JP2630462B2 - Veneered veneer plastic composite and method for producing the same - Google Patents
Veneered veneer plastic composite and method for producing the sameInfo
- Publication number
- JP2630462B2 JP2630462B2 JP1075974A JP7597489A JP2630462B2 JP 2630462 B2 JP2630462 B2 JP 2630462B2 JP 1075974 A JP1075974 A JP 1075974A JP 7597489 A JP7597489 A JP 7597489A JP 2630462 B2 JP2630462 B2 JP 2630462B2
- Authority
- JP
- Japan
- Prior art keywords
- veneer
- resin
- impregnated
- sheet
- thermosetting resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Description
【発明の詳細な説明】 〔産業上の利用分野〕 本発明は、例えば自動車の内装部品であるセンターク
ラスタ、コンソールアッパーパネル、ドアトリムオーナ
メントパネル等に使用される透明樹脂表面被覆層を有す
る化粧単板プラスチック複合材及びその製造方法に関
し、これは中でも高級車両に使用される天然銘木の木目
の見える透明樹脂表面被覆層を有する化粧単板プラスチ
ック複合材を包含する。DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a decorative veneer having a transparent resin surface coating layer used for, for example, a center cluster, a console upper panel, a door trim ornament panel, etc. which are interior parts of an automobile. The present invention relates to a plastic composite material and a method for producing the same, including a veneer veneer plastic composite material having a transparent resin surface covering layer with a visible grain of a natural precious wood used for a luxury vehicle, among others.
自動車内装用の天然木化粧単板に透明樹脂表面被覆層
を有する高級装飾複合材は第２図に示す如く、ぶな、し
な、かば、ワラン等の合板を基材４とし、これに木目の
美しいバーズアイメープル、ウォルナット、くす等の天
然銘木を厚さ0.2−1.5mm程度にスライスした化粧単板２
を被せ、この積層物をフェノール樹脂、ユリア樹脂系の
接着剤または樹脂含浸接着フィルム５の使用のもとに熱
プレスして接着一体化した後、内外周のトリミングカッ
トを行ない、次いで透明樹脂塗膜６のスプレーガン７に
よる塗装仕上げ工程を行なうことによって作られてい
る。As shown in FIG. 2, a high-grade decorative composite material having a transparent resin surface coating layer on a natural wood decorative veneer for an automobile interior is made of a plywood such as bunna, shinana, birch, or warran as a base material 4 and Veneer veneer 2 sliced from natural precious wood such as beautiful bird's-eye maple, walnut, and nut to a thickness of 0.2-1.5 mm
The laminate is bonded by heat pressing under the use of a phenolic resin, urea resin-based adhesive or a resin-impregnated adhesive film 5, and the inner and outer peripheries are trimmed and cut. The film 6 is formed by performing a paint finishing process using a spray gun 7.
最近の一般的経済レベルの向上から、天然素材が見直
され、自動車市場でも天然木化粧単板に透明樹脂塗装を
施して、高級ピアノの如く鏡のように高光沢で、平滑且
つ、透明感を有するものが高級車の内装部品を中心に実
用化されつつある。Due to the recent improvement in the general economic level, natural materials have been reviewed. In the automotive market, natural wood veneer veneers have been coated with transparent resin to provide high gloss, smoothness, and transparency like mirrors like high-end pianos. It is being put to practical use mainly for interior parts of luxury cars.
しかしその透明樹脂塗装は塗装前の準備として化粧単
板の平滑化と汚れ除去のためのサンデイング、目ヤセや
ヤニ防止と外観色調の均一化のためのポリエステルまた
はウレタン系着色塗料のエアースプレーによる複数回の
下塗り作業、再サンデイング等を行なった上で仕上げ工
程として、肉もち感、深み感、透明感の付与、目ヤセ防
止のためのポリエステルやウレタン系の透明塗料による
中塗り及び上塗り、そして最後にサンデイング及びコン
パウンドワックスによる研磨仕上げが必要である。However, the transparent resin coating is prepared as a preparation before painting by sanding to smooth the veneer veneer and removing stains, and air spraying of polyester or urethane-based coloring paint to prevent eye fraying and tarnish and uniform appearance color. After undercoating work, re-sanding, etc., as a finishing process, the middle coat and top coat with polyester or urethane-based transparent paint for imparting meaty feeling, deep feeling, transparency, Requires sanding and polishing with compound wax.
またこれらの塗装は一般にエアースプレー塗装で施さ
れるが、塗料の塗着効率が低いため、その損失が多く、
平滑で均一な塗装膜厚に仕上げるのが難かしく、塗装面
に沸き、タレ、色むら、白化、オレンジビール等の表面
欠陥を生じ易い。このため熟練塗装技能者により、注意
深い配慮で且つ、充分時間をかけて、厳重な作業管理を
行なって仕上げていた。In addition, these coatings are generally applied by air spray coating, but the coating efficiency is low, so the loss is large,
It is difficult to finish to a smooth and uniform coating film thickness, and the coating surface tends to boil, causing surface defects such as sagging, uneven color, whitening, and orange beer. For this reason, a skilled painting technician takes care of the work carefully, takes a long time, and performs strict work management.
上述のように、化粧単板プラスチック複合材の製造に
おいて、従来の技法による場合は特に透明樹脂塗膜６の
スプレーガン７による塗装工程において高度の熟練技術
及び多数の工程と塗装設備、多くの時間とを要するた
め、生産能率が低く、製造コストへの影響が大きいので
その改善が強く望まれていた。As described above, in the production of decorative veneer plastic composites, in the case of the conventional technique, especially in the coating process of the transparent resin coating film 6 with the spray gun 7, a high level of skill and a large number of processes and coating equipment, many hours Therefore, the production efficiency is low and the production cost is greatly affected.
