JP3055315B2 - Wood panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a woody, lightweight, tough, sound-absorbing, workable, semi-flammable,
The present invention relates to a wood panel material that can be used for ceiling materials, wall materials, and the like.

[0002]

2. Description of the Related Art Various types of panel materials conventionally used as ceiling materials and wall materials have been sold. For example,
(A) rock wool-based material, (b) mixed panel made of aluminum hydroxide, glass fiber, phenol resin, etc., (c) calcium silicate plate,
(D) Gypsum board and the like (d) General wood boards, plywood, particle boards, fiber boards, etc., and those mainly made of wood.

In such a conventional panel material,
(A) those mainly composed of rock wool are nonflammable and have sound absorbing properties, but have a specific gravity of about 0.4, have no woody feel, are easily broken when bent, and have low rigidity and workability. The one made of aluminum hydroxide, glass fiber, and phenol resin of (b) has a large specific gravity of about 0.45, has no woody feeling, is inferior in sound absorption, and is expensive. In the case of (c), the specific gravity is as large as about 0.7, and the sound is reflected and has no sound absorbing property. (D) is made of wood, which is tough and has a woody appearance. However, since it is flammable, its use is limited by interior restrictions and its specific gravity is large.

[0004]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a wood material, a high rigidity on the surface, light weight and toughness, excellent sound absorption and workability, and a quasi-incombustible material for a wall material. Another object of the present invention is to obtain a wood panel material suitable as a ceiling material.

[0005]

An object of the present invention is to provide a core made of wood fibers obtained by fibrillating wood, inorganic microbubble granules, a flame retardant, and an organic binder for binding them. The problem is solved by providing a wood panel material obtained by laminating and integrating a surface layer portion composed of fibers, an inorganic filler, a flame retardant, and an organic binder binding these. In this wood panel material, the mixing ratio of each material of the core is
10 inorganic fine bubble particles per 100 parts by weight of wood panel
The mixing ratio of 0 to 600 parts by weight, the flame retardant is 5 to 60 parts by weight, the organic binder is 10 to 200 parts by weight, and the mixing ratio of each material of the surface layer portion is 100 parts by weight of the wood panel and the inorganic filler is 100 parts by weight. It is preferable that the mixing ratio is 20 to 60 parts by weight, the flame retardant is 5 to 60 parts by weight, and the organic binder is 10 to 200 parts by weight. In this wood panel material, the thickness of the surface layer is preferably 0.8 to 3.0 mm.

Hereinafter, the present invention will be described in detail. Examples of the wood as a raw material of the wood fiber used for the wood panel material of the present invention include conifers such as pine, pine, Japanese cypress, cypress, cedar, and spruce, and broadleaf trees such as buna, nara, birch, and maple. Can be A method is used in which these woods are chipped, steamed with high-pressure steam, and then defibrated by a refiner. The fiber is dried and, if necessary, classified and used.

[0007] The inorganic microbubble particles used for the core of the wood panel material of the present invention is a granular material containing an inorganic oxide such as silicon oxide or aluminum oxide as a main component and having fine closed cells therein. Body, having a bulk specific gravity of 0.05 to
It is lightweight at about 0.25, has a melting temperature of 1200 ° C. or more, is excellent in fire resistance, and has a thermal conductivity of 0.036 to 0.05.
It has a good thermal insulation of kcal / m · h · ° C and is chemically stable. For example, pearlite, which is obtained by rapidly heating and expanding crushed grains of natural volcanic glass, pearlite or pine stone, and the like. Or a volcanic ash or a zonolite-based calcium silicate powder.

The inorganic filler used for the surface layer includes:
Any of those generally used as inorganic fillers can be used. Examples thereof include aluminum hydroxide, calcium carbonate, marble powder, clay, diatomaceous earth, silica sand and the like. In particular, aluminum hydroxide, which itself has a flame retarding effect, is preferred.

The flame retardant used in the present invention is not particularly restricted but includes, for example, triphenyl phosphate, tricresyl phosphate, cresyl phenyl phosphate, tris (halopropyl) phosphate, tris (haloethyl) phosphate, carbamate polyphosphate and the like. Phosphoric ester flame retardants, chlorinated paraffin, chlorinated polyethylene, perchloropentacyclodecane, hexabromobenzene, decabromodiphenyl ether, tetrabromobisphenol A and its derivatives, halogen-containing organic compounds such as hexabromocyclododecane, Antimony oxide, antimonate, barium metaborate,
Inorganic flame retardants such as zinc borate, aluminum hydroxide and ammonium bromide, tetrabromophthalic anhydride,
Reactive flame retardants such as bromostyrene and vinyl bromide are used, and among them, phosphorus-based flame retardants and halogen-based flame retardants are preferred.

