JPH10114021A - Laminated finishing material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide laminated finishing material consisting of material difficult to be marred as finishing material even if decorative material is a thin plate or soft material by forming a rigid layer just under the decorative material. SOLUTION: A sheet material 2 containing a glass fiber is superposed on a base material 1. The whole or a part of both the base material 1 and the sheet material 2 is impregnated with a thermosetting resin 3 and both materials 1, 2 are mutually bonded. A decorative material 4 is stuck on the sheet material 2. Thereby, since a rigid layer is formed under the decorative material, marring resistance is enhanced and also the laminated finishing material is easily produced at a low cost. Further, dimensional stability is excellent even for charge in temperature and humidity because of existence of the sheet and the aspect of strength is enhanced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated finishing material used as a building interior material for floors, walls, ceilings, etc., or as a furniture or automobile interior material, or as a surface finishing material for various works. About.

[0002]

2. Description of the Related Art As an interior finishing material, a laminated finishing material in which a thin decorative board is stuck on the surface of a plywood or the like is widely used. Alternatively, a material in which a vinyl chloride sheet, printed paper, a plastic sheet, or the like is attached to the surface of a particle board or a plywood is known.

[0003]

However, the interior finishing material often comes into contact with an object for the purpose of use, so that the finished surface is scratched (especially dents) and the appearance is deteriorated. In particular, when the decorative material is a thin material such as veneer, paper, or the like, it is impossible to prevent the surface from being broken due to dents.

Therefore, according to the present invention, by forming a hard layer directly below the decorative material, even if the decorative material is a thin plate or a soft material, it can be made a material which is hardly damaged as a finishing material. In other words, an object of the present invention is to provide a laminated finishing material having excellent scratch resistance at low cost.

[0005]

SUMMARY OF THE INVENTION In order to achieve the above-mentioned object, the present invention relates to a method of laminating a sheet material containing glass fibers on a base material, and thermally curing the whole or a part of both the base material and the sheet material. It is impregnated with a conductive resin and adhered to each other, and a decorative material is stuck on a sheet material.

[0006]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

In the embodiment shown in FIG. 1, a sheet material 2 containing glass fibers is superimposed on a base material 1, and the base material 1 and the sheet material 2
Are impregnated with the thermosetting resin 3 on the whole or a part thereof and adhered to each other (the base material 1 and the sheet material 2 are adhered to each other by reference numeral 10). Shown is a decorative material 4 attached.

As the base material 1, a material that can be impregnated with a thermosetting resin, for example, a plywood, a wood fiber board, a particle board, a wafer board, or a composite board thereof can be suitably used.

As the sheet material 2, a woven or non-woven fabric containing glass fibers can be suitably used. As the woven cloth, for example, a glass fiber of 1200 denier having a length of 3 fibers / cm in the longitudinal direction and a width of 3 fibers / cm in the horizontal direction can be used. Substrate strength,
From the viewpoint of handling and the scratch resistance of the molded product, the basis weight is 10
1000 g / m ² , more preferably 50 to 250 g / m
² , a mixture of short fibers having a short fiber length (3 mm or more) and long fibers having a length of 10 mm or more (50 mm or less) is preferable.
If the basis weight of the glass nonwoven fabric is less than 10 g / m ² , it is difficult to develop scratch resistance, and if the basis weight is more than 1000 g / m ² , it becomes difficult to impregnate the resin. Short fibers having a glass fiber length of less than 3 mm have a low reinforcing effect, while long fibers exceeding 50 mm make it difficult to form a uniform sheet, and as a result, an excellent reinforcing effect cannot be obtained. In addition, that the short fiber of 3 to 15 mm accounts for 20 to 100% of the total fiber, the strength (reinforcement),
It is preferable from the viewpoint of the uniformity of the nonwoven fabric. 20% short fibers
If the amount is less, uniformity of the nonwoven fabric cannot be achieved. 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. The non-woven fabric containing glass fibers is formed into a sheet by a method of mechanically, chemically, thermally or using a solvent by bonding and / or entanglement of raw fibers, or a combination thereof. A material obtained by matting fiber raw materials by a wet papermaking or dry nonwoven fabric manufacturing method and bonding them with a binder resin can be suitably used.