また、化粧単板には天然銘木を用いるため、そのスラ
イス時に発生する裏割れや木質繊維導管等の微細空隙
部、凹凸部には空気や水分（接着剤に含まれる）が集り
易く、塗膜乾燥時に塗膜内または塗膜と化粧単板界面に
発生する白濁斑や沸き等の表面欠陥の原因ともなり、更
に色むら、オレンジビール、タレ、研ぎ足し、ヤセ等の
塗装時の不具合の解消や、スプレー塗装時の塗料の損
失、及び塗料のスプレーダストや有機溶剤の揮散による
設備や環境等の汚染の防止もまた、塗装仕上げの管理に
おける課題となっている。In addition, since natural veneer is used for decorative veneer, air and moisture (included in the adhesive) are likely to collect in the fine voids and irregularities such as back cracks and wood fiber conduits that occur during slicing. It causes surface defects such as white spots and boiling that occur in the coating film or at the interface between the coating film and the veneer veneer during drying, and also eliminates problems during painting such as uneven color, orange beer, sauce, sharpening, and waste. Also, prevention of paint loss at the time of spray coating and prevention of pollution of equipment and environment due to evaporation of spray dust and organic solvent of the paint have been issues in the management of paint finish.
本発明は上記の諸課題を解決するためになされたもの
で、高い耐久性と強度とを備えた表面を有し、且つ高強
度、高品質の化粧単板プラスチック複合材、及びこれを
好ましい作業条件で製造するための、複雑な塗装工程を
必要としない製造方法を提供することを目的とするもの
である。The present invention has been made to solve the above-mentioned problems, and has a surface having high durability and strength, and has high strength and high quality. It is an object of the present invention to provide a manufacturing method which does not require a complicated coating process for manufacturing under conditions.
本発明者らは上述の諸課題を解決するために従来の塗
装工程に代えて透明樹脂表面被覆層を別に形成した樹脂
シートの熱プレス硬化によって形成することに着眼して
種々研究を行ない、基材と、化粧単板と、及び透明樹脂
表面被覆層としていずれも熱硬化性樹脂を含浸させたも
のを重ね合わせて、内面の鏡面化されたプレス金型の中
で熱プレスした場合に、美麗な光沢表面を有し、しかも
高強度で耐久性の高い透明樹脂被覆層を備えた３次元曲
面形状の化粧単板プラスチック複合材が複雑な塗装仕上
げ工程を必要とすることがなく、少ない作業工程で経済
的に製造できることを見出し、本出願人が同時出願する
特許出願において提案しているが、本発明者らはまた、
上記の化粧単板としては特に熱硬化性樹脂で含浸されて
いない天然銘木薄板を用いても従来品に匹敵する外観品
質、強度と耐久性とを備えた化粧単板プラスチック複合
材が得られることを見出し、本発明に到達した。In order to solve the above-mentioned problems, the present inventors have conducted various studies with an emphasis on forming a transparent resin surface coating layer by hot press curing of a separately formed resin sheet instead of the conventional coating process. When a material, a veneer veneer, and a transparent resin surface coating layer, all of which are impregnated with a thermosetting resin, are overlaid and hot-pressed in a press die having a mirror-finished inner surface, 3D curved decorative veneer plastic composite with transparent resin coating layer with high gloss and high strength and high durability without complicated painting finishing process Have been found in a patent application filed concurrently by the present applicant.
Even if a natural precious wood thin plate not impregnated with a thermosetting resin is used as the veneer veneer, a veneer veneer plastic composite material having appearance quality, strength and durability comparable to conventional products can be obtained. And arrived at the present invention.
本発明の化粧単板プラスチック複合材は、熱硬化性樹
脂と低収縮剤とを含む樹脂液で無機又は有機の繊維より
なる強化材を含浸して予備硬化させた繊維強化プラスチ
ックよりなるコンパウンドのシート状基材、樹脂含浸さ
れていない化粧単板、及び上記シート状基材の熱硬化性
樹脂と互いに架橋反応し得る熱硬化性樹脂で含浸された
繊維シート材から熱プレスにより一体に硬化形成されて
おり、その際上記樹脂含浸繊維シート材の熱硬化層を透
明樹脂表面被覆層として備えていることを特徴とする。The decorative veneer plastic composite material of the present invention is a sheet of a compound made of a fiber-reinforced plastic preliminarily cured by impregnating a reinforcing material made of inorganic or organic fibers with a resin solution containing a thermosetting resin and a low-shrinking agent. -Shaped base material, decorative veneer not impregnated with resin, and a fiber sheet material impregnated with a thermosetting resin capable of cross-linking with the thermosetting resin of the sheet-shaped base material, are integrally formed by hot pressing. In this case, a thermosetting layer of the resin-impregnated fiber sheet material is provided as a transparent resin surface coating layer.
基材としては上記熱硬化性樹脂のプレポリマー又はモ
ノマー、架橋剤、並びに他の通常的な充填剤、増粘剤、
離型剤、着色剤、触媒、重合安定剤等と低収縮剤として
熱可塑性樹脂を添加、混合してなる混合液を無機または
有機の繊維よりなる補強材に含浸させ、経時的にタッグ
フリー状態まで熟成したシート状コンパウンド（以下、
低収縮SMCと記す）を使用するのが好ましい。As the substrate, a prepolymer or monomer of the thermosetting resin, a crosslinking agent, and other usual fillers, thickeners,
A mixture of a release agent, a colorant, a catalyst, a polymerization stabilizer, and a thermoplastic resin as a low-shrinkage agent is mixed and impregnated with a reinforcing material made of inorganic or organic fibers, and the tag-free state with time. Aged compound (hereinafter referred to as
It is preferred to use low-shrink SMC).