The organic binder is not particularly limited as long as it has good adhesion to wood fibers and inorganic microbubble particles or inorganic fillers. Examples thereof include urethane resins, urea resins, and phenol resins. Melamine resin, epoxy resin, unsaturated polyester resin, aryl resin and the like. Of these, urethane resins, phenolic resins, and mixtures thereof are preferred. These provide the wood panel with appropriate toughness, rigidity and water resistance.

The wood panel material of the present invention is formed by laminating and integrating the core and the surface layer. Of these, the core is formed by adding inorganic fine cell granules, a flame retardant, and an organic binder to the wood fiber, and then performing preforming and applying heat and pressure. At this time, 100 to 600 parts by weight of inorganic microbubble particles, 5 to 60 parts by weight of a flame retardant, based on 100 parts by weight of the wood fiber,
It is desirable that the mixing ratio be 5 to 40 parts by weight of the organic binder.

The surface layer is formed by adding and mixing an inorganic filler, a flame retardant, and an organic binder to the wood fibers, performing preforming, and applying heat and pressure. At this time, the wood fiber 10
It is desirable that the mixing ratio is 20 to 60 parts by weight of the inorganic filler, 5 to 60 parts by weight of the flame retardant, and 5 to 40 parts by weight of the organic binder with respect to 0 part by weight.

When these are laminated and integrated, the core and the surface layer may be individually hot-press molded, and the molded members may be laminated and adhered thereafter to be integrally molded. However, it is more preferable to laminate and integrate them in the process of preforming, and then to form the laminate by heating and pressing. For example, on the base, first, the composition forming either the core portion or the surface layer portion is formed into a desired thickness (accumulation / shaping), and the other composition is further formed on the base. It can be carried out by laminating the sheet, and preforming the obtained preform in a hot press (for example, hot press) by heating and pressurizing to form a single piece. In the wood panel material manufactured by such a manufacturing method, since the respective fibers are entangled at the interface between the core and the surface layer, and both organic binders are united and adhered to each other, the interlayer is also affected by bending stress and shear stress. No delamination occurs.

The wood panel material of the present invention may be one in which a surface portion is laminated and integrated on one surface of a core portion, but it is more preferable that a surface layer portion is laminated and integrated on both surfaces of a core portion. At this time, the composition of both surface portions may be the same or different. In order to produce a wood panel material having a surface layer on both sides of the core in this way, for example, first, a composition for forming a surface layer on a base is formed into a desired thickness, and on this,
The composition for forming the core portion is laminated and formed to a desired thickness, and the composition for forming the surface layer portion is further laminated and formed to a desired thickness thereon, and the thus obtained surface layer composition / It can be manufactured by heating and pressurizing a preformed product consisting of three layers of a core composition / a surface layer composition and integrally forming the preformed product.

At this time, the thickness of the surface layer is 0.8 to 3.0.
mm is preferable. This thickness is 0.8mm
If it is less than 30 mm, sufficient toughness and rigidity cannot be obtained on the surface of the wood panel material. If it exceeds 3.0 mm, it becomes not only heavy but also difficult to maintain semi-flammability. Although the thickness of the wood panel material of the present invention is not particularly limited, it is 9 to 50.
mm is preferable.

The wood panel material of the present invention is not limited to a flat plate, but may be a curved one, or an embossed or sculpture-like uneven pattern formed on the surface of the surface layer. Such a concavo-convex pattern can be provided, for example, by performing intaglio on the surface of the mold when the preform is heated and pressed.

The wood panel material of the present invention may have a pigment, an insect repellent, an antiseptic / fungicide, a water repellent,
An additive such as a reinforcing material may be included. These additives can be blended, for example, by adding them to the respective pre-forming compositions of the core and the surface layer.

The wood panel material of the present invention as described above has excellent woodiness and toughness because the ratio of wood fibers in the composition forming the surface layer is high. It also has high rigidity because it contains an inorganic filler. Since the core contains a high percentage of inorganic microbubble particles with a low specific gravity and excellent sound absorption,
The wood panel material of the present invention is lightweight and excellent in sound absorption. The surface layer is formed thin, and the core is formed by a large amount of non-combustible heat insulating material (inorganic microbubble particles) and a small amount of combustible material (wood fiber and organic binder). Due to the inclusion of the flame retardant, the wood panel material of the present invention is semi-flammable despite containing combustible wood fibers. The wood panel material of the present invention has good workability since the surface layer having high rigidity is formed thinly and the core is mostly composed of easily cut air bubbles.

Here, if the amount of the inorganic microbubble particles contained in the core is less than 100 parts by weight, the incombustibility of the wood panel material is not sufficient, the specific gravity is large, and the sound absorbing property is low. Also, 60
If the amount exceeds 0 parts by weight, rigidity and toughness decrease. If the amount of the inorganic filler contained in the surface layer is less than 20 parts by weight, the rigidity of the surface as the wood panel material is not sufficient, and if it exceeds 60 parts by weight, the woody feel and toughness are reduced. If the amount of the flame retardant is less than 5 parts by weight, incombustibility is insufficient, and if it exceeds 60 parts by weight, the rigidity is reduced. When the amount of the organic binder is less than 10 parts by weight in the core portion and less than 5 parts by weight in the surface layer portion, it is insufficient for adhesion of the composition. If the core exceeds 200 parts by weight, the specific gravity is large, and both the sound absorbing property and the nonflammability deteriorate. If it exceeds 40 parts by weight in the surface layer, the woody feel and workability are impaired.

