JPH11320516A - Woody board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve flame retardance, fire resistance, termite proofness and antiseptic properties. SOLUTION: A woody board is formed of a woody core material 1, on both faces of which a surface material 2 is laminated, and the surface material 2 is formed of a sheet 20 formed of a sheet base 21, into which resin can be impregnated, impregnated with resin, and phenol resin having the 2-50% flow rate in the prepreg state is used as heat-setting resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to floors, walls, ceilings,
Alternatively, the present invention relates to a wooden board suitably used as a base material for columns, furniture, cabinets, and the like, an interior material for an automobile, and a base material for various features.

[0002]

2. Description of the Related Art In order to impart antiseptic property and termite resistance, compounding with a nonflammable inorganic substance, a chemical modification method, and a chemical impregnation method have been used.

[0003]

In each case, the wood is modified by immersing the wood in the treatment liquid and allowing the treatment liquid to penetrate the wood. In order to obtain a sufficient effect, a skilled technique is required. Furthermore, the price is high, and the workability and productivity are poor.

[0004] Therefore, an object of the present invention is to provide a low-cost wooden board excellent in flame retardancy, fire resistance, termite resistance, antiseptic properties, and scratch resistance, with good productivity.

[0005]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention relates to a wooden board in which a surface material is laminated on both sides of a wooden core material. It is made of a sheet in which a material is impregnated with a thermosetting resin, and a phenol resin having a flow rate in a prepreg state of 2 to 50% is used as the thermosetting resin.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings.

In FIG. 1, a surface material 2 is provided on both sides of a wooden core material 1.
Are shown in a state of being bonded and laminated, and usable as the wood-based core material 1 include particle board, oriented wafer board, wafer board, wood-based fiber board (hard board, MDF, insulation board), wood Wool cement board, wood chip cement board and the like can be mentioned.

As the surface material 2, a sheet 20 in which a thermosetting resin is impregnated into a sheet base material 21 capable of impregnating a resin is used. The thermosetting resin has a flow rate in a prepreg state of 2 to 50%. A phenolic resin was used.

The sheet 20 is obtained by impregnating a sheet base material 21 (see FIG. 2) made of paper, woven fabric, nonwoven fabric or the like with a thermosetting resin. Gypsum board paper, kraft paper, rayon paper, or the like can be suitably used as the paper impregnated with the thermosetting resin as the sheet base 21. As the woven fabric, a woven fabric of an organic fiber, a woven fabric of an inorganic fiber such as a glass fiber, a carbon fiber, an inorganic whisker, a rock fiber, a rock wool, or a woven fabric of an amorphous metal fiber can be suitably used. As the non-woven fabric, glass fibers, cotton, rayon, and other raw fibers are bonded or entangled, or mechanically using both.
It is in the form of a sheet made by a method of chemical / heating or using a solvent, or a combination thereof. As the fiber raw material, a material obtained by matting fibers cut to 3 to 50 mm by a wet papermaking or dry nonwoven fabric manufacturing method and bonding them with a binder resin is suitable for use. As the fiber raw material, glass fiber alone, glass fiber and alumina fiber, alumina silica fiber, carbon fiber, inorganic fiber such as metal fiber, aramid fiber, rayon fiber, vinylon fiber, nylon fiber, polyester fiber, polypropylene fiber, Organic fibers such as polyethylene fibers can be used alone or in combination. In consideration of the strength of the sheet base 21 and the ease of resin impregnation, it is preferable to use glass fibers. Further, the basis weight is 10 in terms of impregnation, defoaming, sheet substrate strength, handling, and scratch resistance of the molded product.
Is preferably to 1000 g / m ^2, more preferably the basis weight is 50 to 250 g / m ^2. When the amount is less than 10 g / m ² , scratch resistance is hardly developed, and 1000 g / m ²
If it is larger, impregnation becomes difficult. These fibers have a low reinforcing effect with short fibers of 3 mm or less, while it is difficult to form a uniform sheet with long fibers exceeding 50 mm, and as a result, an excellent reinforcing effect cannot be obtained. In addition, it is preferable that the short fiber having a length of 3 to 15 mm accounts for 20 to 100% of the total fiber from the viewpoint of strength (reinforcing property) and uniformity of the nonwoven fabric. If the short fibers are less than 20%, a uniform nonwoven fabric is not obtained. Mixing short fiber cellulose pulp or the like in addition to these fiber materials may be used. When using glass fibers, the reinforcing effect can be enhanced by coating the fiber surface with a silane coupling agent.

