JP5828673B2 - Wood fiber board, wood composite board and floor material using the wood fiber board, and methods for producing them - Google Patents
Wood fiber board, wood composite board and floor material using the wood fiber board, and methods for producing them Download PDFInfo
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Description
本発明は、反りの発生を大幅に抑制することが可能な寸法安定性の高い木質繊維板、該木質繊維板を用いた木質複合板および床材ならびにこれらの製造方法に関する。 The present invention relates to a wood fiber board having high dimensional stability capable of greatly suppressing the occurrence of warping, a wood composite board and a floor material using the wood fiber board, and a method for producing them.
ＭＤＦなどの木質繊維板は、木質複合板や床材といった建築用パネルの基材として広く使用されている。木質複合板は、木質繊維板の表面に合板を接着剤で貼着し、両者を圧締（熱圧若しくは冷圧）した後、これを一定期間養生することにより形成することができる。床材は、木質繊維板の表裏両面に合板と化粧板（無垢の板材等の表面化粧材）とを接着剤でそれぞれ貼着し、三者を圧締（熱圧若しくは冷圧）した後、これを一定期間養生することにより形成することができる。 Wood fiber boards such as MDF are widely used as base materials for building panels such as wood composite boards and flooring materials. A wood composite board can be formed by sticking a plywood to the surface of a wood fiber board with an adhesive, pressing them together (hot or cold), and curing them for a certain period of time. The flooring is made by sticking plywood and a decorative board (surface decorative material such as solid board) on the both sides of the wood fiberboard with an adhesive, and pressing the three members together (hot or cold), This can be formed by curing for a certain period.
ところで、木質繊維板は、合板や化粧板に比べて水分の吸放湿による寸法変化が非常に大きいため、その伸縮率の差によって木質複合板や床材に反りやねじれ等の変形を生じさせるという問題があった。そして、この問題は、合板と木質繊維板との接着に、例えば、水性高分子ビニルウレタン系接着剤のような汎用的な水性高分子系接着剤を使用する場合に特に顕著である。 By the way, the wood fiber board has a very large dimensional change due to moisture absorption and desorption compared to the plywood and the decorative board. Therefore, the wood composite board and flooring are deformed such as warping and twisting due to the difference in expansion and contraction. There was a problem. This problem is particularly noticeable when a general-purpose aqueous polymer adhesive such as an aqueous polymer vinyl urethane adhesive is used for bonding the plywood and the wood fiber board.
例えば木質複合板を例にとって説明すると（床材においても同様である）、水性高分子系接着剤中に含まれる多量の水分が合板の表面層や木質繊維板の裏面層に吸収されるため、養生後の木質複合板は、（非水系の接着剤を使用した場合と比較して）より多くの水分を含むことになる。したがって、この水分をより多く含んだ養生後の木質複合板を乾燥雰囲気下で長期間使用していると、非水系の接着剤を使用した木質複合板と比較してより多くの水分が放湿し、その分、反り量が大きくなってしまうのである。 For example, taking a wood composite board as an example (the same applies to flooring materials), a large amount of water contained in the aqueous polymer adhesive is absorbed by the surface layer of plywood and the back layer of the wood fiber board, The cured wood composite board will contain more water (compared to using a non-aqueous adhesive). Therefore, when this hardened wood composite board containing more water is used in a dry atmosphere for a long time, more moisture is released compared to the wood composite board using a non-aqueous adhesive. However, the amount of warpage increases accordingly.
このように、水性高分子系の接着剤は、取り扱いが容易であるというメリットがある反面、使用すると大きな反りが発生しやすいというデメリットも大きいため、水性高分子系の接着剤を積極的に使用し難いという問題があった。 In this way, water-based polymer adhesives have the advantage of being easy to handle, but the use of water-based polymer adhesives is proactive because of the demerit that large warpage tends to occur when used. There was a problem that it was difficult.
かかる問題を解消すべく、例えば特許文献１（特開２００６−１９２８１７）では、木質繊維板の裏面側に貼り合わせる合板として、所定厚さの４枚の単板を、各単板の繊維方向が交互に直交するように積層させたものを使用し、木質複合板の反りを防止することが提案されている。 In order to solve such a problem, for example, in Patent Document 1 (Japanese Patent Laid-Open No. 2006-192817), as a plywood to be bonded to the back side of a wood fiber board, four single boards of a predetermined thickness are used, and the fiber direction of each single board is It has been proposed to prevent the wood composite board from warping by using ones that are alternately stacked.
しかしながら、この方法では、複合板の反りやねじれの解消には一定程度寄与するが水性高分子系接着剤の使用による反りやねじれを軽減するには不十分であり、その結果、木質複合板の変形を防止する効果が十分であるとはいえなかった。また、合板の構成が極めて特殊であるため、応用性に乏しく、生産性が悪くなるという問題もあった。 However, this method contributes to a certain extent in eliminating warping and twisting of the composite board, but is insufficient to reduce warping and twisting due to the use of the water-based polymer adhesive. It could not be said that the effect of preventing deformation was sufficient. Moreover, since the structure of the plywood is very special, there is a problem that the applicability is poor and the productivity is deteriorated.
一方、木質繊維板の反りやねじれ等を軽減する技術として、例えば、特許文献２（特開２００２−３３７１１６）が知られている。この第２の従来技術は、例えばＰＥＧ（ポリエチレングリコール）に代表される寸法安定化処理剤を木質繊維板に塗布または含浸させることにより木質繊維板の変形を軽減させるというものである。 On the other hand, as a technique for reducing warping or twisting of a wood fiber board, for example, Patent Document 2 (Japanese Patent Laid-Open No. 2002-337116) is known. The second prior art is to reduce deformation of the wood fiber board by applying or impregnating the wood fiber board with a dimension stabilizing treatment agent represented by, for example, PEG (polyethylene glycol).
しかしながら、ＰＥＧに代表される寸法安定化処理剤は水に可溶であるため、木質繊維板の使用により、接着剤に含まれる水分によってＰＥＧの溶脱が生じて木質繊維板の寸法安定性や強度が低下する虞れがあるだけでなく、寸法安定化処理剤を塗布または含浸させるための工程や設備が別途必要となって生産性が低下するという問題もある。 However, since the dimensional stabilization treatment agent represented by PEG is soluble in water, the use of wood fiberboard causes PEG leaching due to moisture contained in the adhesive, resulting in dimensional stability and strength of the wood fiberboard. In addition, there is a problem that productivity is reduced because a process and equipment for applying or impregnating the dimension stabilizing treatment agent are required separately.
さらに、特許文献３（特開平１１−６２７７）の加熱水蒸気処理や、特許文献４（特開２００７−１０６０７３）のガラス繊維を添加処理等も提案されているが、これらの処理は工程が複雑であり、経済性や生産性の点で問題がある。 Furthermore, heating steam treatment in Patent Document 3 (Japanese Patent Laid-Open No. 11-6277) and glass fiber addition processing in Patent Document 4 (Japanese Patent Laid-Open No. 2007-106073) have been proposed, but these processes are complicated. There is a problem in terms of economy and productivity.
本発明は、かかる従来の問題に鑑みてなされたものであり、その目的は、寸法安定性の高い木質繊維板、該木質繊維板を用いた木質複合板および床板ならびにこれらの製造方法を提供することにある。 The present invention has been made in view of such conventional problems, and an object of the present invention is to provide a wood fiber board having high dimensional stability, a wood composite board and a floor board using the wood fiber board, and a method for producing them. There is.
請求項１に記載した発明は、「木質繊維１２を母材とし、添加剤として浸透性接着剤とイソシアネート系接着剤と内添ワックスとが添加されている木質繊維板１０であって、浸透性接着剤は水溶性であり、その数平均分子量が２００以下であり、その分子量分布が、単量体と多量体との混合物であってその数平均分子量が５０〜１００のものを重量比で４０〜７０％含み、数平均分子量が３００〜５００の多量体を重量比で３０〜６０％含むように構成されている」ことを特徴とする木質繊維板１０である。 The invention described in claim 1 is “a wood fiber board 10 in which wood fiber 12 is used as a base material, and a permeable adhesive, an isocyanate-based adhesive, and an internal wax are added as additives. the adhesive is water-soluble, der number average molecular weight of 200 or less that is, the molecular weight distribution, a weight ratio of that of the number average molecular weight or a mixture of a monomer and multimers 50-100 wherein 40% to 70%, a wood fiber plate 10 having a number average molecular weight and wherein the configured that have "it to contain 30% to 60% by weight multimers of 300-500.
