JPH0679843B2 - Abrasion resistant plate and method for producing the same - Google Patents

Description

TECHNICAL FIELD The present invention relates to a plate material having excellent wear resistance suitable for use as a floor material such as a container and other surface plate materials, and a method for producing the same.

(Prior Art) Conventionally, as a method of manufacturing a plate material such as a floor material having abrasion resistance, a method of applying a paint mixed with abrasion-resistant granules such as silica or alumina to the substrate surface or abrasion resistance A method of impregnating a sheet material such as paper or cloth into a coating material to which the abrasive particles are added and adhering the wear-resistant particles to the sheet material, and adhering the sheet material to the surface of the substrate is available. Are known.

(Problems to be solved by the invention) However, according to the former method of applying a wear-resistant granular material-containing paint, in order to impart desired wear resistance without impairing the cosmetic properties of the obtained plate material, It is not possible to increase the wear resistance of the body due to the limited amount of the abradable granules mixed.Moreover, if the proportion of the abradable granules mixed in the paint is increased, most of the granules settle in the paint. Therefore, it is impossible to coat the substrate with the required amount of abrasion-resistant granules, and the coating machine is worn by the abrasion-resistant granules in the paint during coating.

Furthermore, if a large-diameter granular material is used for the purpose of improving wear resistance, the coating surface becomes uneven, impairing cosmetic properties, and the thickness of the wear-resistant layer cannot be increased by coating. However, since the granular material easily falls off together with the limitation of the mixing amount, the plate material obtained does not have sufficient wear resistance, and it is difficult to exert the wear resistance effect for a long period of time.

In addition, when the substrate is a wood plate, there is a problem that the number of manufacturing processes is increased because the undercoating, the intermediate coating and the topcoating must be sequentially performed after drying.

On the other hand, the latter method, that is, the method of adhering the impregnated sheet-like material of the abrasion-resistant granular material-containing paint on the surface of the substrate has the advantage that the manufacturing process can be simplified. Since it is necessary to add and disperse wear-resistant granules therein, wear-resistant granules having a large particle size cannot be used and the addition amount is limited, and a plate material having high wear resistance cannot be obtained. Is.

The present invention solves such a problem, and provides a plate material with greatly improved wear resistance by a simple method and a method for manufacturing the same.

(Means for Solving Problems) In order to achieve the above object, the wear-resistant plate material of the present invention comprises:
A substrate, a non-woven fabric layer of inorganic fibers impregnated with a synthetic resin integrally laminated on the substrate, and a non-woven fabric layer of inorganic fibers impregnated with the synthetic resin were uniformly dispersed at a rate of 30 to 100 g / m ² . It is composed of wear-resistant granules with a particle size of 100-300μ and a new Mohs hardness of 10 or more, which are buried in the state.

Further, the manufacturing method of this plate material is such that, after the thermosetting synthetic resin liquid is impregnated into the inorganic fiber nonwoven fabric, the abrasion-resistant granules are evenly dispersed and adhered on the nonwoven fabric when the thermosetting synthetic resin liquid is uncured. Then, the thermosetting synthetic resin liquid is dried to obtain a resin-impregnated inorganic fiber non-woven fabric, and this resin-impregnated inorganic fiber non-woven fabric is placed on a substrate for thermocompression integration and abrasion resistance. It is characterized in that the granular material is embedded and held in a non-woven fabric of inorganic fibers.

(Function) Since the wear-resistant granules are scattered and adhered to the resin-impregnated inorganic fiber non-woven fabric, a large amount of granules can be evenly adhered over the entire surface and the large-diameter resistance It is also possible to use abradable granules, and even if the abradable granules have a large diameter, they are more porous than paper and used as a decorative sheet when the substrate and the resin-impregnated non-woven fabric are thermocompressively integrated. The thickness of the non-woven fabric is larger than that of the non-woven fabric, and it is embedded in the voids between the fibers of the inorganic fiber that is impregnated with a large amount of resin and is firmly held, and the surface treatment such as surface embossing of the resin-impregnated non-woven fabric against this heat pressure and the substrate. The back surface treatment can be performed simultaneously, and the process can be simplified. The inorganic fiber non-woven fabric has a thickness such that the granular material can be embedded therein, but it does not sink completely, and the weight thereof is preferably 35 to 60 g / m ² .

