JPH10114016A - Woody finishing material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable a woody finishing material which is inexpensive and has good scratch resistance to be obtained by a method in which a prepreg sheet containing a thermosetting phenol resin is overlaid on a base plate, a decorative material which can be impregnated with the resin is laminated on the sheet to be hot-pressed and bonded. SOLUTION: A sheet 2 containing a thermosetting resin is stuck on a base plate 1, and a decorative material 3 is stuck on it. A material which makes the impregnation of a resin possible, for example plywood, a woody fiber board, etc., or complex plywood of these are used preferably as the base plate 1. The sheet 2 is a material in which a sheet backing of paper, a fabric, a nonwoven fabric, etc., is impregnated with the thermosetting resin. As paper impregnated with the resin as the sheet backing, gypsum board paper, craft paper, etc., are suitable. As regards the decorative material 3, a wood thin plate for a decorative sheet, paper on which a pattern, etc., are printed in advance or the surface of which is made uneven, etc., can be used appropriately. A material which makes the impregnation of the resin possible is selected as the material of the decorative material 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface finishing material for floors, walls, ceilings and the like, or a surface finishing material for columns, cabinets, furniture and the like, an interior material for automobiles, and a wood finishing used as a surface material for various works. About materials.

[0002]

2. Description of the Related Art In recent years, wood finishing materials have been rapidly increasing from the viewpoint of prevention of occurrence of ticks and the like, but there has been an increasing demand for improvement in scratch resistance of the surface. A general wooden finishing material is one in which a veneer (decorative material), which is a thin wooden plate for decorative veneer, is attached to a base plate, and is subjected to WPC processing so that the surface of the veneer is hardly damaged. Things are being developed. WPC is an abbreviation of Wood-Plastic Combination. A veneer is put into a heating / pressurizing container, and the veneer impregnated with plastic is hot-pressed onto a base plate coated with adhesive. And stuck together.

[0003]

The conventional WPC process has a disadvantage that the price is high.

[0004] Therefore, an object of the present invention is to provide a wooden finishing material which is inexpensive and has excellent scratch resistance.

[0005]

In order to achieve the above-mentioned object, the present invention is to superimpose a sheet in a prepreg state containing a thermosetting resin on a base plate capable of impregnating the resin.
A wood finishing material formed by laminating a cosmetic material capable of impregnating the resin on the sheet and bonding them by hot pressing, and using a phenol resin dissolved or dispersed in water as a thermosetting resin. Things.

[0006]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

In the embodiment shown in FIG. 1, a sheet 2 containing a thermosetting resin is stuck on a base plate 1, and a decorative material 3 is stuck on the sheet 2.

As the base plate 1, a material that can be impregnated with a resin, for example, a plywood, a wood fiber board, a particle board, a wafer board, or a composite board thereof is preferably used.

The sheet 2 is obtained by impregnating a sheet base material 20 (see FIG. 2) made of paper, woven cloth, non-woven cloth or the like with a thermosetting resin. Gypsum board paper, kraft paper, rayon paper, or the like can be suitably used as the paper impregnated with the thermosetting resin as the sheet base material 20. As the woven fabric, a woven fabric of an organic fiber, a woven fabric of an inorganic fiber such as a glass fiber, a carbon fiber, an inorganic whisker, a rock fiber, a rock wool, or a woven fabric of an amorphous metal fiber can be suitably used. As a non-woven fabric, glass fiber, cotton, rayon or other raw material fibers are bonded or entangled, or a sheet-like material made by a method using mechanical, chemical, heating or solvent using both, or a combination thereof. Things.
As the fiber raw material, a material obtained by matting fibers cut to 3 to 50 mm by a wet papermaking or dry nonwoven fabric manufacturing method and bonding them with a binder resin is suitable for use. As the fiber raw material, glass fiber alone, glass fiber and alumina fiber, alumina silica fiber, carbon fiber, inorganic fiber such as metal fiber, aramid fiber, rayon fiber, vinylon fiber, nylon fiber, polyester fiber, polypropylene fiber, Organic fibers such as polyethylene fibers can be used alone or in combination.
In consideration of the strength of the sheet substrate and the ease of resin impregnation, it is preferable to use glass fibers. Furthermore, the basis weight is 10 to 1000 g from the viewpoint of impregnation, defoaming, sheet substrate strength, and scratch resistance of the handling molded product.
/ M ² , and a more preferred basis weight is 5
0 to 250 g / m ² . If the amount is less than 10 g / m ² , scratch resistance is hardly exhibited, and if the amount is more than 1000 g / m ² , impregnation becomes difficult. These fibers have a low reinforcing effect with short fibers of 3 mm or less, while it is difficult to form a uniform sheet with long fibers exceeding 50 mm, and as a result, excellent reinforcing effects cannot be obtained. In addition, short fibers of 3 to 15 mm account for 20% of all fibers.
It is preferable that it is 100% from the viewpoint of strength (reinforcing property) and uniformity of the nonwoven fabric. If the short fibers are less than 20%, a uniform nonwoven fabric is not obtained. Mixing short fiber cellulose pulp or the like in addition to these fiber materials may be used. When using glass fibers, the reinforcing effect can be enhanced by coating the fiber surface with a silane coupling agent.