本願明細書において熱硬化性樹脂で含浸したと言う表
現は上記のような混合液で含浸したことを意味する。In the present specification, the expression "impregnated with a thermosetting resin" means impregnated with the above-mentioned mixed solution.
本発明による化粧単板プラスチック複合材の製造法に
よれば、熱硬化性樹脂と低収縮剤とを含む樹脂液で無機
又は有機の繊維よりなる強化材を含浸して予備硬化させ
た繊維強化プラスチックよりなるコンパウンドのシート
状基材、樹脂含浸されていない化粧単板、及び上記基材
の熱硬化性樹脂と互いに架橋して熱硬化し得る熱硬化性
樹脂で含浸された繊維シート材を順に重ねて鏡面研磨内
面を有するプレス金型の中にセットし、型締め加圧直前
に金型内部を減圧脱気してワンショットで熱プレスす
る。According to the method for producing a decorative veneer plastic composite material according to the present invention, a fiber-reinforced plastic preliminarily cured by impregnating a reinforcing material composed of inorganic or organic fibers with a resin liquid containing a thermosetting resin and a low-shrinking agent A sheet-like base material of a compound, a decorative veneer not impregnated with a resin, and a fiber sheet material impregnated with a thermosetting resin capable of thermosetting by being cross-linked with the thermosetting resin of the base material in order. The mold is set in a press mold having a mirror-polished inner surface, and the inside of the mold is degassed under reduced pressure and hot-pressed with one shot just before the mold clamping pressure.
上記製造方法の別の態様において、化粧単板の裏面に
繊維質裏打ち補強材を接着剤により接着して用いる。In another embodiment of the above manufacturing method, a fibrous backing reinforcing material is bonded to the back surface of the decorative veneer with an adhesive and used.
本発明に従う化粧単板プラスチック複合材は、強化繊
維材に熱硬化性樹脂を含浸したシート状基材、樹脂含浸
されていない化粧単板、及び上記シート状基材の熱硬化
性樹脂と互いに架橋反応し得る熱硬化性樹脂で含浸され
た繊維シート材から熱プレスにより一体に硬化形成され
ていることによって、全体を通じて架橋反応により強固
に結合しており、従来品にない高い強度を有する。また
上記樹脂含浸繊維シート材の熱硬化層が透明樹脂表面被
覆層として用いられていることにより化粧単板が強く保
護されて高い強度と共に高い耐久性を示す。The veneer veneer plastic composite material according to the present invention is a sheet-like base material in which a thermosetting resin is impregnated into a reinforcing fiber material, a veneer veneer not impregnated with a resin, and a thermosetting resin of the sheet-like base material cross-linked with each other. Since the fiber sheet material impregnated with a thermosetting resin capable of reacting is integrally formed and cured by hot pressing, it is firmly bonded by a cross-linking reaction throughout and has a high strength not found in conventional products. In addition, since the thermosetting layer of the resin-impregnated fiber sheet material is used as a transparent resin surface coating layer, the decorative veneer is strongly protected and exhibits high strength and high durability.
基材と透明樹脂表面被覆層用シート材との熱硬化性樹
脂としてはジアリルフタレート樹脂、不飽和ポリエステ
ル樹脂、アルキッド樹脂等の中から選ばれる互いに架橋
反応可能な少なくとも１種以上が用いられる。As the thermosetting resin for the base material and the sheet material for the transparent resin surface coating layer, at least one or more selected from diallyl phthalate resin, unsaturated polyester resin, alkyd resin and the like, which can be cross-linked with each other, is used.
基材として、上記のような熱硬化性樹脂のプレポリマ
ーに加えて、低収縮剤としての熱可塑性樹脂（ポリエチ
レン、ポリエステル、ポリ酢酸ビニル、ポリスチレン、
スチレンブタジエンブロックコポリマー、ポリメタアク
リル酸メチル等）、並びに他の通常的な、例えば充填
材、増粘剤、離型剤、着色剤、触媒、重合安定剤等から
なるコンパウンドをガラス繊維等のシート状強化材に含
浸させ、経時的にタッグフリーの状態まで熟成して得ら
れるシート状の低収縮SMCを用いることにより寸法安定
性の良い高強度の製品が得られる。As a base material, in addition to the above-described thermosetting resin prepolymer, a thermoplastic resin (polyethylene, polyester, polyvinyl acetate, polystyrene,
Styrene-butadiene block copolymer, polymethyl methacrylate, etc.), and other common compounds such as fillers, thickeners, release agents, coloring agents, catalysts, polymerization stabilizers, etc. By using a sheet-like low-shrinkage SMC obtained by impregnating a shape reinforcing material and aging to a tag-free state over time, a high-strength product with good dimensional stability can be obtained.
化粧単板としてはチーク、ローズウッド、ウオールナ
ット、くす、バーズアイメープル等の天然銘木の板目ま
たは柾目及び杢の薄板が特に樹脂含浸することなくその
まま用いられるが、これは染色または塗装等によって調
色処理されていてもよい。化粧単板に和紙や薄い合成繊
維の不織布等を補強裏打ち材として、耐熱性のよいエラ
ストマー系接着剤で張り付けて用いると熱プレス成形す
るときに化粧単板のワレが防止でき、良好な製品を得る
ことができる。As a decorative veneer, a natural precious wood grain such as teak, rosewood, walnut, box, bird's eye maple, or a straight grain or heather thin sheet is used without any particular resin impregnation. Color processing may be performed. Using a decorative veneer made of Japanese paper or a thin synthetic fiber non-woven fabric as a reinforcing backing material and sticking it with a heat-resistant elastomeric adhesive can prevent cracking of the veneer veneer during hot press molding, resulting in a good product. Obtainable.
