JP2008179049A - Wood decorative board and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a wood decorative board with a surface decorative material improving peeling resistance, chipping resistance and crack resistance. <P>SOLUTION: A wood fiber board 10 is impregnated with a resin 1. A resin film 11 formed on the surface is removed by polishing or grinding the surface of the wood fiber board impregnated with the resin. The wood fiber board 12 impregnated with the resin where the resin film 11 on the surface is removed is bonded to overlie the wood substrate 13 to form a wood-based composite base material 15. The surface decorative material 16 is bonded to overlie the surface of the wood fiber board 12 impregnated with the resin where the resin film on the surface of the wood-based composite base material 15 is removed to form the wood decorative board 20. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a wooden decorative board used as a flooring material or an interior material and a method for producing the same.

  A wood fiber board is bonded and laminated to the surface of a wood substrate, such as plywood, to form a wood-based composite base material, and a surface decorative material such as a veneer or a synthetic resin decorative sheet is laminated to the surface of the wood fiber board It is known to use a wooden decorative board. A medium density wood fiber board (MDF) is mainly used as the wood fiber board, and this kind of wood decorative board is often used as a flooring material or an interior material.

  The wooden decorative board in this form is excellent in surface smoothness because the wooden fiber board is present between the wooden substrate and the surface decorative material. However, in general, the wood fiberboard is not enough for the peel resistance and chipping resistance by the caster test, so the wood fiberboard is impregnated with resin to form a resin-impregnated wood fiberboard, and the surface decorative material is bonded and laminated on it. By doing so, it is known to make a wooden decorative board with improved peeling resistance and chipping resistance (see Patent Document 1, etc.).

JP 11-114911 A

  The inventors of the present invention have continuously conducted experiments and research on a wood decorative board formed by adhering and laminating a surface decorative material on the surface of a resin-impregnated wood fiber board adhered and laminated to a wooden substrate as described above. However, in the process, it has been experienced that a number of cracks that can not be ignored may occur in a surface decorative material such as a veneer after being used for many days. If a large number of cracks occur in the surface decorative material, the design of the wooden decorative board is degraded. Therefore, in this type of wooden decorative board, reducing the number of occurrences of cracks remains a problem to be solved. Recognized.

  The present invention has been made to solve the above problems, and is formed by bonding a surface decorative material to the surface of a wood-based composite base material that is a laminate of a wood substrate and a resin-impregnated wood fiber board. An object of the decorative board is to improve the crack resistance of the surface decorative material.

  In order to solve the above-mentioned problems, the present inventors further conducted an experiment on a wooden decorative board in which a surface decorative material was bonded and laminated on the surface of a wooden composite substrate, which is a laminate of a wooden substrate and a resin-impregnated wooden fiber board. As a result of the research, a thin resin film is formed on the surface of the wood fiber board when the resin is impregnated into the wood fiber board. It was found that a large number of cracks occurred in the surface decorative material over time due to the behavioral effect of moisture absorption and release of the material.

  The present invention is based on the above knowledge, and a surface decorative material is bonded and laminated on the surface of the wood-based composite base material, which is a laminate of a wood substrate and a resin-impregnated wood fiber board, on the resin-impregnated wood fiber board side. In the method for manufacturing a wood decorative board, the first invention is a step of impregnating a wood fiber board with a resin, and polishing or grinding the surface of the wood fiber board impregnated with the resin to remove the resin film formed on the surface A step of bonding the back side of the resin-impregnated wood fiber board from which the resin film on the surface has been removed to a wooden substrate to form a wood-based composite base material, and a resin impregnation from which the resin film on the surface has been removed It includes at least a step of bonding and laminating a surface decorative material on the surface of the wood fiber board.

  According to a second aspect of the present invention, in the manufacturing method, a step of impregnating a wooden fiberboard with a resin, a step of bonding and laminating the wooden fiberboard impregnated with the resin to a wooden substrate to form a wooden composite base material, the wooden composite Polishing or grinding the surface of the resin-impregnated wood fiber board in the substrate to remove the resin film formed on the surface, and a surface decorative material on the surface of the resin-impregnated wood fiber board from which the resin film on the surface has been removed At least a step of bonding and laminating.

