Warp-resistant, soundproof and heat-insulating MDF board

Abstract

To provide a warp-resistant, soundproof and heat-insulating MDF board that is excellent in warp resistance, soundproofing and heat insulation and is suitable as a building material for wall materials, floor materials, fittings and the like. [Solution] The warp-resistant, soundproof and heat-insulating MDF board is a laminate of MDF, paper, polyethylene film and aluminum foil, with laminate sheets bonded in the following order: reinforced paper, polyethylene film with hot melt adhesive, aluminum foil, polyethylene film with hot melt adhesive and reinforced paper, attached to both sides of the MDF with a urethane adhesive.

Description

[Technical Field]

[0001] The present invention relates to warp-resistant, sound-proof and heat-insulating MDF boards. [Background technology]

[0002] MDF (medium density fiberboard) is a fiberboard made from plant fibers such as wood through a dry process, and has a density of 0.35 grams per cubic centimeter or more (JIS A5905). Wood chips are steamed and defibrated, then a synthetic resin adhesive is added and thermo-pressed into a sheet. Like wood, it is lightweight and highly workable, but it loses the inherent resistance of wood, is vulnerable to water and moisture, and is prone to mold if not treated. MDF has the property of expanding and contracting by absorbing and releasing moisture from the air. This absorption and release of moisture from the air occurs in response to changes in the environmental conditions around the MDF board, such as temperature and humidity. In particular, if the environmental conditions on the front and back of the MDF board are significantly different, a phenomenon known as warping will occur.

[0003] There are two types of soundproofing technology: sound insulation and sound absorption. Sound absorption is a technique that prevents sound from being reflected; it does not necessarily mean that sound-absorbing materials block sound from passing through. In fact, perforated materials are sometimes used, often allowing sound to pass through. Porous materials have numerous voids or interconnected air bubbles within them. When sound strikes these materials, the air within the material vibrates, creating resistance. The sound energy is converted into heat energy through friction between the fibers, resulting in a sound-absorbing effect. Plate (membrane) materials are used with an air layer behind them. When sound of a frequency that easily vibrates (a resonant frequency) enters the plate (membrane) in this state, the internal friction of the plate (membrane) converts the sound energy into heat energy, resulting in a sound-absorbing effect. Examples of materials that can be used include plywood and vinyl sheets.

[0004] Soundproofing is a technique that blocks sound with materials that make it difficult for sound to pass through. Basically, soundproofing is achieved by increasing the mass of the wall, but there is a limit to how much soundproofing can be achieved. Therefore, a great effect can be achieved by doubling up the walls, floors, and ceilings. Common building materials such as plasterboard and plywood are usually used. MDF has the same properties as wood, in that its cells contain air, making it difficult for heat to pass through, making it an excellent heat insulator (Non-Patent Document 1).

[0005] As a prior art, a moisture-proof heat insulating material has been devised in which aluminum is vapor-deposited onto a synthetic resin film, and the aluminum vapor-deposited layer is bonded to wood plywood via paper (Patent Document 1). This invention requires a process of vapor-depositing aluminum onto a synthetic resin film. A warp-resistant composite board has been devised in which metal foil such as iron foil or aluminum foil is laminated on both sides of an improved wood board such as plywood or fiberboard via an adhesive layer (Patent Document 2). This design does not provide sufficient protection for the metal foil.

[0006] A building material and building fixture have been invented in which an aluminum foil layer sandwiched between polyethylene films is adhered to a wood board via a paper layer, and the paper is adhered to the polyethylene film on the surface side of the aluminum foil layer (Patent Document 3). It is difficult to prevent warping when applying to one side of wood plywood. A wood decorative board has been invented in which a composite sheet consisting of aluminum foil, a polyethylene resin sheet, and paper is laminated to at least one side of a wood substrate via an adhesive (Patent Document 4). The aluminum foil side of the composite sheet is bonded to the wood substrate with an aqueous vinyl urethane resin adhesive, and the aluminum foil side of a sheet compounded with aluminum foil and decorative paper on the other side is bonded to the wood substrate with an aqueous vinyl urethane resin adhesive. The technique of adhering the aluminum foil surface of the composite sheet to the wood substrate using a water-based vinyl urethane resin adhesive is not simple.