As the thermosetting resin to be impregnated into the sheet substrate 21, a resin having the necessary properties as a surface material is selected. For example, a phenol resin obtained by the reaction of phenols and aldehydes, Resin obtained by adding a curing agent to an oligomer having a functional epoxy group, thermosetting ethylene-vinyl acetate copolymer, urea resin, melamine resin, urethane resin, DAP (diaryl phthalate) resin, unsaturated polyester resin, etc. Can be illustrated. These resins are used alone or as a mixture of two or more, and are mainly combined with the fiber material by impregnation. The resin solution to be impregnated may be any of an aqueous solution, a solvent varnish, an emulsion, and the like, or may be a method of spraying solid resin powder. Among them, it is preferable to use those dissolved or dispersed in water, alcohol, or the like from the viewpoint of cost and safety. When an alcohol is used, MeOH is suitable because it has a low fluff and is easy to dry.

Further, various fillers such as lead stearate, dibutyltin dilaurate, carbon black, calcium carbonate, titanium white, mica, glass spheres, aluminum hydroxide, antimony oxide, tri (2,
A heat stabilizer, a reinforcing agent, a flame retardant, an antistatic agent, and the like, such as 3 dibromopropyl) phosphate, an aliphatic sulfonate, a higher alcoholate, and the like can also be compounded and used.

When a phenol resin is selected as the thermosetting resin, the catalyst required for producing the phenol resin includes alkylamine, ammonia, sodium hydroxide,
Barium hydroxide and the like are preferred. In particular, alkylamines,
Ammonia has a higher molecular weight than the other two,
Due to the low hydration property in the molecular structure, the water resistance after bonding is remarkably improved. At this time, it is preferable that the phenol resin is dissolved or dispersed in a solvent such as water or an organic solvent so as to have a solid content of 20 to 80% by weight from the viewpoint of easy impregnation. As an organic solvent that dissolves or decomposes a phenol resin, methanol, ethanol, and other lower alcohols, acetone, ketones such as methyl ethyl ketone,
One or a mixture of two or more of toluene and xylene is used. In particular, lower alcohols having a low boiling point, particularly methanol are preferably used in consideration of ease of drying. If the solid content is less than 20% by weight, it becomes difficult to impregnate the required amount, and if it is more than 80% by weight, the impregnation becomes difficult due to an increase in viscosity.

The thermosetting resin is a phenol resin having a flow rate in a prepreg state of 2 to 50%, more preferably 5 to 20%. If the flow rate exceeds 50%, the resin will protrude from the sides during pressing, and will not exhibit sufficient scratch resistance. If the flow rate is less than 3%, the composite of the base material and the resin becomes insufficient, and the exudation to the surface of the decorative material 3 during pressing is reduced, so that sufficient scratch resistance is not exhibited. The flow rate of the phenolic resin in the prepreg state is the ratio of the protruding resin when ten prepreg sheets having a diameter of 5 cm are stacked and pressed under predetermined conditions (protruding resin / total resin × 100). The relationship between the flow rate and the scratch depth is shown in the graph of FIG.

The viscosity of the phenol resin contained in the prepreg sheet is 0.1 to 50 poise at a temperature of 25 ° C. If the viscosity is less than 0.1 poise, the phenol resin is impregnated in an amount sufficient to exhibit scratch resistance. In addition, since the resin protrudes from the side during pressing, sufficient scratch resistance cannot be exhibited. If the viscosity exceeds 50 poise, it becomes difficult to impregnate the resin uniformly, and one of the surface
Exudation to the surface of a decorative material (not shown) to be laminated thereon is reduced, so that sufficient scratch resistance is not exhibited.

The phenolic resin used as the thermosetting resin has a solid content of 50 to 500 g /
m ² , preferably 150 to 350 g / m ² . If it is less than 50 g / m ^2, it is difficult to develop sufficient scratch resistance, and if it is less than 500 g / m ² , it takes a long time to cure and there is a problem in appearance such as protruding from an end. In the impregnation method, for example, as shown in FIG. 2, the sheet base material 21 is dipped into the phenol resin solution 10 by a roller, and then dried under a certain condition to obtain the prepreg-state sheet 20.