The sheet material 2 and the base material 1 are impregnated with the thermoplastic resin 3 in a semi-cured state beforehand, and the sheet material 2 (prepreg) impregnated with the semi-cured resin is used. Can be realized by superimposing on the base material 1 and hot pressing. The resin to be impregnated in the sheet material 2 is, for example,
Phenol resins obtained by the reaction of phenols and aldehydes, and epoxy resins, urea resins, and urethane resins obtained by adding a curing agent to an oligomer having a reactive epoxy group at the terminal can be suitably used. These resins may be used alone or as a mixture of two or more, and are mainly combined with the fiber material (sheet material 2) by impregnation. The resin solution to be impregnated into the sheet material 2 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 these, it is preferable to use those dissolved or dispersed in water, alcohol, or the like from the viewpoint of cost and safety. Furthermore, various fillers such as lead stearate, dibutyltin dilaurate, carbon black, calcium carbonate, titanium white, mica, glass spheres, aluminum hydroxide, antimony oxide, tri (2,3 dibromopropyl) phosphate, fat A heat stabilizer, a reinforcing agent, a flame retardant, an antistatic agent, and the like are used in combination. As a catalyst required for the production of a phenol resin, alkylamine, ammonia, sodium hydroxide, barium hydroxide and the like are preferable. In particular, alkylamine and ammonia have higher molecular weights than the other two and have low hydration properties in terms of molecular structure, so that the water resistance after bonding is remarkably improved. At this time, the phenol resin is preferably dissolved or dispersed in water or alcohol so as to have a solid content of 20 to 75% from the viewpoint of easy impregnation. When alcohol is used, it has a low boiling point and is easy to dry.
Is preferred. If the solid content is less than 20%, it becomes difficult to impregnate the required amount, and if it is more than 75%, the impregnation becomes difficult due to an increase in viscosity. The resin to be impregnated into the sheet material 2 contains 50% or more of a fiber ratio (weight ratio), and desirably 100 to 300%. When the sheet material 2 is impregnated, the solid content is 50 to 500 g / m ² , preferably 1 to 500 g / m ² .
It is preferable that the amount be 50 to 350 g / m ² . If it is less than 50 g / m ^2, it is difficult to exhibit sufficient scratch resistance, and if it is less than 500 g / m ² , it takes a long curing time,
There is also a problem in appearance such as protruding from the end.

After impregnating the sheet material 2 with the resin solution as described above, the sheet material 2 is dried under a certain condition to bring the resin into a semi-cured state. That is, the prepreg is formed. Pre-preg is made of fiber reinforced material and thermosetting resin, other thermoplastic resin if necessary,
This is a semi-cured molding material before the completion of curing, which is a reinforced plastic obtained by admixing a coloring agent, a curing catalyst, etc., while maintaining the adhesiveness and moldability. The preferred gel time is 150 ° C.
30 to 800 seconds.

The thermosetting resin impregnated in the sheet material 2 is
As the drying conditions for setting the cured state in the latter half of the impregnation, the solvent content in the prepreg state is 3 to 15% by weight, more preferably 5 to 15% by weight.
The content is preferably set to 10% by weight, and if it is less than 3% by weight, poor adhesion to the substrate 1 is caused, and if it is not less than 15% by weight, blocking between prepregs is caused. 90-12
A preferable semi-cured prepreg can be obtained at a temperature of 0 ° C. and a drying time of 2.5 to 20 minutes.

[0013] The tensile strength of the prepreg is preferably 10 kgf or more in order to sufficiently develop scratch resistance. If it is less than 10 kgf, sufficient scratch resistance is not exhibited. The measurement of the breaking strength was performed after the prepreg was sandwiched between two release papers and the resin was cured by hot pressing at 150 ° C. for 5 minutes under a condition of 10 kgf / cm ² .

As described above, when the prepreg, in which the sheet material 2 is impregnated with the thermosetting resin in a semi-cured state, is overlaid on the base material 1 and hot pressed, the conditions are as follows.
0 ° C. to 180 ° C. is preferred, and 140 ° C. to 160 ° C.
Is preferred. If the temperature is lower than 130 ° C., the curing of the resin is not sufficient, and if the temperature is higher than 180 ° C., the curing of the resin is too fast, the contact with the substrate 1 becomes insufficient, and the warpage of the substrate 1 increases. . The pressure is 1 to 20 k
gf / cm ² is preferable, and more preferably 5 to 15 kg.
f / cm ² , and if it is lower than 1 kgf / cm ² , the resin will not sufficiently exude to the base material 1 and the adhesive strength will be reduced.
If it is greater than 0 kgf / cm ^2, problems such as an increase in the warpage of the substrate 1 occur. Further, the pressing time is preferably 2.5 to 20 minutes, more preferably 3 to 20 minutes.
~ 12.5 minutes. If the time is shorter than 2.5 minutes, the curing of the resin is not sufficient, and if the time is longer than 20 minutes, the resin is deteriorated and the warpage of the substrate 1 is increased.

