JP2610193B2 - Decorative plate composite and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a decorative plate composite having a transparent resin surface coating layer used for a center cluster, a console upper panel, a door trim ornament panel, etc. which are interior parts of an automobile, for example. The present invention relates to a material and a method for producing the same, and particularly to a decorative panel composite material provided with a transparent resin surface coating layer with a visible grain of a natural precious wood used for a luxury vehicle.

[Conventional technology]

A high-grade decorative composite material having a transparent resin surface coating layer on a natural wood decorative veneer for an automobile interior, as shown in FIG.
Plywood such as Shina, birch, warran, etc. is used as the base material 4 and has beautiful wood grain teak, bird's eye maple, walnut,
A veneer veneer 2 obtained by slicing a natural precious wood such as a sack to a thickness of about 0.2-1.5 mm is laminated, and the laminate is hot-pressed using a phenol resin or urea resin-based adhesive or a resin-impregnated adhesive film 5. After bonding and integration, the inner and outer peripheries are trimmed and cut, and then the transparent resin coating 6 is coated with a spray gun 7 for finishing.

Due to the recent improvement in the general economic level, natural materials have been reviewed, and in the automotive market, natural wood veneer veneers are coated with transparent resin, and the painted surface is high-gloss, like a high-end piano, like a mirror, and smooth. Further, those having a sense of depth are being put to practical use mainly for internal parts of luxury cars.

However, as a preparation before painting, the transparent resin coating is applied several times with polyester or urethane colored paint for smoothing the veneer veneer and removing stains, and for preventing eyelashes and tarnish and uniforming the appearance color. After undercoating, drying, resanding, etc., as a finishing process, apply a polyester or urethane-based transparent paint to impart a sticky feeling, a deep feeling, and a clear feeling and to prevent burrs. It is necessary to dry after painting, and then again to sanding and polishing with compound wax. In addition, these coatings are generally applied by an air spray coating method using a spray gun 7. However, the coating efficiency is low and the loss is large, and it is difficult to finish a smooth and uniform coating film. Surface defects such as boiling, sagging, uneven color, whitening, and orange peel are likely to occur. For this reason, the finishing has been performed by a skilled coating technician with careful attention and with sufficient time and strict work management.

Furthermore, decorative laminate composites as interior materials for automobiles are subject to temperature,
Substrates made of natural wood plywood are susceptible to expansion and contraction because they are strongly exposed to external effects such as humidity and sunshine, and the effects of microbubbles and moisture contained in decorative veneers adhered on this substrate In addition, the transparent resin coating film expands and contracts due to the difference in wood grain density, giving minute unevenness to the coated surface, not only impairing smoothness and luster, but also causing cracks, peeling, warping and deformation in the long term. .

As described above, in the production of a decorative laminate composite, in the case of using a conventional technique, a highly skilled technique and a large number of processes and accompanying coating equipment are required particularly in the coating process of the transparent resin coating layer 6 by the spray gun 7. In addition, since the operation takes time, the production efficiency is low and the production cost is greatly affected. Further, since the product lacks long-term durability, the improvement has been strongly desired.

Furthermore, since natural precious wood is used for decorative veneer and plywood is used for the base material, air or moisture (adhesive ), Which are likely to collect, which may be caused by white spots or boiling occurring in the coating film or at the interface between the coating film and the veneer veneer when the coating film is dried. This causes problems such as cracks and peeling, so that measures to solve them are problems.

Thin veneers such as teak, rosewood (grain and straight grain), box, bird's eye maple (grain), walnut (grain, straight grain and grate), etc.
It is used by bonding to a plywood such as a birch, but it has a drawback that it can be formed into only a flat or simple curved surface even in general furnishings because it has low tensile strength, low elongation, and is easily broken during molding.

Also, in the painting process, eliminate paint defects such as uneven color, orange beer, sauce, sharpening, and waste, and prevent paint loss during spray painting, equipment and environmental pollution due to the evaporation of paint dust and organic solvents. Was also a problem.

In order to solve the above-mentioned problems in the prior art, the present inventors have previously developed and applied for a patent by developing several decorative board composite material manufacturing technologies using a mold press that can omit the finish coating process. (Japanese Patent Application No. 1-75974, 1
-75975 and 1-95987).

[Problems to be Solved by the Invention] The present invention further improves the design quality of the appearance, since there is room for improvement particularly in the depth and thickness of the composite material of the prior invention. It is an object of the present invention to provide a decorative panel composite of the kind mentioned at the beginning, comprising such a base material, a decorative veneer and a transparent resin surface coating layer overlaid thereon, and a method for producing the same.

