JPH021002B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board in which a synthetic resin injection-treated thin wood board is integrally adhered to the surface of a base material.

Synthetic resin injection-treated thin wood sheets (hereinafter referred to as WPC thin sheets) have superior hardness, strength, abrasion resistance, water absorption, etc. compared to wood, and have a beautiful wood grain pattern with increased transparency due to the injected resin. It can be attached to the surface of plate-shaped substrates made of various materials including wood substrates such as plywood, LVL, particle board, etc. to create flooring materials, other construction materials, furniture materials, etc.
It is widely used as other decorative materials.

Conventionally, methods for producing such decorative materials include: (a) placing a WPC thin plate directly or with an adhesive on the surface of plywood or other base material and heat-pressing it, curing the injected resin liquid, and at the same time removing the base material; (b) After the resin liquid injected into the WPC thin plate is once cured, it is bonded and integrated with the surface of the base material using an adhesive.

According to the first of these methods,
The adhesion of the WCP thin plate and the curing of the injected resin liquid can be carried out in a single heat-pressure treatment, which has the advantage of good workability and is suitable for mass production of decorative laminates. Because the injected resin liquid inside flows toward the adhesive surface with the base material, many conduit grooves are exposed on the surface of the base material when plywood, LVL, etc. made of hardwood such as lauan wood is used as the base material. As a result, the resin liquid flows into concave areas such as conduit grooves on the surface of the base material, the amount of resin in the WPC thin plate decreases, the transparency decreases, and some areas become cloudy (hereinafter referred to as smudges). In addition, the resin liquid that flows out remains in the conduit groove on the surface of the base material, and this forms dark spots or lines (hereinafter referred to as spots) through the WPC thin plate. There were defects that were exposed on the surface and significantly impaired the appearance.

On the other hand, according to the latter method, the problem of scratches and spots does not occur, but the
WPC thin plates are thin and hard, so when handling them during transportation etc.
Another disadvantage is that cracks tend to occur along the fiber direction of the thin sheet during cutting, and production efficiency is poor because curing of the injected resin and adhesion of the WPC thin sheet to the base material are performed separately. .

The present invention eliminates such drawbacks and provides a method for efficiently producing a WPC laminated decorative board with excellent cosmetic properties without causing fading, spotting, etc., by using the former method with high productivity. It is something.

To explain the method of the present invention in more detail, in the figure, the base material 1 of the decorative board is a wooden board-like base material such as plywood, particle board, hardboard, or a non-woven material such as plaster, silicon board, wood wool cement board, etc. A wooden plate-like base material or the like is used, and a softwood veneer 2 is attached to the surface of this base material 1 with an adhesive.
When the base material 1 is made of a coniferous material such as coniferous plywood, the outermost coniferous veneer 2 may be used without attaching the coniferous veneer 2 separately.

Next, the WPC thin plate 3 injected with a synthetic resin liquid is placed on the softwood veneer 2 provided on the surface of the base material 1 in an uncured state.

This WPC thin plate 3 includes rotary veneer,
A veneer such as a sliced veneer or a sawn veneer is used, and this veneer is coated with polycondensation type synthetic resin such as phenol resin or melamine resin, polyester, MMA,
Addition polymerization type synthetic resins such as DAP are processed by vacuum method, pressurization method,
It is obtained by injection treatment using a dipping method or the like.

The WPC thin plate 3 obtained in this way is placed on the softwood veneer 2 on the surface of the base material as described above, and then heated and pressurized by a hot press.
WPC thin plate 3
If the synthetic resin injected into the veneer has no adhesive strength or has weak adhesive strength, an appropriate adhesive is applied to the surface of the softwood veneer 2 in advance.

When hot pressed by hot press of WPC thin plate 3,
The injected resin liquid inside the WPC thin plate flows and tries to flow out to the base material side, but the softwood veneer 2
Unlike hardwood, softwood does not have a conduit part and more than 90% are tracheids, so the surface of the softwood veneer 2 is smooth, and the surface allows the inside of the WPC thin plate to This prevents the injected resin liquid from flowing out and solidifies in that state, resulting in a decorative board with good cosmetic properties without scratches or spots.

In addition, if there are concave parts such as conduits in hardwood, the injected resin liquid will enter the concave parts and the adhesive strength will deteriorate, but the method of the present invention eliminates this drawback by using softwood veneer. This allows the WPC thin plate to be solidified and firmly adhered to the surface of the base material at the same time.

Next, specific examples of the present invention will be shown.

Example 1 A spruce slice veneer with a thickness of 0.3 mm was placed in a vacuum tank, and a resin solution prepared by adding 2 parts of BPO to a mixture of 10 to 15 parts by weight of styrene and 85 to 90 parts by weight of an unsaturated polyester resin was heated at 10 mmHg. The veneer was injected for 1 hour.

This synthetic resin injection treated veneer was placed on a 12mm thick southern pine plywood whose surface was coated with an adhesive containing a mixture of urea and vinyl acetate resin, and then hot pressed to produce a 10Kg/plywood board.
cm ² , 120° C., and heat and pressure for 18 minutes to integrate.

The obtained decorative laminate had good adhesion of the synthetic resin injection treated veneer to the plywood and the decorative properties of the veneer.

Example 2 A spruce slice veneer treated with resin injection in the same manner as in Example 1 was placed on a 2.0 mm thick spruce rotary veneer adhered to the surface of a particle board, and then hot-pressed into Example 1. They were heated and pressed under the same conditions as above to integrate them.

The obtained decorative board was free from fading and markings and had good cosmetic properties and adhesion properties compared to a decorative board made by heat-pressing and integrating a resin-injected veneer directly onto a particle board.

As described above, in the present invention, a synthetic resin injection-treated thin wood board is placed on the surface of a base material having a softwood veneer on the surface, heated and pressurized, and the injected resin in the thin wood board is cured and the base material is cured. This relates to a method for manufacturing decorative laminates, which is characterized by the simultaneous integration of
Since the softwood veneer interposed between the base material and the synthetic resin injection-treated thin wood sheet has no conduit and has a smooth surface, the injected resin tends to flow out from the synthetic resin injection-treated thin wood sheet during hot pressing using a hot press or the like. It is possible to uniformly prevent the resin from forming on the entire surface of the softwood veneer, thereby eliminating the occurrence of smearing caused by outflow, and also preventing the resin from partially staying and solidifying, thereby eliminating the occurrence of spots. It is possible to obtain a decorative board with good cosmetic properties that exhibits a beautiful wood grain pattern with uniformly enhanced transparency throughout.

Furthermore, in the present invention, the injected resin in the wood veneer is cured at the same time as it is integrated with the softwood veneer.
It is possible to efficiently produce a decorative board pasted with a WPC thin plate, and also to reliably and firmly bond the softwood veneer and the WPC thin plate.

[Brief explanation of drawings]

The drawing is a simplified cross-sectional view of a decorative board obtained by the method of the present invention. 1... Base material, 2... Softwood veneer, 3... Synthetic resin injection treated wood thin board.

Claims (1)

[Claims] 1. A thin wooden board treated with synthetic resin injection is placed on the surface of a base material having a softwood veneer on the surface, and heated and pressurized to harden the injected resin in the thin wooden board and bond it to the base material. A method for manufacturing a decorative board characterized by simultaneously performing integration. 2. The method for producing a decorative laminate according to claim 1, wherein the base material is a coniferous veneer adhered to the surface of a plate-like object.