JP2017080986A - Laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate having improved workability at a construction site and also having excellent moisture permeability.SOLUTION: A laminate 3 has a thermoplastic polyurethane layer 1 and a wooden board layer 2 put on each other, where, preferably, the thermoplastic polyurethane layer 1 and wooden board layer 2 are welded together. The thermoplastic polyurethane layer 1 has a moisture permeability of 1000 g/m2 24h or more. The laminate is a structural face material and a housing substrate material.SELECTED DRAWING: Figure 1

Description

The present invention relates to a laminate. More specifically, it is a structural base material that can be applied to housing base materials, housing interior materials, living space components, automobile interior materials, toys, audio equipment, etc., and more specifically, floor base materials and roof base materials (fields) used as building materials. The present invention relates to a load-bearing face material for a house that can be applied to a housing base material such as a base plate) or an outer wall base (bearing wall).

As shown in FIG. 5, the structure of the wall of the wooden house is provided with a heat insulating material 11 between two studs 10 (intermediate pillars 10 a and 10 b). A particle board 12 is provided on the side opposite to the inner side so as to cover the two pillars 10 and the heat insulating material 11 provided therebetween.

In recent years, a sheet having moisture-proof and air-tight performance has been applied to the entire surface facing the inner wall of the heat insulating material 11 so as to prevent indoor air and moisture from moving behind the wall or under the floor, so-called high air-tightness and high heat insulation. Construction methods have been provided, and the airtightness of houses has been increasing.

However, if ventilation is not performed well in a highly airtight indoor space, condensate occurs and an environment in which various germs and pests can easily propagate is provided.

In addition, once moisture enters the airtight space such as the walls and attic spaces from the joints of the components, there is no way for moisture to escape, so there are slight cuts in the moisture-proof sheet and nailing parts for fixing the members. Moisture is concentrated and absorbed, causing corrosion.

As a solution to this problem, a moisture permeable waterproof sheet has the property of blocking water droplets but allowing water vapor (moisture) to permeate the entire surface of the wooden board such as the particle board 12 facing the outer wall. Ventilation method has been adopted in which a ventilation layer is provided between the particle board 12 and the outer wall 14. As a result, even if moisture enters the sealed space, it gradually passes through the sheet in the state of water vapor, and is released to the outside through the ventilation layer (the arrows shown in FIG. 5 schematically indicate the air flow in the ventilation layer). Therefore, corrosion is unlikely to occur.

Therefore, in a recent construction site of a house, after installing a wooden board such as particle board, a moisture-permeable waterproof sheet (moisture-permeable waterproofing in FIG. 5) is applied to the entire surface facing the outer wall side of the wooden board using an adhesive. The work of stretching the sheet 13) is required. This work needs to be completed before it rains after the wooden board is installed because the wooden board is easily damaged by water, and in general, the moisture-permeable tarpaulin is very long. The workability is poor.

In order to improve such workability, a construction board is proposed in which a wood fiber board is used as a substrate, and at least the surface thereof is partially coated with an adhesive and a waterproof / moisture permeable sheet is adhered ( Patent Document 1).

JP 2001-113511 A

The building board described in Patent Document 1 can certainly improve the workability of the construction site. However, as a result of studies by the present inventors, it was found that the building board described in Patent Document 1 has insufficient moisture permeability due to the adhesive used, and there is room for improvement.

In spite of the existence of such technology, the construction site still has a moisture-permeable waterproof sheet attached to the entire surface facing the outer wall of the wooden board after installing the wooden board. Tensioning work is being done.

Thus, the laminated body (housing base material) which has favorable moisture permeability performance, improving the workability | operativity in a construction site is not yet known.

This invention is made | formed in view of the said present condition, and it aims at providing the laminated body which has favorable moisture-permeable performance, improving the workability | operativity in a construction site.

Adhesion of a moisture permeable waterproof sheet to a laminate (housing base material) is usually performed using an adhesive, and in this technical field, a construction method using an adhesive has been known as technical common sense. . In the presence of such technical common sense, the present inventors have intensively studied, and as a result, laminated the waterproof and moisture permeable layer and the wood board layer without substantially using the adhesive, resulting in the adhesive. It was found that a decrease in moisture permeability performance can be suppressed.

Furthermore, as a result of intensive studies, a porous polyolefin resin sheet has been conventionally used as a moisture-permeable waterproof sheet. However, the sheet has a low polarity of the material itself, and when welded, a hole (hole) is used. However, there is room for improvement in the point of laminating with the wood board layer without substantially using an adhesive, for example, due to the blockage of moisture and a decrease in moisture permeability. Therefore, as a result of examining the ease of lamination with the wood board layer and the moisture permeability of various resins, it was found that thermoplastic polyurethane is suitable as the waterproof moisture-permeable layer, and the present invention was completed.

That is, the present invention relates to a laminate in which a thermoplastic polyurethane layer and a wood board layer are laminated.

