JPH02175101A - Decorative material and manufacture thereof - Google Patents

Abstract

PURPOSE:To manufacture a decorative material having reinforcing properties and heat resistance by laminating a heat curable resin impregnated paper laminate curing material on the rear surface of a wood piece.synthetic resin composite decorative material. CONSTITUTION:A paste-like resin composition 2 in the uncured state, curable resin liquid, is provided. Then, a number of small wood pieces 3... are mixed with said resin composition 2 and kneaded, and then said mixture is formed into a flat plate shape, which is laminated on the heat curable resin impregnated paper laminate curing material 4 and heat pressurized and bonded integrally by using a hot press or the like to form a laminate cured molded product 5. The laminate cured molded product 5 thus provided and a heat curable resin impregnated paper laminate curing material 6 prepared separately are laminated through a base 7 in a manner that a pack sheet 4 of the laminate cured molded material 5 is brought into contact with the base 7, and bonded layers 8, 8 are provided between said respective materials and heat pressurized and bonded to manufacture a desired decorative material 9.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention can be used as a surface material for wooden fixtures such as tables, counters, furniture, and sounder cases, wooden building materials such as flooring materials and wall materials, and car interior fixtures. Regarding the decorative material that is suitably used and its manufacturing method, when heating and pressing a mixture consisting of a large number of small wood pieces and a curable resin liquid to make a wood piece/synthetic resin composite decorative material, thermosetting resin-impregnated paper lamination and curing is used. A back sheet made of wood is cured and molded to form a laminated hardened molded product having a thermosetting resin-impregnated paper laminated hardened material on the back side of the wood piece/synthetic resin composite decorative material, and then a substrate and the laminated hardened molded product are formed. By laminating and adhering these materials, the wood piece/synthetic resin composite decorative material is reinforced, making it easier to handle, and preventing defects in the manufacturing of the decorative material.

[Prior art] Conventionally, as this type of decorative material, 1495
DESCRIPTION OF RELATED ART A decorative material as described in Japanese Patent No. 99 is known, in which a colored opaque resin layer in which small pieces of wood are dispersed is provided on a substrate. This decorative material is made by mixing and kneading small pieces of wood with an uncured paste-like resin composition, molding the mixture into a flat plate 15, heating and pressing it using a hot press or the like to make it a solid, and then The surface of the solid material is ground by sanding, etc., the small pieces of wood are exposed on the surface, a colored opaque resin layer is formed by dispersing the small pieces of wood, and this is then attached to the substrate, so it is derived from small pieces of wood. The wood grain pattern appears effectively on the surface of the decorative board without waste, and a beautiful decorative material with strong wood grains can be obtained.

[The problem that the invention tries to solve! i] However, the colored opaque resin layer of this decorative material dispersed in wood pieces, that is, the wood piece/synthetic resin composite decorative material, is prone to cracking during handling, such as when pasting it to a substrate, and is also prone to unevenness because it is heated and molded. Therefore, in the present invention, by providing a thermosetting resin-impregnated paper lamination hardening (O) on the back side of the wood piece/synthetic resin composite decorative material, reinforcing properties and The purpose of the present invention is to provide a method for manufacturing a decorative material with added heat resistance and the decorative material.

[Means for Solving the Problems] In the present invention, when a mixture consisting of a large number of small wood pieces and a curable resin liquid is heated and pressed to form a wood piece/synthetic resin composite decorative material, thermosetting resin-impregnated paper is used. It is cured together with a back sheet made of a laminated hardening material to form a laminated hardened molded product in which a wood piece/synthetic resin composite decorative material and a back sheet made of a thermosetting resin-impregnated paper laminated hardening material are adhered, and then;
The solution was to laminate and adhere the laminate cured molded article No. 171 and the substrate.

[Function] When heating and pressing a mixture consisting of a large number of small wood pieces and a curable resin liquid to make a wood piece/synthetic resin composite decorative material,
By curing and molding it together with a backsheet made of a thermosetting resin-impregnated paper laminated hardening material, reinforcing properties, heat resistance, and smoothness can be added to the wood piece/synthetic resin composite decorative material.

[Example] Figures 1 and 2 show an example of the manufacturing method of the cosmetic H of the present invention in the order of steps, and the reference numeral l in the figures is the wood piece/synthetic resin composite decorative material used in the present invention. . To obtain this wood piece/synthetic resin composite decorative material 1, first, an uncured base resin composition 2, which is a curable resin liquid, is used.

Thermosetting resins that are in a liquid state before curing are mainly used for this resin, such as unsaturated polyester resins, polyurethane resins, noaryl phthalate resins, Evokin resins, Noricone resins, phenolic resins, and acrylic resins. Appropriate additives such as fillers and colorants are added thereto as necessary.

Calcium carbonate, talc, titanium oxide, glue, glass powder, etc. are used as fillers here, and the blending amount thereof is about 100 to 400 parts by weight per 100 parts by weight of the resin liquid. Furthermore, the four-color agent preferably includes dyes, pigments, and the like having yellow, brown, and brownish tones that are the same as the color tone of the small wood piece 3, but other color tones may be used. The amount to be added may be within a normal range and is not particularly limited.