透明樹脂表面被覆層用のシート材に用いる繊維シート
としては好ましくは目付量20−40g/m2のパルプ紙、種々
の合成繊維の布、中でも不織布が用いられる。As the fiber sheet used for the sheet material for the transparent resin surface coating layer, pulp paper having a basis weight of 20 to 40 g / m 2 , various synthetic fiber cloths, and in particular, nonwoven fabrics are used.
透明樹脂表面被覆層用のシート材（以下樹脂シートと
呼ぶ）としては、前述した熱硬化性樹脂のプレポリマー
を単独で、または混合して、溶剤、触媒、内部離型剤、
重合安定剤等と共に、また必要に応じて他の樹脂或はそ
のモノマーや無機充填材の添加のもとに混合し、この混
合液を上記のような紙又は合成樹脂繊維不織布に含浸、
乾燥させたものを用いる。このようなシート材の１ない
し数枚を上記のような化粧単板の上に載せ、これを基材
と積層して、内面の仕上げ研磨されたプレス金型の中に
セットし、熱プレスすることにより各層内及び層間で熱
硬化性樹脂プレポリマーの架橋反応、即ち熱硬化反応が
活発に行なわれ、得られた製品は高い層間接着力により
結合されていてしかも美しい表面光沢を有する。As the sheet material for the transparent resin surface coating layer (hereinafter, referred to as a resin sheet), a prepolymer of the above-described thermosetting resin is used alone or as a mixture to form a solvent, a catalyst, an internal release agent,
It is mixed with a polymerization stabilizer, etc., and if necessary, with the addition of another resin or its monomer or an inorganic filler, and impregnated this mixed solution into the above-mentioned paper or synthetic resin fiber nonwoven fabric,
Use the dried one. One or several of such sheet materials are placed on the decorative veneer as described above, laminated with a base material, set in a press mold having a finish-polished inner surface, and hot-pressed. As a result, the crosslinking reaction of the thermosetting resin prepolymer in each layer and between the layers, that is, the thermosetting reaction, is actively performed, and the obtained product is bonded by high interlayer adhesion and has a beautiful surface gloss.
本発明の化粧単板プラスチック複合材を製造する方法
において、熱硬化性樹脂と低収縮剤とを含む樹脂液で無
機又は有機の繊維よりなる強化材を含浸して予備硬化さ
せた繊維強化プラスチックよりなるコンパウンドのシー
ト状基材、樹脂含浸されていない化粧単板、及び上記基
材の熱硬化性樹脂と互いに架橋して熱硬化し得る熱硬化
性樹脂で含浸された繊維シート材（樹脂シート）を順に
重ねて鏡面研磨内面を有するプレス金型の中で熱プレス
することにより、上記被覆層用樹脂シートは得られた熱
プレス成形体の表面で特に複雑な塗装仕上げ工程を要せ
ず美麗な表面光沢と内側層の化粧材の木目を明瞭に示す
透明性とを有する透明樹脂表面被覆層を与え、その際こ
の表面被覆層の樹脂と基材層の樹脂とが化粧単板中に浸
透してここで互いに架橋反応を起こし、間挿された化粧
材薄板と一体に強固な接合を形成するので、工程が大幅
に合理化され且つ、従来品にはない高機能性、即ち表面
層強度の大幅な上昇を達成すると共に種々の成形物をワ
ンショットで作り出すことが達成される。In the method for producing a decorative veneer plastic composite material of the present invention, a fiber-reinforced plastic pre-cured by impregnating a reinforcing material composed of inorganic or organic fibers with a resin liquid containing a thermosetting resin and a low-shrinking agent. Base material, veneer veneer not impregnated with a resin, and a fiber sheet material (resin sheet) impregnated with a thermosetting resin capable of being thermoset by cross-linking with the thermosetting resin of the base material Are successively stacked and hot-pressed in a press mold having a mirror-polished inner surface, whereby the resin sheet for the coating layer is beautiful without requiring a particularly complicated coating finishing step on the surface of the obtained hot-pressed molded body. A transparent resin surface coating layer having a surface gloss and transparency that clearly shows the grain of the decorative material of the inner layer is provided. At this time, the resin of the surface coating layer and the resin of the base material layer penetrate into the decorative veneer. Here and each other A bridging reaction occurs, forming a strong joint integrally with the inserted decorative thin sheet, greatly streamlining the process and achieving high functionality not found in conventional products, that is, a significant increase in surface layer strength In addition, various moldings can be produced in one shot.
熱プレスに際し、型締めに先立って金型内部を減圧脱
気することにより、塗膜内または塗膜と化粧単板の界面
に微細気泡より発生する白濁斑や塗面のクラック、ハガ
レ、反り、変形等の発生が防止され、品質管理面、生産
性の向上面に大きく寄与する。During hot pressing, the interior of the mold is degassed under reduced pressure prior to mold clamping, so that white spots and cracks, peeling, warping, and the like occur in the coating film or at the interface between the coating film and the decorative veneer due to fine bubbles. The occurrence of deformation and the like is prevented, which greatly contributes to quality control and productivity improvement.
上記化粧単板プラスチック複合材の熱プレスに際し
て、化粧単板の裏面に予め和紙や薄い合成繊維の不織布
等を補強裏打ち材として、耐熱性の良いエラストマー系
接着剤で張り付けて用いると成形時に化粧単板のワレが
防止でき、不良品発生率が低下する。When hot-pressing the decorative veneer plastic composite material, if the back of the veneer veneer is made of a Japanese paper or a thin synthetic fiber non-woven fabric as a reinforcing backing material and pasted with an elastomeric adhesive having good heat resistance, the veneer veneer can be molded at the time of molding. Cracking of the plate can be prevented, and the incidence of defective products decreases.