It is preferable that the polyurethane layer and the wood board layer are welded.

The polyurethane layer preferably has a moisture permeability of 1000 g / m ² · 24 h or more.

The laminate is preferably a structural face material, and more preferably a housing base material.

Since the laminate of the present invention is a laminate in which a thermoplastic polyurethane layer and a wood board layer are laminated, it has good moisture permeability. In addition, by using the laminate of the present invention as a wooden board at a construction site, the work of stretching a moisture permeable waterproof sheet is not necessary, and the workability at the construction site can be improved.

It is the cross-sectional schematic diagram which showed the cross-sectional structure of the laminated body which concerns on embodiment. It is the isometric view schematic diagram which showed the whole structure of the laminated body which concerns on embodiment. It is a schematic diagram which shows an example of the manufacturing method of a laminated body. It is a schematic diagram which shows an example of the manufacturing method of a laminated body. It is the isometric view schematic diagram which showed the structure of the wall which concerns on a prior art. It is the isometric view schematic diagram which showed the structure of the wall which concerns on embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to the following embodiments, and it is possible to appropriately change the design within a range that satisfies the configuration of the present invention.

The laminate of the present invention is a laminate in which a thermoplastic polyurethane layer and a wood board layer are laminated.

FIG. 1 is a schematic cross-sectional view illustrating a cross-sectional configuration of the laminate according to the embodiment, and FIG. 2 is a schematic perspective view illustrating the overall configuration of the laminate according to the embodiment. As shown in FIGS. 1 and 2, the laminate 3 according to the embodiment is a laminate having a two-layer structure in which a wood board layer 2 and a thermoplastic polyurethane layer 1 are laminated in this order.

<Wood board layer>
The wood board layer 2 is a layer that forms a skeleton of the laminated body 3, and is a layer that imparts strength and rigidity to the laminated body 3.

The kind of the wood board constituting the wood board layer 2 is not particularly limited as long as the material is wood, and is a fiber board such as hard board, medium density fiber board (MDF), insulation board, particle board, plywood, solid. Materials, veneer materials, orientated strand boards (OSB), decorative boards, and the like. Among these, particle board is preferable because it has excellent shear performance, sound insulation performance, and heat insulation performance.

The thickness of the wood board layer 2 is preferably 5 to 50 mm, more preferably 8 to 30 mm. By setting the thickness of the wood board layer within the above range, a laminate having excellent moisture permeability and water pressure resistance, and excellent strength and rigidity can be obtained.

The shape of the wood board layer is not particularly limited, and examples thereof include various shapes such as a plate shape and a sheet shape, and a shape in which the corners of the end portions are rounded or a shape in which a groove is dug can be used. . Among them, it is easy to bond with the thermoplastic polyurethane layer, good adhesion after bonding with the polyurethane layer, can be stacked and transported, and can be sized to an appropriate size and shape for post-processing at the construction site. A plate shape is preferred because a step or a gap is unlikely to occur at the seam when a plurality of laminated bodies are used side by side.

<Thermoplastic polyurethane layer>
The thermoplastic polyurethane layer 1 is a layer formed of thermoplastic polyurethane, covers the wood board layer 2, and constitutes the outermost surface of the laminate 3. The thermoplastic polyurethane layer does not allow liquid water to permeate (good water pressure resistance) and gas state water vapor permeates (good moisture permeability), so has good moisture permeability and water pressure resistance. A laminate is obtained. Furthermore, by directly covering the wood board layer with the thermoplastic polyurethane layer having such characteristics, it is possible to suppress a decrease in moisture permeability caused by the adhesive, and a laminate having better moisture permeability can be obtained. .

The shape of the thermoplastic polyurethane layer is not particularly limited, and examples thereof include various shapes such as a plate shape and a sheet (film) shape, such as a shape in which the corners of the end portion are rounded and a shape in which a groove is dug. It can also be used. Among these, a sheet shape is preferable because it exhibits uniform water pressure resistance and moisture permeability and obtains a good adhesive force with the wood board layer.

It is preferable that at least one main surface (the main surface located on the side opposite to the main surface 2a in FIG. 2) of the main surfaces of the wood board layer 2 is covered with the thermoplastic polyurethane layer 1. Further, at least one main surface may be entirely covered with the thermoplastic polyurethane layer 1 and laminated so that the thermoplastic polyurethane layer 1 protrudes from the main surface. The thermoplastic polyurethane layer covers at least one main surface and is laminated so as to protrude from the main surface, so that when the plural laminates are used side by side, the seam portion is also thermoplastic. A polyurethane layer will be present, and even better moisture permeability and water pressure resistance can be exhibited.
Here, the main surface of the wood board layer means a surface (two faces) having the largest area among the surfaces of the wood board layer.