請求項２に記載した発明は、「木質繊維１２が１００重量部に対し、前記浸透性接着剤を７〜２０重量部、イソシアネート系接着剤を２〜３重量部、内添ワックスを０．５〜１．５重量部の割合で添加した」ことを特徴とする木質繊維板１０である。 According to the second aspect of the present invention, “the wood fiber 12 is 100 parts by weight, the permeable adhesive is 7 to 20 parts by weight, the isocyanate adhesive is 2 to 3 parts by weight, and the internal wax is 0.5 The wood fiber board 10 is characterized by being added at a ratio of ˜1.5 parts by weight ”.
請求項３に記載した発明は、「請求項１または２に記載の木質繊維板１０と合板２０とを接着剤で貼着一体化した」ことを特徴とする木質複合板２２である。 The invention described in claim 3 is a wood composite board 22 characterized in that “the wood fiber board 10 and the plywood 20 according to claim 1 or 2 are bonded and integrated with an adhesive”.
請求項４に記載した発明は、「化粧板２４と、請求項１または２に記載の木質繊維板１０と、合板２０とをこの順で積層するとともに、隣合う板材同士を接着剤で貼着一体化した」ことを特徴とする床材２６である。 The invention described in claim 4 is “the decorative board 24, the wood fiber board 10 according to claim 1 or 2 and the plywood 20 are laminated in this order, and the adjacent board members are adhered with an adhesive. The flooring 26 is characterized by being “integrated”.
請求項５に記載した発明は、請求項４において接着剤の種類を限定したもので「接着剤が水性高分子ビニルウレタン系接着剤である」ことを特徴とする。 The invention described in claim 5 is characterized in that the kind of the adhesive is limited in claim 4 and “the adhesive is an aqueous polymer vinyl urethane adhesive”.
請求項６に記載した発明は、「木質繊維１２に、数平均分子量が２００以下であり、その分子量分布が、単量体と多量体との混合物であってその数平均分子量が５０〜１００のものを重量比で４０〜７０％含み、数平均分子量が３００〜５００の多量体を重量比で３０〜６０％含むように構成されている浸透性接着剤とイソシアネート系接着剤と内添ワックスとをそれぞれ噴霧混合してマット状に成形した後、熱圧プレスで成型する」ことを特徴とする木質繊維板１０の製造方法である。 The invention described in claim 6 is: “The wood fiber 12 has a number average molecular weight of 200 or less , and its molecular weight distribution is a mixture of a monomer and a multimer, and the number average molecular weight is 50 to 100”. A permeable adhesive, an isocyanate-based adhesive, and an internally added wax configured to contain 40 to 70% by weight and a polymer having a number average molecular weight of 300 to 500 in a weight ratio of 30 to 60%. Are each formed by spray-mixing and forming into a mat shape, followed by forming with a hot-pressing press ”.
請求項７に記載した発明は、「請求項１または２に記載の木質繊維板１０と合板２０とを接着剤を用いて貼着した後、前記木質繊維板１０の含水率が平衡状態になるまで静置養生し、その後、木質繊維板１０と化粧板２４とを接着剤を用いて貼着する」ことを特徴とする床材の製造方法である。 The invention described in claim 7 is: “After adhering the wood fiber board 10 and the plywood 20 according to claim 1 or 2 using an adhesive, the water content of the wood fiber board 10 is in an equilibrium state. And then sticking the wood fiber board 10 and the decorative board 24 using an adhesive ”.
請求項１に記載の木質繊維板によれば、浸透性接着剤として数平均分子量が２００以下と低分子量のものを使用しているので、浸漬や減圧・加圧などの煩雑な工程を経なくても接着剤を木質繊維に浸透させ、細胞壁が固化された木質繊維を有する木質繊維板を得ることができる。つまり、この低分子量の浸透性接着剤を木質繊維に塗布することにより浸透性接着剤が木質材料の細胞壁内部に浸透し、固化させることができる。これにより、細胞壁の動きを物理的に抑制することができる（固定効果）と共に、湿気や水分の細胞壁内外への移動を防ぐことができる（充填効果）ので、寸法安定性ならびに耐水性の高い木質繊維板を得ることができる（バルキング効果）。 According to the wood fiber board of claim 1, since the permeable adhesive has a number average molecular weight of 200 or less and has a low molecular weight, it does not go through complicated steps such as dipping, decompression and pressurization. However, it is possible to obtain a wood fiber board having wood fibers in which cell walls are solidified by allowing the adhesive to penetrate into the wood fibers. That is, by applying this low molecular weight permeable adhesive to wood fibers, the permeable adhesive can penetrate into the cell wall of the wood material and solidify. As a result, the movement of the cell wall can be physically suppressed (fixing effect), and moisture and moisture can be prevented from moving in and out of the cell wall (filling effect), so that the wood has high dimensional stability and water resistance. A fiberboard can be obtained (bulking effect).
また、この寸法安定性の高い木質繊維板の表面に合板を張り合わせて木質複合板を形成する場合や、木質繊維板の表裏両面に合板と化粧板とをそれぞれ張り合わせて床材を形成する場合には、取り扱いが容易な水溶性の浸透性接着剤であっても使用することが可能となり、生産性の向上に資するという利点もある。 Also, when plywood is laminated to the surface of this highly dimensional stable wood fiber board to form a wood composite board, or when plywood and decorative board are laminated on both sides of the wood fiber board to form a flooring material, respectively. Can be used even if it is a water-soluble permeable adhesive that is easy to handle, and has the advantage of contributing to an improvement in productivity.
そして、浸透性接着剤の分子量分布を請求項２に記載の発明の範囲とすれば、単量体による高い浸透性と、多量体による高い結合力をバランスよく引き出すことができ、取扱性にも優れるので、寸法安定性が高く強度低下を抑制した木質繊維板が生産性よく得られる。 If the molecular weight distribution of the permeable adhesive is within the scope of the invention described in claim 2, high penetrability due to the monomer and high binding force due to the multimer can be extracted in a well-balanced manner. Since it is excellent, a wood fiber board having high dimensional stability and suppressing strength reduction can be obtained with high productivity.
なお、浸透性接着剤、イソシアネート系接着剤および内添ワックスの配合量を請求項３に記載の数値範囲にすれば、実用的に実施可能である。すなわち、低分子量の浸透性接着剤による寸法安定性、耐水性の効果を保ちつつ、イソシアネート系接着剤によって木質材料の表面がコーティングされ、かつ、木質材料同士の隙間に充填されることにより、木質繊維板の強度、耐水性、耐ワックス性等を向上させ、更には内添ワックスの撥水効果によって耐水性や耐ワックス性をも向上させた木質繊維板が、生産性よく実現できる。 In addition, if the blending amount of the permeable adhesive, the isocyanate-based adhesive, and the internally added wax is within the numerical range described in claim 3, it can be implemented practically. In other words, while maintaining the dimensional stability and water resistance effect of the low molecular weight penetrating adhesive, the surface of the wood material is coated with the isocyanate-based adhesive, and the gap between the wood materials is filled, so that the wood A wood fiberboard that improves the strength, water resistance, wax resistance, etc. of the fiberboard and further improves the water resistance and wax resistance due to the water repellent effect of the internally added wax can be realized with high productivity.
請求項４に記載の発明によれば、木質複合板の材料として、寸法安定性が高い木質繊維板を使用することによって、合板との間の寸法変化の差が小さくなり、その結果、反りやねじれの生じにくい寸法安定性の高い木質複合板を得ることができるようになる。 According to the invention described in claim 4, by using a wood fiber board having high dimensional stability as the material of the wood composite board, a difference in dimensional change with the plywood is reduced, and as a result, warping and It becomes possible to obtain a wood composite board with high dimensional stability in which twisting does not easily occur.
請求項５に記載の発明によれば、床材の材料として、寸法安定性が高い木質繊維板を使用することによって、合板や化粧板との寸法変化の差が小さくなり、その結果、反りやねじれの生じにくい寸法安定性の高い床材を得ることができるようになる。 According to the invention described in claim 5, by using a wood fiber board having high dimensional stability as a flooring material, a difference in dimensional change from a plywood or a decorative board is reduced. It becomes possible to obtain a flooring material with high dimensional stability in which twisting is unlikely to occur.