  3rd invention is the manufacturing method WHEREIN: The process of carrying out the adhesion lamination | stacking of a wood fiber board and a wood substrate to make a wood type composite base material, the process of impregnating the wood fiber board in the said wood type composite base material, Polishing or grinding the surface of the wood fiber board impregnated with resin to remove the resin film formed on the surface, and applying a surface decorative material to the surface of the resin-impregnated wood fiber board from which the resin film on the surface has been removed A step of bonding and laminating at least.

  The first, second and third inventions all include a step of polishing or grinding the surface of the wood fiber board impregnated with resin to remove the resin film formed on the surface. Therefore, the surface decorative material is adhered and laminated on the surface where the wood part of the wooden fiberboard appears, and the behavior absorbing ability due to moisture absorption / release is not hindered. The number of cracks that occur is greatly reduced. That is, the crack resistance of the surface decorative material is greatly improved.

  The present application further provides a surface decorative material on the surface of the wood-based composite base material, which is a laminate of a wood substrate and a resin-impregnated wood fiber board, as a wood-made decorative board manufactured by the above-described manufacturing method. The resin-impregnated wood fiberboard has a wood part that is exposed without a resin film on the surface, and the wood fiber board on which the wood part appears. Also disclosed is a wooden decorative board characterized in that a surface decorative material is bonded and laminated on the surface.

  In the present invention, the material used for the wood substrate is not particularly limited, and materials such as plywood, particle board, OSB, and LVL can be used. However, plywood is a preferred material from the viewpoint of cost and processability. The thickness of the wooden substrate is usually about 12 mm.

  In the present invention, conventionally known medium density wood fiber board (MDF), high density wood fiber board (HDF), hard fiber board (HD), etc. can be used as the wood fiber board. Preferably, it is a medium density wood fiber board (MDF) with a specific gravity of about 0.6 to 1.0. Although the thickness is arbitrary, it is desirable to use a wood fiber board of about 0.3 mm to 5 mm.

  In general, the wood fiberboard is composed of a high-density surface layer portion (rock layer) and a low-density layer having a lower density than the surface layer portion. The wood fiber board may be bonded and laminated to the wood substrate as it is, and when it is desired to use a thin wood fiber board, the wood fiber board divided into two in the thickness direction may be used. In the latter case, the surface layer portion (rock layer) side may be an adhesive surface with the wooden substrate, and the divided surface side may be an adhesive surface with the wooden substrate. In either case, the wood fiber board is impregnated with resin, and the resin film formed on the surface of the wood fiber board after the impregnation is removed by polishing or grinding. The removal of the resin film is preferably performed after the resin is cured and formed, but may be polished or ground in a state where the resin is cured and formed to such an extent that the resin does not flow. Further, in the polishing or grinding process, in addition to the resin film formed on the surface of the wood fiber board, a part of the surface layer portion (rock layer) or the low density layer may be removed.

  In the present invention, the resin impregnated into the wood fiber board is arbitrary, and conventionally known thermoplastic resins (for example, vinyl acetate resins, vinyl chloride resins, etc.) and thermosetting resins (urea resins, melamine resins). Resin, isocyanate resin, polyester resin, urethane resin, and the like).

  In the present invention, as the surface decorative material, any material used as a surface decorative material in a normal woody decorative material can be used. Examples include a veneer or resin-impregnated veneer having a thickness of about 0.1 mm to 0.6 mm, a synthetic resin decorative sheet, and a printed sheet.

  In the present invention, there is no particular limitation on the adhesive for adhering and laminating the wood substrate and the wood fiber board, and the wood fiber board and the surface decorative material, and an appropriate adhesive can be used in consideration of the material to be used. Examples include an adhesive made of urea resin, urea / melamine cocondensation resin, polyurethane resin, aqueous vinyl urethane resin, vinyl acetate resin, urea / vinyl acetate resin, and the like.

  ADVANTAGE OF THE INVENTION According to this invention, the wooden decorative board with the surface decorative material which improved the crack resistance with peeling resistance and chipping resistance can be obtained.

  Hereinafter, the present invention will be described based on embodiments with reference to the drawings. FIG. 1 is a diagram for explaining the manufacturing method according to the first invention in the order of steps, FIG. 2 is a diagram for explaining the manufacturing method according to the second invention in the order of steps, and FIG. 3 is a manufacturing method according to the third invention. It is a figure explaining these in process order.

