength, making it excellent in abrasion resistance even when used as a flooring material, and even when the surface is painted, the synthetic resin penetrates and hardens the filler in the gaps. Since the coating is filled with silica, it provides a beautiful finish without causing uneven coating.

In addition, the filler in the gap is fixed and fixed integrally with the veneer and the sheet by the injected resin liquid inside the veneer and the resin liquid exuded from the sheet and hardened, so it is not affected by impact. There is no risk of it falling off from the gaps even if the surface is worn, and the beautiful decorative surface can be maintained for a long period of time.In addition, since it is reinforced with the same resin as the veneer veneer, the overall strength is uniform, and there is no wear due to hardness. Overall, it is possible to form a decorative surface with extremely excellent wear resistance.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention; FIG. 1 is a simplified sectional view before resin injection, FIG. 2 is a simplified sectional view of the resulting decorative board, and FIG. 3 is a perspective view thereof. A... Mainly decorative board, 1... Heather veneer veneer, 2, 2'
...Gap or crevice portion, 3...Sheet-like material.

Claims (1)

[Claims] 1. After applying a resin-permeable sheet material to the entire surface or a portion of one side of a heathered veneer that has a large number of gaps such as knot holes and cracks to cover the gaps, the resin liquid is applied to the gaps. A wettable filler is filled, and then a synthetic resin liquid is injected into the veneer veneer, the sheet-like material, and the filler, and then heated under pressure to remove a portion of the synthetic resin liquid in the sheet-like material. A method for manufacturing a reinforced decorative board, characterized in that the entire synthetic resin liquid is cured by leaching it into the gap portions of the heathered veneer and inside the filler.