[Means for solving the problem]

The present inventors have been conducting various studies to solve the above-described problems, and as a result, in the decorative composite by the die press as described above, the transparent resin surface coating layer has a plurality of different layers. The present inventors have found that the appearance of the resulting composite material, especially the depth and thickness, is significantly improved when it is composed of laminates, and especially when they have distinctly different refractive indices from each other. The invention has been reached.

That is, the decorative board composite material of the present invention is integrally formed by a hot press comprising a base material, a decorative veneer bonded onto the base material, and a transparent resin surface coating layer further formed on the base material. Hot pressing of sheet-like compound made of fiber reinforced plastic impregnated with resin liquid containing thermosetting resin and low shrinkage agent and reinforcing material consisting of inorganic or organic fibers The molded veneer is made of a natural nameplate impregnated with a thermosetting resin that can make a decorative veneer crosslink with the thermosetting resin of the base material and strongly adhere to it, and the transparent resin surface coating layer The first layer formed by the leaching of the impregnating resin inside the decorative veneer during hot pressing in the mold, and the thermosetting that can be cross-linked with the impregnated resin of the decorative veneer on the fiber sheet material overlaid thereon Heat of coated sheet impregnated with resin And a second layer formed by hot press hardening of a thermosetting resin that can crosslink or at least strongly adhere to the resin of the second layer, which covers the second layer, and that further covers the second layer. It is characterized by comprising three layers, wherein the first, second and second layers have mutually different light refractive indices.

In an advantageous embodiment of the decorative panel composite according to the present invention, the first, second and third layers of the transparent resin surface coating layer have different optical refractive indices from each other, preferably this refractive index is different. The ratio is preferably gradually reduced in the order of the first layer> the second layer> the third layer, so that the appearance is very rich in design and excellent in appearance and depth.

The method for producing a decorative board composite material according to the present invention comprises the steps of: bonding a substrate such as described above to a thermosetting resin capable of strongly bonding to the substrate or a crosslinking reaction with the impregnating resin of the substrate; A decorative veneer made of a thin plate of natural precious wood and having a fibrous reinforcing sheet adhered to the back surface in advance, and further impregnated with a thermosetting resin capable of undergoing a crosslinking reaction with the impregnating resin of the decorative veneer. The laminated body is made by covering the fiber sheet material, and the laminated body is degassed under reduced pressure in a press mold, and then subjected to primary heat press to thereby form the base material, the decorative veneer and the fiber sheet material. Immediately before the preform is formed, and immediately before the preform is completely cured, the mold is opened and a liquid of a thermosetting resin capable of undergoing a crosslinking reaction with the resin of the fiber sheet material or at least strongly adhering thereto. Or slightly raise the upper die to The surface of the preformed body is coated by injecting a liquid, and then the coated formed body is further subjected to secondary hot pressing, thereby completely curing the base material, the resin-impregnated decorative veneer, and the transparent resin surface coating layer. It is characterized by being integrally molded under Instead of pouring the liquid of the thermosetting resin, it is conceivable to inject the resin liquid by slightly lifting the upper mold.

According to the present invention, a fibrous reinforcing sheet is bonded to the back surface of the veneer in advance. Thereby, the decorative veneer can be prevented from cracking during molding, and a good product can be obtained.

According to the present invention, the interior of the mold is degassed under reduced pressure prior to the mold clamping pressure at the time of the primary heat press. This is because the holes and recesses present in the veneer and the like are filled with resin and the It is effective in preventing surface defects such as white spots and boiling, as well as minute irregularities, cracks, peeling, and the like that occur under environmental conditions where the temperature and humidity change significantly.

[Action]

If the procedure of the method for producing a decorative laminate composite according to the present invention is described with reference to the drawings, as shown in FIG. 1, the above-described base material 11 and a thermosetting material capable of at least strongly adhering to this base material. Veneer veneer 12 of natural precious wood impregnated with a conductive resin, and a fiber sheet material 13B impregnated with a resin capable of undergoing a cross-linking reaction with the resin of the veneer veneer are laminated in order to form a laminate. First, in a mirror-finished press die, first, a primary hot press is performed to form a preform of base material 11, decorative veneer 12, and fiber sheet material 13B, and then immediately before the preform is completely cured. This preformed body can be crosslinked with the thermosetting resin of the fiber sheet material 13B, or at least strongly adhered thereto, for example, coated with a thermosetting resin liquid 13A such as a thermosetting polyurethane resin. , And further apply this coated molded body to secondary heat Resushi, whereby the base 11, the resin impregnated decorative veneer 12, the resin-impregnated sheet material layer 13B and the surface coating a transparent resin layer 13A is completely cured molded integrally. The coating of the thermosetting resin layer 13A may be performed by a casting method by once opening the mold, but slightly raising the upper mold corresponding to the cavity of the mold and applying the resin liquid in the mold. It may be performed by injection.