Next, this resin composition 2 is mixed with a large number of small pieces of wood 3 and kneaded, and then this mixture is molded into a Heisei shape, which is laminated on a thermosetting resin-impregnated paper laminated hardening material 4 and hot pressed. The laminated cured molded product 5 is formed by bonding and integrating by heating and pressurizing using a laminate or the like. The molding conditions for this laminated cured molded product 5, that is, the conditions for heating and pressurizing, are a pressure of 1 to 3 MPa,
Preferably, the temperature is 130 to 150°C and the time is about 10 to 60 minutes.

The wood pieces 3 used here include black tan, beech,
Small pieces of wood are used, such as hardwoods such as oak, horse chestnut, horse chestnut, spider, maple, birch, and can, and softwoods such as cedar, cypress, pine, subruce, and agathis, and the shape is not particularly limited. . Moreover, the size of this small piece of wood 3 is 3 to 7 mm in width when the shape is a rectangular parallelepiped.
, preferably 5~G+! 116. Length 3~2001+
11, preferably 12-20 +ua, thickness 0.2-3
1!1I111 Preferably 0.2~II, so width 20
~25mm, length 20~! 00ffi11, preferably 30-60 mm, thickness 0.2-3 mm, preferably 0.
A flat piece of 2 to 1 mm is preferable; a cylindrical piece has a diameter of 5 to 100+nn and a thickness of about 0.2 to 51111R; a crushed piece has a width of 1 to 4 mm.

Length 3-3-3O, preferably 5-30s+m, thickness 0
゜2~3m-1, preferably about 02~I@+a. Further, the wood pieces 3 may include pieces of wood of different species, wood of different colors, etc.

In addition, the small pieces of wood 3 may be dimensionally stabilized if necessary, or organic halogen preservatives may be mixed into polyethylene glycol or liquid resin to stabilize the dimensions. Treatment and preservative treatment can also be carried out at the same time. Furthermore, the wood pieces 3 may be partially or entirely colored in various tones such as black or brown, but this is preferable since it takes advantage of the natural color of the wood. Coloring treatment is performed using colorants such as dyes and pigments dissolved in water or solvents such as organic solvents.
A method is used in which a large number of small pieces of wood are immersed in a colored liquid of about 1 to 10% by weight. It is possible to heat the coloring liquid to promote penetration of the coloring liquid and color it in one color. Further, during the dimensional stabilization treatment, a coloring agent can be dissolved in various liquid resins, and the coloring treatment can be performed simultaneously with the dimensional stabilization treatment. In addition, the total exposed area of the small wood pieces 3 occupying the surface area of the wood piece/synthetic resin composite decorative material 1 is:
This wood piece/synthetic resin composite decorative material is 10 to 90%, preferably about 70 to 90%! Pl is 1 to 21
Ira1 is preferably about 1 to 1.5 mm.

The back sheet 4 is a prepreg laminate made by laminating a plurality of sheets of prepreg notebook whose base material is impregnated with a curable resin liquid, and is a thermosetting resin-impregnated paper laminate and cured product. Here, as the base material, cloth made of glass fiber, synthetic fiber such as polyamide, polyester, etc., glass paper, acrylic fiber, nonwoven fabric made of vinylon [1, etc.], etc. are used. Furthermore, the same curable resin as in the resin composition 2 is used for the curable resin liquid, and additives such as appropriate fillers and colorants are added as necessary. The work of impregnating the base materials with these curable resin liquids can be carried out by preparing, for example, a constant temperature layer filled with the uncured curable resin liquid inside, and then soaking each base material. This is done by immersion. The immersed substrate may be allowed to stand still for about 1 to 3 minutes, but at a speed of 5 to II.
Impregnation can be carried out continuously by moving at a rate of about 1/min. Next, each base material impregnated with the resin liquid was
After taking it out from the layer and drying it at room temperature overnight, it was heated to a temperature of 90~
Drying is performed at 100° C. for 5 to 10 minutes to create a prepreg notebook. The prepreg notebooks are then laminated and heated and pressurized.Prior to this, they are allowed to stand at a temperature of 15 to 30 degrees Celsius for about 3 to 4 hours to advance the curing of the curable resin, and the impregnated resin liquid It is possible to increase the viscosity of the resin, make it easier to handle, and remove air bubbles in the impregnated resin liquid. The heating and pressing is performed using a heating and pressing means such as a well-known pot press, and the pressure is 1 to 2 MPa.

It is carried out at a temperature of 130 to 150°C and for a time of about 10 to 20 minutes. By this heating and pressurization, multiple sheets of Buri Pregun-] are fixed and integrated, the impregnated resin is hardened,
Obtain back sheet 4. Here, the thickness of this back sheet 4 is preferably about 03 to 2III11, and the thickness is 0.
．． If it is less than 3III11, it is too thin and a reinforcing effect cannot be obtained when it is simultaneously attached to the wood piece/synthetic resin composite decorative board 1, and if it is thicker than 2■, it may cause warping.