Further, unlike the cardboard, a non-woven fabric of inorganic fibers is used, so that the resin-impregnated layer can be formed thick and abrasion resistance and impact resistance are improved.

Furthermore, by spraying, it can be manufactured without sliding contact with the wear-resistant granules like a painting machine, so there is no damage to the machine, and moreover, as described above only on the surface where wear resistance is required. Since the granules can be scattered and adhered, the abrasion-resistant granules can be used without waste, and the obtained plate material exhibits great abrasion resistance due to the adhering abrasion-resistant granules.

(Embodiment) An embodiment of the present invention will be described with reference to the drawings. (1) is a wood board such as plywood, or an appropriate substrate such as a fiber board or a synthetic resin board, and a synthetic resin having an appropriate thickness on the surface thereof. Inorganic fiber non-woven fabric (2) impregnated with is integrally layered, and on this synthetic resin-impregnated non-woven fabric (2), a large number of abrasion-resistant granules (3) are uniformly dispersed over the entire surface. A wear resistant layer (4) is embedded in the state.

(5) is an embossed decorative surface provided on the surface of the synthetic resin-impregnated non-woven fabric (2), and (6) is a back surface treatment layer lined with the back surface of the substrate (1).

In order to obtain such an abrasion resistant plate material, first, a nonwoven fabric made of glass fiber, carbon fiber or the like and having a weight of 10 to 60 g / m ² is impregnated with a thermosetting synthetic resin liquid.

Synthetic resin to be impregnated into the inorganic fiber nonwoven fabric is phenol, polyester, melamine, diallyl phthalate,
A thermosetting synthetic resin such as epoxy is used, and it is not necessary to use a transparent one if the surface cosmetic properties of the plate material are not a particular problem.

Since the inorganic fiber nonwoven fabric is porous and thicker than the base paper for resin impregnation, a large amount of resin liquid can be impregnated and held.

This resin impregnation amount is limited by the weight and thickness of the inorganic fiber nonwoven fabric, but is 100 to 250 g / m ² in terms of solid content,
In order to obtain a large layer of resin-impregnated non-woven fabric by increasing the amount of resin impregnation, a non-woven fabric having a large weight may be used.

Then, the resin-impregnated nonwoven fabric (2) is left in an uncured and undried state, and a large number of abrasion-resistant granular materials (3) are formed on one surface thereof.
Is evenly spread over the entire surface and adhered.

As the wear-resistant granules (3), alumina oxide (Al
₂ O ₃ ), silicon carbide (SiC), silicon oxide (SiO ₂ ), boron carbide (B ₄ C), etc. with a new Mohs hardness of 10 or more are used, and they are sprayed differently when mixed with paint etc. Since its particle size is not particularly limited, it can be embedded in a non-woven fabric, and a large particle is not preferable in order to prevent unevenness on the surface, and it is suitable to use a particle size of 300 μ or less. There is.

Further, the abrasion-resistant granular material (3) can be applied to the resin-impregnated non-woven fabric (2) by adhering it to the resin-impregnated non-woven fabric (2). 30
~ 100 g / m ² .

Thus, the resin-impregnated non-woven fabric (2) to which a large amount of abrasion-resistant granules (3) is adhered is then dried to a so-called B-stage state, and thus can be stored for a certain period of time, like the resin-impregnated paper. It will be possible.

The resin-impregnated nonwoven fabric (2) dried in this state is placed on the substrate (1) and integrated with the substrate (1) by hot pressing with a hot press.

At this time, the thermosetting synthetic resin impregnated in the non-woven fabric by heat and pressure is once in a fluidized state and then cured, and during that time, a part of the resin flows out to the substrate (1) side and the resin passes through the resin. The impregnated non-woven fabric (2) is integrally bonded to the substrate (1), and the abrasion-resistant granules (3) sprinkled on the resin-impregnated non-woven fabric (2) are partially or wholly pressed between fibers of the non-woven fabric by pressurization. Even if particles having a large diameter are buried in a gap or the like and impregnated with the resin, the abrasion resistant layer (4) firmly held on the nonwoven fabric is formed after the resin is cured.