なお、請求項６に記載の発明のように、接着剤として汎用的で取り扱いの容易な水性高分子ビニルウレタン系接着剤を使用した場合には、寸法安定性が高く、耐水性、耐ワックス性に優れた床材を経済的で生産性高く得ることができる。 As in the invention described in claim 6, when a general-purpose and easy-to-handle water-based polymer vinyl urethane adhesive is used as the adhesive, the dimensional stability is high, and the water resistance and wax resistance are high. Can be obtained economically and with high productivity.
請求項７に記載の発明によれば、低分子量（数平均分子量が２００以下）の浸透性接着剤とイソシアネート系接着剤と内添ワックスとをそれぞれ木質繊維に噴霧して混合するだけで上述したバルキング効果を発現させることができるので、浸漬や減圧・加圧などの煩雑な含浸工程や別バッチでの作業を行う必要がなく、既存の繊維板設備をそのまま利用して簡便に寸法安定性のよい木質繊維板を得ることができる。 According to the seventh aspect of the present invention, the low molecular weight (number average molecular weight is 200 or less) permeable adhesive, the isocyanate-based adhesive, and the internal wax are each sprayed and mixed on the wood fibers, respectively. Since the bulking effect can be exhibited, there is no need to perform complicated impregnation processes such as immersion, decompression and pressurization, and work in separate batches. Good wood fiberboard can be obtained.
請求項８に記載の発明によれば、寸法安定性の高い木質繊維板を使用しているので、その表裏両面に合板や化粧板を貼着する際に水性高分子ビニルウレタン系接着剤のような水性高分子系の汎用接着剤を用いた場合であっても反りやねじれ等が生じにくい。 According to the invention described in claim 8, since the wood fiber board having high dimensional stability is used, when sticking a plywood or a decorative board on both the front and back surfaces, it is like an aqueous polymer vinyl urethane adhesive. Even when a water-based general-purpose adhesive based on water is used, warping, twisting, and the like hardly occur.
［実施例１］
以下、本発明について説明する。本発明に係る木質繊維板１０は、木質繊維１２を主原料とし、これに添加剤を加えて熱圧成型することにより得られる板状の部材である（図１参照）。なお、木質繊維板１０と、合板２０とを接着剤で貼着一体化したものが木質複合板２２であり、合板２０と木質繊維板１０と化粧板２４とをこの順で積層するとともに、隣り合う板材同士を接着剤で貼着一体化したものが床材２６である（図４参照）。
[Example 1]
The present invention will be described below. The wood fiber board 10 according to the present invention is a plate-like member obtained by using wood fiber 12 as a main raw material and adding an additive thereto to hot-press molding (see FIG. 1). The wood fiber board 10 and the plywood 20 are bonded and integrated with an adhesive to form a wood composite board 22, and the ply board 20, the wood fiber board 10, and the decorative board 24 are laminated in this order, and adjacent to each other. The floor material 26 is obtained by attaching and integrating matching plate materials with an adhesive (see FIG. 4).
木質繊維１２（図２参照）は、チップやフレークなどの木片を繊維化したものであり、より具体的に説明すると、木片を粉砕し、これを蒸気加熱（蒸煮）した後、繊維または繊維束に解離（解繊）することにより得ることができる。 The wood fiber 12 (refer to FIG. 2) is obtained by converting wood pieces such as chips and flakes into fibers. More specifically, the wood pieces are pulverized and steam-heated (steamed), and then a fiber or fiber bundle. Can be obtained by dissociation (defibration).
各木質繊維１２の長さは、０．１〜４．０ｍｍの範囲に設定することが実用上望ましい。各木質繊維１２の長さが０．１ｍｍ以下の場合には、木質繊維板１０に必要な強度を付与しにくくなるし、各木質繊維１２の長さが４．０ｍｍを超える場合は、後述する添加剤との混合性や分散性が低くなるため、添加剤を木質繊維１２に含浸させるための時間がかかり過ぎ、生産性が低下するという問題がある。なお、上述した木質繊維１２の長さは、木質繊維板１０の原料として一般的に採用されている数値範囲である。 It is practically desirable to set the length of each wood fiber 12 in the range of 0.1 to 4.0 mm. When the length of each wood fiber 12 is 0.1 mm or less, it becomes difficult to give the necessary strength to the wood fiber board 10, and when the length of each wood fiber 12 exceeds 4.0 mm, it will be described later. Since the mixability and dispersibility with the additive are lowered, there is a problem that it takes too much time to impregnate the wood fiber 12 with the additive, and the productivity is lowered. In addition, the length of the wood fiber 12 mentioned above is a numerical range generally adopted as a raw material of the wood fiber board 10.
各木質繊維１２にあっては、細胞１４間のマトリックス（基質）が、蒸煮工程と解繊工程とを経ることにより除去されて細胞壁１６が剥き出しになっている（図２参照）。 In each wood fiber 12, the matrix (substrate) between the cells 14 is removed through the steaming process and the defibrating process, and the cell wall 16 is exposed (see FIG. 2).
添加剤は、木質繊維１２に各種機能を付与するもので、本実施例では、浸透性接着剤とイソシアネート系接着剤と内添ワックスとが使用される。なお、各添加剤を混合して使用する場合は、分散力を高めるため、必要に応じて水で希釈するようにしてもよい。 The additive imparts various functions to the wood fiber 12, and in this embodiment, a permeable adhesive, an isocyanate-based adhesive, and an internally added wax are used. In addition, when mixing and using each additive, in order to improve a dispersion power, you may make it dilute with water as needed.
浸透性接着剤は、木質繊維１２同士を接着させる接着機能と、各木質繊維１２の寸法安定性を高めるための寸法安定効果付与機能とを併有するものであり、例えば、水性で低分子量（数平均分子量が２００以下、望ましくは１５０以下）のフェノール樹脂やメラミン樹脂が好適に用いられる。 The permeable adhesive has both a bonding function for bonding the wood fibers 12 to each other and a function for imparting a dimensional stability effect for enhancing the dimensional stability of the respective wood fibers 12. Phenol resins and melamine resins having an average molecular weight of 200 or less, preferably 150 or less are preferably used.
浸透性接着剤の数平均分子量として２００以下の低分子量のものを使用するのは、数平均分子量が２００を超えると後述するバルキング効果が得られにくく、期待する寸法安定性効果が得られないからである。 The reason why the number average molecular weight of the permeable adhesive is 200 or less is that if the number average molecular weight exceeds 200, the bulking effect described later is difficult to obtain and the expected dimensional stability effect cannot be obtained. It is.
ここで、浸透性接着剤の分子量分布は、単量体と多量体の混合物であってその数平均分子量が５０〜１００のものを重量比で４０〜７０％含み、数平均分子量が３００〜５００（重合度は３〜５程度）の多量体を重量比で３０〜６０％含むように構成されている。 Here, the molecular weight distribution of the permeable adhesive is a mixture of a monomer and a multimer having a number average molecular weight of 50 to 100 and containing 40 to 70% by weight, and the number average molecular weight is 300 to 500. The polymer is configured to contain 30 to 60% by weight of the polymer (degree of polymerization is about 3 to 5).
単量体は、比較的浸透性が高いため、木質繊維の壁内に容易に浸透固化し、寸法安定性に寄与することとなる。一方、数平均分子量が３００〜５００の多量体は、比較的浸透性が低いため、壁外に留まり固化して木質繊維同士の結合に寄与する。 Since the monomer has a relatively high permeability, it easily permeates and solidifies into the wall of the wood fiber and contributes to dimensional stability. On the other hand, a multimer having a number average molecular weight of 300 to 500 has a relatively low permeability, and therefore remains outside the wall and solidifies and contributes to the bonding of wood fibers.
このように、浸透性接着剤の分子量分布を上述した範囲に設定することにより、期待される寸法安定性と強度をバランスよく得ることができる。 Thus, by setting the molecular weight distribution of the permeable adhesive in the above-described range, the expected dimensional stability and strength can be obtained in a balanced manner.
浸透性接着剤の添加量は、木質繊維１００重量部に対して、固形分（蒸発残分）で７〜２０重量部（望ましくは７〜１０重量部）の範囲に設定するのが好ましい。なぜならば浸透性接着剤の添加量が７重量部より少ないと寸法安定性向上の効果が少なく、２０重量部より多く添加しても一定以上の寸法安定性向上効果が得られず経済的でないからである。 The addition amount of the permeable adhesive is preferably set in a range of 7 to 20 parts by weight (desirably 7 to 10 parts by weight) in terms of solid content (evaporation residue) with respect to 100 parts by weight of the wood fiber. This is because if the added amount of the permeable adhesive is less than 7 parts by weight, the effect of improving the dimensional stability is small, and even if added more than 20 parts by weight, the effect of improving the dimensional stability beyond a certain level cannot be obtained and it is not economical. It is.