本発明による化粧単板プラスチック複合材の製造方法
において、上述のような樹脂シート及び基材の低収縮SM
Cは樹脂の含まれない化粧単板を挟んで第１図に示すよ
うな積層状態で、内面の仕上げ研磨されたプレス金型の
中で、金型温度140−145℃、圧力100kgf/cm2程度で熱プ
レスされる。その際化粧単板の層内部へ熱と圧力との作
用のもとに樹脂シート及び低収縮SMCから樹脂プレポリ
マーが浸透して、その微細空隙部、凹凸部を充填し、同
時にその上下両界面に可撓性を有する樹脂層が形成され
て接着剤を使用せずとも、耐湿性や耐熱性の劣化による
ハガレ、フクレ、クラック等の表面欠陥の発生が防止さ
れる。また各層内及び各層間では樹脂の架橋反応、即
ち、熱硬化反応が活発に行なわれ、高い層間接着力を達
成すると共に美しい表面光沢が得られる。In the method for producing a decorative veneer plastic composite material according to the present invention, the resin sheet and the base material described above have a low shrinkage SM.
C is a laminated state as shown in Fig. 1 sandwiching a veneer veneer without resin, and in a press mold having a finish-polished inner surface, a mold temperature of 140-145 ° C and a pressure of 100 kgf / cm 2. Hot pressed to the extent. At that time, the resin prepolymer permeates from the resin sheet and low shrinkage SMC under the action of heat and pressure into the interior of the decorative veneer layer, filling the fine voids and irregularities, and at the same time, the upper and lower interfaces Even if a flexible resin layer is formed on the substrate, the occurrence of surface defects such as peeling, blisters and cracks due to deterioration of moisture resistance and heat resistance can be prevented without using an adhesive. In addition, a bridging reaction of the resin, that is, a thermosetting reaction is actively performed in each layer and between the layers, so that a high interlayer adhesive force is achieved and a beautiful surface gloss is obtained.
得られる化粧単板プラスチック複合材は天然銘木の木
目の美しさの生かされた高光沢で平滑な樹脂シート層
（透明樹脂表面被覆層）を有して高剛性、高強度、薄肉
化、高耐熱性、高耐水性等の優れた性質を示し、また高
い寸法安定性と共に部品組付けの際、ねじ用金具やリテ
ーナ用ボス等を埋込み、これにリテーナ打ち込み金具等
を嵌込むことが可能となるので、デザイン設計の自由度
が向上し、部品取り付けコストも大幅に低減できる。The resulting veneer veneer plastic composite has a high gloss, smooth resin sheet layer (transparent resin surface coating layer) that makes use of the beauty of the wood of natural precious wood, and has high rigidity, high strength, thinness, and high heat resistance. In addition to high dimensional stability, it is possible to embed screw fittings and retainer bosses, and to insert retainer driving fittings etc. into parts when assembling parts with high dimensional stability. Therefore, the degree of freedom in design is improved, and the cost for mounting parts can be significantly reduced.
本発明による化粧単板プラスチック複合材の良好な表
面光沢性、平滑性、成形性、高剛性、高耐水性等はいず
れも上記の本発明に従う透明樹脂表面被覆層用シート材
の樹脂プレポリマーと基材の低収縮SMCの中で用いられ
ている熱硬化性樹脂プレポリマーとの間の架橋反応、及
び基材の高強度、高剛性、高耐水性によるものである。The good surface gloss, smoothness, moldability, high rigidity, high water resistance, etc. of the decorative veneer plastic composite material according to the present invention are all the same as those of the resin prepolymer of the sheet material for the transparent resin surface coating layer according to the present invention described above. This is due to the crosslinking reaction with the thermosetting resin prepolymer used in the low-shrinkage SMC of the substrate and the high strength, high rigidity and high water resistance of the substrate.
以下本発明を実施例及び比較例に基づき図面の参照の
もとに詳細に説明する。Hereinafter, the present invention will be described in detail based on examples and comparative examples with reference to the drawings.
例 １ 平板の金型の投影面積に対して表面積が基材について
は90％、化粧単板及び透明樹脂表面被覆層用の樹脂含浸
シート材については95％になるようにそれぞれ予め裁断
した。Example 1 The base material was cut in advance so that the surface area was 90% with respect to the projected area of the flat die, and the resin-impregnated sheet material for the decorative veneer and the transparent resin surface coating layer was 95%.
基材11としては、ガラスロービングのチヨップドスト
ランドマット（長さ1/4−２″）を熱可塑性ポリマーよ
りなされる低収縮剤が熱硬化性樹脂に対し５重量部配合
されている不飽和ポリエステル系樹脂混合物で含浸した
低収縮SMC（三井東圧化学社製エスターマットAU−120）
を用いた。As the base material 11, a glass-roving chopped strand mat (length: 1 / 4-2 ″) is mixed with a thermosetting resin in an amount of 5 parts by weight with a low-shrinkage agent made of a thermoplastic polymer. Low shrinkage SMC impregnated with polyester resin mixture (Estermat AU-120 manufactured by Mitsui Toatsu Chemicals, Inc.)
Was used.
化粧単板12としてはチーク柾目の厚さ0.3mmの薄板を
用い、その裏側に和紙を補強裏打ち材としてスチレンブ
タジエンラバー系接着剤で接着強化した。As the decorative veneer 12, a thin plate having a thickness of 0.3 mm and a vertical grain of teak was used, and the back side of the veneer was reinforced with a styrene-butadiene rubber-based adhesive as a backing material of Japanese paper.
樹脂含浸シート材13は目付量25g/m2のパルプ紙にジア
リルフタレートプレポリマー（大阪曹達社製ダップＡ）
40重量部、不飽和ポリエステル樹脂（富士高分子社製SP
−１）60重量部、及び触媒としてのtert−ブチルパーオ
キサイド５重量部、並びに溶剤、有効量の重合安定剤、
無機充填材、離型材等を含む混合液を含浸させ、乾燥し
て作ったもので、110g/m2の樹脂含有量を有する。この
シート材４枚を重ねて用いた。Resin-impregnated sheet material 13 is a pulp paper with a basis weight of 25 g / m 2 and diallyl phthalate prepolymer (Dap A manufactured by Osaka Soda Co., Ltd.).
