JP2003278363A - Electron beam curable resin impregnated flooring - Google Patents

Abstract

[PROBLEMS] To provide an excellent surface hardness, excellent scratch resistance, abrasion resistance, crack resistance and stain resistance, and a good appearance equal to or better than general wood flooring in design. An electron beam-curable resin-impregnated flooring material can be produced at low cost while expanding the range of choice of thin wood veneers. As an electron beam-curable resin impregnated floor material A, a base material 1 provided with an MDF layer 2 on the surface, a barrier layer 3 provided on the surface of the MDF layer 2, and an adhesive bonded to the surface of the barrier layer 3 0.15 mm to 0.1 mm impregnated with an electron beam curable resin.
The structure is provided with a 5-mm thin wooden veneer layer 4 and a coating layer 5 composed of two or more layers provided on this surface.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technical field of an electron beam-curable resin-impregnated floor material having a low VOC and having an enhanced surface strength by being impregnated or press-fitted with an electron beam-curable resin to be cured.

[0002]

2. Description of the Related Art Conventionally, as a resin-reinforced floor material, a thin wood veneer or the like in which resin has been infiltrated by a pressure reduction method in a pressure kettle is attached to the surface of the base material, or It is already known that a thin wood veneer is applied and impregnated with a thermosetting resin, and the resin is cured by hot pressing under a high pressure condition of 130 to 140 ° C.

However, these conventional resin-reinforced floor materials made of thermosetting resins have the following problems in order to obtain desired performance as floor materials. That is, the method of impregnating a resin into a thin wooden veneer or the like is of a batch type using a pressure kettle, resulting in very poor productivity.

On the other hand, in the hot press method, since heat curing requires a long time, productivity is extremely deteriorated and
An energy cost for applying a heat such as a release sheet or 130 to 140 ° C. is required, and a large production cost is required. Specifically, in the line production, these resin impregnation process and thermosetting process are the factors that determine the line speed. Therefore, a method other than thermosetting resin and a method for efficiently carrying out curing impregnation were used. Improvements in wood materials have been desired.

Further, most of these thermosetting resins are solvent type resins, and these solvents remain even after they are made into products and volatilize during indoor use, causing an indoor pollution problem. It is well known.

In view of these points, a building material using an electron beam curable resin is being studied. When using the electron beam curable resin, the following merits can be mentioned. In other words, it is energy saving because it does not require heating.

Compared with general thermosetting resins, the volume shrinkage due to curing is extremely small.

[0008] Because of the curing by the electron beam, it is possible to cure with a uniform thickness without unevenness.

Since a monomer that itself participates in the curing reaction is used as a diluent, a volatile organic solvent is not necessary, and components that cause sick house such as VOC do not occur.

Based on these merits, as shown in, for example, JP-A Nos. 11-207918 and 2000-25190, a paper whose surface is impregnated with an electron beam curable resin is used. It has been considered to use paper mainly as a coating agent for the surface of a decorative material.

As the decorative sheet, for example, as shown in Japanese Patent Laid-Open Nos. 10-44331 and 10-86309, a decorative material using electron beam curable resin-impregnated paper is provided, and this decorative sheet is used. A material using a material as, for example, a surface material for an interior door or a storage is known and is already on the market.

[0012]

However, when the above-mentioned conventional paper impregnated with an electron beam-curing resin is used, it is extremely difficult to obtain the desired performance required as a flooring material, and moreover, it is a design that is generally made of wood. There was a drawback that it was inferior to the floor material. Therefore, as a surface decorative material, instead of paper, a thin wood veneer is impregnated and cured with an electron beam curable resin,
A surface makeup method using this on the surface of a floor material has been studied, but has the following problems.

That is, the most important problem in using a thin wooden veneer on the surface of a floor material is resin impregnation. Unlike wood and other materials, thin wood veneer is a non-uniform material, and it is extremely difficult to evenly infiltrate the resin with a collection of resin paths called conduits and fine tubes called wood fiber parts. Is. For this reason, the tree species used on the surface are currently limited to those with relatively large conduits such as oak.