イソシアネート系接着剤は、木質繊維板の強度、耐水性、耐ワックス性を向上させるためのものであり、例えばＭＤＩ（メチレンジフェニルジイソシアネート）、ＴＤＩ（トリレンジイソシアネート）、ＨＤＩ（ヘキサメチレンジイソシアネート）などが使用できるが、中でもＭＤＩは汎用的で、経済的にも優れている。 Isocyanate-based adhesives are for improving the strength, water resistance and wax resistance of wood fiber boards. For example, MDI (methylene diphenyl diisocyanate), TDI (tolylene diisocyanate), HDI (hexamethylene diisocyanate), etc. Among them, MDI is general-purpose and economically superior.
特に、低分子量浸透性接着剤と内添ワックスとを併用することにより、フロアー用ワックスの浸入を抑制し、耐ワックス性や剥離強度の向上効果が得られる（この点については後述する）。 In particular, the combined use of the low molecular weight penetrating adhesive and the internally added wax suppresses the intrusion of the wax for the floor, and the effect of improving the wax resistance and peel strength can be obtained (this will be described later).
イソシアネート系接着剤の添加量は、木質繊維１００重量部に対して、３重量部以下にするのが好ましい。イソシアネート系接着剤の添加量が３重量部を超えると、木質繊維同士の結合が強固となる反面、水分による木質繊維の伸縮が隣接する木質繊維に伝達しやすくなること等により木質繊維板の寸法安定性が悪化するという問題が顕在化するからである。 The addition amount of the isocyanate-based adhesive is preferably 3 parts by weight or less with respect to 100 parts by weight of the wood fiber. When the amount of the isocyanate-based adhesive exceeds 3 parts by weight, the bonding between the wooden fibers becomes strong, while the expansion and contraction of the wooden fibers due to moisture can be easily transmitted to the adjacent wooden fibers, etc. This is because the problem of deterioration of stability becomes obvious.
内添ワックスは、木質繊維板１０に撥水機能を発現させるためのものであり、撥水効果を与えるワックスであれば特に選ばないが、浸透性接着剤（フェノール樹脂やメラミン樹脂）との混和性に優れたパラフィン系ワックスを使用することが望ましい。 The internally added wax is used for causing the wood fiber board 10 to exhibit a water repellency function, and is not particularly selected as long as it provides a water repellency effect, but is mixed with a permeable adhesive (phenolic resin or melamine resin). It is desirable to use a paraffin wax having excellent properties.
なお、内添ワックスの添加量は、木質繊維１００重量部に対して１重量部程度（０．５〜１．５重量部）添加すれば十分である。 In addition, about 1 weight part (0.5-1.5 weight part) addition is sufficient for the addition amount of an internal addition wax with respect to 100 weight part of wood fibers.
次に、木質繊維板１０の製造方法について説明する。まず、図示しない混合容器に木質繊維１２を充填し、これをメカニカルブレンダーで攪拌しながら、添加剤であるフェノール樹脂、内添ワックスならびにＭＤＩを順次、スプレーガンを用いてスプレー噴霧した。なお、添加剤のスプレー噴霧の順序は必ずしもこの順である必要はなく、任意に設定してもよい。木質繊維１２に添加剤を塗布すると、添加剤中の浸透性接着剤が木質繊維１２（より詳しくは細胞壁）に浸透して細胞壁が固化される。なお、図３（Ａ）は、木質繊維１２の細胞壁に浸透性接着剤が浸透する前の状態を模式的に示した図であり、図３（Ｂ）は、木質繊維１２の細胞壁に浸透性接着剤が浸透した後の状態を模式的に示した図である。 Next, the manufacturing method of the wood fiber board 10 is demonstrated. First, the wood fiber 12 was filled in a mixing container (not shown), and the phenol resin, the internal wax, and the MDI as additives were sequentially sprayed using a spray gun while stirring the mixture with a mechanical blender. Note that the order of spraying the additives is not necessarily in this order, and may be set arbitrarily. When the additive is applied to the wood fiber 12, the permeable adhesive in the additive penetrates the wood fiber 12 (more specifically, the cell wall), and the cell wall is solidified. 3A schematically shows a state before the permeable adhesive penetrates the cell wall of the wood fiber 12, and FIG. 3B shows the permeability of the cell wall of the wood fiber 12. As shown in FIG. It is the figure which showed typically the state after the adhesive agent osmose | permeated.
そして、得られた添加剤付きの木質繊維１２をフォーミングしてマット状に成形し、このマット状物を熱圧プレスすることにより、目的とする木質繊維板１０を得た。なお、熱圧プレスの条件は、目標とする木質繊維板１０の密度や厚さ等に応じて任意に設定すればよい。 And the obtained wood fiber 12 with an additive was formed and formed into a mat shape, and the mat-like material was hot-pressed to obtain the intended wood fiber board 10. In addition, what is necessary is just to set the conditions of a hot press according to the density, thickness, etc. of the target wood fiber board 10 arbitrarily.
以上のようにして得られた木質繊維板１０が外部の水分と接触すると、木質繊維１２の細胞壁が僅かに膨張する（図３のＢからＣの状態になる）が、その寸法変化は、浸透性接着剤による処理を行っていない場合（図３のＡからＣの状態になる）に比べて小さく、その寸法安定性は非常に高いものであった。 When the wood fiber board 10 obtained as described above comes into contact with external moisture, the cell wall of the wood fiber 12 is slightly expanded (from B to C in FIG. 3). Compared to the case where the treatment with the adhesive was not performed (the state from A to C in FIG. 3), the dimensional stability was very high.
発明者らは、上述した手法によって木質繊維板を製作し、得られた木質繊維板の寸法安定性について試験を行い、その実用性を検証した。以下には、その試験方法および試験結果について説明する。 The inventors manufactured a wood fiber board by the method described above, tested the dimensional stability of the obtained wood fiber board, and verified its practicality. Hereinafter, the test method and test results will be described.
［木質繊維板の寸法安定性試験］
（試料１ａ）
木質繊維１００重量部に対し、浸透性接着剤を固形分で７重量部、イソシアネート系接着剤を固形分で２重量部、内添ワックスを固形分で１重量部用意した。
[Dimensional stability test of wood fiberboard]
(Sample 1a)
For 100 parts by weight of wood fiber, 7 parts by weight of a permeable adhesive, 2 parts by weight of an isocyanate-based adhesive, and 1 part by weight of an internal wax were prepared.
具体的には、木質繊維（ラワン材を素材とする）を９００ｇ用意し、これを含水率が８〜１０％となるように調整したものを使用した。浸透性接着剤としては、数平均分子量１１０の低分子量フェノール樹脂（単量体と多量体との混合物であって数平均分子量８４のものを重量比で６６％、数平均分子量３４０の多量体を重量比で３４％に調整したもの。）を用意し、これを固形分が３２．５％となるよう水で希釈したものを１８０ｇ使用した。イソシアネート系接着剤としては、ＭＤＩを用意し、これを固形分が５０％となるよう水で希釈したものを３３．２ｇ使用した。内添ワックスは、水で希釈して固形分を２０％としたものを４１．６ｇ使用した。 Specifically, 900 g of wood fiber (made from Lauan material) was prepared, and this was adjusted so that the water content was 8 to 10%. As the permeable adhesive, a low molecular weight phenol resin having a number average molecular weight of 110 (a mixture of a monomer and a multimer having a number average molecular weight of 84 is 66% by weight, and a multimer having a number average molecular weight of 340 is used. The weight ratio was adjusted to 34%.) Was prepared, and 180 g of the product diluted with water so that the solid content was 32.5% was used. As the isocyanate-based adhesive, 33.2 g of MDI was prepared and diluted with water so that the solid content was 50%. The internally added wax used was 41.6 g of a 20% solid content diluted with water.