Next, the cured laminate 5 obtained as described above and the cured thermosetting resin-impregnated paper laminate 6 used separately are interposed with a substrate 7 in between, so that the back sheet 4 of the cured laminate 5 is formed into a substrate. 7, and an adhesive layer 8.8 between each layer.
The desired decorative material 9 is obtained by heat-pressure bonding.

In this heating and pressure bonding, urea adhesive is used for the adhesive layer 8, and the temperature is 100 to 120°C, the pressure is OIM Pa
This is done by heating and pressurizing for about 1 to 3 minutes using a hot press or the like under the following conditions.

The backsheet 6 used here is similar to the backsheet 4 described above, and its molding method is the same as that of the backsheet 4.

The substrate 7 may be made of wood such as lauan plywood, backnote, lumber core board, or solid wood, or of resin such as fiber-reinforced synthetic resin board.
The thickness is preferably about 15 to 30 Il111.

In the decorative material 9 obtained in this way, when a mixture consisting of a large number of wood pieces 3 and a curable resin liquid is heated and pressurized to form a wood piece/synthetic resin composite decorative material 1,
By curing and molding the thermosetting resin-impregnated paper laminated hardening material 4 and B, the wood piece/synthetic resin composite decorative material 1 is reinforced, so the intended decorative material 9 can be easily and heat-resistant without defects. It can be made with flexibility and rigidity.

In addition, the upper surface of the laminated cured molded product 5, that is, the surface of the wood piece/synthetic resin composite decorative material l, is ground by sanding or the like to form a polished surface, and a transparent synthetic resin film is further formed on the surface of this polished surface. It is also possible. In order to form this transparent synthetic resin film, there are two methods: laminated adhesive or pressure bonding of transparent resin films, unsaturated polyester resin,
A method of applying a transparent paint made of polyurethane resin, diallyl phthalate resin, epoxy resin, etc. to a thickness of about 50 to 300 μm is adopted. When a transparent synthetic resin film is formed in this way, the polished surface 5, which once had a dry white appearance, becomes wet-colored and the aesthetic appearance is improved.

It is also possible to prevent the color pattern from fading by applying a transparent UV-shielding paint mixed with a UV-absorbing agent to the polished surface. It is coated to a thickness of about 100 to 300 μm using a well-known coating method such as a flow coater method or a spray method, and the surface of the obtained transparent synthetic resin layer is air polished, wet polished, and then puffed. The makeup It9 may be completed by polishing and applying a mirror finish. in this way,
When a transparent synthetic resin layer is provided to achieve a mirror finish, this mirror resin layer plays the role of a lens, and the lens effect increases the three-dimensional appearance of the decorative material 9.

[Effects of the Invention] The decorative material of the present invention comprises a substrate, a thermosetting resin-impregnated paper laminated hardening material provided on the substrate, and a wood piece provided on the thermosetting resin-impregnated paper laminated hardening material.・What is the synthetic resin composite decorative material made of? Also, its manufacturing method involves heating and pressing a mixture of a large number of small pieces of wood and a curable resin liquid to create the wood pieces/synthetic resin composite decorative material. When this is done, it is cured and molded together with a back sheet made of a thermosetting resin-impregnated paper laminated hardening material, and the wood pieces/synthetic resin composite decorative material and the thermosetting resin-impregnated paper laminated hardening material are pasted together. Then, the laminated cured molded product and the substrate,
Since the material is laminated and bonded together, a thermosetting resin-impregnated paper laminated hardening material is simultaneously pasted on the back side of the wood piece/synthetic resin composite decorative material, so it has no reinforcing effect. , a decorative material with improved heat resistance, rigidity, and smoothness because it is less likely to break and the unevenness of the wood chips/synthetic resin composite decorative material is reduced compared to when handling the wood chips/synthetic resin composite decorative material alone. , and a method for producing the same.

[Brief explanation of the drawing]

FIG. 1 and FIG. 2 are schematic sectional views showing an example of the manufacturing method of the decorative material of the present invention in the order of steps. l... Wood piece/synthetic resin composite decorative material, 3...
... Small piece of wood, 4 ... Thermosetting resin-impregnated paper hardening material (bank sort), 5 ... Laminated hardened molded product,
7 - Substrate, 9... Decorative material.

Claims (2)

[Claims] (1) A substrate, a thermosetting resin-impregnated paper laminated hardening material provided on this substrate, and a wood piece/synthetic resin composite decorative material provided on a back sheet made of this thermosetting resin-impregnated paper laminated hardening material. A decorative material characterized by comprising wood. (2) When heating and pressing a mixture consisting of a large number of small pieces of wood and a curable resin liquid to make a composite decorative material of wood pieces and synthetic resin, the mixture is cured and molded together with a back sheet made of a thermosetting resin-impregnated paper laminated curable material. The method is characterized in that a wood piece/synthetic resin composite decorative material and a thermosetting resin-impregnated paper laminated hardened material are adhered to form a laminate cured molded product, and then the laminate hardened molded product and a substrate are laminated and bonded. A manufacturing method for decorative materials.