  In the manufacturing method according to the first invention shown in FIG. 1, first, a wood fiber board 10 (for example, MDF) having a predetermined size is prepared (FIG. 1a). The resin 1 of the wood fiber board 10 is impregnated, for example, by putting it in a pressure tank 2 containing the resin 1 (FIG. 1b). Thereby, a resin-impregnated wood fiber board 12 having a thin resin film 11 on the surface is obtained (FIG. 1c). After the resin 1 of the resin-impregnated wood fiber board 12 is cured, the resin film 11 formed on one surface is removed using a rotary cutter 3 or the like (FIG. 1d). The resin-impregnated wood fiberboard 12 from which the resin film 11 on one surface has been removed is adhered and laminated to a wood substrate 13 such as plywood using an adhesive so that the surface thereof is on the upper surface side. The substrate 15 is assumed (FIG. 1e). Finally, a surface decorative material 16 such as a veneer is bonded and laminated to the surface of the resin-impregnated wood fiber board 12 of the wood-based composite base material 15 to form the wood decorative board 20 according to the present invention. .

  In the manufacturing method according to the second invention shown in FIG. 2, a wood fiber board 10 (for example, MDF) having a predetermined size is first prepared (FIG. 2a). The resin 1 of the wood fiber board 10 is impregnated, for example, by putting it in a pressure tank 2 containing the resin 1 (FIG. 2b). Thereby, a resin-impregnated wood fiber board 12 having a thin resin film 11 on the surface is obtained (FIG. 2c). Preferably, after the resin 1 of the resin-impregnated wood fiberboard 12 is hardened, it is adhered and laminated to a wood substrate 13 such as a plywood using an adhesive to form a wood-based composite base material 15 (FIG. 2d). Next, the resin film 11 formed on the surface of the resin-impregnated wood fiber board 12 in the wood composite base material 15 is removed using the rotary cutter 3 or the like (FIG. 2e). As a result, a wood-based composite base material 15 in which the resin film 11 does not exist on the surface of the resin-impregnated wood fiber board 12 is formed (FIG. 2f). Finally, a surface decorative material 16 such as a veneer is bonded and laminated to the surface of the resin-impregnated wood fiber board 12 of the wood-based composite base material 15 to form the wood decorative board 20 according to the present invention. .

  In the manufacturing method according to the third invention shown in FIG. 3, first, a wood fiber board 10 (for example, MDF) of a predetermined size and a wood substrate 13 are bonded and laminated to form a wood-based composite base material 15 (FIG. 3a). Resin-impregnated wood fiber board 12 is obtained by impregnating wood fiber board 10 with resin 1 by applying an aqueous resin to the surface of wood fiber board 10 in wood-based composite base material 15 (FIG. 3b). A thin resin film 11 is formed on the surface of the resin-impregnated wood fiber board 12. After the resin 1 is cured, the resin film 11 formed on the surface of the resin-impregnated wood fiber board 12 in the wood composite base material 15 is removed using the rotary cutter 3 or the like (FIG. 3c). As a result, a wood-based composite base material 15 in which the resin film 11 does not exist on the surface of the resin-impregnated wood fiber board 12 is formed (FIG. 3d). Finally, a surface decorative material 16 such as a veneer is bonded and laminated to the surface of the resin-impregnated wood fiber board 12 of the wood-based composite base material 15 to form the wood decorative board 20 according to the present invention. .

  Although not shown, in any of the manufacturing methods, a wood fiber board divided into two in the thickness direction can also be used as the wood fiber board 10. In that case, the surface which adhere | attaches and laminates | stacks with the wooden base material 13 may be a high-density surface layer part (rock layer), and may be a division surface which is a low-density layer with a low density compared with it.

  Hereinafter, the present invention will be described with reference to examples and comparative examples.

[Example 1-Crack resistance]
A MDF with a thickness of 2.5 mm was divided into two in the thickness direction to obtain a MDF with a thickness of 1.0 mm. The dividing surface was ground to a thickness of 0.8 mm. The ground MDF was impregnated with a urea / vinyl acetate aqueous resin by a coating impregnation method. The plywood deck and the divided surface of the MDF impregnated with resin were bonded and laminated using a vinyl acetate adhesive to obtain a wood-based composite base material. After the impregnated resin was cured, the surface of the MDF impregnated with the resin was ground until the wood part of the MDF appeared. After grinding, a veneer with a thickness of 0.3 mm was adhered and laminated to the ground surface using a vinyl acetate adhesive, and a polyurethane resin coating was performed to obtain a wood decorative board.