As the thermosetting resin to be impregnated into the sheet substrate 20, a resin having necessary properties as a surface material is selected, and therefore, a phenol resin obtained by a reaction between a phenol and an aldehyde is used. Use those dissolved or dispersed in water from the viewpoint of cost and safety. Furthermore, various fillers such as lead stearate, dibutyltin dilaurate, carbon black, calcium carbonate, titanium white, mica, glass spheres, aluminum hydroxide, antimony oxide, tri (2,3 dibromopropyl) phosphate, fat A heat stabilizer, a reinforcing agent, a flame retardant, an antistatic agent, and the like, such as an aromatic sulfonate and a higher alcoholic acid ester, can also be blended and used. Further, as a catalyst necessary for the production of a phenol resin, alkylamine, ammonia, sodium hydroxide, barium hydroxide and the like are preferable. In particular, alkylamine and ammonia have larger molecular weights than the other two, and have low hydration properties in terms of molecular structure, so that the water resistance after bonding is remarkably improved. At this time, the phenol resin is preferably dissolved or dispersed in water so as to have a solid content of 20 to 80% from the viewpoint of easy impregnation. If the solid content is less than 20%, it becomes difficult to impregnate the required amount, and if it is more than 80%, the impregnation becomes difficult due to an increase in viscosity.

The phenol resin used as the thermosetting resin is added to the sheet base 20 in a solid content of 50 to 500 g /
m ² , preferably 150 to 350 g / m ² . If it is less than 50 g / m ^2, it is difficult to develop sufficient scratch resistance, and if it is less than 500 g / m ² , it takes a long time to cure and there is a problem in appearance such as protruding from an end. In the impregnation method, for example, as shown in FIG. 2, the sheet base material 20 is dipped into the phenol resin solution 10 by a roller, and then dried under a certain condition to obtain the prepreg-state sheet 2.

As the sheet 2, any one of a glass nonwoven fabric as a sheet substrate 20 and a thermosetting resin impregnated with the sheet substrate 20 is not used alone. The combined sheet can be used as the sheet 2. For example, if an uncured phenolic resin is impregnated into a glass nonwoven fabric and paper is bonded thereto, the overall strength and dimensional stability are dramatically improved.

The thermosetting resin to be impregnated into the sheet base material 20 is preferably in a state of being cured in the latter half of the impregnation, and the sheet 2 is in a prepreg state. When the materials 3 are overlapped and hot-pressed, they are firmly bonded to each other. The prepreg is the half of the reinforced plastic made by mixing the fiber reinforcing agent and the thermosetting resin, and other thermoplastic resins, coloring agents, curing catalysts, etc., as necessary, before the completion of curing, while maintaining the adhesiveness and moldability. It is a molding material in a cured state, and a preferable gel time is 30 seconds to 800 seconds at a set temperature of 150 ° C.

As a drying condition for bringing the thermosetting resin impregnated into the sheet substrate 20 into a cured state in the latter half of the impregnation, the lower limit of the completed moisture content of the sheet 2 is 3% or more, preferably 5% or more, and more preferably. Is 8% or more, and the upper limit is 15% or less, preferably 10% or less. If it is less than 3%, poor adhesion to the decorative material 3 or the base plate 1 is caused, and if it is not less than 15%, blocking between sheets is caused. Table 1 shows the relationship between the drying time and the temperature. In the table, ○ indicates that the finished prepreg sheet can be used, △ indicates that the prepreg sheet is not preferable for use, and X indicates that it cannot be used.

[0015]

[Table 1]

As shown in Table 1, a preferable semi-cured sheet can be obtained at a temperature of 80 to 120 ° C. and a drying time of 2.5 to 30 minutes.

[0017] The tensile strength of the prepreg sheet is preferably 10 kgf or more in order to exhibit sufficient scratch resistance. If it is less than 10 kgf, sufficient scratch resistance is not exhibited. The measurement of the breaking strength was performed by sandwiching the sheet 2 in the prepreg state between two release papers at 150 ° C. for 5 minutes.
The test was performed after the resin was cured by hot pressing under the condition of kgf / cm ² .

