JPH0716922B2 - Method for manufacturing decorative veneer sheet - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a decorative thin veneer sheet.

INDUSTRIAL APPLICABILITY The present invention is generally used for producing a decorative veneer sheet having the following uses. : Interior materials for building such as wall surface, ceiling surface material, column covering material and surface material for movable partition, etc .; surface material for interior products of automobiles and ships; external decorative material for furniture such as chests of drawers; external decorative material for general wooden products such as furniture. Materials; and external decorative materials for electronic devices and musical instruments.

In particular, the present invention is a decorative thin veneer useful as a raw material for decorative veneer products having a fitting pattern made of different materials, particularly in the production of veneer veneer sheets where high dimensional stability and non-deformation are required. Applied to the manufacture of sheets.

(Prior Art) Due to the depletion of natural wood resources, especially natural wood resources, today, instead of solid wood boards, decorative veneer sheets in which a thin wood board is lined with a fiber or resin sheet are widely used.

The decorative veneer sheet is generally required to have the following quality characteristics.

Deformation of the sheet, such as warpage, waving (waviness) and cracks, should not occur.

Above all, it is required that the deformation does not occur.

 The residual stress inside the seat is as low as possible.

There is little directionality and high homogeneity over the entire sheet.

The sheet has high dimensional stability and is not affected by changes in ambient temperature and humidity conditions.

 The surface of the sheet has high smoothness.

The sheet is flexible and has an appropriate strength.

 Good secondary adhesion on the back of the sheet.

In particular, the above conditions (1) and (2) are required when the present sheet is used to process a decorative wood product (for example, an inlaid natural wood decorative board) having a fitting pattern between a plurality of different tree species materials.

(Problems to be Solved by the Invention) However, the decorative veneer sheets heretofore have not satisfied all the quality characteristics described above.

In particular, the properties (above) of the decorative veneer sheet required when processing a decorative wood product having a fitting pattern made of different materials have been greatly required to be improved.

These properties will be discussed further below.

-Regarding characteristics-The reason why the occurrence of flapping deformation and the like is required is because it is difficult to process the deformed decorative veneer sheet such as cutting.

The decorative veneer is susceptible to the conditions of the main body, ambient temperature and humidity, and when it is used by itself, it becomes larger or smaller and deforms without fail. The degree of cracking differs depending on the tree species, the state of the standing tree when it grows, and the cutting conditions (particularly the drying conditions). In particular, the grain of wood, which is said to be the highest-grade wood veneer, and the wood of hump grain (the types of wood are, for example, 条, zelkova, maple, walnut, etc.), are severely exposed.

On the other hand, in a thick-walled decorative wood board in which such a decorative veneer is attached to a general plywood, the strong rigidity of the plywood forces the veneer to be held in a flat shape, so it is possible to suppress the occurrence of flaking. is there.

However, in a decorative veneer sheet, since the rigidity of the backing material on the lower side of the veneer is generally weak, the problem of dent deformation has always been included.

By the way, in the past, relatively thick decorative veneer with a thickness of 0.5 to 0.6 mm was mainly used, but recently, with the progress of depletion of name tree resources, the thickness has decreased to 0.15 to 0.30 mm. The veneer veneer has come to be used from the viewpoint of economical efficiency.

Therefore, the need for prevention of rashes has increased more than ever, and further improvements have been required.

-Regarding characteristics-It is required to reduce the internal residual stress of the decorative veneer sheet as much as possible.If the residual stress is large, the decorative veneer sheet is deformed immediately after cutting and the desired cutting is performed. Because it will not be possible.

-Regarding Properties-Wood is an inhomogeneous material that is directional in nature and has different cutting conditions in the fiber direction, radial direction, and tangential direction. Wood has a spring material part that is hard and a summer material part that is soft due to growth, and also has heterogeneity due to the arrangement of the conduits and temporary conduits, the orientation of the wood fibers, and the like. Therefore, if such a non-uniformity remains strong in the decorative veneer sheet, the cutting locus of the cutting edge will proceed while avoiding a hard radiant tissue etc. during cutting, and the sheet will be cut off from the predetermined cutting line. It is because

-Regarding characteristics-When forming a fitting pattern of different materials, a part of one material is cut out, and a completely identical shape part made of another material is fitted into the part.

However, when the dimensional stability of the sheet is poor, there arises a disadvantage that the cutout portions are overlapped with each other or a gap is generated between these portions.

Since the present invention has been made in consideration of the above circumstances, its purpose is to ensure that a decorative veneer sheet satisfying all of the above-mentioned quality characteristics that is required, such as occurrence of deformation due to flare, is ensured. Another object of the present invention is to provide a method for producing a decorative thin veneer sheet that can be stably and continuously produced.