A test piece of 150 mm × 280 mm was taken from the wooden decorative board, a test was repeated 10 times by drying at 80 ° C. for 2 hours → freezing at −20 ° C. for 2 hours, and the number of cracks formed on the veneer after the test was counted. The results are shown in Table 1.
[Comparative Example 1]
MDF with a thickness of 0.8 mm was obtained in the same manner as Example 1. Without performing the resin impregnation, the plywood deck and the divided surface of the MDF were bonded and laminated using a vinyl acetate-based adhesive to obtain a wood-based composite base material. A veneer was bonded and laminated on the MDF surface of the wood-based composite base material in the same manner as in Example 1 and painted to obtain a wood decorative board.

  A test piece of 150 mm × 280 mm was taken from the wooden decorative board, and in the same manner as in Example 1, the test was repeated 10 times in the cycle of drying at 80 ° C. for 2 hours → freezing at −20 ° C. for 2 hours. The number of cracks was counted. The results are shown in Table 1.

[Comparative Example 2]
In the same manner as in Example 1, a woody composite base material in which MDF impregnated with resin was bonded and laminated on plywood was obtained. A veneer was bonded and laminated on the resin-impregnated MDF surface of the wood-based composite base material in the same manner as in Example 1 without performing surface grinding, and a wooden decorative board was obtained by coating.

  A test piece of 150 mm × 280 mm was taken from the wooden decorative board, and in the same manner as in Example 1, the test was repeated 10 times in the cycle of drying at 80 ° C. for 2 hours → freezing at −20 ° C. for 2 hours. The number of cracks was counted. The results are shown in Table 1.

[Example 2-Crack resistance]
A 3.0 mm thick MDF was divided into two in the thickness direction to obtain a 1.3 mm thick MDF. The dividing surface was sanded to a thickness of 1.0 mm. The plywood deck and the MDF rock layer (the side opposite to the split surface) were bonded and laminated using a urea / vinyl acetate adhesive to form a wood-based composite base material. The MDF surface of the wood-based composite base material was coated and impregnated with a styrene / butadiene-based synthetic rubber latex resin. After the impregnation, the surface of the resin-impregnated MDF was ground until the wood part of the MDF appeared after the resin was cured. After grinding, a veneer with a thickness of 0.3 mm was adhered and laminated using a vinyl acetate adhesive, and a polyurethane resin coating was performed to obtain a wood decorative board.

A test piece of 150 mm × 280 mm was taken from the wooden decorative board, a test was repeated 10 times by drying at 80 ° C. for 2 hours → freezing at −20 ° C. for 2 hours, and the number of cracks formed on the veneer after the test was counted. The results are shown in Table 2.
[Comparative Example 3]
MDF with a thickness of 1.0 mm was obtained in the same manner as Example 2. Without performing resin impregnation, the plywood deck and the MDF rock layer were bonded and laminated using a urea / vinyl acetate adhesive to obtain a wood-based composite base material. A veneer was bonded and laminated to the MDF surface of the wood-based composite base material in the same manner as in Example 2 and painted to give a wood decorative board.

A test piece of 150 mm × 280 mm was taken from the wooden decorative board, and in the same manner as in Example 1, the test was repeated 10 times in the cycle of drying at 80 ° C. for 2 hours → freezing at −20 ° C. for 2 hours. The number of cracks was counted. The results are shown in Table 2.
[Comparative Example 4]
In the same manner as in Example 2, resin-impregnated MDF was adhered and laminated to plywood to obtain a wood-based composite base material. A veneer was bonded and laminated on the surface of the resin-impregnated MDF of the wood-based composite base material in the same manner as in Example 2 without performing surface grinding to obtain a wood-made decorative board.

  A test piece of 150 mm × 280 mm was taken from the wooden decorative board, and in the same manner as in Example 1, the test was repeated 10 times in the cycle of drying at 80 ° C. for 2 hours → freezing at −20 ° C. for 2 hours. The number of cracks was counted. The results are shown in Table 2.