The present invention has been made in view of the above points, and an object thereof is a structure of a flooring material provided with a thin wooden veneer impregnated and cured with an electron beam curing type resin as described above. Electron beam with excellent surface hardness, excellent scratch resistance, abrasion resistance, crack resistance and stain resistance, and a design that is as good as or better than ordinary wood flooring The purpose of the present invention is to make it possible to produce a curable resin-impregnated flooring material at low cost while expanding the range of tree species selection for thin wood veneer.

[0015]

In order to achieve the above object, the present invention has the following points.

1. The desired performance as a floor material is realized by a thin wooden veneer that is hardened by impregnating or press-fitting an electron beam curing type resin.

2. The thin wood veneer attached to the surface is 0.1
5 to 0.50 mm is used, and the tree species is not limited.

3. A barrier layer for preventing resin impregnation is provided between the thin wood veneer layer and the MDF layer immediately below the thin veneer layer.

4. The resin with which the thin wood veneer is impregnated is an electron beam curable resin.

5. The electron beam irradiation device necessary for curing the resin impregnated or applied to the product can be a low energy type electron beam irradiation device such as 150 to 300 keV, which requires low initial investment of the equipment.

Specifically, in the invention of claim 1, a substrate having an MDF layer provided on the surface thereof, a barrier layer provided on the surface of the MDF layer, and an electron beam curing agent adhered to the surface of the barrier layer. 0.15 mm to 0.5 mm thin wood veneer layer impregnated with mold resin, and 2 provided on the surface of the wood thin veneer layer
And a coating layer having a constitution of at least one layer.

In the invention of claim 2, the resin impregnated in the wood thin veneer layer has a viscosity of 100 at 40 ° C.
Two types of resins are used: a low-viscosity resin of mPa · s or less and a high-viscosity resin whose viscosity at 40 ° C. is adjusted to 1000 to 3500 mPa · s.

According to the structures of these inventions, the barrier layer is provided on the surface of the MDF layer directly below the thin wood veneer layer,
Moreover, as a thin wood veneer, a thin wood veneer of 0.15 mm to 0.5 mm is used, so 150 to 300 keV
Such a low energy type electron beam irradiation apparatus can completely cure the resin impregnated or pressed into the thin wood veneer on the surface.

Since two kinds of resins having different viscosities are used, the resin can be uniformly impregnated into the conduit portion and the wood fiber portion of the thin wood veneer. Therefore, even a tree species having a small conduit such as birch can be used as a thin wood veneer. Therefore, the electron beam curable resin-impregnated floor that has excellent surface hardness, excellent scratch resistance, abrasion resistance, crack resistance and stain resistance, and that has a good appearance that is equivalent to or better than general wood flooring in terms of design The wood can be produced inexpensively while expanding the range of tree species selection of thin wood veneer.

According to a third aspect of the present invention, in the electron beam curable resin-impregnated floor material according to the first or second aspect, the barrier layer provided on the surface of the MDF layer is formed of a sheet-like material impregnated with a colored resin. Shall be.

That is, generally, the MDF used in the MDF layer is dark. In order to solve this, a light-colored MDF may be used, but the cost increases due to bleaching costs and the like. Also, a method of increasing the thickness of the veneer on the surface can be adopted, but in any case, it becomes high.
When using a thin wooden veneer of 0.15 to 0.50 mm, if the thin wooden veneer is directly attached to the surface of this dark MDF, especially in the case of a light-colored design that is said to be natural Uses thin wood veneer,
The color of MDF is reflected and the design becomes bad.

However, as in the invention of claim 3, the MDF
When the barrier layer provided on the surface of the layer is made of a sheet-like material impregnated with a colored resin, excellent designability can be realized regardless of the color of the MDF layer.

Further, by using a sheet-like material for the barrier layer, it is possible to secure a certain thickness, and it is possible to effectively prevent the electron beam curable resin from soaking into the substrate.

