JPH0578401B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for producing a resin-reinforced decorative material in which the transparent wood grain pattern and the color of the backing material are in harmony.

Structure of conventional examples and their problems Conventionally, in order to manufacture this type of decorative material, resin liquid is injected into a wood veneer using reduced pressure, increased pressure, or reduced pressure in an airtight container such as an injection pot. A known method is to place and bond a resin-injected wood veneer onto a plate-shaped base material coated with a colored adhesive, but this method involves injecting a resin solution into the wood veneer, solidifying process, and colored plate-like base material. Since the bonding process with the base material is a separate process, the manufacturing process requires considerable effort, and the resin injection process is performed in a closed container such as an injection pot, which causes the following problems.

It is difficult to change the type, blending ratio, color, etc. of the resin liquid to be injected frequently and for each small lot.
It is not possible to handle low-volume, high-mix production.

Immediately after the injection treatment, the wood veneer has a large amount of unsolidified resin liquid attached to the entire surface.
When transferring to the next curing process or adhesion process with other materials, there are problems such as resin liquid adhering to conveyance equipment etc. and contaminating the equipment, making it difficult to handle.

There is also a lot of waste of resin liquid as it adheres to the wood veneer.

Purpose of the Invention The present invention has been made in view of the above-mentioned problems of the conventional art.The present invention has been made in view of the above-mentioned problems of the conventional art. Manufacture of decorative wood materials that have excellent flexibility and can be produced inexpensively and efficiently without requiring large-scale equipment such as injection pots, are easy to handle during the process, and can be produced in small quantities and in a wide variety of products. The present invention provides a method.

Structure of the Invention In order to achieve the above-mentioned object, the method for manufacturing a reinforced wooden decorative board material of the present invention includes a thin wood board and a gap between the thin wood board and the backing material having air permeability. A synthetic resin liquid layer with a coating amount sufficient to make the spring material part of the thin plate transparent is placed so that this synthetic resin liquid layer faces the transparent sheet side, and this is pressurized between upper and lower pressure plates. By press-fitting the synthetic resin liquid layer into the void of the thin wood board, at the same time it permeates to the surface of the backing material to integrate the thin wood board, the transparent sheet, and the backing material, thereby making the spring material portion of the thin wood board transparent.

Transparent sheets used in the method of the present invention include synthetic resin sheets, films, or thin plates such as PVC, acrylic, ABS, polyethylene, polypropylene, and polyester; and thin paper and linter paper that become transparent by impregnating them with resin liquid. There are fibrous sheets such as synthetic paper, etc., and such sheets are selected and used depending on the properties of the decorative material to be obtained.

Incidentally, such a transparent sheet may be colored as appropriate to the extent that transparency is not lost, or may be partially printed with a wood grain pattern or the like as necessary.

Furthermore, after the transparent sheet is integrated with the colored backing material through the thin wood board, it may be removed by peeling or grinding after confirming that the synthetic resin liquid has been filled.
Alternatively, it may be bent and attached to a synthetic base plate and then removed. After that, a decorative finish such as painting may be applied.

On the other hand, breathable lining materials include paper,
A fibrous sheet such as non-woven fabric, or an organic or inorganic porous plate such as plywood, particle board, gypsum board, or calcium silicate board is used.
Depending on the intended use of the decorative material, an opaque material colored in an appropriate color or a sheet-like material that becomes transparent upon penetration of a resin liquid is selected.

That is, when obtaining a decorative material that has translucency and flexibility, a fibrous sheet that becomes transparent upon penetration of resin liquid is used; A colored fibrous sheet is used, and a porous plate-like material is used when obtaining a plate-like decorative material having appropriate rigidity.

The thin wood plates that are superimposed and integrated between the breathable backing material and the transparent sheet may be thin wood plates of any species, such as softwood or hardwood. Because of this, a thin plate with a thickness of 0.6 or less is used.

Further, the thin wood board may be a thin board made by laminating and bonding a plurality of wood blocks in advance to form an assembled block body, and slicing this block body, and further dyeing, bleaching, etc., as necessary. You can stay there.

Further, the thin wood board may be bonded to the backing material, but in this case, the interface between the thin wood board and the backing material is partially bonded to maintain air permeability.

The reason for using a thin wood board with a pressure of 0.6 mm or less is as follows.

In other words, when thin wood boards are sliced to a thickness of 0.6 mm or less, a portion of the conduit or tracheid penetrates from the surface to the back of the thin board, which improves air permeability and resin liquid permeability. This is because the applied amount of the resin liquid can be applied to the surface of the thin plate using a pressure plate and can be sufficiently penetrated from the surface to the inside.

The synthetic resin liquid that is press-fitted into the thin wood board is composed of either thermosetting resin or thermoplastic resin, or a mixture of both.

According to general classification, thermosetting resins are phenol formaldehyde cocondensates,
These include melamine/formaldehyde cocondensates, polyurethane resins, polyester resins, epoxy resins, diallyl phthalate resins, benzoguanamine resins, etc. Thermoplastic resins include acrylic resins, modified vinyl resins, etc., and these prepolymers and polymers alone Alternatively, a mixture of monomers and oligomers may be used.

In addition, when forming a flexible decorative material, it is desirable to use a synthetic resin liquid that has appropriate flexibility after curing, for example,
As long as it is thermosetting, it is possible to use a resin produced in advance under formulation or reaction conditions that exhibits flexibility, or a resin that is imparted with flexibility by adding a plasticizer.

Further, this synthetic resin liquid can be colored by adding dyes or pigments to the extent that transparency is not lost.

The following methods are available for interposing a synthetic resin liquid between a thin wood board and a transparent sheet.

a method of applying resin liquid directly to the surface of thin wood boards;
For example, a method of coating one or both sides of a thin wood board with a device such as a spray gun, roll coater, flow coater, knife coater, etc., and polymerizing a transparent sheet on the surface coated with the resin liquid.

b. A method in which a synthetic resin liquid is applied to a transparent sheet, and the surface coated with this resin liquid is overlapped with a thin wood board.

c. A method of combining a and b.

Among the above methods, if a synthetic resin liquid is applied to a transparent sheet and the coated layer of the synthetic resin liquid is superimposed on a thin wood board, the transparent sheet absorbs almost no synthetic resin liquid compared to a thin wood board, so the resin It is possible to provide a uniform coating thickness of the liquid layer and overlap it with the thin wood board, making it easy to adjust the coating thickness of the resin liquid layer, achieving uniform transparency, and making it possible to overlap the thin wood board. The resin layer is easier to handle because the sheet does not crack compared to when it is applied and handled, and in addition, air does not enter the interface between the thin wood board and the transparent sheet, resulting in stable cosmetic properties. is obtained.

The viscosity of the synthetic resin liquid is preferably such that it does not drip from the thin wood board, transparent sheet, or backing material.

In addition, the amount of synthetic resin liquid to be applied depends on the performance required of the reinforced wood thin board to be obtained, such as water resistance, abrasion resistance, weather resistance, tensile strength, etc., and the thickness of the reinforcing layer depending on the degree of transparency, and the resin. It is difficult to make a general statement because it varies depending on the amount distribution or the amount of impregnation, etc., but it is sufficient if the amount of application is sufficient to fill the voids inside the thin wood board and make the spring material transparent.
A coating amount of 150 to 450 g/m ² is sufficient for thin wood boards of 0.2 to 0.6 mm.

In this way, the synthetic resin liquid layer is placed between the transparent sheet and the breathable backing material along with the thin wood board so that it faces the transparent sheet, and then this is inserted between a pair of upper and lower heating press plates. The synthetic resin liquid is sufficiently pressed against the thin wood board, and at the same time, the pressure of the resin liquid is increased. Under this condition, the temperature of the resin liquid is gradually raised using a hot platen to lower the viscosity of the resin liquid, and the resin liquid is press-fitted from the surface of the thin wood board toward the inside.

Here, the resin liquid is press-fitted into most of the cell cavities of the thin wood board, but if the heating method or resin composition is such that the viscosity of the resin liquid drops rapidly, the resin liquid will flow into the minute voids in the thin wood board. As a result, not only can the resin liquid not be sufficiently press-fitted into the thin wood board, but also the hot press platen and pressure equipment may be contaminated with the resin liquid. It is necessary to adjust the viscosity.

In addition, the pressurizing force, pressurizing schedule, and temperature rise rate of the resin liquid of the hot pressing plate depend on the amount of voids in the thin wood board, the size of the voids,
It is determined by taking into account the length of the cavity, the thickness of the resin injected, the change in viscosity due to temperature of the resin liquid, the surface tension and fluidity of the resin.

In addition, the pressurizing method and device may be either a commonly used flat press or continuous press.
Further, the pair of upper and lower plates for pressurizing may be any plate-like material, such as a metal plate or a plastic plate, as long as the pressure can be uniformly transmitted to the resin liquid.

Further, a method for heating the resin liquid is to directly heat the disk body with heated steam, heated oil, or an electric heater, and use this heat to raise the temperature of the resin liquid through a suitable material. Alternatively, the plate may be used as a pressure plate, and heating may be performed by directly increasing the temperature of the resin liquid using high frequency waves or electromagnetic waves.

Depending on the tree species, cavity diameter, moisture content, void volume, resin composition, etc. of the thin wood board, it may be difficult for the resin liquid to enter, but in the present invention, air permeability is created between the thin wood board and the pressure plate. Since the backing material is provided with a lining material, it is possible to improve the escape of air in the voids of the thin wood board through this backing material, and uniform resin press-fitting is possible. It penetrates the surface and the two become firmly integrated.

In this way, the synthetic resin liquid press-fitted into the voids of the thin wood board is either solidified as it is between the press plates, or taken out from the press plate and solidified by appropriate means such as heating or cooling.

At this time, as described above, the backing material and the transparent sheet are integrated with the thin wood board by solidification of the synthetic resin liquid.

The thus obtained decorative material is made of synthetic resin-impregnated thin wood boards with a transparent sheet and a backing material integrally layered on the front and back surfaces, respectively, when a fibrous sheet such as colored paper is used as the backing material. The combination of the transparent thin wood board and the color of the opaque colored backing material creates a wood decorative material with a new wood color. It is flexible.

Furthermore, when applying this decorative material to the surface of another material such as a base material, by pasting it through a backing material, the defects of the base material are hidden and the defects of the base material do not appear.

In addition, by using a fibrous sheet that becomes transparent when the resin liquid permeates as the backing material and allowing the resin liquid layer to penetrate into the inside of the backing material, the transparent sheet and the transparent backing material are integrated on both sides of the thin wood board. A wood decorative sheet having translucency as a whole can be obtained. The transparent sheet on the surface can be used as a protective layer during processing and transportation, and may be peeled off during use or removed by polishing during finishing.

DESCRIPTION OF EMBODIMENTS Next, embodiments of the present invention will be described based on the drawings.

A brown-colored breathable paper 3 is placed on the lower heat-pressing plate 2 of a pair of upper and lower heat-pressing plates 1 and 2, and a thin plate 5 of cypress wood with a thickness of 0.2 mm is placed on top of this.
Polyester resin liquid (40% unsaturation) on the bottom side:
A transparent polyester film 6 made by applying 150 g/m ² of resin liquid 4 mixed at a ratio of curing agent (BPO) = 100:1 is sequentially superimposed, and then the upper hot press plate 1 is moved down to move it up and down. Between heat pressing plates 1 and 2
The resin liquid 4 is press-fitted into the gap of the thin wood board 5 by heating and pressurizing at 100℃, 15 Km/cm ² for 15 minutes, and a part of it penetrates into the lower surface of the thin wood board 5, making the spring material transparent. At the same time, the resin liquid is cured and a polyester film 6 and colored paper 3 are applied to the front and back surfaces of the thin wood board 5.
were integrated through each cured resin.

The decorative material obtained in this way has extremely excellent translucency due to the transparent spring material portion of the thin wood board 5, and the brown color of the colored backing paper 3 is visible from the spring material portion of the thin wood board to the surface. It had a deep wood grain and excellent flexibility.

When this decorative material was further adhered to the surface of the plywood with an ethylene vinyl adhesive, defects such as scratches on the surface of the plywood, which was the base plate, were hidden and the cosmetic properties were not affected in any way.

Effects of the Invention As described above, the method for producing a reinforced decorative material of the present invention involves interposing a synthetic resin liquid layer on the surface of a thin wood board in an amount sufficient to make at least the spring wood portion of the thin wood board transparent. At the same time, a transparent sheet is arranged on the back side, and a breathable backing material is polymerized on the back side, and this is placed between the upper and lower pressure plates, and the pressure plate is applied with pressure, and at the same time, the transparent sheet and the backing material are integrated with the thin wood board,
Because it is used to make the spring material of thin wood boards transparent,
Instead of reducing the complicated process of injecting synthetic resin liquid into thin wood boards in batches under reduced pressure or pressurization, and then solidifying it in another process, as in the past, the synthetic resin liquid is injected into at least the wood by means of upper and lower pressure plates. By press-fitting into most of the cell cavities of the thin wood board, it is possible to make the thin wood board transparent and at the same time obtain a reinforced wood decorative material, which simplifies the process and eliminates wastage of the injected resin solution, significantly reducing manufacturing costs. This is the result.

Furthermore, when the synthetic resin liquid solidifies, the transparent thin wooden board, the transparent sheet, and the backing material are integrated to obtain a decorative material with excellent translucency and flexibility. By setting the color of the ingredients, the color appears on the surface through the spring wood part of the thin wood board, creating a beautiful decorative material with a rich three-dimensional effect.

In addition, it is now possible to continuously perform various processes such as applying resin liquid to thin wood boards, transparent sheets, and backing materials, laminating the thin wood boards, transparent sheets, and backing materials, and integrating them using upper and lower pressure plates. At the same time, thin wood boards of a certain size are continuously fed between pressure plates via a backing material, and a long transparent sheet, etc., is fed out, and then integrated by heat and pressure using a resin liquid to create a continuous band-shaped decoration. In addition, when pressurized, air is expelled from the breathable backing material, and the resin smoothly penetrates into the backing material, making it possible to firmly integrate the resin into the backing material.

In addition, since the resin liquid layer can be placed and handled only on thin wood boards or transparent sheets, equipment etc. will not be contaminated by resin liquid adhesion as in conventional injection methods, and the work can be carried out smoothly. and
Furthermore, since the process from applying the synthetic resin liquid to press-fitting and solidifying can be carried out in a short time, it becomes possible to use resins with a short pot life, which widens the range of resins that can be selected depending on the purpose and use.

The wood decorative material obtained in this way can be used for many purposes, such as flooring materials, furniture surface materials, wall materials, ceiling materials, etc., and can also be used as decorative materials for screens, lighting decorations, etc. Can be used alone,
Furthermore, since it has excellent flexibility, it can be continuously molded and bonded to the surface of a member molded at a predetermined angle or curvature. Also, in the widely known V-cutting method, this reinforced wood decorative material is pasted on a base material with the transparent sheet facing up in advance, and then cutting is performed.
This is possible by using a porous plate-like material as the backing material and making a V cut on the back side of this backing material, and the transparent sheet on the surface prevents cracks in the thin wood board at the bending part, resulting in good bending processing. It is something that can be done.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention; Fig. 1 is a front view of a state in which a synthetic resin liquid is applied to a backing material and superimposed on a thin wood board, and Fig. 2 is a front view of a state in which it is hot-press molded. 3 is a perspective view of the obtained decorative material, and FIG. 4 is a perspective view of the decorative material with the transparent sheet removed. 1, 2... Upper and lower heat pressing plate, 3... Breathable lining material, 4... Resin liquid layer, 5... Thin wood plate, 6
...transparent sheet.

Claims (1)

[Scope of Claims] 1. A thin wood board between the transparent sheet and the breathable backing material, and an amount of coating sufficient to fill the voids in the thin wood board and make the spring material portion of the thin wood board transparent. By disposing the synthetic resin liquid layer so as to face the transparent sheet side and applying pressure between the upper and lower pressure plates, the synthetic resin liquid layer is press-fitted into the void of the thin wood board at the same time. A method for producing a reinforced wood decorative material, which comprises making the spring material part of the thin wood board transparent by allowing the thin wood board to penetrate to the surface of the backing material to integrate the thin wood board, the transparent sheet, and the backing material. 2. The method for producing a reinforced wood decorative material according to claim 1, characterized in that the thickness of the thin wood board is 0.6 mm or less. 3. The method for producing a reinforced wood decorative material according to claim 1 or 2, wherein the breathable backing material is a fibrous sheet such as paper or nonwoven fabric. 4. The method for producing a reinforced wood decorative material according to claim 1 or 2, wherein the breathable backing material is an organic or inorganic porous plate. 5 Claim 1, characterized in that the backing material is opaque and colored in an appropriate color.
A method for producing a reinforced wood decorative material according to item 2, item 3, or item 4. 6 Claim 1, characterized in that the backing material becomes transparent by penetration of resin liquid.
2. A method for producing a reinforced wood decorative material according to item 2, item 3, or item 3.