JP2683695B2 - Plastic composite veneer and method for manufacturing decorative base plate using the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a plastic composite veneer and a method of manufacturing a decorative base plate using the same.

[Prior Art] and [Problems to be Solved] Timber veneers are juxtaposed and joined to produce a joined decorative veneer. One of the manufacturing methods is a method in which an adhesive tape is attached to one side of a veneer veneer and joined, and a glass fiber coated with a hot melt adhesive is sewn in a zigzag shape using a machine called a cooper. A joining method is also employed. Furthermore, Japanese Patent Publication No. 53-30773 discloses that timbers boiled and steamed and heated and moistened are placed side by side via an adhesive and compressed, and the adhesives are cured to integrally bond the timbers. After that, a method of cutting to obtain a bonded decorative veneer is also adopted.

On the other hand, in the field of decorative veneers and decorative plywood in which the decorative veneers are laminated as a surface material (overlay), it is said that the veneer (wood) is given a plastic property to improve the defect while utilizing the properties of the wood. The composite technology (WPC technology) of wood and plastic has been attracting attention, and by this, expansion and contraction due to moisture absorption and desorption, which are the drawbacks of wood, are suppressed, and water resistance, stain prevention, and hardness Movements to improve various properties, such as improvement, have become popular, especially in the field of flooring.

As shown in FIG. 5, in the conventional method for manufacturing the WPC decorative veneer and the plywood, as shown in FIG. 5, generally, timbers obtained by cutting wood from raw wood and joining them with an adhesive are boiled and steamed (1) and then wet with water. In the state, the veneer is cut (2) to obtain, for example, a veneer having a thickness of 0.2 to 3 mm, and then, after drying (3), a polymerizable resin liquid (mainly containing a polymerizable monomer) is injected ( 4), this is polymerized and cured (5) to obtain a WPC decorative veneer. Then, in the case of a decorative plywood, the polymerized and cured WPC decorative veneer obtained above is laminated on the plywood and heated and pressed (6). In some cases, polymerization and curing (5) may be performed after sticking (6) to the plywood.

In other words, in the conventional method of producing the WPC decorative veneer and the decorative plywood, it is difficult to cut the joined square bar into a sliced veneer in a dry state. Veneer cutting is performed in a wet state. Then, to inject the polymerizable resin liquid, dehydration is necessary,
Then, drying is performed. Next, the polymerizable resin is injected, and the thin resin plates, for example, having a thickness of 0.2 to 3 mm are placed in an injection can in a state of being stacked, and the polymerizable resin liquid is injected. After the injection, a plurality of veneers are taken out in a stacked state, polymerized and cured. In the case of a decorative plywood, the laminated veneers are peeled off one by one, both ends of the veneer are held by two people, laminated on the plywood, and transferred to the heating and pressing step.

For that reason, in the method of manufacturing a WPC decorative veneer as described above,
If the veneer is dried to adjust the water content when injecting (impregnating) the resin solution, the veneer may be slackened (expanded / contracted) or the veneer may be broken because the veneer is thin.

In addition, since a thin veneer having a thickness of 0.2 to 3 mm is impregnated with the resin liquid, the resin liquid seeps out from the surface of the veneer, and the veneers stick to each other on the surface, so-called `` sticking '' occurs, If you try to peel off the stacked veneers, the veneers may be damaged.

Further, the veneer may be damaged in an attempt to remove the resin adhering to the veneer surface, resulting in a very low yield.

Further, extra steps such as removal of the resin adhered to the veneer and peeling of the veneered veneer increase, resulting in poor work efficiency.

Furthermore, the loss of resin due to the removal of the resin adhered to the surface of the veneer causes the cost of the veneer to be high.

The present invention solves the drawbacks of the prior art WP
An object of the present invention is to provide a method for manufacturing a C-bonded decorative veneer and a decorative base plate using the veneer as a surface material.

Other objects and novel features of the present invention will become apparent from the description throughout the present specification and the accompanying drawings.