According to a fourth aspect of the present invention, in the electron beam curable resin-impregnated floor material according to the first or second aspect, the barrier layer provided on the surface of the MDF layer is subjected to pigment-based coloring applied to the surface of the MDF. Sealer coating. In this case, the effect is similar to the effect of the sheet-like material impregnated with the colored resin, which is the barrier layer provided on the surface of the MDF layer.

That is, when a thin wooden veneer having a thickness of 0.15 to 0.50 mm is used, if the thin wooden veneer is directly attached to the surface of this dark MDF, a light-colored coloring which is said to be a natural type is produced. In the case of the applied design, the color of MDF is reflected, so that the design becomes bad.

However, as in the invention of claim 4, the MDF
If the barrier layer provided on the surface of the layer is made of a pigment-based sealer coating applied to the surface of the MDF, excellent designability can be realized regardless of the color of the MDF layer. .

According to a fifth aspect of the present invention, in the electron beam-curable resin-impregnated floor material according to any one of the first to fourth aspects, at least the outermost layer of the coating layer having two or more layers is an electron beam-curable type. It is assumed that paint has been applied. This way
By irradiating the coating film with an electron beam in the top coating step constituting the outermost layer, the coating film can be completely cured, and the adhesion between the resin impregnated in the thin wood veneer and the coating film can be improved. Furthermore, since the outermost coating layer is an electron beam curing type, there is no emission of organic solvent from the coating, excellent surface hardness, scratch resistance, abrasion resistance, excellent crack resistance and stain resistance, and The electron beam curable resin-impregnated flooring material can be designed to have an appearance equal to or higher than that of a general wooden flooring material.

[0033]

1 shows an electron beam curable resin-impregnated floor material A according to an embodiment of the present invention. The electron beam curable resin-impregnated floor material A is a base material 1 and a base material 1. MDF layer 2 provided on the surface of MDF layer 2, barrier layer 3 provided on the surface of MDF layer 2, thin wood veneer layer 4 provided on the surface of barrier layer 3, and thin wood veneer layer 4 is provided with a clear coating layer 5 provided on the surface. Hereinafter, these components will be described in detail.

(Substrate) The substrate 1 is, for example, plywood or LV.
L, MDF, particle board, OSB, wood-based and gypsum board such as laminated wood, inorganic material such as calcium silicate board, volcanic vitreous multi-layer board, or those laminated with multiple layers are used. To be done.

(MDF Layer) As the MDF used for the MDF layer 2 provided on the surface of the base material 1, any MDF can be selected from U type, M type and P type. However, in order to obtain desired performance as a flooring material, it is desirable to use P type or M type MDF in consideration of water resistance. In this case, it is desirable to use E0 type MDF that emits as little formaldehyde as possible.

In the present invention, the MDF color (dark color system,
Since it does not depend on the light-colored shape, etc., it is possible to select either cheap tropical hardwood, which is commonly used for dark-colored materials, or light-colored MDF, which is made of softwood. Is.

(Barrier Layer) The barrier layer 3 provided on the surface of the MDF layer 2 is a sheet-like product impregnated with a colored resin, or a pigment-based sealer coating applied on the MDF surface. Is a barrier layer.

When the barrier layer 3 is the former sheet-like article impregnated with the colored resin, the sheet-like article impregnated with the resin is formed into the MDF.
It is possible to use a dense sheet-like material capable of preventing the resin from seeping into the layer 2, such as paper, non-woven fabric, or a glass fiber sheet. As the resin with which the sheet-like material is impregnated, a thermosetting resin, a modified thermosetting resin, a mixture thereof or the like is preferably used. Specific examples include melamine resins, urea resins, urea / melamine resins, phenol resins, polyester resins, epoxy resins, acrylic resins, vinyl acetate resins, and modified products and mixtures of these resins. . In this case, a resin having moderate toughness after being cured is preferable, and particularly a melamine resin, a vinyl acetate resin,
A mixture of an ethylene-modified vinyl acetate resin and an acrylic emulsion resin, or a methylol melamine in which a methylol group is acrylic-modified or allyl-modified is preferably used.

