JPH0326544A - Decorative composite material and manufacture thereof - Google Patents
Decorative composite material and manufacture thereofInfo
- Publication number
- JPH0326544A JPH0326544A JP1163263A JP16326389A JPH0326544A JP H0326544 A JPH0326544 A JP H0326544A JP 1163263 A JP1163263 A JP 1163263A JP 16326389 A JP16326389 A JP 16326389A JP H0326544 A JPH0326544 A JP H0326544A
- Authority
- JP
- Japan
- Prior art keywords
- resin
- impregnated
- decorative veneer
- base material
- 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.)
- Granted
Links
- 239000002131 composite material Substances 0.000 title claims description 38
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 229920005989 resin Polymers 0.000 claims abstract description 119
- 239000011347 resin Substances 0.000 claims abstract description 119
- 239000000463 material Substances 0.000 claims abstract description 80
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 43
- 239000000835 fiber Substances 0.000 claims abstract description 26
- 239000002023 wood Substances 0.000 claims abstract description 15
- 238000004132 cross linking Methods 0.000 claims abstract description 12
- 239000010410 layer Substances 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 19
- 238000000576 coating method Methods 0.000 claims description 17
- 239000002345 surface coating layer Substances 0.000 claims description 16
- 239000011248 coating agent Substances 0.000 claims description 15
- 239000007788 liquid Substances 0.000 claims description 15
- 238000003825 pressing Methods 0.000 claims description 15
- 238000000465 moulding Methods 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- 150000001875 compounds Chemical class 0.000 claims description 5
- 239000011247 coating layer Substances 0.000 claims description 4
- 238000007731 hot pressing Methods 0.000 claims description 4
- 230000003014 reinforcing effect Effects 0.000 claims description 4
- 239000012779 reinforcing material Substances 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 3
- 229920002430 Fibre-reinforced plastic Polymers 0.000 claims description 2
- 239000011151 fibre-reinforced plastic Substances 0.000 claims description 2
- 238000002386 leaching Methods 0.000 claims description 2
- 230000003287 optical effect Effects 0.000 claims description 2
- 238000006243 chemical reaction Methods 0.000 abstract description 7
- 229920005749 polyurethane resin Polymers 0.000 abstract description 4
- 238000010030 laminating Methods 0.000 abstract 1
- 239000003973 paint Substances 0.000 description 9
- 239000004641 Diallyl-phthalate Substances 0.000 description 5
- 239000003677 Sheet moulding compound Substances 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 5
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 5
- 235000004522 Pentaglottis sempervirens Nutrition 0.000 description 4
- 239000004745 nonwoven fabric Substances 0.000 description 4
- 238000010422 painting Methods 0.000 description 4
- 239000011120 plywood Substances 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- 229920006337 unsaturated polyester resin Polymers 0.000 description 4
- 241000758789 Juglans Species 0.000 description 3
- 235000009496 Juglans regia Nutrition 0.000 description 3
- 240000002871 Tectona grandis Species 0.000 description 3
- 229920000180 alkyd Polymers 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000002845 discoloration Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 239000003381 stabilizer Substances 0.000 description 3
- 229920002994 synthetic fiber Polymers 0.000 description 3
- 239000012209 synthetic fiber Substances 0.000 description 3
- 235000020234 walnut Nutrition 0.000 description 3
- 235000018185 Betula X alpestris Nutrition 0.000 description 2
- 235000018212 Betula X uliginosa Nutrition 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 240000000731 Fagus sylvatica Species 0.000 description 2
- 235000010099 Fagus sylvatica Nutrition 0.000 description 2
- 244000086363 Pterocarpus indicus Species 0.000 description 2
- 235000009984 Pterocarpus indicus Nutrition 0.000 description 2
- 235000013405 beer Nutrition 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000007591 painting process Methods 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- CNHDIAIOKMXOLK-UHFFFAOYSA-N toluquinol Chemical compound CC1=CC(O)=CC=C1O CNHDIAIOKMXOLK-UHFFFAOYSA-N 0.000 description 2
- 229920006305 unsaturated polyester Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 230000002087 whitening effect Effects 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 239000004971 Cross linker Substances 0.000 description 1
- 239000005057 Hexamethylene diisocyanate Substances 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 238000007723 die pressing method Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000004043 dyeing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000005562 fading Methods 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 1
- NWVVVBRKAWDGAB-UHFFFAOYSA-N hydroquinone methyl ether Natural products COC1=CC=C(O)C=C1 NWVVVBRKAWDGAB-UHFFFAOYSA-N 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000007592 spray painting technique Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 238000009849 vacuum degassing Methods 0.000 description 1
- 239000002025 wood fiber Substances 0.000 description 1
Abstract
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
化粧板複合材及びその製造方法に関し、特に高級車両に
使用される天然銘本の木目の見える透明樹脂表面被覆層
を備えた化粧板複合材を包含する．
〔従来の技術〕
自動車内装用の天然木化粧単板に透明樹脂の表面被覆層
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、ラワン等の合板を基材４とし、これに木目の
美しいチーク、バーズアイメーブル、ウォルナット、く
ず等の天然銘木を厚さ０．２ − １．５ ｍｌ１程度
にスライスした化粧単板２を重ね、この積層物をフェノ
ール樹脂やエリア樹脂系の接着剤または樹脂含浸接看フ
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．
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６天然木化粧単板に透明樹脂塗装を施
して、塗装面を高級ピアノのような、鏡のように高光沢
で、平滑且つ、深み感を有するものが高級車の内部部品
を中心に実用化されつつある．
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
やヤニ防上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による複数回の下塗り塗装及び
乾燥、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、透明感の付与と目ヤセ防よの
ためにポリエステル系或いはウレタン系の透明塗料によ
り中塗り及び上塗り塗装を行なった後乾燥し、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．またこれらの塗装は一般にスプレーガン
７によるエアスプレー塗装法で施されるが、塗料の塗着
効率が低いため．その損失が大きく、しかも平滑で均一
な塗装塗膜に仕上げるのが難かしく、塗装表面に沸き、
タレ、色ムラ、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
のもとに、且つ充分な時間をかけて厳重な作業管理を行
なって仕上げていた．
更に、自動車用内装材としての化粧板複合材は温度、湿
度、日照等の外的作用に強く曝されるので天然木合板で
作った基材は伸縮を起こし易く、またこの基材の上に接
看される化粧単板に含まれる微小気泡や水分の影響並び
に木目の密度差等により透明樹脂塗膜に伸縮を生じて塗
面に微小凹凸を与え、平滑性やツヤ感を損なうばかりで
なく、長期的にはクラック、ハガレ、反り、変形の原因
となる。DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a decorative laminate composite having a transparent resin surface coating layer used for, for example, automobile interior parts such as center clusters, console upper panels, door trim ornament panels, etc. Concerning materials and their manufacturing methods, they include decorative laminate composite materials with a transparent resin surface coating layer that allows the natural wood grain to be visible, especially those used in high-end vehicles. [Prior Art] As shown in Figure 2, a high-grade decorative composite material with a surface coating layer of transparent resin on a decorative natural wood veneer for automobile interiors is made of plywood such as beech, shina, birch, or lauan as a base material. 4, and on top of this, a decorative veneer 2 made by slicing beautiful natural wood such as teak, bird's eye mable, walnut, and scrap into a thickness of about 0.2 to 1.5 ml1 is layered, and this laminate is coated with phenolic resin and area. After bonding and integrating by heat pressing using a resin adhesive or resin-impregnated viewing film 5, the inner and outer peripheries are trimmed and then finished by painting with a spray gun 7 for a transparent resin coating film 6. It is made by doing. With the recent improvement in the general economic level, natural materials have been reconsidered, and in the automobile market, 6 natural wood decorative veneers are coated with transparent resin to create a high-gloss, mirror-like surface. Products that are smooth and have a sense of depth are being put into practical use mainly for internal parts of luxury cars. However, the transparent resin coating requires several preparations, including sanding to smooth the decorative veneer and remove dirt, and multiple coats of polyester or urethane-based colored paint to prevent discoloration and tar, and to even out the exterior color tone. After applying a second undercoat, drying, and re-sanding, as a finishing process, an intermediate coat of polyester or urethane-based transparent paint is applied to give a sense of texture, depth, and transparency, and to prevent eye discoloration. After applying a top coat and drying, it is necessary to finish by sanding and polishing with compound wax. In addition, these coatings are generally applied using an air spray coating method using a spray gun 7, but the coating efficiency of the coating is low. The loss is large, and it is difficult to finish a smooth and uniform paint film, causing boils to form on the painted surface.