40 parts by weight, unsaturated polyester resin (Fuji Polymer SP
-1) 60 parts by weight, 5 parts by weight of tert-butyl peroxide as a catalyst, a solvent, an effective amount of a polymerization stabilizer,
It is made by impregnating with a mixed solution containing an inorganic filler, a release material and the like, and then dried, and has a resin content of 110 g / m 2 . The four sheet materials were used in an overlapping manner.
第１図に示すように、基材11、化粧単板12、及び樹脂
含浸シート材13はこの順に重ね合わせた後、平板用鏡面
仕上げ金型（300X300X3mm）内に積層セットし、金型温
度を上型145℃、下型140℃に設定し、型締め速度2mm/se
c、圧力100kgf/cm2で10分間熱プレスした。室温まで強
制的に冷し、脱型後表面を＃800耐水ペーパーで軽く空
研ぎした後、仕上げ用液体コンパウンド（石原薬品社製
FMC−11）にて仕上げた。As shown in FIG. 1, the base material 11, the decorative veneer 12, and the resin-impregnated sheet material 13 are superposed in this order, and then stacked and set in a flat-plate mirror-finished mold (300X300X3mm). Set upper die 145 ° C, lower die 140 ° C, mold closing speed 2mm / se
c, hot-pressed at a pressure of 100 kgf / cm 2 for 10 minutes. After forcibly cooling to room temperature, removing the mold, light-sharpening the surface with # 800 water-resistant paper, and then finishing liquid compound (Ishihara Chemical Co., Ltd.)
Finished by FMC-11).
成品は化粧単板のワレ、ハガレ、フクレ、泡、白濁、
反り等の問題もなく、天然銘木であるチークの柾目の有
する美しさと豪華さを保持しながら別表に示すように、
従来品と較べ同等以上の光沢感、深み感、透明感、平滑
感等の外観品質に優れたものが得られた。The product is a veneer veneer, peeling, blister, foam, cloudiness,
There is no problem such as warpage, as shown in the attached table while maintaining the beauty and luxuriousness of the straight grain of natural teak,
A product excellent in appearance quality such as glossiness, deepness, transparency, smoothness and the like, which is equal to or more than that of the conventional product, was obtained.
例 ２ 例１と同様に裏面に和紙をSBR系接着剤で接着して強
化した板厚0.6mmの杢目のバーズアイメープルの化粧単
板12と、例１に用いたと同じ低収縮剤添加不飽和ポリエ
ステル系SMCで作った基材11と、及び樹脂含浸シート材1
3とを用い、これらを例１と同様に裁断した。樹脂含浸
シート材13はジアリルフタレートプレポリマー（大阪曹
達社成ダップＡ）60重量部、不飽和ポリエステル樹脂
（三井東圧化学社製エスターＤ−400）40重量部、触媒
としてのベンゾイルパーオキサイド３重量部、及び有効
量の内部離型材並びに重合安定剤を有機溶剤中で混合し
た混合液を目付け量23g/m2のポリビニルアルコールの不
織布（クラレ社製クラトン）に含浸させ、乾燥した樹脂
量110g/m2のもので、これを４枚重ね合わせて使用し
た。Example 2 In the same manner as in Example 1, a decorative veneer 12 of a bird's-eye maple with a thickness of 0.6 mm, which was reinforced by bonding Japanese paper to the back surface with an SBR-based adhesive, and the same unsaturated additive with a low shrinkage agent as used in Example 1 Base material 11 made of polyester-based SMC, and resin-impregnated sheet material 1
And cut them in the same manner as in Example 1. The resin-impregnated sheet material 13 is composed of 60 parts by weight of diallyl phthalate prepolymer (Dap A manufactured by Osaka Soda Co., Ltd.), 40 parts by weight of an unsaturated polyester resin (Ester D-400 manufactured by Mitsui Toatsu Chemicals, Inc.), and 3 parts by weight of benzoyl peroxide as a catalyst. Part, and a mixed liquid obtained by mixing an effective amount of an internal release material and a polymerization stabilizer in an organic solvent is impregnated into a polyvinyl alcohol nonwoven fabric having a basis weight of 23 g / m 2 (Kuraton manufactured by Kuraray Co., Ltd.). intended m 2, and used by superimposing four this.
基材11、化粧単板12、及び樹脂含浸シート材13はこの
順に予め重ね合わせて平板用の鏡面仕上げ金型内にセッ
トし、型締め加圧直前から加圧時まで型内を160mmHgに
減圧脱気し、金型温度を上型145℃、下型140℃に設定し
て型締め速度2mm/sec、圧力100kgf/cm2で10分間熱プレ
スした。脱型後に軽い表面研磨を例１と同様に行った。
得られた成品は例１と同様、表面欠陥がなく、別表に示
すように従来品と較べ同等以上の光沢感、深み感、透明
感、平滑感等の外観品質に優れたものが得られた。The base material 11, the veneer veneer 12, and the resin-impregnated sheet material 13 are superimposed in this order in advance and set in a mirror-finished die for a flat plate. After degassing, the mold temperature was set to 145 ° C. for the upper mold and 140 ° C. for the lower mold, and hot-pressed at a mold clamping speed of 2 mm / sec and a pressure of 100 kgf / cm 2 for 10 minutes. After demolding, light surface polishing was performed in the same manner as in Example 1.
As in Example 1, the obtained product had no surface defects and was excellent in appearance quality such as glossiness, depth, transparency, smoothness and the like as compared with the conventional product as shown in the separate table. .