図示しない混合容器に木質繊維を充填し、これをメカニカルブレンダーで攪拌しながら、添加剤であるフェノール樹脂、内添ワックスならびにＭＤＩを順次、スプレーガンを用いてスプレー噴霧した。次に、得られた添加剤付きの木質繊維をフォーミングしてマット状に成形した。そして、このマット状物を１８０℃で６０秒間の熱圧プレスを行った後、更に、２００℃で１２０秒（２分）間の熱圧プレスを行い木質繊維板（試料１ａ）を完成させた。なお、得られた木質繊維板（試料１ａ）は、横の長さが３２０ｍｍ、縦の長さが９１０ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．８０１ｇ／ｃｍ3であった。 A wooden container (not shown) was filled with wood fibers, and while stirring the mixture with a mechanical blender, the phenol resin, internal wax, and MDI as additives were sequentially sprayed using a spray gun. Next, the obtained wood fiber with an additive was formed into a mat shape. The mat-like material was hot-pressed at 180 ° C. for 60 seconds, and further pressed at 200 ° C. for 120 seconds (2 minutes) to complete a wood fiber board (sample 1a). . The obtained wood fiber board (sample 1a) is a plate having a horizontal length of 320 mm, a vertical length of 910 mm, and a thickness of 3.2 mm, and its density is 0.801 g / cm 3 .
（試料１ｂ）
浸透性接着剤（数平均分子量１１０の低分子量フェノール樹脂）の添加量を、木質繊維１００重量部に対して１０重量部（固形分が３２．５％となるよう水で希釈したものを２５６ｇ使用）とした以外は、試料１と同じようにして得られた木質繊維板を試料１ｂとした。なお、得られた試料１ｂは、横の長さが３２０ｍｍ、縦の長さが９１０ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．８０８ｇ／ｃｍ3であった。
(Sample 1b)
Use 256 g of permeable adhesive (low molecular weight phenol resin having a number average molecular weight of 110) diluted with water so that the solid content becomes 32.5% with respect to 100 parts by weight of wood fiber. Except for the above, a wood fiber board obtained in the same manner as Sample 1 was used as Sample 1b. The obtained sample 1b was a plate having a horizontal length of 320 mm, a vertical length of 910 mm, and a thickness of 3.2 mm, and its density was 0.808 g / cm 3 . .
（比較試料１）
浸透性接着剤を添加しない点、イソシアネート系接着剤（ＭＤＩ）の添加量を、木質繊維１００重量部に対して１０重量部（固形分が５０％となるよう水で希釈したものを１６６．６ｇ使用）とした点以外は、試料１ａと同じようにして得られた木質繊維板を比較試料１とした。なお、得られた比較試料１は、横の長さが３２０ｍｍ、縦の長さが９１０ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．８６３ｇ／ｃｍ3であった。
(Comparative sample 1)
A point where no permeable adhesive is added, and an addition amount of isocyanate adhesive (MDI) is 10 parts by weight with respect to 100 parts by weight of wood fiber (166.6 g diluted with water so that the solid content becomes 50%) A wood fiber board obtained in the same manner as Sample 1a was used as Comparative Sample 1 except that it was used. The obtained comparative sample 1 was a plate having a horizontal length of 320 mm, a vertical length of 910 mm, and a thickness of 3.2 mm, and its density was 0.863 g / cm 3. It was.
（寸法安定性試験の方法）
各試料を２３℃、相対湿度５３％ＲＨの雰囲気下で７２時間静置したときの長さを基準値とする。
(Dimensional stability test method)
The length when each sample is allowed to stand for 72 hours in an atmosphere of 23 ° C. and a relative humidity of 53% RH is taken as a reference value.
次に、各試料を（１）４０℃、相対湿度９０％ＲＨ雰囲気下で１６８時間静置、（２）４０℃、相対湿度４０％ＲＨ雰囲気下で１６８時間静置、（３）６０℃、乾燥雰囲気下で１４日間（３３６時間）静置した後の長さをそれぞれ測定し、基準値からの寸法変化率を算出する。 Next, each sample was (1) left for 168 hours in an atmosphere of 40 ° C. and a relative humidity of 90% RH, (2) left for 168 hours in an atmosphere of 40 ° C. and a relative humidity of 40% RH, and (3) 60 ° C. The length after standing for 14 days (336 hours) in a dry atmosphere is measured, and the dimensional change rate from the reference value is calculated.
各試料における寸法変化量は［表１］の通りである。 The amount of dimensional change in each sample is as shown in [Table 1].
［表１］
[Table 1]
［表１］から分かるように、試料１ａ〜１ｂと比較試料１とを比較すると、いずれの雰囲気下で測定した場合であっても、試料１ａ〜１ｂの方が比較試料１に比べて寸法変化量が小さいことがわかる。このことから、添加剤として低分子量の浸透性接着剤を添加することにより、寸法安定性が向上することが分かった。 As can be seen from [Table 1], when the samples 1a to 1b and the comparative sample 1 are compared, the sample 1a to 1b has a dimensional change compared to the comparative sample 1 regardless of the atmosphere. You can see that the amount is small. From this, it was found that dimensional stability is improved by adding a low molecular weight penetrating adhesive as an additive.
［浸透性接着剤の分子量の違いによる寸法安定効果確認試験］
（試料２ａ）
木質繊維１００重量部に対し、浸透性接着剤を固形分で１０重量部用意した。
[Dimensional stability confirmation test by molecular weight difference of permeable adhesive]
(Sample 2a)
10 parts by weight of a permeable adhesive with a solid content was prepared with respect to 100 parts by weight of the wood fiber.
具体的には、木質繊維（ラワン材を素材とする）を２８０ｇ用意し、これを含水率が８〜１０％となるように調整したものを使用した。浸透性接着剤としては、数平均分子量１１０の低分子量フェノール樹脂（単量体と多量体との混合物であって数平均分子量８４のものを重量比で６６％、数平均分子量３４０の多量体を重量比で３４％に調整したもの。）を用意し、これを固形分が３２．５％となるよう水で希釈したものを７６ｇ使用した。 Specifically, 280 g of wood fiber (made from Lauan material) was prepared, and this was adjusted so that the water content was 8 to 10%. As the permeable adhesive, a low molecular weight phenol resin having a number average molecular weight of 110 (a mixture of a monomer and a multimer having a number average molecular weight of 84 is 66% by weight, and a multimer having a number average molecular weight of 340 is used. The weight ratio was adjusted to 34%.) Was prepared, and 76 g of the product diluted with water so that the solid content was 32.5% was used.
図示しない混合容器に木質繊維を充填し、これをメカニカルブレンダーで攪拌しながら、フェノール樹脂をスプレーガンで噴霧した。得られたフェノール樹脂付きの木質繊維をフォーミングしてマット状に成形した。そして、このマット状物を１８０℃で６０秒間の熱圧プレスを行った後、更に、２００℃で１２０秒（２分）間の熱圧プレスを行い木質繊維板（試料２ａ）を完成させた。なお、得られた木質繊維板（試料２ａ）は、横の長さが３２０ｍｍ、縦の長さが３２０ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．９０５ｇ／ｃｍ3であった。 A wood container was filled in a mixing container (not shown), and the phenol resin was sprayed with a spray gun while stirring with a mechanical blender. The obtained wood fiber with phenol resin was formed into a mat shape. The mat-like material was hot-pressed at 180 ° C. for 60 seconds, and further pressed at 200 ° C. for 120 seconds (2 minutes) to complete a wood fiber board (sample 2a). . The obtained wood fiber board (sample 2a) is a plate having a horizontal length of 320 mm, a vertical length of 320 mm, and a thickness of 3.2 mm, and its density is 0.905 g / cm 3 .
（試料２ｂ）
浸透性接着剤として、数平均分子量１２０の低分子量フェノール樹脂（単量体と多量体との混合物であって数平均分子量７１のものを重量比で４７％、数平均分子量３７０の多量体を重量比で５３％に調整したもの。）を用いた以外は、試料２ａと同じようにして得られた木質繊維板を試料２ｂとした。なお、得られた試料２ｂは、横の長さが３２０ｍｍ、縦の長さが３２０ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．８５８ｇ／ｃｍ3であった。
(Sample 2b)
Low molecular weight phenolic resin having a number average molecular weight of 120 (a mixture of a monomer and a multimer having a number average molecular weight of 71 having a weight ratio of 47% and a weight average molecular weight of 370 having a weight average molecular weight of 370) Sample 2b was a wood fiber board obtained in the same manner as Sample 2a except that the ratio was adjusted to 53%. The obtained sample 2b was a plate having a horizontal length of 320 mm, a vertical length of 320 mm, and a thickness of 3.2 mm, and its density was 0.858 g / cm 3 . .