The thickness of the thermoplastic polyurethane layer 1 is preferably 10 to 500 μm, more preferably 20 to 300 μm. If the thickness is less than 10 μm, tearing is likely to occur in the step of covering the wood board layer, and the uniform water pressure resistance and strength as a laminate may be impaired. If the thickness exceeds 500 μm, the moisture permeability as a laminate may be impaired, and it is not preferable from the viewpoint of workability and cost. By setting the thickness of the thermoplastic polyurethane layer within the above range, a laminate having good moisture permeability and water pressure resistance can be obtained.

The moisture permeability of the thermoplastic polyurethane layer 1 is preferably 200 g / m ² · 24 h or more, more preferably 1000 g / m ² · 24 h or more, still more preferably 1500 g / m ² · 24 h or more, particularly preferably 2000 g / m ² · 24 h or more, most preferably 3000 g / m ² · 24 h or more. Although an upper limit is not specifically limited, For example, it is about 7000 g / m < ² > * 24h. By setting the moisture permeability of the thermoplastic polyurethane layer within the above range, a laminate having good moisture permeability can be obtained.
In the present specification, the moisture permeability of the thermoplastic polyurethane layer is a value measured under conditions of a temperature of 40 ° C. and a relative humidity of 90% in accordance with JIS Z0208 (1976) cup method.

The water pressure resistance of the thermoplastic polyurethane layer 1 is preferably 10 kPa or more, more preferably 15 kPa or more, and further preferably 50 kPa or more. Although an upper limit is not specifically limited, For example, it is about 300 kPa. By setting the water pressure resistance of the thermoplastic polyurethane layer within the above range, a laminate having good water pressure resistance can be obtained.
In the present specification, the water pressure resistance of the thermoplastic polyurethane layer is a value measured according to JIS L1092 (2009) hydrostatic pressure method B (high water pressure method).

The durometer hardness of the thermoplastic polyurethane used in the thermoplastic polyurethane layer 1 is preferably Shore 65A to Shore 70D, more preferably Shore 75A to Shore 60D. By setting the hardness of the thermoplastic polyurethane layer within the above range, suitable stretchability, strength and workability can be obtained. If it is softer than 65A, stickiness is generated, and there is a risk of handling difficulties such as workability and sticking to each other when stacked at the time of storage, and further, molding may be difficult. If it is harder than 70D, the followability is lost and it may be difficult to bond to the wood board layer.

The hardness of the thermoplastic polyurethane layer is a value measured according to JIS K7311 (1995).

Thermoplastic polyurethane is not particularly limited as a thermoplastic polyurethane that can be used for the thermoplastic polyurethane layer 1 because it is easily laminated with a wood board layer and has good moisture permeability and water pressure resistance.

In this specification, a thermoplastic polyurethane is a resin obtained by polymerizing a polyol and a polyisocyanate in the presence of a chain extender.

The polyol is not particularly limited, and conventionally known polyols can be used.
Examples of the polyol include polymer polyols such as polyester polyols, polyether polyols, polycarbonate polyols, and polylactone polyols. These polyols may be used independently and may use 2 or more types together.

The average molecular weight of the polyol is preferably 500 to 5000, more preferably 800 to 4000. The lower limit is more preferably 1200, particularly preferably 1500, and most preferably 1800.
In this specification, the average molecular weight of a polyol is calculated from the hydroxyl value obtained by measurement according to JIS K1557-1 (2007) and the acid value obtained by measurement according to JIS K1555-5 (2007). It is the value.

The polyester polyol is not particularly limited as long as it is a condensate of a polyvalent carboxylic acid or a reactive derivative thereof and a polyhydric alcohol. For example, it can be obtained by condensation polymerization of a dicarboxylic acid and a glycol.

Examples of the dicarboxylic acid include aliphatic dicarboxylic acids such as succinic acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, dodecanedicarboxylic acid, fumaric acid, maleic acid, etc .; orthophthalic acid, terephthalic acid, isophthalic acid, 2,6 -Aromatic dicarboxylic acids such as naphthalenedicarboxylic acid; and reactive derivatives thereof; 1,3-cyclopentanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid Examples thereof include alicyclic dicarboxylic acids such as acids. These dicarboxylic acids may be used alone or in combination of two or more.

Examples of glycols include dimethylene glycol, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,3-propanediol, neopentyl glycol, 2,2-diethyl. -1,3-propanediol, butylethylpropanediol, 1,2-butanediol, butylene glycol, 1,4-butanediol, dimethylbutanediol, 1,5-pentanediol, 2,4-diethylpentanediol, 1 , 6-hexanediol, 3-methyl 1,5-pentanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 1,12-dodecanediol, etc. Recall; alicyclic glycol such as 1,3-cyclopentanediol, 1,4-cyclohexanediol, 1,4-cyclohexanedimethanol, 2,2-bis (4-hydroxycyclohexyl) propane; m-xylylene glycol , P-xylylene glycol, bisphenol A, bisphenol F, bisphenol S and other aromatic glycols. These glycols may be used alone or in combination of two or more.