Such a wood panel material of the present invention has a woody feel and breathability, is tough, has an appropriate rigidity, has a specific gravity of 0.20 to 0.23, is lightweight, and has a sound absorption coefficient. It has a good normal incidence sound absorption coefficient of 0.50 to 0.65, good workability, and satisfies the quasi-nonflammability requirement, so that it can be suitably used as a wall material or a ceiling material.

[0021]

The present invention will be specifically described below with reference to examples. Manufactures a wood panel material in which a surface layer is laminated and integrated on both sides of a core. (1) The following materials were mixed in a mixer to obtain a core composition. Wood fiber 100 parts by weight Inorganic microbubble granules (Mitsui perlite B: made by Mitsui Metals) 400 parts by weight Organic binder Urethane resin (C-MDI: made by Sumitomo Chemical) 60 parts by weight Phenol resin (OTE113A: made by Showa Polymer) 15 parts by weight Part Flame retardant (phosphorus compound) 20 parts by weight (2) The following materials were mixed in a mixer to obtain a surface layer composition. Wood fiber 100 parts by weight Inorganic filler (aluminum hydroxide) 40 parts by weight Organic binder Urethane resin (C-MDI) 18 parts by weight Phenol resin (OTE113A: manufactured by Showa Polymer) 5 parts by weight Flame retardant (phosphorus compound) 20 parts by weight Department

The surface layer composition was uniformly spread and laminated on a smooth hot plate of a hot press at a ratio of 423 g per 1 m ² . Next, the core composition was uniformly dispersed and laminated on the laminate at a rate of 1,620 g per 1 m ² . Further, the surface layer composition was uniformly spread on the laminate at a rate of 423 g per 1 m ² to obtain a laminated preform having three layers of a surface layer portion / a core portion / a surface layer portion. This was pressed to 15 kg / cm ² with a smooth pressure plate and heated at 150 ° C. for 10 minutes.

The obtained wood panel material has a thickness of 9 mm, a core thickness of 6 mm and a surface layer thickness of 1.5 m each.
m. This panel had a smooth, hard surface with a woody feel, and the interface between the surface layer and the core was tightly adhered.

The panel was subjected to a physical property test and compared with a conventional rock wool ceiling material. The specific gravity was 0.22 (the rock wool ceiling material was 0.39 to 0.43). The flexural strength was 17-20 kg / cm ² (rock wool ceiling material 8-18 kg / cm ² ). The normal incidence sound absorption coefficient was determined by JIS-A-1405 “Measurement of normal incidence sound rate of building material by in-pipe method” and was 0.60 (0.45 for rock wool ceiling material).

Next, a flame retardancy test was carried out based on JIS-A-1321 "Test method for flame retardancy of building interior materials and construction methods". The standard for passing the semi-flammable surface test is Tc: 3.
0 minute or more, Tdθ: 100 or less, CA: 60 or less, afterflame: 30 or less, penetration: none. The test result is T
c: 3.0 minutes or more, Tdθ: 37.1, CA: 13.
2, residual flame: 0, penetration: none, and passed as a quasi-noncombustible material.

It is clear that the woody panel material of the above embodiment has a woody feel, is lightweight, has excellent sound absorption, and can be used as a quasi-noncombustible material.

[0027]

As described above, the wood panel material according to the present invention comprises a core made of wood fiber, inorganic microbubble particles, a flame retardant and an organic binder, a wood fiber, an inorganic filler and a flame retardant. And a surface layer consisting of an organic binder are laminated and integrated, giving a woody feel, high surface rigidity, toughness and light weight, excellent sound absorption, good workability, and quasi-incombustibility. Sex.

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Shiro Hanao 10-1 Nakazawa-cho, Hamamatsu-shi, Shizuoka Yamaha Corporation (56) References JP-A-58-180700 (JP, A) 15619 (JP, A) Japanese Utility Model Showa 63-82504 (JP, U) Japanese Patent Publication No. 49-49037 (JP, B1) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35 / 00 B27N 1/00-3/28 B27K 3/00-3/52 E04C 2/00-2/54 E04F 13/00-13/18

Claims (1)

(57) [Claims] 1. A core comprising wood fibers, inorganic microbubble particles, a flame retardant and an organic binder for binding them, and a surface layer comprising wood fibers, an inorganic filler, a flame retardant and an organic binder for binding them. Wood panel material characterized by being laminated and integrated with parts.