（比較試料２）
浸透性接着剤として、数平均分子量１１００の高分子量フェノール樹脂を用いた以外は、試料２ａと同じようにして得られた木質繊維板を比較試料２とした。なお、得られた比較試料２ｃは、横の長さが３２０ｍｍ、縦の長さが３２０ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．８５８ｇ／ｃｍ3であった。
(Comparative sample 2)
A wood fiberboard obtained in the same manner as Sample 2a was used as Comparative Sample 2 except that a high molecular weight phenol resin having a number average molecular weight of 1100 was used as the permeable adhesive. The obtained comparative sample 2c was a plate having a horizontal length of 320 mm, a vertical length of 320 mm, and a thickness of 3.2 mm, and its density was 0.858 g / cm 3. It was.
（寸法安定性試験の方法）
各試料を２３℃、相対湿度５３％ＲＨの雰囲気下で７２時間静置したときの長さを基準値とする。
(Dimensional stability test method)
The length when each sample is allowed to stand for 72 hours in an atmosphere of 23 ° C. and a relative humidity of 53% RH is taken as a reference value.
次に、各試料を（１）４０℃、相対湿度９０％ＲＨ雰囲気下で７２時間静置、（２）４０℃、相対湿度４０％ＲＨ雰囲気下で７２時間静置、（３）４０℃、乾燥雰囲気下で７２時間静置、（４）６０℃、乾燥雰囲気下で７２時間静置した後の長さを測定し、基準値からの寸法変化率を算出する。 Next, each sample was left to stand (1) at 40 ° C. in a relative humidity of 90% RH for 72 hours, (2) left at 40 ° C. in a relative humidity of 40% RH for 72 hours, (3) 40 ° C., The length after standing for 72 hours in a dry atmosphere and (4) standing for 60 hours at 60 ° C. in a dry atmosphere is measured, and the dimensional change rate from the reference value is calculated.
各試料における寸法変化率は［表２］の通りである。 The dimensional change rate in each sample is as shown in [Table 2].
［表２］
[Table 2]
［表２］から分かるように、試料２ａ〜２ｂと比較試料２とを比較すると、いずれの雰囲気下で測定した場合であっても、試料２ａ〜２ｂの方が比較試料２に比べて寸法変化率が小さくなっていることがわかる。このことから、寸法変化を抑制するためには、浸透性接着剤として、低分子量フェノール樹脂が有効であり、高分子量フェノール樹脂では寸法抑制効果が低いことが分かった。 As can be seen from [Table 2], when the samples 2a to 2b and the comparative sample 2 are compared, the sample 2a to 2b has a dimensional change compared to the comparative sample 2 regardless of the atmosphere. It can be seen that the rate is decreasing. From this, in order to suppress a dimensional change, it turned out that a low molecular weight phenol resin is effective as a permeable adhesive, and a high molecular weight phenol resin has a low dimensional suppression effect.
［イソシアネート系接着剤（ＭＤＩ）の効果確認試験］
（試料３ａ）
木質繊維１００重量部に対し、浸透性接着剤を固形分で７重量部、イソシアネート系接着剤を固形分で２重量部、内添ワックスを固形分で１重量部用意した。
[Isocyanate-based adhesive (MDI) effect confirmation test]
(Sample 3a)
For 100 parts by weight of wood fiber, 7 parts by weight of a permeable adhesive, 2 parts by weight of an isocyanate-based adhesive, and 1 part by weight of an internal wax were prepared.
具体的には、木質繊維（ラワン材を素材とする）を２８０ｇ用意し、これを含水率が８〜１０％となるように調整したものを使用した。浸透性接着剤としては、数平均分子量１１０の低分子量フェノール樹脂（単量体と多量体との混合物であって数平均分子量８４のものを重量比で６６％、数平均分子量３４０の多量体を重量比で３４％に調整したもの。）を用意し、これを固形分が３２．５％となるよう水で希釈したものを５５．６ｇ使用した。イソシアネート系接着剤としては、ＭＤＩを用意し、これを固形分が５０％となるよう水で希釈したものを１０．８ｇ使用した。内添ワックスは、水で希釈して固形分を２０％としたものを１０．８ｇ使用した。 Specifically, 280 g of wood fiber (made from Lauan material) was prepared, and this was adjusted so that the water content was 8 to 10%. As the permeable adhesive, a low molecular weight phenol resin having a number average molecular weight of 110 (a mixture of a monomer and a multimer having a number average molecular weight of 84 is 66% by weight, and a multimer having a number average molecular weight of 340 is used. The weight ratio was adjusted to 34%.) Was prepared, and 55.6 g of the product diluted with water so that the solid content was 32.5% was used. As the isocyanate-based adhesive, 10.8 g of MDI was prepared and diluted with water so that the solid content was 50%. The internal wax used was 10.8 g diluted with water to a solid content of 20%.
図示しない混合容器に木質繊維を充填し、これをメカニカルブレンダーで攪拌しながら、添加剤であるフェノール樹脂、内添ワックスならびにＭＤＩを順次、スプレーガンを用いてスプレー噴霧した。次に、得られた添加剤付きの木質繊維をフォーミングしてマット状に成形した。そして、このマット状物を１８０℃で６０秒間の熱圧プレスを行った後、更に、２００℃で１２０秒（２分）間の熱圧プレスを行い木質繊維板（試料３ａ）を完成させた。なお、得られた木質繊維板（試料３ａ）は、縦と横の長さがそれぞれ３０３ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．７５０ｇ／ｃｍ3であった。 A wooden container (not shown) was filled with wood fibers, and while stirring the mixture with a mechanical blender, the phenol resin, internal wax, and MDI as additives were sequentially sprayed using a spray gun. Next, the obtained wood fiber with an additive was formed into a mat shape. The mat-like material was hot-pressed at 180 ° C. for 60 seconds, and further pressed at 200 ° C. for 120 seconds (2 minutes) to complete a wood fiber board (sample 3a). . The obtained wood fiber board (sample 3a) was a plate having a length and width of 303 mm and a thickness of 3.2 mm, respectively, and its density was 0.750 g / cm 3. It was.
（試料３ｂ）
浸透性接着剤（数平均分子量１１０の低分子量フェノール樹脂）の添加量を、木質繊維１００重量部に対して１０重量部（固形分が３２．５％となるよう水で希釈したものを７６ｇ使用）とした以外は、試料３ａと同じようにして得られた木質繊維板を試料３ｂとした。なお、得られた試料３ｂは、縦と横の長さがそれぞれ３０３ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．７３１ｇ／ｃｍ3であった。
(Sample 3b)
Use 76 g of permeable adhesive (low molecular weight phenol resin with a number average molecular weight of 110) diluted with water so that the solid content is 32.5% with respect to 100 parts by weight of wood fiber. Except for the above, a wood fiber board obtained in the same manner as the sample 3a was used as a sample 3b. The obtained sample 3b was a plate having a length and width of 303 mm and a thickness of 3.2 mm, respectively, and its density was 0.731 g / cm 3 .
（比較試料３ａ）
イソシアネート系接着剤（ＭＤＩ）を添加しない以外は、試料３ａと同じようにして得られた木質繊維板を比較試料３ａとした。なお、得られた比較試料３ａは、縦と横の長さがそれぞれ３０３ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．７２０ｇ／ｃｍ3であった。
(Comparative sample 3a)
A wood fiberboard obtained in the same manner as Sample 3a except that no isocyanate-based adhesive (MDI) was added was used as Comparative Sample 3a. The obtained comparative sample 3a was a plate having a length and width of 303 mm and a thickness of 3.2 mm, respectively, and its density was 0.720 g / cm 3 .
（比較試料３ｂ）
浸透性接着剤（数平均分子量１１０の低分子量フェノール樹脂）の添加量を、木質繊維１００重量部に対して１０重量部とし、イソシアネート系接着剤（ＭＤＩ）の添加量を、木質繊維１００重量部に対して４重量部とした以外は、試料３ａと同じようにして得られた木質繊維板を比較試料３ｂとした。なお、得られた比較試料３ｂは、縦と横の長さがそれぞれ３０３ｍｍで、厚さが３．２ｍｍの板状のものであり、その密度は０．７４１ｇ／ｃｍ3であった。
(Comparative sample 3b)
The addition amount of the permeable adhesive (low molecular weight phenol resin having a number average molecular weight of 110) is 10 parts by weight with respect to 100 parts by weight of the wood fiber, and the addition amount of the isocyanate adhesive (MDI) is 100 parts by weight of the wood fiber. A wood fiber board obtained in the same manner as the sample 3a was used as a comparative sample 3b except that the amount was 4 parts by weight. The obtained comparative sample 3b was a plate having a length and width of 303 mm and a thickness of 3.2 mm, respectively, and its density was 0.741 g / cm 3 .