In particular, it is an object of the present invention to provide a method for producing a decorative veneer sheet which is optimum as a material for processing a decorative wood product having a fitting pattern made of different materials.

(Means for Solving the Problem) The present inventor has conducted diligent research in order to solve such a problem. First, the resin-impregnated sheet is fixed on the resin surface of the fixing plate,
It can be obtained by applying a manufacturing procedure in which a decorative veneer is pasted on it, heat-pressed and then deposited and cured for a certain period of time, then the veneer surface is painted, and finally the fixed plate is separated. The decorative thin veneer sheet does not undergo deformation such as flaking, has high dimensional stability and is not affected by changes in ambient temperature and humidity conditions, etc., and is capable of reliably cutting as prescribed. In particular, they have found that it is the most suitable material for processing a decorative wood product having a fitting pattern made of different materials, and completed the present invention.

Therefore, the method for producing a decorative thin veneer sheet according to the present invention includes: (a) a step of impregnating a fibrous sheet with a resin solution and drying to produce a resin-impregnated fibrous sheet; (b) the resin-impregnated fibrous sheet Is placed on a flat fixing plate having a plate surface coated with a resin and fixed by heating, (c) a step of applying an adhesive onto the resin-impregnated fibrous sheet of the fixing plate, (d) A decorative thin veneer on the adhesive of the fixing plate, and heat-pressing the fixing plate in a hot press machine. (E) Next, a plurality of heat-pressing fixing plates are attached. Stacking and deposit curing, (f) mechanically polishing the surface of the decorative thin veneer sheet on the fixed plate after completion of curing, (g) then coating the surface of the polished decorative veneer sheet (H) Finally, the applied makeup thin unit It is characterized in that comprising the step of peeled off the sheet from the fixing plate.

Heretofore, a typical conventional method for producing a decorative veneer sheet has been to successively laminate each element of the decorative veneer sheet and then adhere or press it to finish the sheet (JP-A-60-104329). JP-A-60-165241 and JP-A-2-15
No. 384).

In some cases, a release base material is used (Japanese Patent Laid-Open No. 56-3390).
No. 1, JP-A No. 64-0258, JP-B No. 61-53204), these are merely base materials for forming a layer by curing an adhesive, a molten resin and the like above the release base material. It was

In contrast to these, the main feature of the method of the present invention is that the fixing plate is passed through the steps (b) to (h) for producing the veneer sheet, and It is to manufacture a decorative thin veneer sheet on a fixed plate while fixing each material, especially a sheet base material (resin-impregnated fibrous sheet), on the fixed plate.

As a result, similar to the case of a decorative plywood with a single plate attached,
Since the decorative veneer is held as it is in a flat shape on the fixed plate during the manufacturing process, it is possible to suppress the occurrence of burrs and the like, and reduce or relieve the internal stress. In addition, the joint work of the decorative veneer becomes easy.

Further, since the fixing plate is separated from the decorative thin veneer sheet in the final step (h), it can be reused for the subsequent production of the veneer sheet by returning it to the step (b). That is, the fixing plate includes steps (b), (c),
It can be circulated and used in a loop process constituted by the flow sequence of (d), (e), (f), (g), (h) and again (b).

The fixing plate may be any one provided with a smooth resin surface layer, but a polyester resin coated on the surface of a wooden base material such as a general plywood or MDF is particularly preferable. The method of resin coating is arbitrary, and the resin solution is applied onto the substrate, or the resin film is attached onto the substrate with an adhesive, preferably with a non-woven fabric interposed. A polyethylene film may be used instead of the polyester film. A means of coating the upper surface of the fixing plate with a release agent such as silicon resin or stearate may be adopted.

Another characteristic of the present invention is to use a resin-impregnated fibrous sheet as a backing material.

The resin-impregnated fibrous sheet not only imparts appropriate strength and flexibility to the whole veneer sheet, but also the step (c).
It plays the role of a stopper that prevents the adhesive applied in step 2 from penetrating to the surface of the fixing plate. In addition, it is convenient in that it can adhere well to the resin surface of the fixing plate.

The resin-impregnated fibrous sheet is produced by impregnating a fibrous sheet such as Japanese paper, paperboard, woven cloth and non-woven cloth with a resin, preferably a polyurethane resin or a styrene-butadiene rubber latex in step (a) and drying. .
The fibrous sheet is preferably a non-woven fabric, more preferably a non-woven fabric made of rayon or nylon.