A woven or non-woven fabric containing glass fibers is used alone as the sheet material 2, and a material impregnated with a semi-cured thermosetting resin (prepreg) is not used alone. Can also be used. For example, if the uncured phenol resin is impregnated into paper and the prepreg is bonded to the paper, the overall strength and dimensional stability are dramatically improved.

After the member 10 is manufactured as described above, the decorative material 4 is bonded to the sheet material 2 with an adhesive such as urea / melamine. As the decorative material 4, a veneer made of a thin wooden board, paper, a nonwoven fabric, a woven fabric, a synthetic resin sheet such as vinyl chloride or the like can be suitably used, and a material having a thickness not exceeding about 1 mm is preferable. As the paper, one printed with wood grain and subjected to unevenness processing along the wood grain has a high texture and is suitable for use.

The thermosetting resin 3 which has been hardened by hot pressing is:
It is preferable that the entirety of the sheet material 2 is impregnated. The base material 1 is impregnated entirely when the thickness of the base material 1 is thin, and partially when the thickness of the base material 1 is thick.

FIG. 2 shows the actual processing 5 and 6 applied to the periphery of the substrate 1, which can be suitably used as flooring.

A plywood having a thickness of 12 mm was used as the base material 1, a veneer veneer having a thickness of 0.3 mm was used as the decorative material 4, and a fiber length of 3 mm
The nonwoven fabric having a basis weight of 100 g / m ² made of the above glass fiber was used as the sheet material 2, and the flooring shown in FIG. This was designated as Example 1. Example 2 was a glass fiber having a fiber length of 12 mm and the other conditions were completely the same as in Example 1, and Example 3 was a case where the phenol resin of Example 1 was 150%, and Example 3 was a phenol resin of Example 2. Was set as 150%, and Example 5 was set as the phenol resin of Example 4 with 300%. A comparative example was obtained by directly bonding a 0.3 mm thick oak veneer with a urea-melamine adhesive as a decorative material 4 directly to the base material 1 (12 mm thick plywood).

In Examples 1 to 5 and Comparative Example, J
The scratch value of the pencil was tested according to IS K-5400, and a ball having a diameter of 6.35 mm and a weight of 150 g
A test (drop test JISA-1408) for measuring the diameter of the pit after dropping 50 times from the height of cm was performed.
The results were as shown in Table 1 below. In the pencil scratch value, "H" is evaluated as "X", "2H" is evaluated as "△", and "3H".
Was evaluated as ○, and “4H or more” was evaluated as ◎. In the ball drop test, the diameter of the pit was 5 mm or more, x: 4 mm to less than 5 mm, ○: 3 mm to less than 4 mm, ○: less than 3 mm.

[0021]

[Table 1]

[0022]

As described above, according to the present invention, a sheet material containing glass fibers is overlaid on a base material,
Since the whole or part of both the base material and the sheet material is impregnated with the thermosetting resin and adhered to each other, and the decorative material is stuck on the sheet material, a hard layer is formed under the decorative material. In addition, the scratch resistance can be improved, and it can be manufactured inexpensively and easily. Also, the presence of the sheet provides excellent dimensional stability against changes in temperature and humidity, and improves strength.

[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 another embodiment.

[Explanation of symbols]

 Reference Signs List 1 base material 2 sheet material 3 thermosetting resin 4 cosmetic material

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04C 2/24 E04C 2/24 Q E04F 13/08 E04F 13/08 A

Claims (4)

[Claims] 1. A sheet material containing glass fiber is superimposed on a base material, and both or a part of the base material and the sheet material are impregnated with a thermosetting resin and adhered to each other, and a decorative material is formed on the sheet material. Laminated finishing material characterized by having affixed thereto. 2. The laminated finishing material according to claim 1, wherein the thermosetting resin is any one of phenol resin, epoxy resin, urethane resin and urea resin, or a mixture of two or more thereof. 3. The laminated finishing material according to claim 1, wherein the base material is paper or wood-based material. 4. The laminated finish according to claim 1, wherein the decorative material is any one of a veneer made of a thin wooden board, paper, and a synthetic resin sheet such as vinyl chloride. Wood.