When the resin-impregnated nonwoven fabric layer (2) is integrated with the substrate (1) by thermocompression, the dispersion surface (4) of the wear-resistant particles is located on the surface side as shown in FIG. Alternatively, as shown in FIG. 2, the dispersion surface (4) of the wear resistant particles may be integrated toward the substrate (1) side, but in the latter case, the product is It is possible to give the plate material having good surface smoothness. Further, as shown in FIG. 3, a plurality of resin-impregnated non-woven fabrics (2) to which the wear-resistant granules (3) are adhered are laminated on the substrate (1) to perform thermocompression-integration to further improve the durability. It is also possible to obtain a plate material having improved wear resistance.

In addition, at the time of this hot pressing, it is possible to perform a back surface treatment such as a barrier on the back surface of the substrate at the same time as a surface cosmetic treatment such as embossing.

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

〔Example〕

A resin mixture of 100 parts of methanol-soluble phenolic resin and 40 parts of methanol was impregnated with a glass fiber non-woven fabric with a weight of 35 g / m ² to a resin adhesion amount of 160 g / m ² (solid content conversion), and then this resin Disperse 100 to 140μ silicon carbide evenly on the impregnated non-woven fabric at a rate of about 60g / m ² , and then 100 to 1
It was dried with a hot air dryer at 20 ° C for 2 to 3 minutes.

Next, this resin-impregnated non-woven fabric is overlaid on plywood, and an embossing plate is placed on the surface of the polypropylene sheet for mold release, and thermocompression molding is performed at a temperature of 140 ° C and a pressure of 12 kg / cm ² for 12 minutes. Then, a wear-resistant decorative plywood was obtained.

When this decorative plywood was tested by "wear test C based on Japanese agricultural and forestry standard for special plywood", the wear value was 17,000 times.

[Comparative example]

200g / m ^{2 of} compounded paint consisting of 100 parts of urethane resin (main agent), 45 parts of urethane resin (hardening agent), 20 to 25 parts of thinner, and 30 parts of alumina 55 to 88μ on plywood prepared by a conventional method. After coating and drying at a ratio of 1, the coating layer was coated with 190 g / m ^{2 of the} same coating composition and dried to prepare a decorative plywood. When the abrasion test was performed on this decorative plywood under the same conditions as above, the abrasion value was 9500 times.

(Effects of the Invention) As described above, the wear-resistant plate material of the present invention includes a substrate, a nonwoven fabric layer of inorganic fibers impregnated with a synthetic resin integrally layered on the substrate, and an inorganic fiber impregnated with the synthetic resin. 30 in the non-woven layer
~ 100g / m ² The new Mohs hardness of 10 or more wear-resistant granules with a particle size of 100-300μ buried in a state of being evenly sprayed is wear-resistant by conventional coating means and impregnation method. It is possible to exhibit greater wear resistance than a plate material to which the granular material adheres. Furthermore, unlike the paper material, the abrasion-resistant granules are embedded in the non-woven fabric of inorganic fibers while being embedded, so that they are rich in impact resistance and the thickness of the non-woven fabric of the inorganic fibers is large, so that a large amount of resin is used. It can be impregnated and wear resistant granules can be firmly held even if they have a large diameter and can exhibit excellent wear resistance for a long period of time. It has abrasion resistance that causes no problem even when the heavy object of (1) runs.