On the other hand, when the barrier layer 3 is the latter, which is a pigment-based sealer coating applied to the surface of the MDF, the sealer is arbitrarily selected from a solvent-based sealer and an emulsion-based sealer. For example, acrylic emulsion sealer, urethane resin sealer,
A polyester resin-based sealer, an alkyd resin-based sealer, or the like is used.

The barrier layer 3 is colored with a pigment having a high concealing property or the like to give 0.15 to 0.50 m in the present invention.
Even when a thin wood veneer having a thickness of m is used, a suitable design can be realized without being influenced by the color of the MDF directly below. At this time, the color of the barrier layer 3 is preferably the same as that of the surface finish. In addition, as the pigment used at this time, an extender pigment having a high hiding property, a coloring pigment such as an inorganic pigment and an organic pigment, and a special pigment such as a metallic pigment can be arbitrarily selected.

Examples of the extender pigment include alumina,
Talc, barite powder, calcium carbonate, anhydrous silicic acid muscovite, etc. are used. As the inorganic achromatic pigment, for example, titanium oxide, zinc white, lithopone, etc. are used. Examples of the inorganic coloring pigments include yellow iron oxide, titanium yellow, red iron oxide, and ultramarine. As the organic pigment, for example, azo pigments such as azo lake pigments, insoluble azo pigments and condensed azo pigments, metal complexes, polycyclic pigments such as slene pigments and quinone pigments, acidic pigments or basic pigments are used.

In the present embodiment, the barrier layer 3 is composed of a sheet material impregnated with a colored resin, or a pigment-based sealer coating applied to the surface of the MDF. Even if the thin wood veneer layer 4 to be attached to is a thin wood veneer of 0.15 mm to 0.5 mm,
Regardless of the lightness and darkness of the DF, excellent designability can be ensured regardless of whether the surface finish is light or dark.

(Wood thin veneer layer) The wood thin veneer layer 4 is 0.
It is composed of a thin wood veneer layer of 15 mm to 0.5 mm, and the veneer is impregnated with an electron beam curable resin from the surface side.
In the case of a wood veneer having a thickness of 0.15 mm or less, the finish is inferior in design.

On the other hand, when a single plate of 0.5 mm or more is used, it is necessary to completely cure the electron beam curing type resin when the impregnated resin penetrates to a depth of 0.5 mm or more. , 300 keV low energy type electron beam irradiation apparatus, the electron beam does not reach the deepest part of the impregnated resin, and the uncured resin remains. This is 500 keV to 1 Me
This can be solved by using a medium energy type or high energy type electron beam irradiation device of V or higher, but the cost required for facility investment jumps to several times or several tens of times that of the low energy type electron beam irradiation device, so it is practical. is not.

The electron beam curable resin impregnated in the thin wooden veneer layer 4 has a low viscosity of 100 mPa · s or less at 40 ° C. and a viscosity of 1000 to 3 at 40 ° C.
Two types of resins are used, a high-viscosity resin adjusted to 500 mPa · s. By using two kinds of resins having different viscosities, the resin can be uniformly impregnated into the conduit portion and the wood fiber portion of the thin wood veneer. Therefore, even a tree species having a small conduit such as birch can be used as a thin wood veneer. This makes it excellent in surface hardness, scratch resistance, wear resistance, crack resistance and stain resistance,
In addition, the electron beam curable resin-impregnated floor material A, which can be designed to have an appearance equal to or more than that of a general wooden floor material, can be produced inexpensively while expanding the range of tree species selection of the thin wooden veneer.