It is prone to surface defects such as sagging, color unevenness, whitening, and orange beer. For this reason, the work was finished with careful consideration by skilled painting technicians, and with sufficient time and strict work management. Furthermore, decorative laminate composite materials used as interior materials for automobiles are strongly exposed to external effects such as temperature, humidity, and sunlight, so the base material made of natural wood plywood is prone to expansion and contraction. Due to the effects of microbubbles and moisture contained in the decorative veneer being viewed, as well as differences in wood grain density, the transparent resin coating will expand and contract, creating minute irregularities on the painted surface, which not only impairs smoothness and gloss. , which may cause cracks, peeling, warping, and deformation in the long term.
上述のように、化粧板複合材の製造において、従来の技
法による場合は、特に透明樹脂塗膜層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、多数の工程
とそれに伴う塗装設備を必要とし、しかも作業に時間が
かかるために生産能率が低くて製造コストへの影響が大
きく、またその製品も長期間の耐久品質に欠けるので、
その改善が強く望まれていた．
更にまた、化粧単板には天然銘木を、また基材には合板
を用いるため、これらのスライス時に発生する裏割れ目
や本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、これは塗膜乾燥時に
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、更には温湿度変化の著しい使用環境条件で発生する
微小の凹凸やクラック、ハガレ等の不具合の原因となる
のでその対策が問題であった．
化粧単板にはチーク、ローズウッド（板目及び柾目）、
＜す、バーズアイメーブル（杢）、ウオールナット（板
目、柾目及び歪）等の薄板が基材のぶな、しな、かば等
の合板に接着して使用されるが引張り強度が低くて伸び
が少なく、成形時に割れ易いため一般調度品においてら
平面状または単純な曲面形状のものにしか成形できない
欠点を有する。As mentioned above, when manufacturing decorative laminate composite materials using conventional techniques, highly skilled techniques, numerous steps, and accompanying painting equipment are required, especially in the painting process of the transparent resin coating layer 6 using the spray gun 7. Moreover, since the work takes time, production efficiency is low, which has a large impact on manufacturing costs, and the product also lacks long-term durable quality.
Improvement was strongly desired. Furthermore, since the decorative veneer is made of natural wood and the base material is plywood, air and moisture (adhesive ), which tend to collect, and this is caused by cloudy spots and boiling that occur within the paint film or at the interface between the paint film and the decorative veneer when the paint film dries, as well as minute irregularities and bumps that occur under usage environmental conditions with significant changes in temperature and humidity. Since it can cause problems such as cracks and peeling, countermeasures have been a problem. Decorative veneers include teak, rosewood (board grain and straight grain),
Thin boards such as bird's eye mable (heathered) and walnut (board grain, straight grain, and distorted) are used by adhering to the base plywood such as beech, shina, birch, etc., but their tensile strength is low and they do not elongate. It has the disadvantage that it can only be molded into flat or simple curved shapes compared to general furniture because it has a small amount of cracking and is easily broken during molding.
また塗装工程においては色ムラ、オレンジビール５タレ
、研ぎ足し、ヤセ等の塗装不具合の解消や、スプレー塗
装時の塗料の損失、塗料のスプレーダストや有機溶剤の
揮敗による設備や環境汚染等の防止も問題であった．
そこで本発明者等は先に、上記のような従来技術におけ
る諸問題を解決するために、仕上げ塗装工程を省略でき
る金型プレスによる幾つかの化粧板複合材製造技術を開
発して特許出願した（特願平１−７５９７４ 号、同
１−７５９７５ 号及び同１−９５９８７号）．
〔発明が解決しようとする課題〕
本発明は、このような先発明の複合材に特に深み感や厚
み感において改良の余地が残されていることから、外観
の意匠的な品質を一層向上させるような基材、その上に
かぶせた化粧単板及び透明樹脂表面被覆層からなる冒頭
に述べた類の化粧板複合材、及びその製造方法を提供す
ることを課題とするものである．
〔課題を解決するための手段〕
本発明者等は上述の課題を解決するために種々研究を続
けてきたが、その結果、上記のような金型プレスによる
化粧板複合材において、その透明Ｆ？Ａ脂表面被覆層が
複数の異なった層の積層よりなり、そして中でもそれら
が互いに明確に異なった屈折率を有している場合に、得
られた複合材の外観的表面品質、特に深み感や厚み感が
著しく改善されることを見出し、本発明に到達した．す
なわち本発明の化粧板複合材は、化粧単板が上記基材と
強力に接着し得る熱硬化性樹脂で含浸された天然銘本の
薄板よりなり、そして上記透明樹脂表面被覆層が金型内
での熱プレスに際して上記化粧単板内部の含浸樹脂の浸
出により形成された第１層と、その上にかぶせた、繊維
シート材に上記化粧単板の含浸樹脂と架橋反応し得る熱
硬化性樹脂を含浸させた被覆シートの熱プレス硬化によ
り形成された第２ｒｖｉと、及び更にその上を被覆する
、上記第２層の樹脂と架嘴反応し得るか又は少なくとも
これに強く接着する熱硬化性樹脂の熱プレス硬化により
形成された第３層とからなることを特徴とするものであ
る．
本発明に従う化粧板複合材の有利な態様のものにおいて
、基材は無機又は有機の繊維よりなる強化材を熱硬化性
樹脂と低収縮剤との含まれる樹脂液で含浸させた低収縮
性シート状コンパウンドの予備成形物から得られる繊維
強化樹脂よりなり、そして化粧単板はこの基材の樹脂と
架橋反応し得る熱硬化樹脂で含浸された天然銘本の薄板
よりなる．この場合には単純形状の複合材のみならず、
種々の３次元構造を有する複合材をも対応する形状の金
型での熱プレスによって得ることができ、そして強度の
高い複合材が得られる。In addition, in the painting process, it is necessary to eliminate paint defects such as uneven color, orange beer 5 drip, sanding, fading, etc., and to prevent paint loss during spray painting, equipment and environmental pollution caused by paint spray dust and organic solvent volatilization. Prevention was also an issue. Therefore, in order to solve the problems in the conventional technology as described above, the present inventors have developed several techniques for manufacturing decorative laminate composite materials using a mold press, which can omit the finishing coating process, and have filed a patent application. (Japanese Patent Application Nos. 1-75974, 1-75975 and 1-95987). [Problems to be Solved by the Invention] The present invention aims to further improve the design quality of the appearance, since there is still room for improvement in the composite material of the previous invention, especially in terms of depth and thickness. It is an object of the present invention to provide a decorative laminate composite material of the type mentioned at the beginning, which comprises a base material such as this, a decorative veneer covered thereon, and a transparent resin surface coating layer, and a method for manufacturing the same. [Means for Solving the Problems] The present inventors have continued various studies in order to solve the above problems, and as a result, in the decorative board composite material produced by die pressing as described above, the transparent F ? When the A-fat surface coating layer is composed of a lamination of multiple different layers, and among them each has a refractive index clearly different from each other, the appearance surface quality of the resulting composite material, especially the depth and It was discovered that the thickness feeling was significantly improved, and the present invention was developed. That is, in the decorative veneer composite material of the present invention, the decorative veneer is made of a thin natural board impregnated with a thermosetting resin that can strongly adhere to the base material, and the transparent resin surface coating layer is formed in the mold. A first layer formed by leaching of the impregnated resin inside the decorative veneer during heat pressing, and a thermosetting resin that can cross-link with the impregnated resin of the decorative veneer on the fiber sheet material covered thereon. a second rvi formed by hot press curing of a coating sheet impregnated with RVI, and a thermosetting resin that can cross-react with the resin of the second layer, or at least strongly adheres thereto, and further coats the second rvi. The third layer is formed by heat press hardening. In an advantageous embodiment of the decorative laminate composite according to the invention, the base material is a low-shrinkage sheet made of a reinforcing material of inorganic or organic fibers impregnated with a resin liquid containing a thermosetting resin and a low-shrinkage agent. The decorative veneer consists of a thin sheet of natural fiber impregnated with a thermosetting resin capable of crosslinking with the base resin. In this case, not only simple shaped composite materials but also
Composites with various three-dimensional structures can also be obtained by hot pressing in molds of corresponding shapes, and composites with high strength can be obtained.
本発明に従う化粧板複合材の更にもう一つの有利な態様
のものにおいては、その透明樹脂表面被覆層の上記第１
、第２及び第３層が互いに異なった光屈折率を有してい
て、好ましくはこの屈折率が第１層〉第２層〉第３層の
順に次第に小さくなるのがよく、それによりこのものは
その外観が深み感、厚み感に優れた極めて意匠性に冨ん
だものとなる．
本発明に従う化粧板複合材の製造方法は、上記のような
基材の上にこの基材と強力に接着し得る熱硬化性樹脂で
含浸された天然銘木の薄板よりなる化粧単板を、また更
にその上にこの化粧単板の含浸樹脂と架橋反応し得る熱
硬化性樹脂で含浸された繊維シート材をかぶせて積層体
を作り、この積層体をプレス金型の中で一次熱プレスす
ることによって基材と化粧単板と繊維シート材との予備
成形体を形成し、次いでこの予備成形体が完全硬化する
直前に、上記繊維シート材の樹脂と架橋反応し得るか、
又は少なくともこれに強く接着する熱硬化性樹脂の液で
上記予備成形体の表面を被覆し、その上でこの被覆成形
体を更に二次熱プレスし、それにより基材、樹脂含浸化
粧単板、及び透明樹脂表面被覆層を完全硬化のもとに一
体に成形することを特徴とする．
上記化粧板複合材の製造方法の有利な態様の一つにおい
て、化粧単板の裏面に予め繊維質の補強シートを接肴し
て用いる．これによって成形時に化粧単板の割れが防止
できて良好な製品が得られる。In yet another advantageous embodiment of the decorative laminate composite according to the invention, the first layer of the transparent resin surface coating layer is
, the second and third layers have different optical refractive indexes from each other, and preferably the refractive indexes gradually decrease in the order of the first layer>second layer>third layer, so that this The exterior has an excellent sense of depth and thickness, and is extremely rich in design. The method for producing a decorative laminate composite material according to the present invention includes, on a base material as described above, a decorative veneer made of a thin board of natural precious wood impregnated with a thermosetting resin capable of strongly adhering to the base material; Further, a fiber sheet material impregnated with a thermosetting resin capable of crosslinking with the impregnated resin of the decorative veneer is placed thereon to form a laminate, and this laminate is subjected to primary heat pressing in a press mold. to form a preformed body of a base material, a decorative veneer, and a fiber sheet material, and then, immediately before this preformed body is completely cured, can a crosslinking reaction be performed with the resin of the fiber sheet material;
Alternatively, the surface of the preform is coated with a thermosetting resin liquid that strongly adheres to the preform, and the coated mold is further heat-pressed for a second time, thereby forming a base material, a resin-impregnated decorative veneer, and a transparent resin surface coating layer are integrally molded under complete curing. In one of the advantageous embodiments of the method for manufacturing the decorative veneer composite material, a fibrous reinforcing sheet is applied to the back side of the decorative veneer in advance. This prevents the decorative veneer from cracking during molding, resulting in a good product.
上記化粧板複合材の製造方法の更に別の有利な態様にお
いては、一次熱プレスに際して型締め加圧に先立って金
型内部を減圧脱気するが、これは化粧単板等の中に存在
する空孔や凹部が樹脂で充填されて製品の白濁班や沸き
等の表面欠陥、更には温度や湿度の変化の著しい環境条
件で発生する微小の凹凸やクラック、ハガレ等の防止に
効果的である．
上記化粧板複合材の製造方法の更に別の有利な態様にお
いては、一次熱プレスの後の予備成形体の樹脂被覆を、
上型の僅かな持ち上げと樹脂液の注入とによって行なう
が、これによれば金型の再度の減圧を不要にし、且つ工
程時間の短縮がもたらされる．
〔作用〕
本発明による化粧板複合材の製造方法はその手順を図に
よって説明するならば、第ｌ図に示すように、前述のよ
うな基材ＩＩと、この基材に少なくとも強力に接着し得
る熱硬化性樹脂で含浸した天然銘木の化粧単板ｌ２と、
及びこの化粧単板の樹脂と架橋反応し得る樹脂で含浸さ
れた＃ａ維シ一ト材 １３Ｂ とを順に重ねて積層体
を作り、この積層体を内面の鏡面化されたプレス金型の
中で先ず一次熱プレスすることによって基材１１と化粧
単板ｌ２と繊維シート材１３８ との予備成形体を形
成し、次いでこの予備成形体が完全硬化する直前にこの
予備成形体を上記繊維シート材１３Ｂ の熱硬化性樹
脂と架橋反応し得るか、又は少なくともこれと強力に接
着し得る、例えば熱硬化性ポリウレタン樹脂等の熱硬化
性樹脂液＋３Ａ で被覆し、その上でこの被覆成形体
を更に二次熱プレスし、それにより基材ＩＩ． ＦＭ
脂含浸化粧単板ｌ２、樹脂含浸シ一ト材層１３Ｂ 及
び表面被覆透明樹脂層！３Ａを一体に完全硬化成形させ
る．上記の熱硬化性樹脂層＋３Ａ の被覆は金型を一
旦開放して注流法により行なってもよいが、金型空洞部
に対応する上型を僅かに上昇させるとともに金型内に樹
脂液を注入することによって行なってもよい．本発明に
従う化粧板複合材は、基材、樹脂含浸化粧単板及び樹脂
含浸シ一ト材と肢Ｗ１ＦＭ脂層とからなる透明樹脂表面
被覆層を一体に硬化成形させることによって、全体を通
じて強固に結合されて従来品にない高い強度を有するが
、特にその透明樹脂被覆層はその熱プレスに際して化粧
単板から浸出した第ｌ層１３Ｃ と、樹脂含浸シ一ト
材の熱プレス硬化により形成された第２＠１３Ｂ と
、及び被覆樹脂の硬化層よりなる第３層＋３Ａ とか
らなり、異なった光屈折透過反射性を有するためにその
外観上極めて意匠性に冨んでいる。また上記の方法で被
覆された樹脂液の熱プレス硬化層により、特に表面研磨
作業が施されなくても、高光沢でしかも耐久性及び強度
において優れている．上記化粧板複合材の基材ＩＩとし
ては、その上にかぶせられる樹脂含浸化粧単板ｌ２と強
力に接合して熱プレスにより一体に硬化し得る限り特に
制限はないが、中でも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た
繊維強化プラスチックよりなるシート状コンパウンドを
用いるのが好ましく、この場合には３次元的な複雑な形
状の金型を使用して対応する３次元的形状の化粧板複合
材を得ることが可能になる．
基材として低収縮性のシート状モールデイングコンパウ
ンドの予備成形体を用いるときは比較的薄肉でも高い型
込め安定性、強度が得られ、得られる製品の寸法安定性
も高い．
このような基材に用いる強化用繊維材は有機及び無磯の
高強度繊維であるが、中でも比較的短繊維のガラス繊維
のロービングが好ましい．この基材の熱硬化性樹脂とし
ては不飽和ポリエステル、エボキシ樹脂、ジアリルフタ
レート樹脂又はアルキッド樹脂の１種以上が用いられる
．これらの熱硬化性樹脂のブレボリマーに加えて、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、スチレンブタジエンコボリマー、ポリメタクリル酸
メチル等）並びに他の通常的な、例えば充填材、架橋剤
、増粘材、離型剤、触媒、着色剤、重合安定剤、溶剤等
を混合してなる混合液を上記のような強化繊維材に含浸
させ、経時的にタッグフリーの状態にまで熟成して得ら
れる低収縮性のシート状モールディングコンパウンド（
以下、ＳＭＣと略記する）の予婦成形物を用いるのが好
ましい．これにより得られる化粧板複合材は、高剛性、
高強度、薄肉、高耐熱性、高耐水性の他に適度の可撓性
も有し、高い寸法安定性と共に、補強リブ、又は部品取
り付け用のねじ金具やリテイナー打ち込み金具のための
ボスを埋め込んでこれにインサートできることとなり、
また平面状のものはもちろん非平面状の装飾材を本発明
に従い熱プレス成形法で作ることができので、デザイン
や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．
化粧単板ｌ２としてはチーク、ローズウッド、ウオール
ナット、くず、バーズアイメーブル等の天然銘木の板目
又は柾目及び杢の薄板に直接、又は染色や塗装によって
調色処理した後、基材と強力に接着し得る熱硬化性樹脂
、中でも上記のようなＳＭＣを用いる場合はその熱硬化
性樹脂と架橋反応し得る樹脂５好ましくは同様にジアリ
ルフタレート樹脂、不飽和ポリエステル樹脂、及びアル
キッド樹脂のうちの一つ以上のブレボリマーを含浸させ
たものが用いられる．化粧単板に含浸させた熱硬化性樹
脂のブレポリマーは熱プレスに際して表面被５１層用樹
脂や基材の樹脂との間に架橋反応を生じて強力に接合す
るが、一方その熱プレスの初期、即ち反応初期には軟化
して可撓性を示すので、成形時の割れ防止に極めて効果
的である．また化粧単板の裏割れ目や、木質繊維導管等
の微細な間隙部内の空気や吸着している水分は金型の型
閉め後に真空脱気工程を取り入れた場合に除去され、そ
してこれらの部分はこの樹脂含浸工程において、予め乾
燥されまた樹脂液で充填され、従って温度や湿度の変化
の繰り返される使用環境のもとでも透明樹脂層や化粧単
板の伸縮差により透明樹脂表面被覆層の表面に生ずる微
小な凹凸（目ヤセ）、白化、ハガレ、クラック等の発生
が防正される。In yet another advantageous embodiment of the method for manufacturing the decorative veneer composite material, the inside of the mold is depressurized and degassed prior to mold clamping and pressurization during the primary heat pressing, which removes air present in the decorative veneer, etc. The pores and recesses are filled with resin, which is effective in preventing surface defects such as cloudy spots and boiling on the product, as well as minute irregularities, cracks, and peeling that occur under environmental conditions with significant changes in temperature and humidity. ．． In yet another advantageous embodiment of the method for producing a decorative laminate composite, the resin coating of the preform after the primary heat pressing is performed by:
This is done by slightly lifting the upper mold and injecting the resin liquid, but this eliminates the need to depressurize the mold again and shortens the process time. [Function] If the method for manufacturing a decorative laminate composite material according to the present invention is to explain the procedure using figures, as shown in Figure 1, the process involves forming a base material II as described above, and a method that is at least strongly adhered to this base material. Decorative veneer l2 of natural precious wood impregnated with thermosetting resin to obtain,
The resin of this decorative veneer and #a fiber sheet material 13B impregnated with a resin capable of crosslinking reaction are sequentially stacked to form a laminate, and this laminate is placed in a press mold with a mirrored inner surface. First, a preformed body of the base material 11, the decorative veneer l2, and the fiber sheet material 138 is formed by primary heat pressing, and then, just before this preformed body is completely cured, this preformed body is pressed into the above fiber sheet material. 13B is coated with a thermosetting resin liquid such as a thermosetting polyurethane resin that can crosslink or at least strongly adhere to the thermosetting resin, and then this coated molded body is further coated with 3A. Secondary heat pressing, thereby substrate II. FM
Grease-impregnated decorative veneer l2, resin-impregnated sheet material layer 13B, and surface coating transparent resin layer! Completely harden and mold 3A in one piece. The above thermosetting resin layer +3A may be coated by the pouring method after once opening the mold, but the upper mold corresponding to the mold cavity is slightly raised and the resin liquid is poured into the mold. It can also be done by injection. The decorative laminate composite material according to the present invention has a transparent resin surface coating layer consisting of a base material, a resin-impregnated decorative veneer, a resin-impregnated sheet material, and a leg W1FM fat layer, which are integrally cured and molded, so that the entire surface is strongly strengthened. It has a high strength that is not found in conventional products due to its combination, and in particular, its transparent resin coating layer is formed by heat press curing of the first layer 13C leached from the decorative veneer during heat pressing and resin-impregnated sheet material. It consists of the second layer 13B and the third layer +3A made of a hardened layer of coating resin, and has different light refraction, transmission and reflection properties, so its appearance is extremely rich in design. Furthermore, the heat-press cured layer of resin liquid coated by the above method provides high gloss and excellent durability and strength even without surface polishing. The base material II of the above-mentioned decorative laminate composite material is not particularly limited as long as it can be strongly bonded to the resin-impregnated decorative veneer l2 to be placed over it and can be cured integrally by heat pressing, but in particular thermosetting resins can be used. It is preferable to use a sheet-like compound made of fiber-reinforced plastic impregnated with a reinforcing material made of inorganic or organic fibers with a resin liquid containing a low-shrinkage agent. Using this method, it becomes possible to obtain a decorative laminate composite material with a corresponding three-dimensional shape. When a preform of a low-shrinkage sheet-like molding compound is used as a base material, high mold-embedding stability and strength can be obtained even with relatively thin walls, and the resulting product also has high dimensional stability. The reinforcing fiber materials used for such base materials include organic and non-silicon high-strength fibers, and among them, relatively short glass fiber rovings are preferred. As the thermosetting resin for this base material, one or more of unsaturated polyester, epoxy resin, diallyl phthalate resin, or alkyd resin is used. In addition to these thermosetting resin brevolimers, thermoplastic resins as low-shrinkage agents (polyethylene, polyester, styrene-butadiene copolymers, polymethyl methacrylate, etc.) as well as other customary materials, such as fillers, crosslinkers, A mixture of thickeners, mold release agents, catalysts, colorants, polymerization stabilizers, solvents, etc. is impregnated into the reinforcing fiber material described above, and aged to a tag-free state over time. The resulting low-shrinkage sheet molding compound (
It is preferable to use a molded product of SMC (hereinafter abbreviated as SMC). The decorative laminate composite material obtained by this method has high rigidity,
It has high strength, thin wall, high heat resistance, high water resistance, and moderate flexibility.It has high dimensional stability and has reinforcing ribs or embedded bosses for screw fittings for attaching parts and retainer drive fittings. Now you can insert it into this,
In addition, not only planar decorative materials but also non-planar decorative materials can be made using the hot press molding method according to the present invention, which improves the degree of freedom in design and significantly reduces parts installation costs. Decorative veneer 12 can be applied directly to the grain or straight-grained or heathered thin boards of natural precious woods such as teak, rosewood, walnut, scraps, and bird's eye maable, or after being colored by dyeing or painting, it can be strongly bonded to the base material. A thermosetting resin capable of adhesion, especially a resin capable of crosslinking with the thermosetting resin when SMC as described above is used 5 Preferably also one of a diallyl phthalate resin, an unsaturated polyester resin, and an alkyd resin A material impregnated with three or more brevolimers is used. During heat pressing, the thermosetting resin Brepolymer impregnated into the decorative veneer causes a crosslinking reaction with the surface coating resin and the base material resin to form a strong bond. In other words, it softens and exhibits flexibility at the early stage of the reaction, making it extremely effective in preventing cracking during molding. In addition, air and adsorbed moisture in the cracks on the back of decorative veneers and minute gaps such as wood fiber conduits are removed when a vacuum degassing process is applied after the mold is closed. In this resin impregnation process, it is pre-dried and filled with resin liquid, so even in a usage environment where temperature and humidity changes repeatedly, the difference in expansion and contraction of the transparent resin layer and decorative veneer will cause the surface of the transparent resin surface coating layer to change. The occurrence of minute irregularities (eye discoloration), whitening, peeling, cracks, etc., is prevented.
また化粧囃仮に和紙や他の合成繊維の不織布等の繊維質
シートを補強裏打ち材として、耐熱性の良いＳＢＲ系接
Ｍ剤等で予め裏張りして使用すると、成形時に化粧単板
のワレが防止でき良好な製品が得られる．この繊維質シ
ートとしては、靭性が強く、物理的及び化学的性質も安
定しているパルブ紙、またはポリエステル繊維、アクリ
ル繊維またはナイロン繊維、ポリビニルアルコール繊維
等の合成繊維の不織布を使用するのが好ましい．化粧単
板Ｉ２の上にかぶせられる樹脂含浸シ一ト材１３Ｂ
としては、熱プレス成形の後に下地の化粧単板の木目が
明瞭に透視できることを損なわない程度の目付け社の繊
維シートに上記化粧単板中の熱硬化性樹脂と架橋反応し
得る、好ましくは同様にジアリルフタレート樹脂、不飽
和ポリエステル樹脂又はアルキッド樹脂のブレポリマー
を含浸させたものが用いられる．好ましくは２０ −
４０ｇ／ｃ一の目付け看の和紙または各種合成繊維の不
織布に上記のような樹脂を含浸させた厚さ ０．３−０
．５ｍ＋ｗ のシートが用いられる．最後に、上記の
樹脂含浸シ一ト材１３Ｂ を被覆するのに用いられる
１３Ａ 層の樹脂としては、熱プレス硬化に際して
樹脂含浸シ一ト材の９ １３８と強力に接着し得る熱硬
化性樹脂が用いられ、従ってもちろんこのシート材１３
Ｂ の樹脂と同じものを用いても良いが、中でも熱硬
化性ポリウレタン樹脂を用いることができ、この場合に
光りの屈折率の違いから特に意匠的に優れた外観が得ら
れる．この被ｍ層１３Ａ を形成するには、上記のよ
うな樹脂のブレボリマーをそれぞれ単独で、又は混合物
として、架橋剤、重合触媒、内部離型削、重合安定剤等
と共に、また必要に応じて改質用の他の樹脂及び充填剤
等の添加のもとに混合してなる樹脂液を用いる。前述し
たように基材、化粧単板及び樹脂含浸シ一ト材の積層体
を金型の中で先ず一次熱プレスし、この積層体の各樹脂
が完全硬化する直前に金型を開いてその予備成形体の表
面に上記の樹脂液を注流してこれを被覆した後、この金
型を再び閉じて二次熱プレスする．或はまた一次熱プレ
スの後で一旦金型を開放することなくＬ型のを僅かに上
昇させると共に型内に上記樹脂液を注入することによっ
て予備成形体を被覆したｆ＆．二次プレスすることによ
って全体を完全硬化させてもよい。In addition, if you use a fibrous sheet such as washi paper or other synthetic fiber non-woven fabric as a reinforcing backing material and line it with a heat-resistant SBR adhesive beforehand, the decorative veneer will not crack during molding. This can be prevented and a good product can be obtained. As this fibrous sheet, it is preferable to use pulp paper, which has strong toughness and stable physical and chemical properties, or a nonwoven fabric made of synthetic fibers such as polyester fiber, acrylic fiber, nylon fiber, or polyvinyl alcohol fiber. ．． Resin-impregnated sheet material 13B to be placed over the decorative veneer I2
After hot press molding, a fiber sheet made by Fabric Co., Ltd. that can cross-link with the thermosetting resin in the decorative veneer to an extent that does not impair the clear visibility of the wood grain of the underlying decorative veneer, preferably a similar material. Impregnated with diallyl phthalate resin, unsaturated polyester resin, or alkyd resin brepolymer is used. Preferably 20 −
Washi paper or various synthetic fiber non-woven fabric with a weight of 40g/c is impregnated with the above resin and has a thickness of 0.3-0.
．． A 5m+w sheet is used. Finally, the resin for the layer 13A used to cover the resin-impregnated sheet material 13B is a thermosetting resin that can strongly adhere to the resin-impregnated sheet material 9138 during heat press curing. and therefore of course this sheet material 13
The same resin as B may be used, but thermosetting polyurethane resin can be used, and in this case, a particularly excellent appearance can be obtained due to the difference in the refractive index of light. In order to form this layer 13A, the Brevolimer resins described above are used alone or as a mixture together with a crosslinking agent, a polymerization catalyst, internal mold release, a polymerization stabilizer, etc., and if necessary, modified. A resin liquid is used that is mixed with other resins for quality, fillers, etc. As mentioned above, the laminate of the base material, decorative veneer, and resin-impregnated sheet material is first heat-pressed in a mold, and the mold is opened just before each resin in this laminate is completely cured. After pouring the resin liquid onto the surface of the preform to cover it, the mold is closed again and a secondary heat press is performed. Alternatively, after the primary hot pressing, the L-shape is slightly raised without opening the mold, and the resin liquid is injected into the mold to cover the preform. The whole may be completely cured by secondary pressing.
この熱プレスによって化粧単板ｌ２の内部に含浸されて
いた熱硬化性樹脂の一部が樹脂含浸繊維シート層 １３
Ｂ との境界面に浸出して透明被覆樹脂層の第ｌ層１
３ｃ を形成する．この第１ｊｌｌ３ｃと上記樹脂含
浸繊維シートの硬化層よりなる第２層１３Ｂ と表面
被覆層１３Ａ よりなる第３Ｎとがそれぞれ異なった
屈折率を有するために本発明に従う化粧板複合材は深み
感、厚み感に優れた美麗な外観を有する．
〔実施例〕
以下本発明の実施例を挙げる．
基材としては熱可型性のボリマーの低収縮剤が熱可塑性
樹脂に対し５重挺部配合されている樹脂を用いた不飽和
ポリエステル系ＳＭＣ （三井東圧化学社製エスター
マットＡＵ−１２０） を用いた。By this heat pressing, a part of the thermosetting resin impregnated inside the decorative veneer l2 becomes the resin-impregnated fiber sheet layer 13
The lth layer 1 of the transparent coating resin layer leaches out to the interface with B.
Form 3c. Since this first layer 3c, the second layer 13B made of the cured layer of the resin-impregnated fiber sheet, and the third layer N made of the surface coating layer 13A have different refractive indexes, the decorative board composite according to the present invention has a sense of depth and thickness. It has a beautiful appearance with an excellent feel. [Example] Examples of the present invention are listed below. The base material is an unsaturated polyester SMC (Estermat AU-120 manufactured by Mitsui Toatsu Chemical Co., Ltd.) using a resin in which 5 parts of a thermoplastic polymer low-shrinkage agent is mixed with the thermoplastic resin. was used.
化粧単板としては板厚０．３問のバーズアイメ−ブルの
玉杢の単板を用い、その裏側に目付け置３６ ｇ／ｎ”
の和紙をスチレン／ブタジエンラバ一系の接着剤（
三井東圧化学社のストラクトボンド１１２３）で接着強
化して用いた．この化粧単板に減圧／加圧法で不飽和ポ
リエステル樹脂（三井東圧化学社のオレスターＲＰ−１
０３３１ １００ 重量部、触媒（Ｄ ｔｅｒｈ−バ
ーベンゾエート０，７ 重量部及び重合安定剤メチル
ハイドロキノン０．２ 重１部よりなる混合液の５０
重量部を含浸させた樹脂含浸化粧単板を用いた．
この化粧単板の上にかぶせる樹脂含浸シ一ト材としては
熱硬化性ジアリルフタレートブレボリマ−（大阪曹達、
ダップＡ）で樹脂量１４０ ｇ／一まで含浸させた日付
け看２５ ｇ／ｃｍ”のアクリル＆１＃ｉ不織布（日本
バイリーン社製品）を用いた．以上の３つを第１図に示
す手順で重ねて積層体を作り、平板金型内にチャージし
て型を閉じた後型内を真空脱気し、次いで型温度１４０
℃、プレス圧力１００ ｋｇｆ／ｃ一 において一次熱
プレスを行なって予備成形体を得た．
次に上記予備成形体が完全硬化する前に金型な開いてこ
の予備成形体の上を数平均分子置４００、ＯＨ価３４０
のポリエステルボリオール（米国キング社製ケーフ
レックス１８８） ６０ 重量部、及びＮＧＯ含有率
２３．１％（固形分換算）のへキサメチレンジイソシア
ネートの３鼠体（旭化成社製ＴＰＡ １００） ４０
重量部を混合してなるウレタン樹脂液の注流によっ
て被覆した後、再び金型を閉じて同じ条件のもとで二次
熱プレスを行ない、完全硬化させた。As the decorative veneer, we used a 0.3 inch thick Bird's Eye Mable veneer with a weight of 36 g/n on the back side.
Japanese paper with styrene/butadiene rubber adhesive (
The adhesive was strengthened with Mitsui Toatsu Chemical Co., Ltd.'s Structbond 1123). This decorative veneer was coated with unsaturated polyester resin (Orestar RP-1 from Mitsui Toatsu Chemical Co., Ltd.) using a vacuum/pressure method.
0331 100 parts by weight, 0.7 parts by weight of catalyst (D terh-barbenzoate) and 0.2 parts by weight of polymerization stabilizer methylhydroquinone.
A decorative veneer impregnated with resin was used. The resin-impregnated sheet material to cover this decorative veneer is thermosetting diallylphthalate Brevolimer (Osaka Soda,
Acrylic & 1 #i nonwoven fabric (product of Nippon Vilene Co., Ltd.) with a weight of 25 g/cm was impregnated with Dap A) to a resin amount of 140 g/1. After stacking them to make a laminate, charging the flat plate mold and closing the mold, the inside of the mold is vacuum degassed, and then the mold temperature is 140℃.
℃ and a press pressure of 100 kgf/c to obtain a preformed body. Next, before the preform is completely cured, the mold is opened and the number average molecular weight is 400 and the OH value is 340.
60 parts by weight of polyester polyol (K-Flex 188, manufactured by King, USA), and 40 parts of hexamethylene diisocyanate (TPA 100, manufactured by Asahi Kasei Corporation) with an NGO content of 23.1% (solid content).
After coating by pouring a urethane resin solution prepared by mixing parts by weight, the mold was closed again and secondary heat pressing was performed under the same conditions to completely cure the resin.
このようにして得られた化粧板複合材は優れた探み感、
厚み感とともに化粧単板の木目が明瞭に浮き出されて極
めて優れた外観を呈する．表面層を調べた結果、樹脂含
浸シ一ト材層の下に化粧単板から浸出した不飽和ポリエ
ステル樹脂の層が存圧し、すなわち屈折率約１，５４の
不飽和ポリエステル樹脂層と屈折率約１．５０のジアリ
ルフタレートａ脂の層と、及び屈折率約１．４６のポリ
ウレタン樹脂層とからなることが認められ、これが上記
の優れた外観的意匠性をもたらしたものであることがわ
かった．
〔発明の効果］
本発明の請求項ｌに従う化粧板複合材は基材，化粧単板
、樹脂含浸シ一ト材及び被覆樹脂よりなる積層体の全体
が一体に強固に結合した高い強度を有するとともに、深
み感、厚み感を備えて意匠性に優れ、しかも耐久性の高
い高級感のある仕上げ面を与える．
請求項２に従い基材として低収縮材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、３
次元的な形状の複合材の形成を許容し、しかもこの複合
材に付与される高い剛性、高い強度、良好な成形性、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．The decorative board composite material obtained in this way has an excellent sense of exploration,
It has a sense of thickness and the wood grain of the decorative veneer is clearly highlighted, giving it an extremely excellent appearance. As a result of examining the surface layer, it was found that there was a layer of unsaturated polyester resin leached from the decorative veneer under the resin-impregnated sheet material layer; It was found that it consisted of a layer of diallyl phthalate a resin with a refractive index of 1.50 and a polyurethane resin layer with a refractive index of about 1.46, and it was found that this was what provided the above-mentioned excellent external design. ．． [Effects of the Invention] The decorative laminate composite material according to claim 1 of the present invention has high strength because the entire laminate consisting of the base material, decorative veneer, resin-impregnated sheet material, and coating resin is firmly bonded together. At the same time, it provides a finished surface that has a sense of depth and thickness, has excellent design, and is highly durable and luxurious. When a sheet-like compound impregnated with a thermosetting resin containing a low shrinkage material is used as a base material according to claim 2, 3.
It allows the formation of composite materials with dimensional shapes, and has added value due to its high functional characteristics such as high rigidity, high strength, good formability, high dimensional stability, and heat and water resistance. can be further enhanced.
第１図は本発明の化粧板複合材の製造手順を説明する断
面図、そして第２図は従来技術による化粧板複合材の製
造手順を説明する断面図である．ＩＩ， ・・・基材
■２、・・・化粧単板＋３Ａ ・・・熱硬化性
樹脂被覆層
１３Ｂ ・・・ｌａ維シ一ト材FIG. 1 is a sectional view illustrating the manufacturing procedure of the decorative laminate composite material of the present invention, and FIG. 2 is a sectional view illustrating the manufacturing procedure of the decorative laminate composite material according to the prior art. II, ... Base material ■2, ... Decorative veneer +3A ... Thermosetting resin coating layer 13B ... LA fiber sheet material
Claims (8)
その上に密着形成された透明樹脂表面被覆層とからなる
、熱プレスにより一体に硬化成形された化粧板複合材に
おいて、化粧単板が上記基材と強力に接着し得る熱硬化
性樹脂で含浸された天然銘木の薄板よりなり、そして上
記透明樹脂表面被覆層が金型内での熱プレスに際して上
記化粧単板内部の含浸樹脂の浸出により形成された第１
層と、その上にかぶせた、繊維シート材に上記化粧単板
の含浸樹脂と架橋反応し得る熱硬化性樹脂を含浸させた
被覆シートの熱プレス硬化により形成された第２層と、
及び更にその上を被覆する、上記第２層の樹脂と架橋反
応し得るか又は少なくともこれに強く接着する熱硬化性
樹脂の熱プレス硬化により形成された第３層とからなる
ことを特徴とする、化粧板複合材。(1) In a decorative veneer composite material that is integrally cured and molded by heat press, consisting of a base material, a decorative veneer placed over the base material, and a transparent resin surface coating layer closely formed thereon, The decorative veneer is made of a thin plate of natural wood impregnated with a thermosetting resin that can strongly adhere to the base material, and the transparent resin surface coating layer is applied to the interior of the decorative veneer during heat pressing in a mold. The first formed by leaching the impregnated resin
a second layer formed by heat press curing of a covering sheet covered thereon, the fiber sheet material being impregnated with a thermosetting resin capable of crosslinking with the impregnated resin of the decorative veneer;
and a third layer formed by heat press curing of a thermosetting resin that can crosslink with or at least strongly adheres to the resin of the second layer, which is coated thereon. , veneer composite.