As the sheet 20, a sheet substrate 21 made of any one of paper, woven fabric and non-woven fabric and impregnated with a thermosetting resin is not used alone. For example, a plurality of sheets may be used. Can be used as the sheet 20. For example, if an uncured phenolic resin is impregnated into a glass nonwoven fabric and paper is bonded thereto, the overall strength and dimensional stability are dramatically improved.

The thermosetting resin to be impregnated into the sheet base 21 is preferably in a state of the latter half of impregnation, ie, in a prepreg state, and the sheet 20 in the prepreg state is stacked on the wood-based core material 1, and If the decorative materials are overlapped and hot pressed, they are firmly adhered to each other. The prepreg is the half of the reinforced plastic made by admixing the fiber reinforcing material and the thermosetting resin, and other thermoplastic resins, coloring agents, curing catalysts, etc., as needed, before the completion of the curing, leaving the ability of adhesiveness and moldability. It is a molding material in a cured state, and a preferable gel time is 30 seconds to 8 at a set temperature of 150 ° C.
00 seconds.

As a drying condition for bringing the thermosetting resin impregnated into the sheet substrate 21 into a cured state in the latter half of the impregnation, the lower limit of the completed solvent fraction of the sheet 20 is 0% by weight, preferably 3% by weight or more. Preferably at least 5% by weight,
The upper limit is 15% by weight or less, more preferably 10% by weight or less. If it is not less than 15% by weight, blocking between sheets occurs. Table 1 shows the relationship between drying time and temperature.
Shown in The thermosetting resin used in Table 1 was a phenol resin dissolved or dispersed in an organic solvent, and methanol was used as the organic solvent. In the table, ○ indicates that the finished prepreg sheet can be used, △ indicates that the prepreg sheet is not preferable for use, and X indicates that it cannot be used.

[0019]

[Table 1]

Table 2 shows the relationship between drying time and temperature for the phenolic resin dissolved or dispersed in water as the thermosetting resin. In the table, ○ indicates that the finished prepreg sheet can be used, △ indicates that the prepreg sheet is not preferable for use, and X indicates that it cannot be used.

[0021]

[Table 2]

As can be seen from the above Tables 1 and 2, when a phenol resin dissolved or dispersed in water or an organic solvent is used, a preferable semi-cured state is obtained at a temperature of 80 to 120 ° C. and a drying time of 3 to 30 minutes. You can get a sheet.

The prepreg sheet has a tensile strength of 10 kgf / cm in order to exhibit sufficient scratch resistance.
It is preferably at least ² . If it is less than 10 kgf / cm ² , sufficient scratch resistance will not be exhibited. The measurement of the breaking strength was performed by sandwiching the sheet 2 in the prepreg state between two release papers,
The test was carried out after the resin was cured by hot pressing at 10 ° C. for 5 minutes at 10 kgf / cm ² . Such a measurement was performed according to JIS K7054.

The sheet 20, the wood-based core material 1, and the sheet 20 were laminated in this order.
180 ° C is preferable, and 140 to 160 ° C is more preferable. If the temperature is lower than 130 ° C., the resin is not sufficiently cured, and the termite-preventive property, antiseptic property, and scratch resistance cannot be exhibited. If the temperature is higher than 180 ° C., the resin is hardened too quickly and the adhesion to the wood-based core material 1 is insufficient. And the warp of the wood-based core material 1 is also increased. The pressure is 1 to 20 kgf / c
m ² is preferred, and more preferably 5 to 15 kgf / cm ² . Anti-termite resistance to exudation is insufficient with less than 1 kgf / cm ² into the resin of the decorative material, antiseptic, scratch resistance is lowered, 20 kgf / cm ² larger than wood-based core material 1
Inconveniences such as increased warpage occur. Furthermore,
The pressing time is preferably from 2.5 to 20 minutes, and more preferably from 3 to 12.5 minutes. If it is shorter than 2.5 minutes, the curing of the resin is not sufficient, and the termiticidal property, antiseptic property and scratch resistance are reduced. In addition, the warp of the wooden core 1 also increases.

Among these resins, a resin which is self-adhesive to the wood-based core material 1, such as an epoxy resin or a urethane resin, is used as it is. Heat-pressing is performed between the two with an appropriate adhesive, thereby forming an integral wood-based core material 1.