Specifically, the viscosity at 40 ° C. is 100 m
As a method for impregnating a resin having a low viscosity of Pa · s or less, a method of applying the resin from the surface of a single plate attached to the base material 1 with a flow coater or a roll coater and then press-fitting with a roll coater or a knife coater is used. It is preferably used.
Furthermore, as the applicant previously proposed (Japanese Patent Application 2000
-71472 specification and drawings), the temperature of wood is 4
If the temperature of the resin is adjusted to less than 40 ° C at 0 to 80 ° C, after applying the low-viscosity resin to the surface of the thin wooden veneer,
It is possible to penetrate by setting the setting time from seconds to 3 minutes. Further, by providing a cooling step at the time of setting, more suitable permeation conditions can be obtained. In addition, by applying pressure with a roll coater or a knife coater after coating the coating material, suitable permeation conditions can be obtained. The roll coater preferably has an embossed surface, as previously proposed by the present applicant (see Japanese Patent Application No. 2000-71472 and drawings).

The viscosity at 40 ° C. is 1000 to 3
As a method of impregnating a high-viscosity resin adjusted to 500 mPa · s, a method of applying pressure by a roll coater or a knife coater is preferably used. In this case, as proposed by the present applicant (see Japanese Patent Application No. 2000-71472 and drawings), the temperature of the wood is 40 to 80 ° C., and the temperature of the resin is adjusted to less than 40 ° C. The condition is obtained. Further, after coating and press-fitting, the surplus resin on the surface is scraped off. By providing a cooling step before this scraping, more suitable press-fitting conditions can be obtained. When a roll coater is used for coating / press-fitting and scraping, it is preferable that the surface has an embossed shape as proposed by the present applicant (see Japanese Patent Application No. 2000-71472 and drawings).

The electron beam curable resin press-fitted into the thin wooden veneer layer 4 may be colored. in this case,
Mainly dye-based colorants are used, for example, acridine dye, anthraquinone dye, azine dye, azo dye, azomethine dye, indigoid dye, indophenol dye, indoaniline dye, indamine dye, naphthalimide dye, phthalocyanine dye, quinophthalone dye,
It is arbitrarily selected from diallylmethane dye, triallylmethane dye, thiazine dye, thiazole dye, xanthine dye and the like.

Further, the wood thin veneer impregnated with the electron beam curable resin is subjected to the base adjustment. Specifically, 240-
Lightly polish the surface with polishing paper No. 320 (0.05 ~ 0.1
About mm) Sanding is performed. At this time, a belt sander is preferably used in line production, but a hand sander may be used.

Further, the substrate is colored. For the base coloring, dye-based aqueous stains, oil-based stains, alcohol stains, pigment-based water-based stains, oil-based stains, alcohol stains, etc. are arbitrarily selected and used. In addition, the base coloring may not be exceptionally performed.

(Coating layer) The coating used for providing at least two clear coating layers 5 on the surface of the thin wood veneer 4 is not limited to any coating material and can be appropriately selected. . At this time, an electron beam curable coating material or an ultraviolet curable coating material is preferably used. The coating is performed in two or more layers, and a pigment or dye is added to the coating as needed. At this time, the outermost coating film layer, that is, the top coating material is preferably an electron beam curing type coating material.

In order to improve wear resistance, at least 10 parts by weight, preferably 30 parts by weight or more of anti-friction is applied to any layer except the outermost layer of the coating layer, that is, the coating layer other than the top coat. Agents may be added. It is common practice in Europe and the United States to add a lubricant to the outermost layer. Also, at this time,
It is possible to commercialize with only one layer to which an anti-friction agent is added, and in some cases, a top coating may not be required. In this case, the surface of the flooring material is less slippery due to the lubricant, and the surface has a rough design and appearance. In Europe and the United States, this is not a problem for living on bare feet, whereas in Japan, it is not preferable to put an anti-friction agent on the outermost surface of the paint to live on bare feet or stockings.

Therefore, in this embodiment, for example, when the coating is performed in two layers, for example, the undercoat is coated with a lubricant containing 10 parts by weight or more, preferably 30 parts by weight or more of the lubricant, Apply topcoat paint to this. At this time, an electron beam curable paint or an ultraviolet curable paint is preferably used as the undercoat paint, and an electron beam curable paint is preferably used as the top coat paint.