[Discussion]
As shown in Tables 1 and 2, the cracks in Examples 1 and 2 are the same as those in the case of the veneer bonded and laminated to the wood fiber board not subjected to resin impregnation (Comparative Examples 1 and 3). The number is larger than the number of cracks generated in the protruding plates of Comparative Examples 2 and 4 where the resin is impregnated and the surface is not ground. Thereby, in the method by this invention, the effectiveness with respect to crack resistance by removing the resin film formed in the surface of the wood fiber board impregnated with resin is shown.
[Reference Example-Plane Tensile Strength]

  A planar tensile test was performed on both the wooden decorative board obtained in Example 1 and the wooden decorative board obtained in Comparative Example 1 in accordance with JIS A5905. That is, a test piece of 50 mm × 50 mm is taken from both wooden decorative boards, and an attachment having a square-shaped adhesive surface with a side of 20 mm is adhered to the center of the surface using an adhesive, and after the adhesive is cured, around the attachment After scratching the depth reaching the wooden substrate, the test piece and attachment are fixed by a predetermined method, and pulled at a load speed of about 2 mm / min in a direction perpendicular to the bonding surface, and the maximum load at the time of peeling (P) Was measured, and the plane tensile strength was calculated by the following formula.

Formula: Plane tensile strength (N / mm ² ) = P / 400
In Example 1, the flat tensile strength was 1.79 N / mm ² , and in Comparative Example 1 was 0.88 N / mm ² . It was shown that the peel strength was improved by using a resin-impregnated wood fiberboard.

The figure explaining the manufacturing method of the wooden decorative board by 1st invention. The figure explaining the manufacturing method of the wooden decorative board by 2nd invention. The figure explaining the manufacturing method of the wooden decorative board by 3rd invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Wood fiber board, 11 ... Resin film | membrane, 12 ... Resin impregnation wood fiber board, 13 ... Wood board | substrate, 15 ... Wood type composite base material, 16 ... Surface decorative material, 20 ... Wood decorative board

Claims (4)

A method for producing a wooden decorative board comprising a laminate of a wooden substrate and a resin-impregnated wooden fiber board, wherein a surface decorative material is bonded and laminated on the surface of the resin-impregnated wooden fiber board side of the wooden composite substrate,
A step of impregnating a wood fiber board with a resin, a step of polishing or grinding a surface of the wood fiber board impregnated with the resin to remove a resin film formed on the surface, and a resin-impregnated wood from which the resin film on the surface is removed A step of bonding and laminating the back side of the fiberboard to a wooden substrate to form a wood-based composite base material, and a step of bonding and laminating a surface decorative material on the surface of the resin-impregnated wood fiberboard from which the resin film on the surface has been removed, A method for producing a wooden decorative board, comprising: A method for producing a wooden decorative board comprising a laminate of a wooden substrate and a resin-impregnated wooden fiber board, wherein a surface decorative material is bonded and laminated on the surface of the resin-impregnated wooden fiber board side of the wooden composite substrate,
A step of impregnating a wood fiber board with a resin, a step of bonding and laminating the wood fiber board impregnated with the resin to a wood substrate to form a wood-based composite base material, and a surface of the resin-impregnated wood fiber board in the wood-based composite base material At least a step of removing a resin film formed on the surface by polishing or grinding, and a step of bonding and laminating a surface decorative material on the surface of the resin-impregnated wood fiber board from which the resin film on the surface has been removed. A method for producing a wooden decorative board, which is characterized. A method for producing a wooden decorative board comprising a laminate of a wooden substrate and a resin-impregnated wooden fiber board, wherein a surface decorative material is bonded and laminated on the surface of the resin-impregnated wooden fiber board side of the wooden composite substrate,
A step of bonding and laminating a wood fiber board and a wood substrate to form a wood-based composite base material, a step of impregnating the wood fiber board in the wood-based composite base material with a resin, and polishing a surface of the wood fiber board impregnated with the resin Or at least a step of removing the resin film formed on the surface by grinding, and a step of adhesively laminating a surface decorative material on the surface of the resin-impregnated wood fiber board from which the resin film on the surface has been removed. A method for producing a wooden decorative board.   A wooden decorative board obtained by adhering and laminating a surface decorative material on the surface of a resin-impregnated wooden fiber board side of a wooden composite substrate, which is a laminate of a wooden substrate and a resin-impregnated wooden fiber board, the resin-impregnated wooden fiber The wood makeup is characterized in that the wood part of the wood fiber board appears without any resin film on the surface, and the surface decorative material is bonded and laminated on the surface of the wood fiber board where the wood part appears Board.

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