The decorative board composite material according to the present invention is firmly bonded throughout by integrally curing and molding the base material, the resin impregnated decorative veneer and the transparent resin surface covering layer composed of the resin impregnated sheet material and the covering resin layer. Although it has high strength not found in conventional products, its transparent resin coating layer is particularly composed of a first layer 13C leached from a decorative veneer at the time of hot pressing and a second layer 13B formed by hot press curing of a resin impregnated sheet material. And a third layer 13A made of a hardened layer of a coating resin. Since the third layer 13A has different light refraction, transmission and reflection properties, the appearance is extremely rich in design. Further, the hot press-cured layer of the resin liquid coated by the above-described method provides high gloss and excellent durability and strength even if the surface polishing work is not particularly performed.

The substrate 11 of the decorative panel composite material is not particularly limited as long as it can be strongly bonded to the resin-impregnated decorative veneer 12 overlaid thereon and cured integrally by hot pressing. It is preferable to use a sheet-like compound made of fiber-reinforced plastic impregnated with a reinforcing material made of inorganic or organic fibers with a resin solution containing a low-shrinkage agent. In this case, a three-dimensional mold having a complicated shape is used. It can be used to obtain a corresponding three-dimensionally shaped decorative laminate composite.

When a low-shrinkage sheet-shaped molding compound preform is used as a base material, high embedding stability and strength can be obtained even with a relatively thin wall, and the resulting product has high dimensional stability.

The reinforcing fiber material used for such a base material is an organic or inorganic high-strength fiber, and among them, roving of a relatively short fiber glass fiber is preferable. As the thermosetting resin for the base material, one or more of unsaturated polyester, epoxy resin, diallyl phthalate resin or alkyd resin is used. In addition to these thermosetting resin prepolymers, thermoplastic resins (polyethylene, polyester, styrene butadiene copolymer, polymethyl methacrylate, etc.) as low shrinkage agents and other common, for example, fillers, crosslinking agents, Impregnate the reinforcing fiber material with a mixture of thickeners, release agents, catalysts, colorants, polymerization stabilizers, solvents, etc., as described above, and aged over time to a tag-free state It is preferable to use a preformed product of the obtained low-shrinkable sheet-shaped molding compound (hereinafter abbreviated as SMC). The decorative board composite material obtained by this has high rigidity,
In addition to high strength, thin wall, high heat resistance, high water resistance, it also has moderate flexibility, and has high dimensional stability, and embeds reinforcing ribs or bosses for screw fittings for mounting parts and retaining metal fittings. Can be inserted into this,
In addition, non-planar decorative materials as well as non-planar decorative materials can be produced by the hot press molding method according to the present invention, so that the degree of freedom of design and design is improved, and the cost for mounting parts can be greatly reduced.

The veneer veneer 12 may be used as a veneer for teak, rosewood, walnut, soot, bird's eye maple, etc., directly on a grain of natural precious wood or a thin grain of straight grain or heather, or after being subjected to toning treatment by dyeing or painting, and then strengthening with the base material. Thermosetting resin that can be adhered to, especially when using the SMC as described above, a resin capable of performing a cross-linking reaction with the thermosetting resin, preferably like diallyl phthalate resin, unsaturated polyester resin, and alkyd resin Impregnated with one or more prepolymers have been used. The prepolymer of the thermosetting resin impregnated in the decorative veneer causes a cross-linking reaction between the resin for the surface coating layer and the resin of the base material during the hot pressing and strongly joins, but at the beginning of the hot pressing, That is, it is softened at the beginning of the reaction and exhibits flexibility, which is extremely effective in preventing cracking during molding. In addition, the back crack of the veneer veneer, air and adsorbed moisture in fine gaps such as wood fiber conduit are removed when the vacuum degassing process is introduced after closing the mold,
In the resin impregnation step, these parts are dried in advance and filled with a resin liquid. Therefore, even in a use environment where the temperature and humidity change repeatedly, the transparent resin layer and the decorative veneer have a difference in expansion and contraction. The generation of minute irregularities (eye frays), whitening, peeling, cracks, etc. occurring on the surface of the coating layer is prevented.