Examples of the polyester polyol include condensed polyester polyols such as polyethylene adipate, polybutylene adipate, and polyhexamethylene adipate.

Examples of the polyether polyol include aliphatic polyether polyols such as polytetramethylene glycol, polyethylene glycol, and polypropylene glycol.

Examples of the polycarbonate polyol include low molecular polyols such as ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, octanediol, nonanediol, 1,4-cyclohexanedimethanol, diethylene carbonate, dipropylene carbonate, Examples thereof include polyols obtained by dealcoholization reaction with carbonate compounds such as diphenyl carbonate.

Examples of the polylactone-based polyol include lactone-based polyester diols such as polylactone diol, polycaprolactone diol, and polymethylvalerolactone diol obtained by ring-opening polymerization of lactone using the above low-molecular polyol as an initiator.

As the polyol, a polyether-based polyol is preferable, and polytetramethylene glycol and polyethylene glycol are more preferable. It is also preferable to use polytetramethylene glycol and polyethylene glycol in combination.

The polyisocyanate is not particularly limited as long as it has two or more isocyanate groups, and conventionally known ones can be used.
Examples of the diisocyanate having two isocyanate groups include 1,6-hexamethylene diisocyanate (HDI), 2,2,4-trimethylhexamethylene diisocyanate, methylene diisocyanate, isopropylene diisocyanate, lysine diisocyanate, lysine diisocyanate methyl ester, 1 Aliphatic isocyanates such as 1,4-octylene diisocyanate; 4,4′-dicyclohexylmethane diisocyanate, isophorone diisocyanate (IPDI), norbornene diisocyanate, hydrogenated tolylene diisocyanate, methylcyclohexane diisocyanate, isopropylidenebis (4-cyclohexyl isocyanate) Alicyclic isocyanates such as dimer acid diisocyanate; 2,4- or 2, 6-tolylene diisocyanate (TDI), 4,4'-diphenylmethane diisocyanate (MDI), 1,5-naphthylene diisocyanate, p- or m-xylylene diisocyanate (XDI), tolidine diisocyanate, p-phenylene diisocyanate, diphenyl ether diisocyanate And aromatic isocyanates such as diphenylsulfone diisocyanate, dianisidine diisocyanate, and tetramethyl-m-xylylene diisocyanate.
Examples of the polyisocyanate having 3 or more isocyanate groups include triphenylmethane triisocyanate, triisocyanate phenylthiophosphate, polymethylene polyphenylene polyisocyanate (polymeric MDI), isocyanurate modified product that is a trimer of HDI and TDI, and biuret modification. Body, etc.
These polyisocyanates may be used alone or in combination of two or more. Among these, as the polyisocyanate, diisocyanates having two isocyanate groups are preferable. Among them, aromatic diisocyanates are more preferable from the viewpoint of developing excellent strength and versatility, and 4,4′-diphenylmethane diisocyanate. (MDI) is more preferred. In addition, when a function such as discoloration resistance is imparted, 1,6-hexamethylene diisocyanate (HDI), 4,4′-dicyclohexylmethane diisocyanate, or the like can be used.

The chain extender is not particularly limited, and conventionally known chain extenders can be used.
As the chain extender, for example, conventionally known polyhydric alcohols and amines can be used, but low molecular polyols having 2 to 10 carbon atoms are preferable.

Examples of the low molecular polyol include ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-butanediol, 1,4-butanediol, 2-methylpentanediol, 1,5-pentanediol, 1,6 -Aliphatic polyols such as hexanediol, neopentyl glycol, octanediol, nonanediol, decanediol, trimethylolpropane, glycerin; alicyclic polyols such as cyclohexanediol, cyclohexanedimethanol; bishydroxyethoxybenzene, xylene glycol, etc. Aromatic polyols; and the like. These chain extenders may be used independently and may use 2 or more types together. Among these, as the chain extender, an aliphatic polyol is preferable, and 1,4-butanediol is more preferable.

The thermoplastic polyurethane used in the present invention is a polyol, polyisocyanate, or chain extender described above, for example, an isocyanate group-terminated prepolymer obtained by previously reacting a polyol and a polyisocyanate, in the same manner as a normal polyurethane resin. The polymer can be produced using a so-called prepolymer method in which a chain extender is reacted, or a so-called one-shot method in which a polyol and a chain extender are mixed in advance and then this mixture is reacted with a polyisocyanate. At that time, the equivalent ratio ([NCO] / [OH]) of the total number of moles of isocyanate groups to the total number of moles of active hydrogen groups of all raw materials is the melt viscosity of thermoplastic polyurethane and other performances (strength, elongation, molecular weight, etc.) Is preferably adjusted to 0.8 to 1.2, and more preferably 0.9 to 1.1.