Further, the amount of the resin to be impregnated is 5 g of the solid amount so that a predetermined adhesion strength can be obtained between the fixing plate and the resin-impregnated fibrous sheet.
Must be at least / m ² . The appropriate resin impregnation amount depends on the material and basis weight of the fibrous sheet, but the basis weight is 20 to 30 g / m ²
In the case of the fibrous sheet (polyester / pulp non-woven fabric), the impregnation amount of the solid amount of 7 to 15 g / m ² is suitable.

Then, the fixing of the resin-impregnated fibrous sheet to the fixing plate is generally performed by using a hot roll or a hot press in the step (b).

Another characteristic feature of the present invention is that the decorative veneer is fixed on the fixing plate during each step of manufacturing by such fixing, bonding and heat pressing.
Then, they were adhered to each other so that they could be peeled off easily and finally without peeling off.

As a result, in the step (f), the surface of the veneer can be mechanically polished by a sander or the like, thus facilitating the formation of a uniform coating film in the subsequent coating step (g). The decorative veneer itself cannot be mechanically polished and uniform coating is impossible.

The degree of such adhesion depends on the type of the resin-impregnated fibrous sheet used, the material of the surface of the fixing plate, the resin impregnation amount, the hot pressing condition, etc. You should choose.

For example, in the step (d), the fixing plate is heat-pressed so that the adhesion strength between the decorative thin veneer sheet and the fixing plate is in the range of 30 to 200 g / 25 mm width with the limit strength at 90 ° peeling as an indication. Preferably.

Further, another characteristic feature of the present invention is that, after such heat-pressing, preferably a predetermined number of fixing plates (decorative veneer, adhesive and resin-impregnated fibrous sheet) are taken out from the hot press machine while hot. The laminated body of is fixed).

During deposition curing, the decorative veneer and the lower surface of the fixing plate come into contact with each other, so that the moisture in the decorative veneer and the adhesive gradually transfers to the wood-based base material of the fixing plate, and the decorative veneer and the like dry. Then, during the drying period, the laminated body of the decorative veneer, the adhesive and the resin-impregnated fibrous sheet remains entirely fixed to the upper surface of the fixing plate. Therefore, the drying set effect works, and the size of the laminated body on the fixed plate is stabilized while being kept in the form of a flat sheet, and the same laminated body is heat-pressed without being fixed to the fixed plate. In comparison, the dimensional stability is significantly improved.

Deposition curing is preferably carried out by hot pressing multiple fixed plates (usually around 10) and then stacking them while hot, and at room temperature until the water content of the decorative thin veneer sheet becomes equal to or less than the equilibrium water content, Usually, continue until about 6-15%.

Further, another characteristic feature of the present invention is that the surface of the decorative thin veneer sheet on the fixed plate subjected to the deposition curing is coated with a polyurethane resin paint, preferably after mechanical polishing.

This makes it possible to keep the planar shape of the decorative thin veneer sheet on the fixed plate held in a flat shape more stable, and to reduce the influence of ambient temperature and humidity conditions, and further to improve the directionality of the sheet. It can be reduced to improve homogeneity.

From the above, the preferred manufacturing method according to the present invention has the following additions.

In the step (a), a polyurethane resin or a styrene-butadiene rubber latex is impregnated into the fibrous sheet to produce a resin-impregnated fibrous sheet, and the step (b)
In the subsequent steps, a fixing plate in which the polyester resin is coated on the surface of the wooden base material is used.

In the step (d), the fixing plate is hot pressed so that the adhesion strength between the decorative thin veneer sheet and the fixing plate is in the range of 30 to 200 g / 25 mm width with the limit strength in 90 ° peeling as an indication.

In the step (e), a plurality of fixing plates are hot-pressed and piled up while they are hot, and then they are piled and cured at room temperature until the moisture content of the decorative thin veneer sheet becomes about 6 to 15%.

In step (g), a polyurethane paint is used for surface coating of the decorative thin veneer sheet.

In the step (c), a thermosetting water-soluble adhesive is used for adhering the decorative thin veneer.

As the decorative veneer that can be used in the present invention, from various kinds of wood, for example, a thickness of 0.10 to 3.0 mm, preferably thin (0.15 to 0.4 mm thickness), a ground board or a board that has been machined. To be Regardless of the grain of the decorative veneer, any of grain, grain, grain or heather may be used. The veneer tree species is not particularly limited. Examples of tree species that are preferably applied include
Japanese cypress, oak, zelkova, cherry, oak, black persimmon, tochi, katsura, enju, maple, kusunoki; rosewood, teak, mahogany, kotan, rosewood, bird's eye maple, american black walnut, claro walnut, latte nut, quince lined walnut , Zebrawood, Mangasiro, Brazilian Rose, Karin, Versimmon, Silver Rose, Palma, Redwood, Purplewood, Silky Oak, Thai Wanks, Cherry,
There are Magnolia, Black Leo (Dao), White Leo, Sapele, Bubinka, Makore, Madroner, Myrtle, Maple, Assin and Inbuyer.