[Means for Solving the Problems] The present invention for achieving the above object includes (1) bonding a dry veneer material or the veneer material in a longitudinal direction, an axial direction and / or a thickness direction. For joining material,
Injecting polymerizable resin, prior to polymerization of polymerizable monomer,
The veneer material or bonding material impregnated with the polymerizable resin liquid or the processing material obtained by bonding the veneer material or the bonding material is cut to obtain a veneer impregnated with the polymerizable resin solution,
Then, the method for producing a plastic composite veneer characterized by polymerizing and curing the polymerizable monomer in a veneer impregnated with the polymerizable resin solution, and (2) the polymerizable resin solution for wood A method for producing a plastic composite veneer as described above, which comprises a dimensional stabilizer, and (3) a dry veneer material or the veneer material is joined in the length direction, the width direction and / or the thickness direction. As a joining material
Prior to the polymerization of the polymerizable monomer by injecting the polymerizable resin liquid, the single plate material impregnated with the polymerizable resin liquid or the bonding material composed of the single plate material is cut to obtain a single resin impregnated with the polymerizable resin liquid. A plate is obtained, and then a single plate impregnated with the polymerizable resin liquid is laminated on the surface of the base plate, heated and pressed, and the heat during the heating is used to polymerize and cure the polymerizable monomer. It exists in the manufacturing method of the decorative base plate which laminated the plastic composite veneer.

Next, details of the present invention will be described with reference to the drawings as appropriate.

In the present invention, as shown in FIG. 1, first, a bonding material such as a block material is dried (FIG. 1, FIG. 7).

Next, a resin liquid is injected into the dry bonding material (FIG. 1,
8).

Next, the joining material into which the resin liquid has been injected is cut (sliced).
(FIG. 1, 9).

By the cutting (9), a bonded veneer impregnated with the resin liquid (FIG. 1, 10) is obtained.

A bonded veneer is obtained by polymerizing and curing the polymerizable monomer in the bonded veneer (10) impregnated with the resin liquid.

If this is adhered onto plywood, a decorative plywood obtained by laminating plastic composite veneers is obtained.

When the bonded veneer impregnated with the resin liquid is laminated on the plywood, heated and pressed, and the heat of the heating is used to polymerize and cure the polymerizable monomer (FIG. 1, 11), the decorative plywood It is convenient for work.

The main differences between the present invention example (FIG. 1) and the conventional example (FIG. 5) are as follows.

(1) In the example of the present invention, first, a joining material, for example, a block material,
dry.

On the other hand, in the conventional example, as shown in FIG. 5 and described above, the bonding material is first boiled and steamed in order to make it wet.

(2) In the conventional example, slice (cut) while wet with water
Perform In other words, it is wetted with water to reduce the power required for cutting.

On the other hand, in the example of the present invention, the resin liquid is injected so as to reduce the power required for such cutting.

In other words, one of the major features of the present invention is to slice in a state in which the resin liquid is injected.

In the present invention, boiling and steaming are not performed for the purpose of slicing. The slicing is performed in an uncured state before the polymerizable monomer is polymerized and cured.

(3) In the conventional example, since the sliced veneer is wet with water, it is dried.

In the present invention, the drying has already been performed on the bonding material, and the sliced veneer is not dried. In other words, in the present invention, a relatively large joining material such as a block material is dried, whereas in the conventional example, a sliced thin veneer is dried.

(4) In the example of the present invention, the resin liquid injected into the dry joining material is sliced, so that after slicing, the obtained sliced veneer is already impregnated with the resin liquid.

On the other hand, in the conventional example, since the resin liquid is not injected into the boiled, steamed and sliced veneer, drying is performed as described above, and the resin liquid is injected into this.

In other words, in the present invention, the resin liquid is impregnated in a relatively large joining material such as a block material, whereas in the conventional example, the resin liquid is injected into a thin veneer.

In the present resin injection can, in the present invention, a relatively large block material is put in the resin liquid injection can.

On the other hand, in the conventional example, many thin veneers are stacked,
This is put into the injection can.

From this difference, the present invention has the following advantages.