In addition, if a veneer veneer is reinforced with a fibrous sheet such as nonwoven fabric of Japanese paper or other synthetic fibers as a backing backing with a heat-resistant SBR adhesive, etc., the veneer of the veneer veneer during molding may be reduced. Good product can be prevented. As the fibrous sheet, it is preferable to use a pulp paper having strong toughness and stable physical and chemical properties, or a nonwoven fabric of a synthetic fiber such as a polyester fiber, an acrylic fiber or a nylon fiber, and a polyvinyl alcohol fiber. .

Resin-impregnated sheet material 13B overlaid on decorative veneer 12
As, after the hot press molding, the fiber sheet of the basis weight of the extent that does not impair that the grain of the base decorative veneer can be clearly seen after the hot press molding can undergo a crosslinking reaction with the thermosetting resin in the decorative veneer, preferably the same Which is impregnated with a prepolymer of diallyl phthalate resin, unsaturated polyester resin or alkyd resin. Preferably 20-40 g / cm
A sheet having a thickness of 0.3 to 0.5 mm obtained by impregnating the above resin with a nonwoven fabric of Japanese paper or various synthetic fibers having a basis weight of ² is used.

Finally, as the resin of the 13A layer used to coat the resin-impregnated sheet material 13B, a thermosetting resin that can strongly adhere to the layer 13B of the resin-impregnated sheet material during hot press curing is used. Of course, the same resin as the resin of the sheet material 13B may be used, but among them, a thermosetting polyurethane resin can be used, and in this case, a particularly excellent appearance can be obtained from the difference in the refractive index of light. In order to form this coating layer 13A, the above resin prepolymers are used alone or as a mixture together with a crosslinking agent, a polymerization catalyst, an internal mold release agent, a polymerization stabilizer, and the like, and if necessary, modified. A resin liquid is used which is mixed with other resins for quality and fillers. As described above, the laminate of the base material, the veneer veneer, and the resin-impregnated sheet material is first subjected to primary hot pressing in a mold, and the mold is opened immediately before each resin of the laminate is completely cured to form a preform. After pouring the above-mentioned resin liquid onto the surface of the body to cover it, the mold is closed again and subjected to secondary hot pressing. Alternatively, after the primary heat press, the upper mold is slightly raised without once opening the mold, and the preform is coated by injecting the resin liquid into the mold, and then subjected to the secondary press. May be completely cured.

By this hot pressing, a part of the thermosetting resin impregnated in the interior of the decorative veneer 12 is leached to the boundary surface with the resin-impregnated fiber sheet layer 13B to form the first layer 13C of the transparent covering resin layer. Since the first layer 13C, the second layer 13B composed of the cured layer of the resin-impregnated fiber sheet, and the third layer composed of the surface coating layer 13A have different refractive indices, the decorative board composite according to the present invention has a high depth. It has a beautiful appearance with excellent feeling and thickness.

〔Example〕

 Hereinafter, examples of the present invention will be described.

As a base material, an unsaturated polyester-based SMC (Estermat A manufactured by Mitsui Toatsu Chemicals Co., Ltd.) using a resin in which 5 parts by weight of a thermoplastic polymer low-shrinkage agent is blended with the thermoplastic resin.
U-120) was used.

As a decorative veneer, a bird's-eye maple veneer veneer with a thickness of 0.3 mm is used, and a 36 g / m ² basis weight Japanese paper on the back side is a styrene / butadiene rubber-based adhesive (Struct Bond of Mitsui Toatsu Chemical Co., Ltd.) 1123). 100 parts by weight of an unsaturated polyester resin (Olester RP-1033 from Mitsui Toatsu Chemicals), 0.7 parts by weight of tert-perbenzoate as a catalyst and 0.2 parts by weight of methylhydroquinone as a polymerization stabilizer were applied to this decorative veneer by a vacuum / pressure method. A resin-impregnated veneer veneer impregnated with 50 parts by weight of a mixed solution of the above was used.

As a resin-impregnated sheet material to be put on the decorative veneer, an acrylic fiber nonwoven fabric with a basis weight of 25 g / cm ² impregnated with a thermosetting diallyl phthalate prepolymer (Osaka Soda, Dap A) to a resin amount of 140 g / m ² (Manufactured by Nippon Vilene Co., Ltd.).

The above three are stacked by the procedure shown in FIG. 1 to form a laminate, charged in a flat plate mold, closed the mold, evacuated the mold, and then pressed at a mold temperature of 140 ° C. and a press pressure of 100 kgf /. Primary heat pressing was performed in cm ² to obtain a preform.