（イソシアネート系接着剤（ＭＤＩ）の効果確認試験の方法）
イソシアネート系接着剤（ＭＤＩ）の効果を確認するための試験として、ワックス浸入長、長さ方向線膨張率（ＬＥ）、２０℃吸水膨張率（ＴＳ）ならびに剥離強度に関する試験をそれぞれ行った。
(Method of confirming effect of isocyanate-based adhesive (MDI))
As tests for confirming the effect of the isocyanate-based adhesive (MDI), tests on wax penetration length, lengthwise linear expansion coefficient (LE), 20 ° C. water absorption expansion coefficient (TS), and peel strength were performed, respectively.
ワックス浸入長は、皿の上にフロアー用ワックス（リンレイオール）を十分に染み込ませた綿（又は紙）を敷き、ワックスが含浸されている綿（又は紙）の上に５０ｍｍ×５０ｍｍに裁断した各試料（試験片）を、その小口面が直接接触するよう載置して３０分放置する。然る後、各試験片をフロアー用ワックスとの接触面から垂直方向に裁断して、フロアー用ワックスの吸い込み長さを測定することで得られる。 Wax penetration length was laid with cotton (or paper) fully soaked with wax for floor (Linleyall) on a plate and cut into 50 mm x 50 mm on cotton (or paper) impregnated with wax. Place each sample (test piece) so that its facet is in direct contact and leave it for 30 minutes. Thereafter, each test piece is cut in the vertical direction from the contact surface with the floor wax, and the suction length of the floor wax is measured.
長さ方向線膨張率（ＬＥ）は、ＪＩＳ Ａ５９０５に準拠し、４０℃／湿度９０％雰囲気から６０℃／乾燥雰囲気まで変化させたときの試験片の伸縮率を測定した。吸水膨張率（ＴＳ）は、ＪＩＳ Ａ５９０５に準拠して測定した（測定温度２０℃）。また、剥離強度もＪＩＳＡ ５９０５に準拠して測定した。 The linear expansion coefficient (LE) in the length direction was measured in accordance with JIS A5905, and the expansion / contraction ratio of the test piece was measured when the temperature was changed from 40 ° C./90% humidity atmosphere to 60 ° C./dry atmosphere. The water absorption expansion coefficient (TS) was measured according to JIS A5905 (measurement temperature 20 ° C.). The peel strength was also measured according to JISA 5905.
上記試験の結果は、［表３］の通りである。 The results of the above test are as shown in [Table 3].
［表３］
[Table 3]
まず、イソシアネート系接着剤（ＭＤＩ）の添加量について検討する。 First, the amount of isocyanate adhesive (MDI) added will be examined.
ワックス浸入長についてみると、試料３ａと比較試料３ａとを比較して分かるように、イソシアネート系接着剤（ＭＤＩ）を若干量（本実施例では、木質繊維１００重量部に対して２重量部）添加することにより、ワックス浸入長が短くなることが分かった。また、剥離強度も向上することが分かった。一方、試料３ｂと比較試料３ｂとを比較して分かるように、イソシアネート系接着剤の添加量を２倍に増やしても、ワックス浸入長の大幅な改善効果は認められない。 As for the wax penetration length, as can be seen by comparing the sample 3a and the comparative sample 3a, a slight amount of isocyanate-based adhesive (MDI) (in this example, 2 parts by weight with respect to 100 parts by weight of wood fiber) It was found that the wax penetration length was shortened by the addition. It was also found that the peel strength was improved. On the other hand, as can be seen by comparing the sample 3b and the comparative sample 3b, even if the amount of the isocyanate-based adhesive added is doubled, no significant improvement effect on the wax penetration length is observed.
次に、線膨張率（ＬＥ）について検討するに、実施例３ａと比較例３ａとの比較ならびに実施例３ｂと比較例３ｂとの比較で分かるように、イソシアネート系接着剤（ＭＤＩ）の添加量を増やすと線膨張率（ＬＥ）が大きくなり、寸法安定性が低下することが分かる。 Next, when examining the linear expansion coefficient (LE), as can be seen from the comparison between Example 3a and Comparative Example 3a and the comparison between Example 3b and Comparative Example 3b, the amount of isocyanate-based adhesive (MDI) added It can be seen that increasing the value increases the linear expansion coefficient (LE), which decreases the dimensional stability.
これらの結果から、イソシアネート系接着剤（ＭＤＩ）は少量添加する必要があるが、過剰に添加しても飛躍的な効果は得られず、反対に、吸放湿の寸法安定性を低下させることが分かった。すなわち、イソシアネート系接着剤（ＭＤＩ）については、木質繊維１００重量部に対して１〜３重量部程度添加するのが効果的であることが分かった。 From these results, it is necessary to add a small amount of isocyanate-based adhesive (MDI), but even if added excessively, a dramatic effect cannot be obtained, and conversely, the dimensional stability of moisture absorption and release is reduced. I understood. That is, it was found that it is effective to add about 1 to 3 parts by weight with respect to 100 parts by weight of the wood fiber for the isocyanate adhesive (MDI).
［実施例２］
本発明にかかる木質繊維板１０の片面に合板を貼着した場合には、寸法安定性の高い木質複合板を得ることができる。また、木質繊維板１０の表裏両面に合板と化粧板とをそれぞれ貼着した場合には、寸法安定性の高い床材を得ることができる。そこで、以下には、木質複合板ならびに床材を製造する方法について説明する。
[Example 2]
When a plywood is stuck on one side of the wood fiber board 10 according to the present invention, a wood composite board having high dimensional stability can be obtained. Moreover, when a plywood and a decorative board are bonded to both the front and back surfaces of the wood fiber board 10, a flooring material with high dimensional stability can be obtained. Therefore, a method for producing a wood composite board and flooring will be described below.
まず、上述実施例１で述べた方法で得られた寸法安定性の高い木質繊維板１０の片側の面に接着剤をその全面に塗布し、その上から合板を重ね合わせ、両部材を熱圧貼着する。接着剤としては、酢酸ビニル系、フェノール系、メラミン系、メラミン樹脂とＳＢＲ樹脂との混合系、ホットメルト系など任意のものが使用できるが、熱硬化性接着剤を用いて熱圧を行うことで、水分の持込を抑えることができ、さらに、ホットメルト系接着剤を用いれば、水分を持ち込ませないことができるので、床材の反りを抑えるのには効果的である。 First, an adhesive is applied to the entire surface of one side of the wood fiber board 10 having a high dimensional stability obtained by the method described in the above-described Example 1, and a plywood is laminated thereon, and both members are heated and pressed. Adhere. As the adhesive, any one such as vinyl acetate, phenol, melamine, mixed system of melamine resin and SBR resin, hot melt system, etc. can be used, but hot pressing is performed using a thermosetting adhesive. Thus, it is possible to suppress moisture from being introduced. Furthermore, if a hot melt adhesive is used, moisture cannot be introduced, which is effective in suppressing warping of the flooring.
次に、木質繊維板の含水率が平衡状態になるまで静置養生する（静置養生する直前に必要に応じて水打ちを行ってもよい）。なお、木質繊維板と木質合板との一体物は「木質複合板」として使用できる。 Next, static curing is performed until the moisture content of the wood fiber board reaches an equilibrium state (water spraying may be performed as necessary immediately before static curing). An integrated body of the wood fiber board and the wood plywood can be used as a “wood composite board”.
木質複合板（すなわち、木質繊維板と木質合板との一体物）の木質繊維板側の面に接着剤をその全面に塗布し、その上から化粧板を重ね合わせ、両部材を熱圧貼着する。化粧板としては、単板や樹脂強化化粧紙などの木質床材の化粧板として通常用いられているものが使用できる。これにより、目的とする寸法安定性の高い床板が得られることになる。 Adhesive is applied to the entire surface of the wood fiberboard side of the wood composite board (that is, an integrated body of wood fiberboard and wood plywood), a decorative board is overlaid on top of it, and both members are bonded with heat and pressure. To do. As a decorative board, what is normally used as a decorative board of wooden flooring materials, such as a veneer and resin reinforced decorative paper, can be used. Thereby, the target floor board with high dimensional stability will be obtained.