例 ３ 基材、化粧単板、及び樹脂含浸シート材は例１と同様
に作ったものを用いたが、但し、化粧単板は0.3mmの板
目のウオールナットとし、樹脂含浸シート材は目付け量
38g/m2のアクリル繊維の不織布（日本バイリーン社製OL
−7351）を樹脂量230g/m2となるように含浸したものを
３枚重ねて使用した。Example 3 The base material, decorative veneer, and resin-impregnated sheet material used were the same as those in Example 1, except that the decorative veneer was a 0.3 mm-thick wall nut and the resin-impregnated sheet material was a basis weight. amount
38g / m 2 acrylic fiber non-woven fabric (OL manufactured by Japan Vilene Co., Ltd.
-7351) was used by impregnating three resins so as to have a resin amount of 230 g / m 2 .
基材11、化粧単板12、及び樹脂含浸シート材13はこの
順に予め重ね合わせて平板用の鏡面仕上げ内面を有する
金型内にセットし、減圧脱気条件以外は例２と同じ条件
で一体に熱プレスし、脱型後の表面仕上げも例１と同様
に施した。減圧脱気条件は真空度を60mmHgとした。The base material 11, the veneer veneer 12, and the resin-impregnated sheet material 13 are stacked in this order in advance and set in a mold having a mirror-finished inner surface for a flat plate. Then, surface finishing after demolding was performed in the same manner as in Example 1. The vacuum deaeration conditions were a vacuum of 60 mmHg.
成品は例１のものと同様、表面欠陥なく、天然銘木で
あるウオールナットの板目を有する美しさと豪華さとを
保持し、しかも下表に示すように従来品と較べ同等以上
の光沢感、深み感、透明感、平滑感等の外観品質に優れ
たものが得られた。As in the case of Example 1, the product retains the beauty and luxuriousness of the natural nut wood walnut with no surface defects and, as shown in the table below, has a glossiness equal to or higher than that of the conventional product, Those having excellent appearance quality such as depth, transparency and smoothness were obtained.
試験方法 （１）鮮明度光沢度は日本色彩研究所製 PGD II型試験
機を用いて測定した。 Test Method (1) The sharpness and glossiness were measured using a PGD II tester manufactured by Japan Color Research Laboratory.
（２）鏡面光沢度はスガ試験機社製のＳ＆Ｍカラーコン
ピューターMoDel−４により測定した。(2) Specular gloss was measured by S & M color computer MoDel-4 manufactured by Suga Test Instruments Co., Ltd.
（３）平滑性は目視による基準板との比較評価である。
但し、基準板は目視による５段階の官能評価のための基
準として用いるもので下記１から５の段階よりなる。(3) Smoothness is a comparison evaluation with a reference plate visually.
However, the reference plate is used as a reference for a five-level sensory evaluation by visual observation and includes the following 1 to 5 steps.
５はオレンジピール無く、全くの平面。（蛍光灯が真
直ぐに写って見える。） ４はオレンジビールが極く僅かに見える。5 has no orange peel and is completely flat. (Fluorescent lamps appear straight.) 4 shows orange beer very slightly.
３はオレンジビールが若干目立つ。 3 is a little noticeable orange beer.
２はオレンジビームが目立つ。 2 stands out for the orange beam.
１はオレンジピールが非常に目立つ。（蛍光灯が著し
くギザギザに写って見える。） 比較品は全て第２図に示す前述した従来の方法で製作
したもので、この内比較品Ａは化粧単板にチーク柾目、
比較品Ｂは化粧単板にバーズアイメープルを用いたもの
である。For 1, the orange peel is very noticeable. (Fluorescent lamps appear to be very jagged.) All the comparative products were manufactured by the above-mentioned conventional method shown in FIG. 2, and comparative product A was a decorative veneer with a teak straight grain,
Comparative product B uses bird's eye maple as a decorative veneer.
本発明は請求項１に従う化粧単板プラスチック複合材
はその製造に際して、請求項３に記載するように、透明
樹脂表面被覆層として、熱硬化性樹脂で含浸した繊維シ
ートを内面の鏡面仕上げされた金型内で熱プレスし、硬
化成形したものを用いるので、従来の製造法で必要な塗
装のための数多くの工程及びそのための設備、作業時
間、熟練技術が大幅に軽減されて作業能率の向上、製造
コストの大幅な低減に寄与するのみならず、樹脂含浸さ
れていない化粧単板の中にも両側から樹脂が浸透してこ
こで互いに架橋反応のもとに熱硬化するので、全体を通
じて強固に結合した高い強度のものが、高耐久性の高級
感のある仕上げ面と共に得られる。更に、強度や剛性を
補強するためのリブや部品取り付け用のねじ込み金具や
リテーナ打ち込み金具等をインサートするためのボスを
基材に埋め込んで成形することができるので、デザイン
や設計の自由度が大幅に向上するばかりでなく、部品取
り付けコストも大幅に低減できる。According to the present invention, the decorative veneer plastic composite material according to claim 1 has a mirror-finished inner surface made of a fiber sheet impregnated with a thermosetting resin as a transparent resin surface coating layer as described in claim 3 during its production. Using a product that has been hot-pressed in a mold and cured and molded, the number of processes required for painting in the conventional manufacturing method and the equipment, work time, and skill required for it are greatly reduced, improving work efficiency. In addition to contributing to a significant reduction in manufacturing costs, the resin penetrates into both sides of the veneer, which is not impregnated with resin, and is thermoset through a cross-linking reaction with each other. And a high-strength finish surface with high durability is obtained. Furthermore, bosses for inserting ribs to reinforce strength and rigidity, screw fittings for attaching parts, and retainer driving fittings, etc. can be embedded in the base material and molded, greatly increasing the degree of freedom in design and design. In addition to the above, the cost for mounting parts can be greatly reduced.