Further, according to the method for producing a wear-resistant plate material of the present invention, after a nonwoven fabric made of inorganic fibers is impregnated with a thermosetting synthetic resin liquid, the thermosetting synthetic resin liquid is uncured to form abrasion-resistant granules on the nonwoven fabric. Disperse and attach the body evenly, then dry the thermosetting synthetic resin liquid to obtain a resin-impregnated inorganic fiber nonwoven fabric, and place this resin-impregnated inorganic fiber nonwoven fabric on the substrate for thermocompression integration. At the same time, the abrasion-resistant granules are embedded and held in a non-woven fabric of inorganic fibers, so the conventional coating method limits the abrasion-resisting granule content to 40% of the resin solid content. In contrast, it can be increased to about 65%,
Moreover, a large amount of granules can be adhered uniformly over the entire surface, and it becomes possible to use wear-resistant granules having a large diameter of 300μ. Moreover, the wear-resisting granules have a large diameter. Even when the substrate and the resin-impregnated non-woven fabric are thermocompressively integrated, they can be embedded and firmly held in the voids between the fibers of the non-woven fabric that are more porous and thicker than paper, and at the same time, the The surface treatment such as surface embossing and the back surface treatment of the back plate of the substrate can be performed at the same time, so that the process can be simplified.

In addition, since a non-woven fabric of inorganic fiber having a large thickness is used depending on the thickness of the cardboard, the resin-containing layer can be formed thick, and the large-diameter granular material can be sufficiently embedded and held to improve wear resistance. .

Furthermore, since it can be manufactured without sliding contact with abrasion-resistant granules like a painting machine, the abrasion of the machine does not occur, and moreover, the granules are formed on the surface where abrasion resistance is required as described above. Since the particles can be sprayed and attached, the wear-resistant granules can be used without waste, and the obtained plate material exhibits great wear resistance due to the large amount of the wear-resistant granules attached.

[Brief description of drawings]

The drawings show an embodiment of the present invention. FIG. 1 is a simplified vertical sectional view of Example 1, FIG. 2 is a simplified vertical sectional view of Example 2, and FIG. 3 is a simplified vertical sectional view of Example 3. The figure is a partially enlarged sectional view thereof. (1) ... Substrate, (2) ... Inorganic fiber non-woven fabric impregnated with synthetic resin, (3) ... Wear-resistant granules, (4) ... Wear-resistant layer.

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Shigeru Yamana 2-3-3 Nakanoshima, Kita-ku, Osaka City, Osaka Prefecture Daiken Kogyo Co., Ltd. (56) Reference JP-A-60-109832 (JP, A) Kai 57-96854 (JP, A) JP 54-10985 (JP, B2) JP 61-44831 (JP, Y2)

Claims (5)

[Claims] 1. A substrate, a nonwoven fabric layer of inorganic fibers impregnated with a synthetic resin integrally laminated on the substrate, and a nonwoven fabric layer of inorganic fibers impregnated with the synthetic resin at a rate of 30 to 100 g / m ² . A wear-resistant plate material comprising a wear-resistant granular material having a particle size of 100 to 300 μ and a new Mohs hardness of 10 or more, which is embedded in a uniformly dispersed state. 2. An inorganic fiber non-woven fabric is impregnated with a thermosetting synthetic resin liquid, and when the thermosetting synthetic resin liquid is uncured, wear-resistant granules are evenly dispersed and adhered on the non-woven fabric, and A thermosetting synthetic resin liquid is dried to obtain a resin-impregnated inorganic fiber nonwoven fabric, and this resin-impregnated inorganic fiber nonwoven fabric is placed on a substrate for thermocompression integration, and at the same time, abrasion-resistant granules are formed. A method for producing a wear-resistant plate material, which comprises burying and holding the same in a nonwoven fabric of inorganic fibers. 3. When disposing a resin-impregnated inorganic fiber non-woven fabric on a substrate, disposing the abrasion-resistant granular material adhering layer provided on the resin-impregnated inorganic fiber non-woven fabric toward the surface side. The method for producing the wear-resistant plate material according to claim 2, which is characterized in that. 4. When disposing an inorganic fiber non-woven fabric impregnated with a resin on a substrate, the abrasion resistant granular material adhering layer provided on the non-woven fabric of inorganic fiber impregnated with the resin is disposed toward the substrate side. The method for producing the wear-resistant plate material according to claim 2, which is characterized in that. 5. A non-woven fabric of inorganic fibers impregnated with a plurality of resins is arranged on a substrate.
Item 5. A method for manufacturing an abrasion resistant plate material according to Item 3, Item 3 or Item 4.