As the decorative material 3, a thin wooden plate for decorative veneer, paper on which a pattern or the like has been previously printed or subjected to uneven processing can be suitably used, and the thickness is preferably 1 mm or less. The material of the cosmetic material 3 is also selected so as to be able to be impregnated with a resin.

Example 1 Base plate 1 ... 12 mm thick plywood Decorative material 3 ... 0.3 mm thick cypress veneer Glass non-woven fabric ... Fiber diameter 10 µm, from mixed fiber of short fiber and long fiber A nonwoven glass nonwoven fabric having a basis weight of 100 g / m ² is impregnated with an aqueous dispersion phenol resin having a solid content of 40% to obtain a nonwoven fabric having a solid content of 200 g / m ^2.
After drying for 2 minutes, a semi-cured sheet 2 was obtained. The sheet 2 is superimposed on the base plate 1, the decorative material 3 is superimposed on the sheet 2, and the pressing temperature is 150 ° C. and the pressure is 10 kgf.
/ Cm ² and a press time of 5 minutes to produce a wood finish.

Example 2 Example 1 uses the same base plate 1 and decorative material 3 as in Example 1.
The same glass nonwoven fabric was impregnated with a water-dispersed phenolic resin having a solid content of 40% to obtain a solid content of 300 g / m ² and dried under the same conditions as in Example 1 to obtain a semi-cured state. The pressing conditions at the time of bonding were such that the pressing time was 10 minutes, and the other conditions were the same as in Example 1.

Example 3 Example 1 was repeated using the same base plate 1 and decorative material 3 as in Example 1.
The same glass nonwoven fabric was impregnated with a water-soluble phenolic resin having a solid content of 54% to obtain a solid content of 200 g / m ² and dried under the same conditions as in Example 1 to obtain a semi-cured state. The pressing conditions during bonding were the same as in Example 1.

Example 4 The base plate 1, the decorative material 3, and the glass non-woven fabric used were the same as those in Example 1, and the glass non-woven fabric was impregnated with a water-soluble phenol resin having a solid content of 54% to obtain a solid content of 300 g / m ^2. Was dried under the same conditions as in Example 1 to obtain a semi-cured state. Pressing conditions at the time of bonding were the same as those in Example 2.

Table 2 below shows the differences between the phenol resins impregnated in the sheet substrate in Examples 1 to 4.

[0024]

[Table 2]

Comparative Example A DAP resin was used in place of the phenol resin used in Example 1, and the other conditions were the same as in Example 1.

With respect to Examples 1 to 4 and Comparative Example described above,
A steel ball drop test was performed according to JIS A-1408. In this test, the pit depth of the sample was measured when a No. 2 steel ball (540 g) was dropped on the sample. The sample should be supported on the entire surface of the sand. The results are as shown in Table 3 below.

[0027]

[Table 3]

[0028]

As described above, according to the present invention, a prepreg-containing sheet containing a thermosetting resin is superimposed on a base plate capable of impregnating a resin, and impregnation of the resin is performed on this sheet. It is a wood finishing material that is made by laminating decorative materials that can be overlapped and hot pressed and bonded to each other. Since a phenol resin dissolved or dispersed in water is used as the thermosetting resin, the thermosetting resin of the sheet is used. Is impregnated and hardened into the decorative material to improve the scratch resistance of the decorative material. Further, an adhesive for bonding the decorative material on the base plate is not required, and the sheet and the decorative material can be securely bonded on the base plate only by hot pressing, so that manufacturing is easy. Furthermore, the presence of the sheet provides excellent dimensional stability against changes in temperature and humidity, and improves strength. Furthermore, by using a water-dispersed or water-soluble phenol resin, it can be manufactured easily at low cost and the scratch resistance is improved.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a preferred embodiment of the present invention.

FIG. 2 is an explanatory view showing a production example of a sheet.

[Explanation of symbols]

 1 Base plate 2 Sheet 3 Cosmetic material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI // B29C 70/06 C08J 5/24 CFB C08J 5/24 CFB B29C 67/14 L B29K 105: 08

Claims (2)

[Claims] 1. A prepreg sheet containing a thermosetting resin is superimposed on a base plate capable of impregnating a resin, and a decorative material capable of impregnating the resin is superimposed on the sheet and hot-pressed. A wood finishing material adhered to each other by using a phenolic resin dissolved or dispersed in water as a thermosetting resin. 2. The method according to claim 1, wherein the phenol resin has a solid content of 20 to 8%.
The wood finishing material according to claim 1, wherein the wood finishing material is dissolved or dispersed in water so as to be 0%.