Further, in the present embodiment, for example, when coating is performed with three layers, for example, an undercoat paint for enhancing the adhesion between the coating film and the thin wood veneer is applied to the undercoat, and the intermediate coat is
A paint containing 0 part by weight or more, preferably 30 parts by weight or more of an anti-friction agent is applied, and a top coat paint is applied thereto. At this time, an electron beam curable paint or an ultraviolet curable paint is preferably used as the undercoat or intermediate coat paint, and an electron beam curable paint is suitably used as the top coat paint.

In particular, when the ultraviolet curing type coating is selected as the undercoating or the intermediate coating, it is preferable to use the electron beam curing type coating as the top coating. This is because the electron beam irradiated during the curing of the top coating allows the coating to be completely cured even if the UV-cured coating of the undercoat or intermediate coating contains colorants and lubricants. is there. Further, for the purpose of improving the adhesion between coating layers such as undercoat and intermediate coating, intermediate coating and top coating, UV drying or electron beam drying in a semi-cured state is generally performed. Drying not only completely cures the semi-cured coating film, but also has the effect of increasing the adhesiveness of the coating film such as undercoat and intermediate coating, and intermediate coating and top coating.

[0056]

[Examples] Next, specific examples will be described.

Example 1 A plywood sheet having a thickness of 9 mm and a thickness of 2.
A 7 mm MDF was attached with a thermosetting adhesive to form a plywood substrate having a total thickness of 11.7 mm as a base material. At this time, MDF
Is a water-resistant phenol type and a dark tea type MDF using tropical hardwood.

A paper impregnated with a phenol resin containing 1 part by weight of a yellow pigment was attached to this surface, and hot pressing was performed to form a barrier layer.

The surface of the barrier layer was coated with a thermosetting adhesive to a thickness of 0.
A 35 mm oak thin veneer was attached by a hot press. This flooring material is heated to 60 ° C with a jet dryer and heated to 35 ° C.
A low-viscosity electron beam curable resin of the following formulation 1 adjusted to 1
It was applied with a flow coater at 50 g / m ² . After standing for 3 minutes, the surplus resin on the surface was scraped off by a reverse coater equipped with a rubber reverse roll having a hardness of 30 ° with a durometer.

[0060]   (Formulation 1)     Viscosity: 75 mPa · s (40 ° C)     Oligomer: 40 parts by weight of modified urethane acrylate     Cross-linking agent: Tripropylene glycol diacrylate 30 parts by weight     Diluent: Tripropylene glycol monoacrylate 30 parts by weight     Coloring dye 0.5 parts by weight

Subsequently, this is 60 with a jet dryer.
A highly viscous electron beam curable resin of the following formulation 2 which was heated to 40 ° C. and adjusted to 40 ° C. was applied at 30 g / m ^{2 by} a roll coater. After standing for 3 minutes, excess resin on the surface was scraped off by a reverse coater equipped with a rubber reverse roll having a hardness of 60 ° with a durometer, and immediately electron beam drying was performed. The electron beam irradiation amount at this time was 300 V
The keV and the irradiation dose were 5 Mrad. Further, the base material was uniformly ground to a thickness of 0.05 mm with a belt sander having a 320-count wear paper roll attached to the surface of the floor material.

[0062]   (Formulation 2)     Viscosity: 3000 mPa · s (40 ° C)     Oligomer: 90 parts by weight of modified urethane acrylate     Diluent: Tripropylene glycol monoacrylate 10 parts by weight     Coloring dye 0.5 parts by weight

Further, using a roll coater equipped with a rubber roll and a rubber reverse roll having a hardness of 60 ° with a durometer, the surface of the base material was ground, and the surface was ground with an aqueous stain containing 2 parts by weight of an ocher pigment. did. This was dried with a jet dryer for 5 minutes.

Thereafter, 9 parts of an epoxy acrylate type electron beam curable coating composition containing 15 parts by weight of an anti-friction agent was added to this surface.
It was applied at 0 g / m ² using a roll coater and immediately dried with electron beam. The electron beam irradiation amount at this time was set to an acceleration voltage of 300 keV and an irradiation dose of 1 Mrad.