The melt viscosity at 190 ° C. of the thermoplastic polyurethane used for the thermoplastic polyurethane layer is preferably 0.1 × 10 ^{4 to} 20.0 × 10 ⁴ dPa · s, more preferably 0.3 × 10 ^{4 to} 15.0. × 10 ⁴ dPa · s. If the melt viscosity is within the above range, the thermoplastic polyurethane is heated and melted, and can be easily applied (laminated) to the wood board layer using a coater such as a roll coater, spray coater, T-die coater, knife coater, etc. Become.
The melt viscosity of the thermoplastic polyurethane is a value obtained by measurement according to JIS K7311 (1995).

As described above, the thermoplastic polyurethane originally has good moisture permeability and water pressure resistance, but in the present invention, it is preferable to use a highly moisture-permeable thermoplastic polyurethane having further improved moisture permeability. As a method for further improving the moisture permeability of the thermoplastic polyurethane, there are (1) a method of providing pores to make it porous, and (2) a method of improving the moisture permeability of the resin itself.

In the method (1), dust or the like adheres to the pores over time, clogging occurs, and the moisture permeability performance deteriorates over time. Moreover, in this invention, a thermoplastic polyurethane layer and a wood board layer are laminated | stacked, without using an adhesive agent substantially. Specifically, for example, since both layers are laminated by welding, in the method (1), there is a possibility that the pores are blocked at the time of welding. Therefore, the method (2) is preferable.

Therefore, the thermoplastic polyurethane layer 1 is preferably non-porous and more preferably non-porous because the moisture permeation performance is excellent in aging resistance and water pressure resistance.
Here, in the present specification, non-porous (non-porous) means a method of providing innumerable pores in the manufacturing process of the thermoplastic polyurethane layer or the surface of the thermoplastic polyurethane layer after formation of the laminate. It means that there are no pores provided by post-processing to become porous.
Examples of the method for imparting pores include a foaming method, a phase separation method, a dissolution recrystallization method, a stretch opening method, and a powder sintering method.
In addition, when the pore is provided in polyurethane by these methods, the diameter of the surface hole (hole) is usually about 0.1 to 100 μm.
That is, in the present specification, non-porous means that the number of holes (holes) on the surface (holes (holes) having a diameter of 0.1 to 100 μm) is 10 / cm ² or less (preferably 5 / cm ^2). The term “non-porous” means 0 / cm ² .

For example, the moisture permeability of the polyurethane resin itself can be improved by increasing the amount of hydrophilic units in the resin. The presence of the hydrophilic unit allows water molecules to move in the resin. By increasing the amount of the hydrophilic unit in the resin, the movement speed of the water molecules in the resin is improved and moisture permeability is increased. Performance is improved. As a result, the non-porous polyurethane may have insufficient moisture permeability, but a thermoplastic polyurethane having excellent moisture permeability can be obtained even if it is non-porous.

As a method for improving the moisture permeation performance of the resin itself, for example, as a polyol, a method using a polyol having an average molecular weight in the above-mentioned preferable numerical range (preferably 500 to 5000), and as a polyol, a polyether polyol (preferably polyethylene) Glycol and / or polytetramethylene glycol), polyisocyanate using aromatic diisocyanate (preferably 4,4′-diphenylmethane diisocyanate (MDI)), chain extender aliphatic polyol (preferably Is a method of using 1,4-butanediol), a method of adjusting the equivalent ratio of the total number of moles of isocyanate groups to the total number of moles of active hydrogen groups in all raw materials for producing polyurethane, and the like. Is mentioned.

Thermoplastic polyurethane can be used as required, such as silane coupling agents, fillers, thixotropic agents, tackifiers, waxes, plasticizers, thermal stabilizers, antioxidants, UV absorbers, light stabilizers, fillers, Fiber reinforcement, pigment, fluorescent brightener, foaming agent, thermoplastic resin, thermosetting resin, dye, conductivity imparting agent, antistatic agent, moisture permeability improver, water repellent, oil repellent, hollow foam , Known additives such as crystallization water-containing compounds, flame retardants, water absorbents, moisture absorbents, deodorants, antibacterial agents, antifungal agents, antiblocking agents, hydrolysis inhibitors, organic water-soluble compounds, inorganic water-soluble compounds, etc. May be blended.

<Laminated body>
Since the laminate 3 having the above configuration is a laminate in which the wood board layer 2 and the thermoplastic polyurethane layer 1 are laminated in this order, the laminate 3 has good moisture permeability. In addition, by using the laminate 3 of the present invention as a wood board at a construction site, the work of stretching a moisture permeable waterproof sheet becomes unnecessary, and the workability at the construction site can be improved. In addition, it is excellent in scratch resistance, slip resistance and water pressure resistance, which are the characteristics of thermoplastic polyurethane. Furthermore, the laminate 3 can be cut in the same manner as a conventional laminate (housing base material).