(A) In the conventional example, a thin veneer is dried, so that the veneer is broken.

On the other hand, in the present invention, since a relatively large joining material such as a block material is dried, such a situation can be avoided.

(B) In the prior art, after slicing, drying, and injecting the resin liquid, the resin liquid exudes to the surface, resulting in "sticking".

On the other hand, in the present invention, the resin liquid is poured into the dry bonding material, and the sliced veneer obtained by cutting (slicing) the resin liquid hardly comes out to the surface, There is little "sticking" because it does not appear on the surface. Therefore, it is possible to avoid the damage of the veneer when attempting to peel off the veneered veneer that has been "attached". Therefore, the yield is improved as compared with the conventional case. Further, it is possible to reduce the loss of the resin and reduce the cost of the veneer, since the step of removing the attached resin as in the conventional case is not particularly required.

 Next, the configuration of the present invention will be supplemented.

The block material was shown in the above example as an example of the dry bonding material used in the present invention, but as the bonding material,
For example, it is possible to use a laminated material in which single plate materials such as a sawing board, a small timber or a lamina are made parallel to each other in the fiber direction and joined (bonded) in the length, width and / or thickness direction. It also includes what is called wood.

 Joining is performed using, for example, a synthetic resin adhesive.

The bonding material is dried before the injection of the resin liquid, but the entire bonding material may be dried, or individual veneer materials constituting the bonding material may be dried.

The bonding material used for resin liquid injection has a water content of 10%, for example.
It is used after being dried.

It is desirable that the water content is as low as possible. The reason for performing the drying is to reduce the power required for cutting and to facilitate the injection of the resin liquid.

By injecting a resin liquid, polymerizing and hardening, and compounding plastic (resin) into a single plate, expansion and contraction are suppressed, water resistance, stain resistance, abrasion resistance, hardness, compression strength, and aesthetics. It can improve the accuracy. The resin injection according to the present invention can utilize the advantages of the WPC and facilitate the cutting of the bonding material as described above.

For the resin liquid, for example, one kind or two or more kinds selected from the group consisting of a polymerizable monomer, a polymerizable oligomer and a polymerizable prepolymer can be used. Specific examples thereof include vinyl monomers such as styrene, methyl methacrylate, vinyl acetate and acrylonitrile, unsaturated polyesters, and acrylic oligomers alone or as a mixture.

Various additives such as a colorant, a flame retardant, and an antiseptic / insecticide can be added to the resin liquid.

Polyethylene glycol (PEG) as a dimensional stabilizer
It is effective to prevent the addition of a thin veneer to prevent the addition of the above.

The injection operation of the resin liquid can be performed by a known injection method.

In order to facilitate cutting, it is desirable that the entire joining material is impregnated with a resin liquid.

The drying step facilitates the impregnation. In addition, in the pouring step, reducing the pressure with a vacuum pump or the like and exhausting the air in the bonding material also facilitates the impregnation.

FIG. 2 shows an example of a bonding material 12 in which a resin liquid is injected.
Is cut in a cutting direction and to a required thickness as shown in the example in FIG.

The cutting is performed by polymerizing monomers etc. in the resin.
It is performed prior to curing.

It is necessary to perform cutting in an uncured (including a semi-cured state).

By the cutting, a resin liquid impregnated single plate 13 as shown in FIG. 2 (b) is obtained.

In the present invention, for example, a decorative plywood can be obtained using the bonded veneer as a surface material.

In the present invention, it is preferable that the resin-impregnated substrate 13 is pasted onto the plywood and then heated and pressed, and the heat at that time causes the polymerizable monomer and the like in the veneer to be thermoset. In order to carry out the heat curing, a polymerization catalyst (polymerization initiator) is added to the resin liquid and heated. Here, an azo compound, a peroxide, or the like is used as the polymerization initiator.

In the present invention, before bonding to a plywood, the cut and bonded veneer may be polymerized by irradiation of radiation (including r-ray and electron beam), and the polymerized veneer may be bonded to the plywood, Or,
After sticking the plywood, radiation polymerization may be used instead of thermal polymerization. However, radiation irradiation increases the cost, so that thermal polymerization is recommended.