Further, a urethane acrylate-based top coat paint of 60 g / m ^{2 was} applied to this surface using a flow coater, and immediately electron beam dried. At this time, the electron beam irradiation dose is 300 keV of acceleration voltage and 5 Mra of irradiation dose.
d. Thus, an electron beam curable resin-impregnated floor material was obtained.

(Embodiment 2) A cover material having a small conduit is used instead of oak material in the above-mentioned Embodiment 1.
Others are the same as those in the first embodiment.

(Comparative Example 1) In the above Example 1, MD
The barrier layer between the F layer and the thin wood veneer layer was not provided. A thin wood veneer was directly attached to the surface of the MDF layer using a thermosetting adhesive by a hot press. The other points are the same as in Example 1.

(Comparative Example 2) In Example 1, a veneer thick veneer having a thickness of 2 mm was used in place of the oak thin veneer. The other points are the same as in Example 1.

Comparative Example 3 A yellow pigment was not added to the phenol resin used in the barrier layer in Example 1. The other points are the same as in Example 1.

(Evaluation Test) For the above Examples 1 and 2 and Comparative Examples 1 to 3, pencil scratching test (pencil hardness test)
(According to JISK5400) and cold repeated B test (according to JAS special plywood) were conducted. In addition, a 15 cm × 15 cm test body was used in all tests. Further, surface abrasion was performed using an abrasion tester to measure the penetration depth of the resin. Further, the appearance of these was evaluated. The results are shown in Table 1. Regarding the “appearance” item in Table 1, the symbol “◯” indicates a good state, and the symbol “Δ” indicates an inferior state.

[0071]

[Table 1]

Considering the results of Table 1, Example 1
For 2 and Comparative Examples 1 and 2, flooring materials having a suitable design were obtained. On the other hand, Comparative Example 3 had a blackish, dull finish appearance as compared with the other Examples and Comparative Examples. It is considered that this is because the barrier layer does not contain a yellow pigment, so that the color of the MDF used for the base material appears through the surface. Regarding performance, Examples 1 and 2
Also, in Comparative Example 3, almost the same performance could be obtained. Equivalent performance could be realized in any of the large oak material having a large conduit in Example 1 and Comparative Example 3 and the birch material having a small conduit in Example 2.

Regarding Comparative Example 1, the results of both the pencil scratching test and the cold heat repetition B test were very poor. Further, as a result of performing surface grinding with an abrasion tester, it was found that the surface was 0.
An uncured resin appeared in the MDF layer ground by 45 mm. MD
It is considered that because the thin wood veneer was attached to the base material to which F was attached without the barrier layer, the resin press-fitted from the surface penetrated into the MDF. From this, it can be confirmed that the barrier layer is an essential component.

Also in Comparative Example 2, the results of the pencil scratching test and the cold heat repeated B test were both poor. Also, as a result of performing surface grinding with an abrasion tester, 0.50 m from the surface
0.5m of uncured resin from the ground wood veneer layer
The resin that penetrated deeper than m was in an uncured state. This is because a thin wood veneer was attached to the surface of the MDF layer via a barrier layer, but the veneer thickness was too thick, 2 mm, so the resin applied and pressed deep from the surface was the low energy type used this time. Conditions of the electron beam irradiation device (accelerating voltage: 300
It is considered that the curing could not be completed at keV).
That is, it is considered that the resin that has penetrated deeper than 0.5 mm remains uncured. In order to solve this, it is sufficient that the electron beam reaches deep, but an electron beam irradiation device of 1M to 2M is required.
In this case, the cost of equipment is more than ten times that of the low-energy electron beam irradiation apparatus used this time, so it cannot be said to be practical. Therefore, in the present invention, a thin wood veneer having a thickness of 0.15 to 0.5 mm at which the impregnated resin is completely cured, and a barrier layer for preventing the resin from penetrating further toward the substrate are essential. It is to be configured.