In the present invention, there is substantially no adhesive layer between the polyurethane layer and the wood board layer. Here, having substantially no adhesive layer between the polyurethane layer and the wood board layer means that the adhesive is between the two layers in the region where the polyurethane layer and the wood board layer are pasted. The proportion of the region where the layer is present is preferably 5% or less, more preferably 1% or less, still more preferably 0.5% or less, particularly preferably 0.01% or less, and most preferably 0%.

In the above-described embodiment, the case where the laminate 3 is a laminate having a two-layer structure in which the wood board layer 2 and the thermoplastic polyurethane layer 1 are laminated in this order has been described. However, in the present invention, the laminate is made of wood. The board layer and the thermoplastic polyurethane layer need only be laminated in this order, and layers other than the wood board layer and the thermoplastic polyurethane layer may be laminated.

Although it does not specifically limit as a laminated body on which layers other than a wood board layer and a thermoplastic polyurethane layer were laminated | stacked, For example, the laminated body on which the wood board layer, the thermoplastic polyurethane layer, and the metal layer were laminated | stacked in this order is mentioned. The metal layer is formed of, for example, a metal such as aluminum, titanium, tin, chromium, copper, platinum, tungsten, molybdenum, tantalum, gold, niobium, zirconium, silver, nickel, iron, cobalt, or a metal compound thereof. Layer.

In the present invention, the laminate may be a laminate in which a thermoplastic polyurethane layer, a wood board layer, and a thermoplastic polyurethane layer are laminated in this order.

The laminated body 3 shown in FIG. 2 has a flat plate shape in which the surface formed from the wood board layer 2 and the surface formed from the thermoplastic polyurethane layer 1 are both flat. And thickness is not specifically limited, It sets suitably according to a use.
It is good also as a structure which formed the rib in one main surface of a wood board layer, and provided the rib also in the surface formed from a thermoplastic polyurethane layer.

<Method for producing laminate>
The method for producing the laminate of the present invention is not particularly limited as long as it is a method in which thermoplastic polyurethane (preferably molten thermoplastic polyurethane) can be laminated by contacting with a wooden board. The laminate of the present invention can be suitably produced by adding a step of laminating a thermoplastic polyurethane layer (thermoplastic polyurethane film) on a wood board in the production process of a wood board such as particle board.

The particle board is a step 1 in which crushed wood chips are mixed with various adhesives, a step 2 in which the wood chips are formed into a layered mat shape, and a step in which the mat obtained in step 2 is compressed by hot press molding. 3, a process 4 for curing with various adhesives, and a process 5 for cutting the board according to the product size. What is necessary is just to add the process of laminating | stacking a thermoplastic polyurethane layer (thermoplastic polyurethane film) on a wooden board between the process 4 and the process 5 of this manufacturing method.

The lamination of the thermoplastic polyurethane layer and the wood board layer is not particularly limited as long as the method does not substantially use an adhesive in order to suppress a decrease in moisture permeability caused by the adhesive. For example, by welding What is necessary is just to laminate. Moreover, you may laminate | stack with fixing tools, such as a needle and a nail. Especially, since it has favorable adhesiveness, it is preferable that the polyurethane layer and the wood board layer are welded. When the polyurethane layer and the wood board layer are welded, the polyurethane enters the recesses on the surface of the wood board layer, and a strong adhesive force is generated. Therefore, peeling of the thermoplastic polyurethane layer can be suitably suppressed.

The method for welding the polyurethane layer and the wood board layer is not particularly limited as long as it is a method capable of contacting the polyurethane and the wood board layer in a molten state, for example, thermal welding, ultrasonic welding, vibration welding, induction welding, Examples include high-frequency welding, semiconductor laser welding, spin welding, and vacuum forming. Among these, thermal welding is preferable because the manufacturing method is relatively simple, the manufacturing cost can be suppressed, and it can be easily welded without breaking the molecular structure of polyurethane.

The heat welding method is not particularly limited as long as it is a method in which thermoplastic polyurethane (preferably molten thermoplastic polyurethane) can be laminated in contact with a wooden board.

For example, thermoplastic polyurethane is heated and melted to 60 to 250 ° C., and is coated and laminated on a wooden board using a coater such as a roll coater, spray coater, T-die coater, knife coater, etc. Examples of the method include laminating by suitably press-molding according to the shape of the wood board using a method such as press, flat press, belt press, membrane press, and profile wrapping.

When applying the thermoplastic polyurethane, a method using a roll coater is preferred from the viewpoint of ease of application if the wood board, which is the base material on which the thermoplastic polyurethane is applied, has a smooth board shape.

The roll coater is preferably provided with a mechanism that can be appropriately heated according to the melting temperature of the thermoplastic polyurethane, and the heating method is not particularly limited. For example, induction heating, oil circulation heating, steam heating, electric heating Etc.