In the present invention, instead of the plywood, other materials such as a wood panel, a particle boat, a laminated wood, and the like may be used as long as they constitute a base plate (substrate).

In the present invention, for example, as shown in FIG. 3, a resin liquid is injected at random into a bonding material 12 in which a plurality of veneer materials 12 ′ such as lamina of various sizes are stuck together. To obtain a joined veneer.

In the present invention, as shown in FIG.
, A resin liquid may be injected into the mold 14, and the resin liquid may be laminated on the mold 14, and the laminated material 15 may be cut in a cutting direction as illustrated to obtain a resin liquid injection veneer.

To laminate the veneer material 12 'on the mold 14, an adhesive may be applied to the resin liquid-injected veneer material, and the material may be pressed at room temperature with a press.

When the resin liquid injection veneers obtained by cutting are arranged on a base plate such as a plywood and subjected to thermocompression bonding, heat is applied to apply the monomer or the like of the resin liquid veneer material 12 ′ to the thermocompression bonding. With the adhesive at the time, it can be thermoset.

As the veneer material 12 'in the present invention, raw wood or veneer itself can be used in addition to those exemplified above.

In the present invention, a veneer material such as a log, a sawn timber is dried, a resin liquid is injected into the dried veneer material, and the veneer material into which the resin liquid has been injected is cut by a slicer or the like to obtain a resin liquid. An injection veneer may be obtained.

Then, the resin-injected veneer may be stuck on the base plate and thermally cured, or the previously hardened veneer may be stuck on the base plate.

Example Next, an example of the present invention will be described.

Example 1. A resin liquid was impregnated into a dry plate material having a thickness of 20 x a width of 300 x a length of 60 m / m, which was made of an elm material.

This resin solution uses a mixture of three types of polymerization monomers of butyl methacrylate 60 Wt%, 2-hydroxyethyl acrylate 20 Wt% and glycidyl methacrylate 20 Wt% with 1% of benzoyl peroxide as a catalyst.
Inject resin solution degassed at 10 torr for 60 minutes and return to normal pressure
After dipping for 60 minutes, a resin-impregnated plate material having a weight increase rate of 65% was obtained.

Then, apply an epoxy resin adhesive to the above plate material, after sequentially depositing, press at room temperature press plate at a pressure of 2 kg / cm ^{2 for} 24 hours, to obtain a laminated plate material of thickness 300 × width 300 × length 600 m / m. Obtained.

Next, as shown in FIG. 2 (a), the laminated cross section of the laminated plate was cut to obtain a thickness of 2 × 300 × length of 600 m / m.
To obtain a resin impregnated bonded veneer.

Further, the above single plate is placed on a 12 m / m plywood coated with a water-based vinyl urethane resin adhesive, and the temperature is 120 ° C, the pressure is 8 kg / cm ² ,
The resin of the single plate was simultaneously polymerized and cured by performing the heat and pressure bonding for 10 minutes, and thus a floor material having a Brinell height 5 kg / mm ² resin-impregnated single plate as the surface material was obtained.

Example 2. Thickness 2 × width 300 × length 600 m / m after cutting obtained in Example 1.
The resin-impregnated bonded veneer was heat-cured at a temperature of 130 ° C for 15 minutes to obtain a bonded veneer.

Example 3. A dried plate material having a thickness of 120, a width of 300, and a length of 900 m / m, which was made of a birch, was impregnated with a polymerizable resin liquid. The polymerizable resin liquid is 40 Wt% of styrene monomer and 60 Wt of unsaturated polyester.
% Benzoyl peroxide as catalyst in 2%
%, Degassed at a reduced pressure of 10 Torr for 60 minutes, inject the polymerizable resin solution, and return to normal pressure,
After immersion for 60 minutes, a resin-impregnated plate material with a weight increase rate of 60% was obtained.

With the monomer in the resin-impregnated plate material uncured, the plate material was cut with a slicer to obtain a 1 m / m thick resin-impregnated uncured veneer.