請求項２に従い基材としての低収縮剤を含む熱硬化性
樹脂で含浸されたシート状コンパウンドを用いたとき
は、この複合材に付与される高剛性、高強度、良成形
性、高い寸法安定性、耐熱耐水性等の高機能的特徴によ
って、その付加価値は一層高められる。When a sheet-like compound impregnated with a thermosetting resin containing a low-shrinkage agent is used as the base material according to claim 2, high rigidity, high strength, good moldability, and high dimensional stability imparted to the composite material are provided. The added value is further enhanced by high functional characteristics such as heat resistance, heat resistance and water resistance.
第１図は本発明のプラスチック複合材の材料構成とその
製造工程を示す断面図、第２図は対応する従来の材料構
成とその製造工程を示す断面図である。 ２、12……化粧単板、４、11……基材 ５……接着剤 ６、13……透明樹脂表面被覆層 ７……スプレーガンFIG. 1 is a cross-sectional view showing a material configuration of a plastic composite material of the present invention and a manufacturing process thereof, and FIG. 2 is a cross-sectional view showing a corresponding conventional material configuration and a manufacturing process thereof. 2, 12 ... veneer veneer, 4, 11 ... base material 5 ... adhesive 6, 13 ... transparent resin surface coating layer 7 ... spray gun
Claims (3)
透明樹脂表面被覆層とからなる化粧単板プラスチック複
合板において、熱硬化性樹脂と低収縮剤とを含む樹脂液
で無機又は有機の繊維よりなる強化材を含浸して予備硬
化させた繊維強化プラスチックよりなるコンパウンドの
シート状基材、樹脂含浸されていない化粧単板、及び上
記シート状基板の熱硬化性樹脂と互いに架橋反応し得る
熱硬化性樹脂で含浸された繊維シートから熱プレスによ
り一体に硬化形成されており、その際上記樹脂含浸繊維
シート材の熱硬化層を透明樹脂表面被覆層として備えて
いることを特徴とする、化粧単板プラスチック複合材。1. A decorative veneer plastic composite plate comprising a substrate, a veneer veneer placed thereon, and a transparent resin surface coating layer, wherein a resin liquid containing a thermosetting resin and a low shrinkage agent is used as an inorganic material. Alternatively, a sheet-shaped substrate made of a fiber-reinforced plastic pre-cured by impregnating with a reinforcing material made of organic fibers, a veneer veneer not impregnated with a resin, and a thermosetting resin of the sheet-shaped substrate crosslinked with each other. It is integrally formed by heat pressing from a fiber sheet impregnated with a thermosetting resin capable of reacting, and at this time, a thermosetting layer of the resin-impregnated fiber sheet material is provided as a transparent resin surface coating layer. A decorative veneer plastic composite.
材を製造するに当り、熱硬化性樹脂と低収縮剤とを含む
樹脂液で無機又は有機の繊維よりなる強化材を含浸して
予備硬化させた繊維強化プラスチックよりなるコンパウ
ンドのシート状基材、樹脂含浸されていない化粧単板、
及び上記基材の熱硬化性樹脂と互いに架橋して熱硬化し
得る熱硬化性樹脂で含浸された繊維シート材を順に重ね
て鏡面研磨内面を有するプレス金型の中にセットし、型
締め加圧直前に金型内部を減圧脱気してワンショットで
熱プレスすることを特徴とする、化粧単板プラスチック
複合材の製造方法。2. A method for producing a decorative veneer plastic composite material according to claim 1, wherein a reinforcing material comprising inorganic or organic fibers is impregnated with a resin solution containing a thermosetting resin and a low-shrinkage agent. Sheet-shaped substrate of compound made of cured fiber reinforced plastic, decorative veneer not impregnated with resin,
And a fiber sheet material impregnated with a thermosetting resin capable of being thermoset by cross-linking with the thermosetting resin of the base material is sequentially stacked, set in a press mold having a mirror-polished inner surface, and clamped. A method for producing a decorative veneer plastic composite material, characterized in that the inside of a mold is degassed under reduced pressure immediately before pressure and hot-pressed in one shot.
シートを接着して用いる、請求項２記載の化粧単板プラ
スチック接着複合材の製造方法。3. The method for producing a decorative veneer plastic adhesive composite according to claim 2, wherein a fibrous backing reinforcing sheet is previously bonded to the back surface of the veneer veneer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1075974A JP2630462B2 (en) | 1989-03-28 | 1989-03-28 | Veneered veneer plastic composite and method for producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1075974A JP2630462B2 (en) | 1989-03-28 | 1989-03-28 | Veneered veneer plastic composite and method for producing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH02252552A JPH02252552A (en) | 1990-10-11 |
| JP2630462B2 true JP2630462B2 (en) | 1997-07-16 |
Family
ID=13591726
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1075974A Expired - Lifetime JP2630462B2 (en) | 1989-03-28 | 1989-03-28 | Veneered veneer plastic composite and method for producing the same |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2630462B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7867622B2 (en) | 2005-08-03 | 2011-01-11 | Yamaha Fine Technologies Co., Ltd. | Coated wood composite and production method thereof |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4917773B2 (en) * | 2005-08-03 | 2012-04-18 | ヤマハファインテック株式会社 | Wood-covered composite and method for producing the same |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS57102341A (en) * | 1980-12-17 | 1982-06-25 | Mitsubishi Petrochemical Co | Manufacture of multilayer composite structure |
| JPS60157607A (en) * | 1984-01-26 | 1985-08-17 | Fanuc Ltd | Numerical control method |
-
1989
- 1989-03-28 JP JP1075974A patent/JP2630462B2/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7867622B2 (en) | 2005-08-03 | 2011-01-11 | Yamaha Fine Technologies Co., Ltd. | Coated wood composite and production method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH02252552A (en) | 1990-10-11 |
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