なお、化粧材の表面には、必要に応じて塗装を施すことができる。塗装用の塗料としては、紫外線硬化型、電子線硬化型、ポリウレタン系、アミノアルキッド系、ポリエステル系など常用の塗料を用いることができる。 In addition, the surface of the decorative material can be painted as necessary. As the coating material for coating, a commonly used coating material such as an ultraviolet curable type, an electron beam curable type, a polyurethane type, an amino alkyd type, or a polyester type can be used.
また、上述実施例では、木質繊維板に合板を貼着した後、化粧板を貼着するようにしているが、これとは逆に、木質繊維板に化粧板を貼着した後、合板を貼着するようにしてもよい。 Moreover, in the above-mentioned Example, after sticking a plywood to a wood fiber board, it is trying to stick a decorative board. On the contrary, after sticking a decorative board to a wood fiber board, a plywood is attached. You may make it stick.
さらに、上述実施例では、各部材を貼着する際、熱圧貼着するようにしているが、冷圧貼着するようにしてもよい。 Furthermore, in the above-mentioned embodiment, when each member is adhered, hot pressure is applied, but cold pressure may be applied.
発明者らは、上述した手法によって床材を製作し、得られた床材の寸法安定性について試験を行い、その実用性を検証した。以下には、その試験方法および試験結果について説明する。 The inventors manufactured a flooring by the above-described method, tested the dimensional stability of the obtained flooring, and verified its practicality. Hereinafter, the test method and test results will be described.
［床材の寸法安定性試験］
（試料４ａ）
木質繊維板（試料３ａ）の表面をサンダーで研削した後、木質繊維板３ａの表面側に接着剤を塗布し、化粧板を熱圧貼着した。化粧板には、樹脂強化化粧紙を使用し、木質繊維板３ａと化粧板とを貼着するための接着剤には、メラミン樹脂とＳＢＲ樹脂との混合接着剤を用いた。
[Dimensional stability test of flooring]
(Sample 4a)
After the surface of the wood fiber board (sample 3a) was ground with a sander, an adhesive was applied to the surface side of the wood fiber board 3a, and a decorative board was attached by heat and pressure. A resin-reinforced decorative paper was used for the decorative board, and a mixed adhesive of melamine resin and SBR resin was used for the adhesive for adhering the wood fiber board 3a and the decorative board.
熱圧後、木質繊維板３ａの裏面側（化粧板が貼着されていない側）の面に水打をし（水打の量は、５４ｇ／ｍ2である）、これを２３℃、相対湿度５３％ＲＨの室内で、木質繊維板３ａの含水率が平衡状態になるまで静置した。 After hot pressing, water is applied to the surface of the back side of the wood fiber board 3a (the side where the decorative board is not adhered) (the amount of water application is 54 g / m 2 ). It left still in the room | chamber interior of humidity 53% RH until the moisture content of the wood fiber board 3a will be in an equilibrium state.
次に、木質繊維板３ａの裏面に接着剤を塗布し、ファルカタ合板（厚さ９ｍｍ）を冷圧貼着した。木質繊維板３ａとファルカタ合板とを貼着するための接着剤には、水性高分子ビニルウレタン系接着剤を用いた。 Next, an adhesive was applied to the back surface of the wood fiber board 3a, and a Falkata plywood (thickness 9 mm) was attached under cold pressure. An aqueous polymer vinyl urethane adhesive was used as an adhesive for adhering the wood fiber board 3a and the Falkata plywood.
その後、木質繊維板３ａと化粧板とファルカタ合板との一体物を２３℃、相対湿度５３％ＲＨの室内で、木質繊維板ａの含水率が平衡状態になるまで静置した。 Thereafter, the integrated body of the wood fiber board 3a, the decorative board, and the Falkata plywood was allowed to stand in a room at 23 ° C. and a relative humidity of 53% RH until the moisture content of the wood fiber board a reached an equilibrium state.
最後に、化粧板の表面を紫外線硬化樹脂によって塗装を施し、床材Ａ（試料４ａ）を完成させた。なお、得られた試料４ａの厚さは、１２ｍｍであった。 Finally, the surface of the decorative board was painted with an ultraviolet curable resin to complete the flooring A (sample 4a). Note that the thickness of the obtained sample 4a was 12 mm.
（試料４ｂ）
化粧板として、樹脂強化化粧紙の代わりにオーク単板（厚さ０．２５ｍｍ）を用いた以外は、試料４ａと同じようにして得られた床材を試料４ｂとした。
(Sample 4b)
A flooring obtained in the same manner as Sample 4a was used as Sample 4b, except that an oak veneer (thickness: 0.25 mm) was used instead of the resin-reinforced decorative paper.
（比較試料４ａ）
木質繊維板として試料３ａの代わりに比較試料３ａを用いた以外は、試料４ａと同じようにして得られた床材を比較試料４ａとした。
(Comparative sample 4a)
A flooring material obtained in the same manner as the sample 4a was used as the comparative sample 4a except that the comparative sample 3a was used instead of the sample 3a as the wood fiber board.
（比較試料４ｂ）
化粧板として、樹脂強化化粧紙の代わりにオーク単板を用いた以外は、比較試料４ａと同じようにして得られた床材を比較試料４ｂとした。
(Comparative sample 4b)
A flooring material obtained in the same manner as the comparative sample 4a was used as a comparative sample 4b except that an oak veneer was used instead of the resin-reinforced decorative paper as the decorative plate.
（床材の寸法安定性試験の方法）
各床材を製造した直後の反り量を測定し、これを基準値とする。
(Method of dimensional stability test for flooring)
The amount of warping immediately after manufacturing each flooring is measured, and this is taken as the reference value.
次に、各試料を６０℃、乾燥雰囲気下で１４日間静置し、基準値からの寸法変化量を算出した。（−は凹みの大きさ：単位ｍｍ） Next, each sample was allowed to stand for 14 days in a dry atmosphere at 60 ° C., and the dimensional change from the reference value was calculated. (-Is the size of the dent: unit mm)
［表４］
[Table 4]
上記結果より、水性高分子ビニルウレタン系接着剤や水性高分子イソシアネート系接着剤などの水性高分子系接着剤を使用しているにも関わらず、試料４ａは比較試料４ａと、試料４ｂは比較試料４ｂと比べて、床材の施工直後においても既に反りは小さく、１４日間における変動値及び最大値も小さいことがわかる。 From the above results, the sample 4a is a comparative sample 4a and the sample 4b is a comparative sample even though an aqueous polymer adhesive such as an aqueous polymer vinyl urethane adhesive or an aqueous polymer isocyanate adhesive is used. Compared with the sample 4b, it can be seen that the warpage is already small even immediately after the construction of the flooring, and the fluctuation value and the maximum value in 14 days are also small.
１０…木質繊維板
１２…木質繊維
１４…細胞壁
２０…合板
２２…木質複合板
２４…化粧板
２６…床材
DESCRIPTION OF SYMBOLS 10 ... Wood fiber board 12 ... Wood fiber 14 ... Cell wall 20 ... Plywood 22 ... Wood composite board 24 ... Dressing board 26 ... Floor material
Claims (7)
前記浸透性接着剤は水溶性であり、その数平均分子量が２００以下であり、
その分子量分布が、単量体と多量体との混合物であってその数平均分子量が５０〜１００のものを重量比で４０〜７０％含み、数平均分子量が３００〜５００の多量体を重量比で３０〜６０％含むように構成されていることを特徴とする木質繊維板。 A wood fiber board in which a wood fiber is used as a base material and a permeable adhesive, an isocyanate-based adhesive, and an internally added wax are added as additives,
The permeable adhesive is water-soluble, and its number average molecular weight is 200 or less,
The molecular weight distribution is a mixture of a monomer and a multimer, the number average molecular weight of which is 50 to 100 containing 40 to 70% by weight, and the number average molecular weight of 300 to 500 is a weight ratio. It is comprised so that 30 to 60% may be included in, The wood fiber board characterized by the above-mentioned.
前記木質繊維板の含水率が平衡状態になるまで静置養生し、その後、
前記木質繊維板と前記化粧板とを接着剤を用いて貼着することを特徴とする床材の製造方法。 After sticking the wood fiberboard and the plywood according to claim 1 or 2 using an adhesive,
Standing curing until the moisture content of the wood fiber board is in an equilibrium state,
The manufacturing method of the flooring characterized by sticking the said wood fiber board and the said decorative board using an adhesive agent.
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