The material of the roll is not particularly limited, and examples thereof include a rubber roll, a metal roll, and a plastic roll, but may be appropriately selected depending on the application.

The coating method is not particularly limited, and may be appropriately selected according to the required quality of the coating amount and the coating appearance. For example, the coating method is performed by rotating the coater roll in the forward direction with respect to the transport direction of the substrate. Examples thereof include a natural coating method to be processed and a reverse coating method in which coating is performed by rotating a coater roll in the opposite direction to the conveyance of the substrate.

Moreover, when a wooden board has a complicated shape, a spray coater is preferable.

As for the method of press molding, if the wooden board is a smooth board-like shape, the method of press molding using a roll press, flat press, belt press or the like is relatively simple and preferable. If the wooden board is a base material having a quadratic curved surface, a method of pressing by profile wrapping or a roll press of a soft rubber material having a rubber hardness of 40 degrees or less is preferable because it is relatively simple. If the plate has a complicated shape having a cubic curved surface, a method of press-molding with a membrane press or the like is preferable.

Hereinafter, an example of a method for producing a laminate will be briefly described with reference to the drawings, particularly a step of laminating a thermoplastic polyurethane layer (thermoplastic polyurethane film) on a wooden board.
3 and 4 are schematic views showing an example of a method for manufacturing a laminate.
In FIG. 3, for example, a thermoplastic polyurethane layer 1 (thermoplastic polyurethane film) extruded from a T-die is attached to a wood board layer 2 (particle board) heated to 60 to 250 ° C. (preferably 110 to 200 ° C.). In addition, pressure bonding may be performed for 10 to 600 (preferably 60 to 180) seconds under a condition of 0.5 to 10 (preferably 1 to 5) MPa. Thereby, a thermoplastic polyurethane layer (thermoplastic polyurethane film) is laminated on the wood board.

In FIG. 4, for example, a thermoplastic polyurethane layer 1 (thermoplastic polyurethane film) extruded from a T-die is attached to a wood board layer 2 (particle board) heated to 60 to 250 ° C. (preferably 110 to 200 ° C.). In addition, the pressure bonding may be performed for 10 to 600 (60 to 180) seconds under conditions of 100 to 250 ° C. (preferably 140 to 200 ° C.) and 0.5 to 10 (preferably 1 to 5) MPa. Thereby, a thermoplastic polyurethane layer (thermoplastic polyurethane film) is laminated on the wood board.

<Use of laminate>
It does not specifically limit as a use of the laminated body of this invention, It can use suitably as a structural surface material. Here, the structural surface material means a surface material (plate material) that constitutes a part of the structure of the object. In addition to the base material for the outer wall of a wooden house, for example, the floor of a building (preferably a wooden house) Housing base materials such as roofs; Housing interior materials used for housing interior materials such as doors; Living space components used for living space components represented by furniture such as chests, storage shelves, and kitchens Face materials; Face materials for automobile interiors used for car seat back panels, consoles, trunk liners, etc .; Face materials for toys used for toys; Face materials for acoustic devices used for audio equipment, and the like. Especially, it is suitable for the housing base material (housing base surface material) which is the base material of the outer wall, floor, roof, etc. of the building, and more suitable for the load bearing surface material for housing that works effectively against the load and external force, It is further suitable as an outer wall base material (outer wall base surface material) of a wooden house.

FIG. 5 is a schematic perspective view showing the wall structure according to the prior art, and FIG. 6 is a schematic perspective view showing the wall structure according to the embodiment.
As shown in FIG. 5, the structure of the wall of the wooden house is provided with a heat insulating material 11 between two studs 10 (intermediate pillars 10 a, 10 b), an inner wall 15 on the indoor side of the stud 10, and a chamber of the stud 10. A particle board 12 is provided on the side opposite to the inner side so as to cover the two pillars 10 and the heat insulating material 11 provided therebetween. By using the laminate of the present invention as a wood board, that is, a laminate in which a wood board layer 2 and a thermoplastic polyurethane layer 1 are laminated in this order as shown in FIG. 6 instead of the particle board 12 of FIG. By using 3, the work of stretching the moisture permeable waterproof sheet 13 becomes unnecessary, and the workability at the construction site can be improved. Moreover, since the laminated body 3 is a laminated body in which the wood board layer 2 and the thermoplastic polyurethane layer 1 are laminated in this order, the laminated body 3 also has good moisture permeability and water pressure resistance.

The width | variety and length of a laminated body can be suitably set according to a use, for example, can be made into width 450-2900mm and length 1800-5700mm.

The embodiment of the present invention has been described above. However, each item described as the description regarding the above-mentioned embodiment also serves as a description of a preferable embodiment related to the present invention in general, and one embodiment of the present invention described in the drawings. It is not limited to form.

The present invention will be specifically described based on examples, but the present invention is not limited to these examples.