Among them, as a material to be used for a building board, a material in which a moisture-proof layer is further laminated on at least one surface of the wood-based core material 1, and at least one of the surfaces of the wood-based core material 1 are used. It is preferable that a tensile strength reinforcing material is arranged on the surface on the side or inside thereof. And the tensile strength reinforcement is
It is preferable that the wood-based core material 1 has a larger elongation at tensile break. Structurally speaking, it is preferable that the side surface of the wooden core 1 is also provided with a moisture-proof layer. Examples of the tensile-resistant reinforcing material include glass mat, glass paper, glass non-woven fabric, inorganic materials such as ceramics and rock wool, organic fabrics such as polyester, acrylic, vinylon, and polypropylene, nets, and non-woven fabrics. Is mentioned.

In an architectural board having such a structure,
In the case where the core material 1 is used for placing floors, a tension-resistant reinforcing material capable of withstanding the stress is provided on the tensile stress side generated in the cross section of the wood-based core material 1 due to the load applied from above the placing floor.
Inside or on its surface. In this way, it is possible to provide, for example, a wooden board for flooring, which can not only cope with an excessive load but also has a small dimensional change amount of the material due to repeated humidification and is excellent in dimensional stability.

In the case of using a plywood as a tensile strength reinforcing material, for example, a material having a Young's modulus larger than that of the wood-based core material 1 is employed, and the particle board alone of the wood-based core material 1 is about 15,000 to 25,000 kg / kg. cm ² whereas the plywood is about 60000 kg / cm ² .

Among the moisture-proof layers as the surface material 2, those applied to the surface of the core material 1 include resins such as acryl, urethane, epoxy and phenol, and various films made of polymer materials are also available. Can be used. Further, examples of the sheet-like material include paper, cloth, and resin. This moisture-proof layer is desirably applied not only to the front and back surfaces of the core material 1 but also to the side surfaces (kiguchi).

A particle board is used as the wood-based core material 1, a nonwoven fabric of glass fiber is used as a sheet substrate 21, and a prepreg-state sheet 20 impregnated with a phenol resin is stacked on the substrate 21 at 180 ° C., 10 kg / cm. Press for 10 minutes under the conditions of ² and apply the surface material 2 on both sides of the wooden core material 1
Example of the present invention having a thickness of 12 mm and a thickness of 12 mm
The fire resistance performance was compared with that of a comparative example consisting of a single particle board having a thickness of 1 mm. Evaluation of fire resistance is based on JIS A13
The test was carried out in accordance with “Fire resistance test method for building structural parts” of No. 04-1975. Specimen A of the above example and Specimen B of the comparative example were vertically held in a heating furnace using propane gas as a heat source, and heated from one side, and the areal density of the specimen (kg / cm ² )
The burn-out time (min) due to the difference was observed. The result was as shown in the graph of FIG. As is clear from FIG. 4, the embodiment of the present invention has improved fire resistance. As shown in Table 3, the heating temperature was increased with time. The “burn-out time” in FIG. 4 refers to the side opposite to the heated surface of the test specimen.
It was the time until a gap or hole where the heating flame could be visually observed.

[0031]

[Table 3]

Next, the evaluation of the flame retardancy was carried out on the test piece A according to the embodiment of the present invention, except that the glass fiber nonwoven fabric was impregnated with a phenol resin in which 20% by weight of calcium carbonate was dispersed. Specimen A and Specimen C manufactured under the same conditions. Table 4 shows the results.

[0033]

[Table 4]

The oxygen index (O.I.) in Table 4 is based on JIS
As defined in K 7201, refers to the value of the lowest oxygen concentration, expressed as a percentage by volume in oxygen required for a material to sustain combustion under given test conditions. The flame retardancy test is performed in accordance with JIS A 1321, and "smoke" in Table 4 refers to a smoke emission coefficient (CA) per unit area.
"Remaining smoke" is the time until the smoke disappears after heating is completed.
The smoke emission coefficient is determined by CA = 240 log 10 I ₀ / I, where I ₀ is the light intensity at the start of the heating test (Ix), and I is the minimum value of the light intensity during the heating test (Ix). It is.