This resin-impregnated uncured bonded single plate was placed on a 12 m / m thick plywood coated with a water-based vinyl urethane resin adhesive, and the temperature was adjusted to 1
Heat-adhesion was performed at 20 ° C., pressure of 8 kg / cm ² , and time of 10 minutes to heat-harden the adhesive and heat-harden the styrene monomer impregnated in the single plate.

A floor material was obtained as a bonded veneer surface material with a Brinell height of 5 kg / mm ² .

Example 4. The plate material was cut with a slicer in the same manner as in Example 3,
A resin-impregnated uncured veneer having a thickness of 1 m / m was obtained.

This resin-impregnated uncured veneer is heated at a temperature of 120
By heat-pressing at ℃, the styrene monomer was polymerized and cured to obtain a resin-impregnated uncured board having a height suitable for a surface of a floor for walking with a Prinell height of 4.5 kg / mm ² .

Although the invention made by the present invention has been specifically described based on the embodiments, the present invention is not limited to the above-described embodiments, and it is needless to say that various changes can be made without departing from the gist thereof. Absent.

[Effects of the Invention] According to the present invention, the following operational effects can be achieved.

(B) In the conventional example, since the thin veneer is dried, the veneer is broken. On the other hand, in the present invention, since the joining material such as the relatively large block material is dried, such a situation can be avoided.

(B) In the conventional example, after slicing and drying, the resin liquid was injected, and the resin liquid oozes out on the surface, causing "sticking". On the other hand, in the present invention, the resin liquid is injected into the dry bonding material, and the sliced veneer obtained by cutting (slicing) the resin liquid does not come out and enters the gap inside the sliced veneer. It was possible to prevent "sticking" without appearing on the screen. For this reason, it was possible to prevent the veneer from being damaged when attempting to peel off the veneer veneered as in the prior art. Therefore, the yield is dramatically improved as compared with the conventional one. Further, it is possible to reduce the loss of the resin and to reduce the cost of the veneer without further needing the step of removing the attached resin as in the conventional case.

[Brief description of the drawings]

FIG. 1 is a process flow chart of an embodiment of the present invention, FIGS. 2 (a) and 2 (b) are process explanatory diagrams in the embodiment of the present invention, and FIG. 3 is another embodiment of the present invention. FIG. 4 is a perspective view, FIG. 4 is an explanatory view showing still another embodiment of the present invention, and FIG. 5 is a flow chart showing a conventional process. 12 …… Dry bonding material 12 ′ …… Veneer material

Claims (3)

(57) [Claims] 1. A polymerizable monomer, an oligomer and / or a prepolymer (hereinafter, simply referred to as a "bonding material" formed by bonding a dried veneer material or the veneer material in a longitudinal direction, an axial direction and / or a thickness direction. , A polymerizable monomer solution) (hereinafter referred to as a polymerizable resin solution) is injected, and prior to the polymerization of the polymerizable monomer, the veneer material or the bonding material impregnated with the polymerizable resin solution or the bonding material or The veneer material or the treated material obtained by joining the joining materials is cut to obtain a veneer impregnated with the polymerizable resin liquid, and then the polymerizable resin in the veneer impregnated with the polymerizable resin liquid A method for producing a plastic composite veneer characterized by polymerizing and curing a monomer. 2. The method for producing a plastic composite veneer according to claim 1, wherein the polymerizable resin liquid contains a dimension stabilizer for wood. 3. A polymerizable resin liquid is injected into a bonding material formed by bonding a dry veneer material or the veneer material in the length direction, the width direction and / or the thickness direction to polymerize a polymerizable monomer. First, the veneer material impregnated with the polymerizable resin solution or the bonding material made of the veneer material is cut to obtain a veneer impregnated with the polymerizable resin solution, and then the polymerizable resin solution is impregnated. A method for producing a decorative base plate in which a plastic composite veneer is laminated, characterized in that the above-mentioned veneer is laminated on the surface of the base plate, heated and compressed, and the heat during the heating is used to polymerize and cure the polymerizable monomer. .