In Comparative Example 3, there was no problem in terms of performance, but the appearance design was black and dull, which was very poor. It is considered that this is because the dark brown of MDF used as the base material was transparent on the surface because the thin wood veneer of 0.35 mm was used. From this, it is considered effective to mix a pigment-based coating material in the barrier layer in order to produce a good design when dark brown MDF is used.

[0076]

As described above, according to the electron beam curable resin-impregnated flooring material of claim 1, a base material provided with an MDF layer on the surface, a barrier layer provided on the surface of the MDF layer,
A thin wood veneer layer of 0.15 mm to 0.5 mm, which is adhered to the surface of the barrier layer and impregnated with an electron beam curable resin, and a coating layer composed of two or more layers provided on the surface. With such a configuration, a resin-reinforced floor material having excellent surface hardness, scratch resistance, wear resistance, crack resistance, and stain resistance can be produced in good design at low cost.

According to the second aspect of the present invention, by using two kinds of resins, the low-viscosity resin and the high-viscosity resin, the range of tree species selection of the thin wood veneer used on the surface is expanded.

Further, according to the invention of claim 3 or 4, since the barrier layer provided between the substrate and the thin wood veneer layer is made of a pigment-based resin having a high hiding property, 0.15 regardless of the MDF color used for the substrate
Excellent designability can be realized even when a thin wood veneer layer of mm to 0.5 mm is used.

Further, according to the invention of claim 5, since at least the outermost layer of the coating film layer composed of two or more layers is coated with an electron beam curing type coating material, an undercoating coating material or an intermediate coating material is used for adhesion. Even if the product is produced in a semi-cured state to improve the property, electron beam curing is performed in the drying process of the top coat, so it is possible to completely cure the paint from the undercoat to the top coat, and to improve the surface hardness. A resin-reinforced floor material having excellent scratch resistance, abrasion resistance, crack resistance, and stain resistance can be produced in good design at low cost.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of an electron beam curable resin-impregnated flooring material according to an embodiment of the present invention.

[Explanation of symbols]

A Electron beam curable resin impregnated floor material 1 base material 2 MDF layer 3 barrier layers 4 thin wood veneer layers 5 coating layer

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 2B002 AA12 BA01 BB06 BB12 DA01                 2B250 AA05 BA03 BA05 CA11 DA04                       EA02 EA13 FA21 FA31 FA33                       GA03                 2E220 AA15 AA16 BA01 BB03 BB04                       EA02 FA05 GA25X GB32X                       GB44X GB45X GB46X

Claims (5)

[Claims] 1. A base material having an MDF layer on its surface, a barrier layer provided on the surface of the MDF layer, and 0.15 mm which is adhered to the surface of the barrier layer and impregnated with an electron beam curable resin. An electron beam curable resin-impregnated flooring material comprising a thin wood veneer layer having a thickness of 0.5 mm and a coating layer having two or more layers provided on the surface of the thin wood veneer layer. . 2. The electron beam curable resin-impregnated floor material according to claim 1, wherein the resin impregnated in the thin wooden veneer layer is a low-viscosity resin having a viscosity of 100 mPa · s or less at 40 ° C., and a resin at 40 ° C. An electron beam curable resin-impregnated flooring material comprising two types of resins, a high-viscosity resin whose viscosity is adjusted to 1000 to 3500 mPa · s. 3. The electron beam curable resin-impregnated flooring material according to claim 1, wherein the barrier layer provided on the surface of the MDF layer is made of a sheet-like material impregnated with a colored resin. Electron beam curable resin impregnated flooring material. 4. The electron beam curable resin-impregnated floor material according to claim 1, wherein the barrier layer provided on the surface of the MDF layer is a pigment-based sealer coating applied to the MDF surface. An electron beam curable resin-impregnated flooring material characterized by: 5. The electron beam-curable resin-impregnated floor material according to claim 1, wherein at least the outermost layer of the coating layer having two or more layers comprises:
An electron beam curable resin-impregnated floor material, characterized in that an electron beam curable paint is applied.