Hereinafter, the various chemicals used will be described together.
Polyethylene glycol: PEG # 2000U (average molecular weight 2000) manufactured by NOF Corporation
Polytetramethylene glycol: PTMG3000 (average molecular weight 3000) manufactured by Mitsubishi Chemical Corporation
1,4-butanediol: 1.4BG manufactured by Mitsubishi Chemical Corporation
4,4′-diphenylmethane diisocyanate (hereinafter referred to as MDI): Sumidur 44S manufactured by Sumika Covestro Urethane Co., Ltd.

(Production example)
(Preparation of thermoplastic polyurethane)
In accordance with the formulation shown in Table 1, polyether polyol and 1,4-butanediol were mixed, MDI was added, and the mixture was sufficiently stirred at high speed, followed by reaction at 160 ° C. for 10 minutes to obtain a thermoplastic polyurethane. . The obtained polyurethane was extruded at 150 to 250 ° C. by an extruder having a flat die (T-die) attached to the tip to obtain a thermoplastic polyurethane (thermoplastic polyurethane sheet) having a thickness of 50 μm.

The following evaluation was performed using the obtained thermoplastic polyurethane. Each test result is shown in Table 1.

(Surface observation with a scanning electron microscope)
When the surface of the obtained thermoplastic polyurethane sheet was observed with a scanning electron microscope, thermoplastic polyurethanes 1 to 3 (TPUs 1 to 3) were nonporous.

(Melt viscosity)
The melt viscosity of the obtained thermoplastic polyurethane was measured according to JIS K7311 (1995) using an elevated flow tester (manufactured by Shimadzu Corp.) and drying the thermoplastic polyurethane at 100 ° C. for 2 hours, and weighing about 2 g of the sample. Thereafter, the load was 30 kgf / cm ² , and the preheating time was 4 minutes and the measurement temperature was 190 ° C. using a 1 mmφ × 1 ml die (unit: 10 ⁴ dPa · s).

(Hardness, tensile strength, elongation, 100% modulus, tear strength)
The hardness, tensile strength, elongation, 100% modulus, and tear strength of the obtained thermoplastic polyurethane were measured according to JIS K7311 (1995). The hardness was measured using a type A durometer.

(Moisture permeability)
The moisture permeability of the obtained thermoplastic polyurethane was measured under the conditions of a temperature of 40 ° C. and a relative humidity of 90% in accordance with JIS Z0208 (1976) cup method.

(Water pressure resistance)
The water pressure resistance of the obtained thermoplastic polyurethane was measured according to JIS L1092 (2009) hydrostatic pressure method B method (high water pressure method).

The thermoplastic polyurethanes 1 to 3 are non-porous but have good moisture permeability. It also has good hardness, tensile strength, elongation, 100% modulus, tear strength, and water pressure resistance.

(Example)
(Production of laminate)
A thermoplastic polyurethane film (thickness 50 μm) synthesized from the T-die and extruded from a T-die is bonded to a particle board that has been left in a constant temperature room at 180 ° C. for 1 hour and heated to 140 to 150 ° C. The laminate (pressure 210 mm and length 300 mm) having a two-layer structure having the configuration shown in FIGS. 1 and 2 was produced by pressure bonding (hot pressing) at 160 ° C. and 3 MPa for 90 seconds.

In the obtained laminate, the thickness of the thermoplastic polyurethane layer was 25 μm, and the thickness of the wood board layer was 9 mm.

Properties other than moisture permeability of the thermoplastic polyurethane shown in Table 1 did not change even when the thermoplastic polyurethane layer was welded to a wooden board. Regarding the moisture permeability, the thickness of the thermoplastic polyurethane is reduced by welding, so the performance was improved by that amount, but there was a fluctuation in moisture permeability due to the effects other than the increase or decrease in thickness. There wasn't.

From this result, it was found that the laminate of the present invention in which the thermoplastic polyurethane layer and the wood board layer were laminated had good moisture permeability and water pressure resistance. In addition, since the laminate of the present invention having a wood board layer and having good strength can be used as a wood board, by using the laminate of the present invention as a wood board at a construction site, moisture permeability and waterproofing are possible. It was found that the work of stretching the sheet is unnecessary, and the workability at the construction site can be improved.

1: Thermoplastic polyurethane layer 2: Wood board layer 2a: Main surface 3: Laminate 10 (10a, 10b): Spacer 11: Heat insulating material 12: Particle board 13: Moisture permeable waterproof sheet 14: Outer wall 15: Inner wall 16: Body edge

Claims (5)

A thermoplastic polyurethane layer;
Laminated body with wood board layer. The laminate according to claim 1, wherein the polyurethane layer and the wood board layer are welded. The laminate according to claim 1 or 2, wherein the moisture permeability of the polyurethane layer is 1000 g / m ² · 24 h or more. The laminate according to any one of claims 1 to 3, which is a structural surface material. The laminate according to any one of claims 1 to 3, which is a housing base material.

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