The test piece A was tested for termite resistance with respect to the test piece D in which the tip of the test piece A was sealed with an epoxy resin. In this test, test specimens A and D were placed on a red pine wood chip, respectively, and the same red pine wood chip was placed on top of this, and was placed in a house termite breeding nest. The result of exposure and standing for 3 months was evaluated by visual change in shape. Specimen A penetrated into the inside from the side and eroded, but Specimen D did not show any harm. In addition, in the test sample A, no damage from the surface was observed.

Further, the test pieces A and D were subjected to a decay resistance test. The test method is the Japan Wood Preservation Association (JWPA)
The test was carried out almost in accordance with the standard No. 3-1979 "Test method for decay resistance of woody materials". In other words, as a test bacterium, brown rot fungus, Tyromyces palustris
And white-rot fungus, Coriolus versicolor
, A quartz medium and a culture solution (composition of glucose, peptone, and malt extract) were put into a mayonnaise bottle to prepare a medium. The mycelium grains that had been shake-cultured were sprinkled. When the mycelia had sufficiently spread, test specimens A and D were placed in a culture bottle, and decayed in a culture room at 26 ° C. for 3 months. Specimens A and D were dried at 60 ° C. before and after the decay operation to determine constant weights (W1, W2). The reduction rate of test specimens A and D is
It was calculated by [(W1−W2) / W1] × 100. The results were as shown in Table 5 below. In addition, about the test body A, the corrosion from the surface material 2 was not recognized, but was only the corrosion from the wood opening.

[0037]

[Table 5]

[0038]

As described above, according to the present invention, in a wooden board in which a surface material is laminated on both sides of a wooden core material, the surface material is heat-cured into a sheet base material capable of being impregnated with a resin. It is composed of a sheet impregnated with a thermosetting resin and has a flow rate of 2 to 50 in a prepreg state as a thermosetting resin.
% Phenolic resin is used, so that the thermosetting resin of the sheet impregnates the wood-based core material, improving flame retardancy, fire resistance, termite resistance, and antiseptic properties, and laminating a decorative material on the surface material Then, the cosmetic material is impregnated with the thermosetting resin and cured, so that the scratch resistance is also improved. In addition, an adhesive for bonding the surface material and the decorative material to the wooden core material is not required, and the surface material and the like can be bonded to the wooden core material only by hot pressing, which facilitates production. Furthermore, the presence of the sheet provides excellent dimensional stability against changes in temperature and humidity, and improves strength. Furthermore, if a phenol resin dissolved or dispersed in water or an organic solvent is used, it can be manufactured at low cost and easily, and the scratch resistance is improved.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a preferred embodiment of the present invention.

FIG. 2 is an explanatory view showing a production example of a sheet.

FIG. 3 is a graph showing a relationship between a flow rate and a wound depth.

FIG. 4 is a graph showing the results of a fire resistance test.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wooden core material 2 Surface material 20 Sheet 21 Sheet base material

Claims (4)

[Claims] 1. A wooden board in which a surface material is adhered to both sides of a wooden core material, wherein the surface material is a sheet in which a thermosetting resin is impregnated into a sheet base material capable of impregnating the resin. A wood board using a phenol resin having a flow rate in a prepreg state of 2 to 50% as a curable resin. 2. A wooden board in which a surface material is adhered to both surfaces of a wooden core material, wherein the surface material comprises a sheet in which a thermosetting resin is impregnated into a sheet base material capable of impregnating the resin. The sheet is made of a thermosetting resin with a solid content of 5 based on the sheet substrate.
A wood board characterized by being impregnated so as to have a weight of 0 to 500 g / m < ² > and then in a semi-cured state. 3. A wooden board in which a surface material is adhered to both surfaces of a wooden core material, wherein the surface material comprises a sheet in which a thermosetting resin is impregnated into a sheet base material capable of impregnating the resin. A wood-based board characterized in that a thermosetting resin is impregnated into a glass nonwoven fabric made of glass fiber alone or a fiber mixed with another fiber. 4. A wooden board in which a surface material is stuck on both sides of a wooden core material, wherein the surface material is a sheet in which a thermosetting resin is impregnated into a sheet base material capable of impregnating the resin. At a press temperature of 150 ° C. and 10 ° C.
A wood-based board, which is 10 kgf / cm ² after being hot-pressed at a pressing pressure of kgf / cm ² for 5 minutes.