(Example) Hereinafter, the Example of this invention is described with reference to drawings.

FIG. 2 shows a decorative thin veneer sheet 1 made by the method of the embodiment. The sheet 1 comprises a resin-impregnated fibrous sheet 3, a thermosetting water-soluble adhesive (for example, styrene-butadiene rubber latex) 4, a decorative veneer 5 having a thickness of 0.15 to 0.40 mm, and a polyurethane resin paint coating. The film 6 is laminated in order.

FIG. 3 shows the fixing plate 2 used in the method of the embodiment. The fixing plate 2 is formed by sticking a polyester film on a wood-based substrate (for example, plywood, MDF) 7 with an adhesive and coating the polyester resin 8.

Next, a method of manufacturing the decorative thin veneer sheet 1 of FIG. 2 according to the embodiment will be described in the order of steps according to FIG.

—Step (a) — The fibrous sheet (polyester / pulp nonwoven fabric) 12 is pulled out from the original roll, immersed in the impregnation tank 14 containing the polyurethane resin 13 (step (1)), and then it Was dried by passing through a drying oven 15 (step (2)), and a resin-impregnated fibrous sheet 3 was produced.

-Step (b) -The resin-impregnated fibrous sheet 3 produced in the step (a) is supplied onto the fixing plate 2, and the sheet 3 is fixed onto the fixing plate 2 by heating and pressing with a heat roll 16, and And cut into the size of the plate 2 by the cutter 17 (steps (a) and (b)).

-Step (c) -Next, using a coating device 18 such as an applicator roll,
A predetermined amount of the thermosetting water-soluble adhesive 4 was applied to the resin-impregnated fibrous sheet 3 on the fixing plate 2 (step (c)).

-Process (d) -Subsequently, the thin decorative veneer 5 was further placed and stacked on the adhesive 4 of the fixing plate 2 (step (d)).

Then, the fixed plate 2 on which the single plate 5 is placed is attached to the hot press machine 19
In this, for example, hot pressing was performed under the conditions of 105 ° C. × 90 seconds × 6 kg / cm ² (step (e)).

In this step, the adhesion strength between the decorative thin veneer sheet 1 and the fixing plate 2 was set in the range of 30 to 200 g / 25 mm width with the limit strength in 90 ° peeling as an indication.

-Step (e) -Next, a laminated product 9 of the fixed plate 2 and the single plate etc.
・ While being taken out from the hot press machine and stacked while still hot, and the stack 10 as it is at room temperature,
Until the water content of the decorative thin veneer sheet is about 8-12%,
It was deposited and cured for 24 hours (stage (f)).

The laminated body of the decorative veneer 5, the adhesive 4, and the resin-impregnated fibrous sheet 3 integrated by heat pressing was maintained on the fixed plate 2 in a stable planar form after the completion of curing (step ( g)).

-Process (f) -After that, the single plate surface of the laminated body on the fixed plate 2 was mechanically polished using the sander 20 (step (h)).

—Step (g) — Then, using the coating device 21, the surface of the polished decorative veneer is coated with polyurethane paint to form the coating film 6 as the uppermost layer (step (i)). The plate sheet 1 was finished on the fixed plate 2 (step (j)).

-Step (h) -After that, the finished decorative thin veneer sheet 1 was peeled off from the fixing plate 2 (step (k)), and the obtained sheet 1 was sent to the patterning step described below. On the other hand, the remaining fixed plate 2 is
It was stored (step (l)), and sent to step (b) for reuse. Thus, the cyclic use of the fixed plate 2 has been possible without problems after thousands or tens of thousands of times.

The prepared thin veneer sheet does not suffer from warping, warpage, etc. even if the ambient temperature and humidity change greatly, always maintains a flat shape, and the amount of dimensional change compared to conventional sheets of this type. It was much smaller.

Further, in the following use example, when cutting out this sheet, the amount and frequency of the locus of the blade deviating from the predetermined cutting line were significantly smaller than those in the conventional case, and there was no problem in practical use.

-Example of use-Using the produced decorative thin veneer sheet 1, a decorative wooden board 23 having a fitting pattern made of different materials as shown in FIG. 5 was manufactured.