Next, before the preform is completely cured, the mold is opened, and a polyester polyol having a number average molecular weight of 400 and an OH value of 340 (K-flex manufactured by King, USA) is placed on the preform.
188) 60 parts by weight and NCO content 23.1% (solid content conversion)
Of hexamethylene diisocyanate (TPA100 manufactured by Asahi Kasei Corporation) was coated by pouring a urethane resin solution mixed with 40 parts by weight, then the mold was closed again and a secondary heat press was performed under the same conditions. And completely cured.

The veneer composite material thus obtained has an excellent depth and thickness, and the grain of the veneer veneer is clearly prominent and exhibits an extremely excellent appearance. As a result of examining the surface layer, there is an unsaturated polyester resin layer leached from the veneer under the resin-impregnated sheet material layer, that is, an unsaturated polyester resin layer having a refractive index of about 1.54 and a diallyl phthalate having a refractive index of about 1.50. It was confirmed that the film was composed of a resin layer and a polyurethane resin layer having a refractive index of about 1.46, and it was found that this resulted in the above excellent appearance and design.

〔The invention's effect〕

The decorative board composite material according to claim 1 of the present invention has high strength in which the whole of the base body, the veneer veneer, the resin-impregnated sheet material, and the entire laminate including the coating resin is firmly bonded together,
It gives a sense of depth and thickness, is excellent in design, and has a durable and high-quality finish.

By using a sheet-like compound impregnated with a thermosetting resin containing a low shrinkage material as a base material, the formation of a three-dimensionally shaped composite material is allowed, and the composite material has high rigidity and high rigidity. The added value is further enhanced by high-performance features such as strength, good moldability, high dimensional stability, and heat and water resistance.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a procedure for manufacturing a decorative panel composite according to the present invention, and FIG. 2 is a cross-sectional view illustrating a procedure for manufacturing a decorative panel composite according to the prior art. 11, base material 12, decorative veneer 13A thermosetting resin coating layer 13B fiber sheet material

Claims (3)

(57) [Claims] 1. A decorative panel composite material integrally formed by hot pressing, comprising a base material, a decorative veneer overlaid thereon, and a transparent resin surface coating layer further adhered thereon. A hot press molded article of a compound on a sheet comprising a fiber reinforced plastic in which a base material is impregnated with a reinforcing material composed of inorganic or organic fibers with a resin liquid containing a thermosetting resin and a low shrinkage agent, The veneer is a thin plate of a natural precious wood impregnated with a thermosetting resin capable of cross-linking and strongly adhering to the thermosetting resin of the base material, wherein the transparent resin surface coating layer is formed in a mold. The first layer formed by leaching of the impregnated resin inside the decorative veneer at the time of hot pressing, and a thermo-effective resin capable of undergoing a cross-linking reaction with the impregnated resin of the decorative veneer on the fiber sheet material overlaid thereon. Of coated sheet impregnated with The second layer formed by the non-curing, and further coated thereon, formed by hot press curing of a thermosetting resin capable of crosslinking reaction with the resin of the second layer or at least strongly adhering thereto. A decorative laminate comprising a third layer, wherein the first, second and third layers have different refractive indices. 2. The first and second transparent resin surface coating layers.
The decorative board composite according to claim 1, wherein the light refractive index of the third layer and the third layer are sequentially reduced. 3. The decorative panel composite material according to claim 1, comprising a base material, a decorative veneer covered on the base material, and a transparent resin surface coating layer further formed on the veneer veneer. In the production of a substrate made of a natural nameplate impregnated with a thermosetting resin capable of strongly adhering to the substrate or cross-linking with the impregnating resin of the substrate, A veneer veneer on which a fibrous reinforcing sheet is bonded in advance, and a fibrous sheet material impregnated with a thermosetting resin capable of undergoing a crosslinking reaction with the impregnating resin of the veneer veneer. This laminate is pressed in a press mold, and after degassing the inside of the mold under reduced pressure, a primary heat press is performed to form a preform of the base material, the decorative veneer, and the fiber sheet material. Then, immediately before the preform is completely cured, the mold is opened. The preforming is carried out by pouring a liquid of a thermosetting resin capable of undergoing a cross-linking reaction with the resin of the fiber sheet material or at least strongly adhering thereto, or by slightly raising the upper mold and injecting the resin liquid. Coating the surface of the body, and then subjecting the coated molded body to secondary hot pressing, whereby the base material, the resin-impregnated decorative veneer and the transparent resin surface coating layer are integrally molded under complete curing. A method for producing a decorative panel composite material, comprising: