KR20170077581A

KR20170077581A - Artificial timber

Info

Publication number: KR20170077581A
Application number: KR1020150187600A
Authority: KR
Inventors: 염경안
Original assignee: 염경안
Priority date: 2015-12-28
Filing date: 2015-12-28
Publication date: 2017-07-06

Abstract

The synthetic wood according to one embodiment of the present invention is a synthetic wood which is molded after impregnating a synthetic resin mixed with a thermosetting resin and a foaming agent into a glass fiber mat, wherein the thermosetting resin is any one of a phenol resin and a melamine resin, Is prepared at a composition ratio of 56 to 84% by weight of a phenol resin or a melamine resin and 5 to 20% by weight of a foaming agent, and the glass fiber is impregnated with the synthetic resin at 11 to 24% by weight. These synthetic timbers are stronger than conventional synthetic timbers or timber, have more strength than natural timber, have fire resistance, have little deformation or damage due to moisture, and are resistant to discoloration due to sunlight or ultraviolet rays. none.

Description

Synthetic Wood {ARTIFICIAL TIMBER}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to synthetic wood, and more particularly to a synthetic wood made of wood such as natural wood by an artificial method.

Generally, synthetic wood is made by extruding or extruding a mixture of wood debris (sawdust and sawdust) and foaming agent, which is foamed when the plastic is molded, to make it look and feel similar to natural wood. Injection molded articles are mainly used in cabinets of television receivers, and extrusion molded articles are mainly used for building materials.

As the plastic raw material, polystyrene, ABS resin or the like is used and is made by injection or extrusion molding. Injection molding products are able to show the texture of wood without secondary processing such as printing or painting because sculptures and grain patterns are put in the molding. Major uses include parts of electrical appliances such as cabinets of television sets, speaker grills, and parts of high-grade furniture.

In the case of an extrusion molded article, it is close to a material, a plate, and a corner material of a wood, and a main use is a building material. The extruded sheet can be rolled up when hot to make something similar to a ringed log.

Synthetic wood has the advantage of less absorbency and decay than natural wood. In addition, since the expansion ratio is relatively low and the skin layer has a high density on the surface, the strength is extremely high and processing such as nailing and planing is also possible. However, it is a drawback that the strength in the longitudinal direction is inferior and the warp is large.

In addition to the thermoplastic resin-based synthetic wood mentioned above, thermosetting resins (foamable phenolic resin and urethane resin) can be used to make frame, mirror, and other similar wood products.

Korean Patent Application No. 10-2015-7001254 (2013.07.01)

An embodiment of the present invention is superior in strength to density compared to existing synthetic wood or wood, has a strength higher than that of natural wood, is fire resistant, has little deformation or damage due to moisture, To provide a synthetic wood with little deterioration due to heat.

According to an aspect of the present invention, there is provided a synthetic wood which is formed by impregnating a glass fiber mat with a synthetic resin mixed with a thermosetting resin and a foaming agent, wherein the thermosetting resin is a phenolic resin and a melamine resin , And the synthetic resin is provided in a composition ratio of 56 to 84% by weight of the phenol resin or melamine resin and 5 to 20% by weight of a foaming agent, and the glass fiberba is impregnated with the synthetic resin in an amount of 11 to 24% by weight .

The synthetic wood may have a water content of 6-15% of the total weight.

The synthetic wood may have a density of 0.2 to 0.8 g / cm < ³ >.

The density can be controlled by the amount of foaming agent to be mixed.

The synthetic wood may have an elastic modulus of 2000 MPa to 15,000 MPa and a breaking coefficient of 14,000 KPa to 95,000 KPa.

The synthetic wood has a compressive strength of 8,000 kPa to 50,000 kPa when the wood is parallel to the pressing direction of the wood, and a compressive strength of 4,000 kPa to 30,000 kPa when the wood is perpendicular to the pressing direction of the wood.

According to one embodiment of the present invention as described above, it is superior in density to conventional synthetic wood or wood, has a strength higher than that of natural wood, has fire resistance, is hardly deformed or damaged by moisture, It is possible to provide a synthetic wood having little discoloration or deterioration due to ultraviolet rays or the like.

1 is a schematic view of an impregnation apparatus for a synthetic wood manufacturing method according to an embodiment of the present invention.
2 is a process flow diagram of a method of manufacturing synthetic wood according to an embodiment of the present invention.
3 is a schematic view of an impregnation apparatus of a synthetic wood manufacturing method according to another embodiment of the present invention.
4 is a process flow diagram of a method of manufacturing synthetic wood according to another embodiment of the present invention.
5 is a schematic front view of an intermediate workpiece by a method of manufacturing synthetic wood according to another embodiment of the present invention.
Fig. 6 is a state in which the intermediate product of Fig. 5 is aged in a mold.
FIG. 7 is a synthetic wood produced by the method of manufacturing synthetic wood according to another embodiment of the present invention.

Various embodiments of the present invention will now be described by way of specific embodiments illustrated in the accompanying drawings. The differences in the embodiments of the present invention described below are to be understood as mutually exclusive matters. That is, the specific features, structures, and characteristics described may be implemented in other embodiments in accordance with one embodiment without departing from the spirit and scope of the present invention, and the position of the individual components within each disclosed embodiment It is to be understood that the present invention may be embodied in many other specific forms without departing from the spirit or essential characteristics thereof.

The synthetic wood according to one embodiment of the present invention is a synthetic wood which is molded after impregnating a synthetic resin mixed with a thermosetting resin and a foaming agent into a glass fiber mat, wherein the thermosetting resin is one of a phenol resin and a melamine resin, 56 to 84% by weight of a phenol resin or a melamine resin and 5 to 20% by weight of a foaming agent, and the glass fiberba is impregnated with the synthetic resin in an amount of 11 to 24% by weight.

The synthetic wood according to an embodiment of the present invention may be manufactured by a synthetic wood manufacturing method described below and may have improved properties than ordinary wood or conventional synthetic wood.

Synthetic wood may have a moisture content of 6 to 15% of the total weight to provide greater rigidity than normal wood. At this time, the synthetic wood may have a density of 0.2 to 0.8 g / cm ³ . The density of such synthetic wood can be controlled by the amount of foaming agent mixed with the thermosetting resin. That is, the density of the synthetic wood is low when the amount of the blowing agent is large, and the density of the synthetic wood is large when the amount of the blowing agent is small.

Synthetic wood having a water content of 6 to 15% of the total weight and a density of 0.2 to 0.8 g / cm ^{3 in total} can have an elastic modulus of 2000 MPa to 15,000 MPa and a breaking coefficient of 14,000 KPa to 95,000 KPa.

The synthetic wood having the above composition ratio has a compressive strength of 8,000 kPa to 50,000 kPa when the wood is parallel to the pressing direction of the wood and a compressive strength of 4,000 kPa to 30,000 kPa when the wood is perpendicular to the pressing direction Lt; / RTI >

As described above, the synthetic wood according to one embodiment of the present invention is formed by impregnating a synthetic resin mixed with a foaming agent and a thermosetting resin into a glass fiber mat to have a predetermined thickness, and a thermosetting resin and a glass fiber mat are mainly constituted. It has more strength than density of synthetic wood or wood, has strength more than natural wood, is fireproof, has almost no deformation or damage due to moisture, and has almost no degeneration due to sunlight or ultraviolet rays.

Hereinafter, the method for producing synthetic wood as described above will be described in detail. The synthetic wood having a plate shape will be described.

1 and 2, in the synthetic wood manufacturing method according to an embodiment of the present invention, the avoidance material feed roll 10, the synthetic resin 110 or the like, in which the glass fiber mat 100 is wound, The impregnation vessel 20 in which the pure resin 160 is contained and through which the avoidance impregnation material of the impregnated material supply roll 10 passes is installed on the impregnation vessel 20 and avoids pressing down the impregnation vessel 20 downward in the impregnation vessel 20 A guide roller 30 for guiding the penetration of impregnation of the slurry, and an impregnation device 50 provided on the impregnation vessel 20 for the rollers 40 can be used.

As shown in FIGS. 1 and 2, in this embodiment, a thermosetting resin and a foaming agent are mixed to prepare a synthetic resin 110. The foaming agent can expand the resin itself during the final aging process, which is the production of synthetic wood.

Thereafter, the synthetic resin 110 is impregnated into the glass fiber mat 100, the glass fiber mat 100 impregnated with the synthetic resin 110 is dried, and the dried glass fiber mat 100 is pressure-molded. The glass fiber mat 100 may have a unwoven structure, and may be composed of a glass fiberba having a cross-sectional size of 5 to 20 micrometers. As the drying method, both natural drying and industrial drying can be used.

The synthetic resin 110 is made by mixing a thermosetting resin such as phenol resin or melamine resin with a foaming agent capable of forming bubbles as described later. At this time, the synthetic resin 110 is contained in the impregnation vessel 20.

The glass fiber mat 100 used as a fiducial material of the synthetic resin 110 can be accurately filled with the synthetic resin 110 by impregnating the synthetic resin 110 as a glass fiber mat as a matt formed with glass fibers.

At this time, in the step of impregnating the synthetic resin 110 into the glass fiber mat 100, the glass fiber mat 100 is soaked in the synthetic resin 110 and then passed through the rollers 40 to transfer the synthetic resin 110 to the glass fiber The mat 100 is impregnated. That is, the glass fiber mat 100 is fed from the avoiding impregnated supply roll 10 to the impregnation vessel 20, guided by the impregnation vessel 20 by the guide rollers 30, (40).

In other words, the glass fiber mat 100 can be fed to the impregnation vessel 20 by being wound around the avoiding impregnated feed roll 10 with the avoiding impregnation, and subjected to deflection pressure by the guide rollers 30 in the impregnation vessel 20 And is compressed by the rollers 40 while passing between the rollers 40 located on the impregnation vessel 20.

Accordingly, the synthetic resin 110, in which the thermosetting resin and the foaming agent are mixed, can be impregnated into the glass fiber mat 100 at a uniform thickness. Thereafter, the impregnated glass fiber mat 100 may be dried to have a certain moisture content. That is, in the step of drying the glass fiber mat 100, the glass fiber mat 100 can be dried such that the water content is in the range of 6% to 15%.

Further, the impregnated and dried glass fiber mat 100 is press-molded and has a solid structure of a certain thickness. In this press forming step, the dried fiber mat can be aged to a certain thickness and size under a pressure of an error range of 20% to 1800 psi at a temperature in the range of 120 to 160 degrees centigrade.

The thermosetting resin is one of a phenol resin and a melamine resin. The synthetic resin 110 is prepared in a composition ratio of 70 ± 14% by weight of phenol resin or melamine resin, 20 ± 4% by weight of glass fiber and 10 ± 5% by weight of blowing agent , And the respective composition ratios are determined so that the total weight% of the composition ratio becomes 100.

According to the method of manufacturing a synthetic wood according to an embodiment of the present invention described above, a synthetic wood material impregnated with a synthetic resin 110 comprising a thermosetting resin and a foaming agent may be provided on the glass fiber mat 100 and dried and aged.

These synthetic timbers can have a modulus of elasticity of 2000 MPa to 15,000 MPa and a tensile modulus of 14,000 KPa to 95,000 KPa and a compressive strength of 8,000 KPa to 50,000 KPa and a compressive strength of 4,000 KPa to 30,000 KPa in the direction perpendicular to the direction of compression , There is a possibility of being fully utilized as a synthetic wood panel.

According to another embodiment of the present invention, a synthetic wood similar to a real wood can be provided because the whole cross section can be formed into a wood grain or a ring. That is, the synthetic wood produced according to another embodiment is log-shaped in that pure synthetic resin-impregnated paper is added to the synthetic wood according to the embodiment.

In the following production processes, processes for producing logwood-like synthetic wood can be added. The synthetic wood manufacturing method according to another embodiment of the present invention described below can be performed substantially the same until the step of impregnating the glass fiber mat with the avoiding material. However, if there is a difference, in the step of drying the glass fiber mat 100, the glass fiber mat 100 is dried so that the moisture content is in the range of 15% to 20%. Therefore, in the following, a process in which the glass fiber mat 100 is additionally provided after being impregnated and dried by the synthetic resin 110 will be described. As described above, it is assumed that the glass fiber mat 100, in which the thermosetting resin is impregnated and dried, is provided in advance according to an embodiment of the present invention.

As shown in FIGS. 3 to 5, impregnated paper 150 may be prepared as a material capable of being joined with the glass fiber mat 100 to form a wood grain. At this time, the main paper of the impregnated paper 150 may be prepared from kraft paper or plain paper.

The impregnated paper 150 may be impregnated with pure resin 160 in a separate or identical impregnation apparatus 50 having the same structure as the impregnating apparatus 50 described above. That is, as shown in FIG. 3, it is assumed that the impregnation device 50 is provided with a paper roll feeder 10 wound with paper, and the pure lane 160 is injected into the impregnation container 20.

At this time, the pure resin 160 is a pure resin 160 to which no foaming agent is added. When the paper 150 is passed through the impregnation vessel 20 containing the pure resin 160, the pure resin 160 is impregnated into the paper 150. As described above, the paper 150 may be provided in the avoiding impregnated supply roll 10, passing through the impregnation vessel 20 under the squeezing pressure by the guide rollers 30, passing through the rollers 40 Under pressure, impregnation is carried out with a uniform composition.

The paper 150 may be a paper 150 having a thickness of 0.02 mm to 0.2 mm and the paper 150 impregnated in the impregnation vessel 20 may be passed through the rollers 40 at a constant speed to form paper 150 The pure resin 160 can be impregnated with a uniform composition.

Thereafter, the paper 150 impregnated with the pure resin 160 is dried to a moisture content of 6% to 15%. Drying can be either natural drying or industrial drying. Accordingly, the paper 150 impregnated with the pure resin 160 at a predetermined thickness can be prepared. The impregnated paper 150 may be adhered to the impregnated dried glass fiber mat 100.

6, the glass fiber mat 100 impregnated with the synthetic resin 110 and the dried paper 150 impregnated with the pure resin 160 are alternately laminated, The intermediate workpiece 170 can be formed in a cylindrical shape. In this embodiment, the intermediate workpiece 170 is referred to as a prepreg.

The glass fiber mat 100 impregnated with the synthetic resin 110 and the paper 150 impregnated with the pure resin 160 are alternately stacked in several layers so that the cylindrical intermediate product 170 is rolled into a ring- Lt; / RTI > These intermediate workpieces 170 may be banded or banded to maintain the dried shape.

5 and 6, the intermediate workpiece 170 is further dried to reduce the moisture content. Further drying of the intermediate workpiece 170 approximately reduces the moisture content to less than 7%. The moisture content of 7% is almost the same as that of dry logs, and it regulates the moisture content almost equal to the moisture content of the elastic wood.

As shown in FIGS. 5 and 6, the further dried intermediate workpiece 170 may be loaded on a mold 180 having a log shape and aged into a log shape. Accordingly, the intermediate processed product 170 can be provided in a log shape having a predetermined shape by being aged into a log shape.

At this time, aging of the intermediate workpiece 170 maintains the intermediate workpiece 170 at a temperature range of 120 to 160 degrees Celsius and a pressure of 20 to 1800 psi for 20 minutes or more. As described above, the intermediate workpiece 170 loaded on the mold 180 can be fixed in a log shape by the set temperature, pressure, and aging time, and can be made into a synthetic wood in the form of a log. The synthetic wood in the final log form may have a cross-sectional shape as shown in Fig.

The synthetic wood according to another embodiment of the present invention as shown in FIG. 7 is made of a glass fiber based on synthetic wood or wood, has excellent strength against density, has strength higher than that of natural wood, and thermosetting resin Is resistant to fire and has little deformation or damage due to moisture etc. It is not only hardly changed by sunshine discoloration or ultraviolet rays but also has wood grain and ring on the entire section to give a feeling like real wood .

According to another embodiment of the present invention, an intermediate workpiece can be made by using glass wool instead of the paper used in the above-described another embodiment. Another embodiment differs from the above embodiment in that glass wool is used instead of paper as a dampening material for impregnating a pure resin which is an impregnation material, and the manufacturing conditions and procedures are the same as those of the above-mentioned other embodiments. However, the thickness of the initial glass wool may be different from the above paper. At this time, glass wool is used instead of paper, so that the strength of synthetic wood can be enhanced. According to another embodiment of the present invention, a synthetic wood material may be provided in which the intermediate processed product impregnated with glass resin is impregnated with glass fiber mat 100, which is impregnated with a thermosetting resin, to form a log shape.

For reference, typical characteristics of the above-mentioned thermosetting resin, phenol resin, melamine resin and blowing agent as well known are described. It is noted that in the above-mentioned embodiments, synthetic wood having properties according to the characteristics of the materials described below is provided.

First, the above-mentioned thermosetting resin is a resin which does not change its shape even when heat is applied again after curing by applying heat, and generally has good heat resistance, solvent resistance, chemical resistance, mechanical properties and electrical insulation. It can also be used to make fiber-reinforced plastics in combination with high-strength fibers.

Such a thermosetting resin is made of a relatively low molecular weight material having three or more reactors in the molecule by using a property that when a low molecular weight polymer is heated, the degree of polymerization is increased and it is not deformed even when a large force is applied. That is, when a liquid having a proper viscosity is used as a raw material in a low molecular weight mixture, heat is applied to form a three-dimensional network structure by progressing crosslinking, so that even when a large stress is applied, it is not deformed nor dissolved in a solvent. Depending on the type of heat, some heat may be removed or the strength may be lowered, but most of it is decomposed or evaporated.

Thermosetting resins are classified into a condensation polymerization type and an addition polymerization type. Examples of the condensation type include a phenol resin, a urea resin and a melamine resin, and an addition polymerization type include an epoxy resin and a polyester resin.

Phenol resins are thermosetting resins produced by the condensation of phenols and formaldehyde. It is similar to rosin, and the phenols used are mainly phenol. Depending on the catalyst used in the manufacturing process, novolac and resole are obtained, respectively. The former is cured by the dry method and the latter by the wet method. It is mainly used as insulating plate or adhesive.

Phenols are usually used as phenolics, but cresols are also used. The first resin produced by the acid catalyst in the manufacturing process is referred to as novolak, and the resin produced by the basic catalyst is referred to as resol, both of which have a small molecular weight. The appearance is similar to the rosin left after removing essential oil from Songji. When hexamethylenetetramine is added to the novolak, it is cured by heating in a mold to form a molded article (dry method).

The resole is cured when it is directly pressurized and heated (wet method). Resol is dissolved in alcohol, impregnated with cloth, paper, board in it, dried, and rolled and heated. The laminated product (laminated product) is used as an insulating plate for an electric distribution board, a large-sized switch, etc., and also gives various kinds of plywood as a bonding agent with water resistance. In addition, rubber and fiber adhesives used in the manufacture of tires are especially made from phenol with resorcin.

Melamine is a heterocyclic amine that is an organic base and a trimer of cyanamide. 66% of the mass is made of nitrogen, and when mixed with resin, it has fire-proof property.

Such melamine is a chemical substance with CAS No. 108-78-1, also referred to as 2,4,6-triamino-1,3,5-triazine or cyanurotriamide. The formula C3H6N6. It is a colorless bar-like crystal with a molecular weight of 126.12, a melting point of 347 ° C (decomposition) and a specific gravity of 1.573 (14 ° C). Melts to some extent in hot water, but does not dissolve in cold water or ethanol and does not dissolve in ether. These melamines are produced by reacting dicyandiamide with liquid ammonia under pressure. When heated together with formalin, the melamine resin (resin) is formed by the condensation reaction.

Blowing agent [blowing agent] is a substance that forms bubbles during a polymer reaction, and is divided into two types, chemical blowing agent and physical blowing agent. Since the chemical foaming agent is foamed in carbon dioxide generated by the reaction with water or the like by using the activity of the isocyanate group, water is used as the foaming agent, the physical foaming agent is mixed with the gas, or the decomposition type or the evaporation type foaming agent is used to cause the reaction heat And thus does not participate in the polymer reaction.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Deletion, addition or the like of the present invention may be variously modified and changed within the scope of the present invention.

10: Feed roller 20: Impregnation vessel
30: guide roller 40: roller
50: Impregnating device 100: Glass fiber mat
110: Synthetic resin 150: Paper
160: pure resin 170: intermediate processed product
180: Mold

Claims

A synthetic wood which is molded after a synthetic resin mixed with a thermosetting resin and a foaming agent is impregnated into a glass fiber mat,
Wherein the thermosetting resin is any one of a phenol resin and a melamine resin,
The synthetic resin is prepared in a composition ratio of 56 to 84% by weight of the phenolic resin or melamine resin and 5 to 20% by weight of a foaming agent,
Wherein the glass fiberbaa is impregnated with the synthetic resin in an amount of 11 to 24% by weight.

The method according to claim 1,
Characterized in that the synthetic wood has a water content of 6 to 15%

The method according to claim 1,
Wherein the synthetic wood has a density of 0.2 to 0.8 g / cm < ³ >.

The method of claim 3,
Characterized in that the density is controlled by the amount of foaming agent to be mixed.

5. The method according to any one of claims 1 to 4,
Wherein the synthetic wood has a modulus of elasticity of 2000 MPa to 15,000 MPa and a coefficient of rupture of 14,000 KPa to 95,000 KPa.

5. The method according to any one of claims 1 to 4,
Wherein the synthetic wood has a compressive strength of 8,000 kPa to 50,000 kPa when the wood is parallel to the pressing direction of the wood and a compressive strength of 4,000 kPa to 30,000 kPa when the wood is perpendicular to the pressing direction of the wood. wood.