Explaining the patterning process, as shown in FIG.
Using an NC knife and an NC laser, cut out a part A of the same shape from the decorative thin veneer sheets 1a and 1b of different tree species, and fit the cut-out portion of the sheet 1a into the cut-out hole of the sheet 1b. Cut the cut-out part of sheet 1b to sheet 1a
Veneered wood boards that form a fitting pattern of veneers with different surface species by fitting them into the cut-out holes, replacing them with each other, sticking them on a suitable base material, and pressing. Was produced (Fig. 5 (a) (b)).

In addition, in the metal (A1) sheet 24, a portion A having the same shape
It was also cut out and fitted into the cut out holes of the sheet 1a to manufacture a decorative wood board 23 whose surface forms a fitting pattern of a single plate and a metal plate (Fig. 5 (c)).

All of the decorative wood boards 23 have extremely good dimensional stability, and defects such as overlap between the cutout portion A and its surrounding portion or a gap between these portions do not occur even when the ambient temperature and humidity conditions change significantly. It was

(Effects of the Invention) As described above, according to the manufacturing method of the present invention, a decorative thin veneer sheet that satisfies all of the various quality characteristics required as a decorative veneer sheet, especially the following characteristics, can be reliably obtained. It can be produced continuously and continuously.

(A) Unaffected by changes in ambient temperature and humidity,
There is no deformation such as cracking or warping.

(B) The residual stress inside the sheet is very small, and the sheet can be cut into a predetermined size.

(C) There is almost no orientation of the sheet, and it is unlikely that the trajectory of the blades will deviate from the predetermined cutting line during cutting.

(D) The influence of ambient temperature and humidity conditions is extremely small,
It has very high dimensional stability.

Therefore, according to the present invention, it is possible to provide a decorative veneer sheet most suitable as a surface material for processing a decorative wood product having a fitting pattern made of different materials.

[Brief description of drawings]

FIG. 1 is an overall view showing a manufacturing process of a decorative thin veneer sheet by the method of the embodiment of the present invention, FIG. 2 is a sectional view showing a decorative thin veneer sheet manufactured by the method of the embodiment, and FIG. Is a cross-sectional view showing the fixing plate of FIG. 1 used in the method of the embodiment, and FIGS. 4 and 5 are views showing a process of producing a decorative wood product having a fitting pattern made of different materials. In the figure, 1 ... Decorative thin veneer sheet 2 ... Fixing plate 3 ... Resin impregnated fibrous sheet 4 ... Adhesive 5 ... Decorative veneer 6 ... Coating film 7 ... Wood base material 8 ... Resin film A ... Fitting pattern Cutout part

Claims (6)

[Claims] 1. (a) A fibrous sheet is impregnated with a resin solution,
A step of producing a resin-impregnated fibrous sheet by drying, (b) a step of placing the resin-impregnated fibrous sheet on a smooth fixing plate having a plate surface coated with a resin, and fixing by heating, (c) adhesion Applying the agent onto the resin-impregnated fibrous sheet of the fixed plate, (d) subsequently laminating a decorative thin veneer onto the adhesive of the fixed plate, and placing the fixed plate in a hot press machine. A step of heat-pressing, (e) a step of stacking a plurality of heat-pressed fixing plates and depositing and curing, and (f) a surface of the decorative thin veneer sheet on the fixing plate after completion of curing. Mechanical polishing, (g) then coating the surface of the polished decorative veneer sheet with paint, (h) finally, peeling the coated decorative veneer sheet from the fixed plate A method for manufacturing a decorative thin veneer sheet. 2. A resin-impregnated fibrous sheet is produced by impregnating a fibrous sheet with a polyurethane resin or a styrene-butadiene rubber latex in the step (a), and using a polyester in the steps after the step (b). The method according to claim 1, wherein a fixing plate coated with the resin on the surface of the wood-based substrate is used. 3. In the step (d), the fixing plate is so arranged that the adhesion strength between the decorative thin veneer sheet and the fixing plate is in the range of 30 to 200 g / 25 mm width with the limit strength in 90 ° peeling as an indication. The manufacturing method according to claim 1 or 2, wherein heat compression is performed. 4. In the step (e), a plurality of fixing plates are hot-pressed and piled up while they are still hot, and they are accumulated at room temperature until the moisture content of the decorative veneer sheet becomes about 6 to 15%. The manufacturing method according to any one of claims 1 to 3, wherein curing is performed. 5. The production method according to claim 1, wherein in step (g), a polyurethane paint is used for surface coating of the decorative thin veneer sheet. 6. The method according to claim 1, wherein in step (c), a thermosetting water-soluble adhesive is used for adhering the laminated veneer.