液で無機または有機の繊維よりなる強化材を含浸した繊
維強化プラスチックよりなるシート状コンパウンドの熱
プレス成形体であり、そして化粧単板の含浸樹脂が上記
基材の熱硬化性樹脂と架橋反応し得る熱硬化性樹脂であ
る、請求項１記載の化粧板複合材。(2) The base material is a hot press molded sheet-like compound made of fiber-reinforced plastic impregnated with a reinforcing material made of inorganic or organic fibers with a resin liquid containing a thermosetting resin and a low-shrinkage agent, The decorative veneer composite material according to claim 1, wherein the impregnated resin of the decorative veneer is a thermosetting resin capable of crosslinking with the thermosetting resin of the base material.
３被覆層が互いに異なった光屈折率を有している、請求
項１記載の化粧板複合材。(3) The decorative laminate composite material according to claim 1, wherein the first, second, and third coating layers of the transparent resin surface coating layer have different optical refractive indexes.
、及び更にその上に密着形成された透明樹脂表面被覆層
とからなる、請求項１記載の化粧板複合材を製造するに
当り、基材の上にこの基材と強力に接着するか、又はこ
の基材の含浸樹脂と架橋反応し得る熱硬化性樹脂で含浸
された天然銘木の薄板よりなる化粧単板を、また更にそ
の上にこの化粧単板の含浸樹脂と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をかぶせて積層体を作
り、この積層体をプレス金型の中で一次熱プレスするこ
とによつて基材と化粧単板と繊維シート材との予備成形
体を形成し、次いでこの予備成形体が完全硬化する直前
に、上記繊維シート材の樹脂と架橋反応し得るか又は少
なくともこれに強く接着する熱硬化性樹脂の液で上記予
備成形体の表面を被覆し、その上でこの被覆成形体を更
に二次熱プレスし、それにより基材、樹脂含浸化粧単板
、及び透明樹脂表面被覆層を完全硬化のもとに一体に成
形することを特徴とする、化粧板複合材の製造方法。(4) Manufacture the decorative laminate composite material according to claim 1, comprising a base material, a decorative veneer bonded to the base material, and a transparent resin surface coating layer closely formed thereon. In order to do this, a decorative veneer made of a thin board of natural precious wood impregnated with a thermosetting resin that strongly adheres to the base material or can crosslink with the impregnated resin of the base material is placed on top of the base material. Further, a fiber sheet material impregnated with a thermosetting resin capable of cross-linking with the impregnated resin of the decorative veneer is placed on top of this to form a laminate, and this laminate is subjected to primary heat pressing in a press mold. Preferably, a preform of the substrate, the decorative veneer, and the fiber sheet material is formed, and then, just before the preform is completely cured, it is possible to crosslink or at least react with the resin of the fiber sheet material. The surface of the preformed body is coated with a thermosetting resin liquid that strongly adheres to the substrate, and then this coated molded body is further heat-pressed for a second time, thereby forming the base material, the resin-impregnated decorative veneer, and the transparent resin. A method for manufacturing a decorative laminate composite material, which comprises integrally molding a surface coating layer while completely curing it.
て用いる、請求項４記載の製造方法。(5) The manufacturing method according to claim 4, wherein a fibrous reinforcing sheet is bonded in advance to the back surface of the decorative veneer.
内部を減圧脱気する、請求項４記載の製造方法。(6) The manufacturing method according to claim 4, wherein the inside of the mold is depressurized and degassed prior to mold clamping pressurization in the primary hot press.
型の開放のもとに樹脂液の注流によって行なう、請求項
４記載の製造方法。(7) The manufacturing method according to claim 4, wherein the resin coating of the preformed body after the primary hot pressing is carried out by pouring a resin liquid while the mold is opened.
型の僅かな上昇と樹脂液の注入とによって行なう、請求
項４記載の製造方法。(8) The manufacturing method according to claim 4, wherein the resin coating of the preformed body after the primary hot pressing is performed by slightly raising the upper die and injecting the resin liquid.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1163263A JP2610193B2 (en) | 1989-06-26 | 1989-06-26 | Decorative plate composite and method for producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1163263A JP2610193B2 (en) | 1989-06-26 | 1989-06-26 | Decorative plate composite and method for producing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0326544A true JPH0326544A (en) | 1991-02-05 |
| JP2610193B2 JP2610193B2 (en) | 1997-05-14 |
Family
ID=15770483
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1163263A Expired - Lifetime JP2610193B2 (en) | 1989-06-26 | 1989-06-26 | Decorative plate composite and method for producing the same |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2610193B2 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6025064A (en) * | 1997-06-12 | 2000-02-15 | Toyoda Gosei Co., Ltd. | Decorative article and process for producing the same |
| JP2007196659A (en) * | 2005-11-08 | 2007-08-09 | Fujitsu Component Ltd | Thermoplastic resin made casing and method for fabricating the casing |
| WO2021093272A1 (en) * | 2019-11-15 | 2021-05-20 | 太仓优上展示器具有限公司 | Prestressed high-strength plywood and manufacturing method thereof |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102501480B (en) * | 2011-09-29 | 2014-08-20 | 桦甸市惠邦木业有限责任公司 | Veneer facing mould pressing resin paint door panel and production process thereof |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5653073A (en) * | 1979-10-05 | 1981-05-12 | Dantani Plywood Co | Manufacture of veneer pasted smoothly planed board |
| JPS58104637U (en) * | 1982-01-04 | 1983-07-16 | 段谷産業株式会社 | Resin-impregnated decorative veneer decorative board |
-
1989
- 1989-06-26 JP JP1163263A patent/JP2610193B2/en not_active Expired - Lifetime
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5653073A (en) * | 1979-10-05 | 1981-05-12 | Dantani Plywood Co | Manufacture of veneer pasted smoothly planed board |
| JPS58104637U (en) * | 1982-01-04 | 1983-07-16 | 段谷産業株式会社 | Resin-impregnated decorative veneer decorative board |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6025064A (en) * | 1997-06-12 | 2000-02-15 | Toyoda Gosei Co., Ltd. | Decorative article and process for producing the same |
| JP2007196659A (en) * | 2005-11-08 | 2007-08-09 | Fujitsu Component Ltd | Thermoplastic resin made casing and method for fabricating the casing |
| WO2021093272A1 (en) * | 2019-11-15 | 2021-05-20 | 太仓优上展示器具有限公司 | Prestressed high-strength plywood and manufacturing method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2610193B2 (en) | 1997-05-14 |
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