[0007] A laminated panel has been invented in which a facing panel made of decorative plywood, an acoustic and thermal insulating material for heat and sound insulation, and a back panel made of plywood are glued together in that order, and the acoustic and thermal insulating material is formed from a core material made of a hard plastic material and soft metal sheets such as aluminum sheets fixed to the front and back of the core material (Patent Document 5). [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Public Practical Application 1982-1214 [Patent Document 2] Public Practical Application Showa 56-163527 [Patent Document 3] Patent 2571094 [Patent Document 4] Patent 3185675 [Patent Document 5] Patent Publication No. 05-302376 [Non-patent literature]

[0009] [Non-Patent Document 1] Masaru Ishimaru et al., eds., "Physics of Wood", Kaiseisha (2022) Summary of the Invention [Problem to be solved by the invention]

[0010] MDF is vulnerable to water and moisture and may warp. Building materials such as wall materials, flooring materials, and fittings require warp resistance, soundproofing, and heat insulation. We provide warp-resistant, soundproof, and heat-insulating MDF boards.

[0011] As a prior art, a moisture-proof heat insulating material has been devised in which aluminum is vapor-deposited onto a synthetic resin film, and the aluminum vapor-deposited layer is bonded to wood plywood via paper (Patent Document 1). This invention requires a process of vapor-depositing aluminum onto a synthetic resin film. A warp-resistant composite board has been devised in which metal foil such as iron foil or aluminum foil is laminated on both sides of an improved wood board such as plywood or fiberboard via an adhesive layer (Patent Document 2). This design does not provide sufficient protection for the metal foil.

[0012] A building material and building fixture have been invented in which an aluminum foil layer sandwiched between polyethylene films is adhered to a wood board via a paper layer, and the paper is adhered to the polyethylene film on the surface side of the aluminum foil layer (Patent Document 3). It is difficult to prevent warping when applying to one side of wood plywood. A wood decorative board has been invented in which a composite sheet consisting of aluminum foil, a polyethylene resin sheet, and paper is laminated to at least one side of a wood substrate via an adhesive (Patent Document 4). The aluminum foil side of the composite sheet is bonded to the wood substrate with an aqueous vinyl urethane resin adhesive, and the aluminum foil side of a sheet compounded with aluminum foil and decorative paper on the other side is bonded to the wood substrate with an aqueous vinyl urethane resin adhesive. The technique of adhering the aluminum foil surface of the composite sheet to the wood substrate using a water-based vinyl urethane resin adhesive is not simple.

[0013] A laminated panel has been invented in which a facing panel made of decorative plywood, an acoustic and thermal insulating material for heat and sound insulation, and a back panel made of plywood are glued together in that order, and the acoustic and thermal insulating material is formed from a core material made of a hard plastic material and soft metal sheets such as aluminum sheets fixed to the front and back of the core material (Patent Document 5).

[0014] This invention was made to solve a problem that has existed in the past. Namely, building materials such as wall materials, floor materials, and fittings require warp resistance, soundproofing, and heat insulation. There is a demand for warp-resistant, soundproof, and heat-insulating MDF boards. [Means for solving the problem]

[0015] In order to solve the above problems and achieve the objectives, we have invented the following warp-resistant, soundproof and heat-insulating MDF board.

[0016] This is a warp-resistant, soundproof, and heat-insulating MDF board, in which laminated sheets of MDF, paper, polyethylene film, and aluminum foil are bonded in the following order: reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper, and the laminated sheets are attached to both sides of the MDF with a urethane adhesive. The polyethylene film acts as a hot melt adhesive, the aluminum foil blocks moisture migration and prevents warping, and the reinforced paper makes the bond stronger. A laminated sheet in which reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper are bonded in this order is produced by a lamination method.

[0017] This warp-resistant, soundproof, and heat-insulating MDF board is made by laminating MDF, paper, polyethylene film, and aluminum foil together in the following order: reinforced paper, polyethylene film with hot-melt adhesive, aluminum foil, polyethylene film with hot-melt adhesive, and reinforced paper. The laminated sheet is attached to one side of the MDF with a urethane adhesive, and a melamine decorative board or polyolefin decorative board is attached to the other side, the former with an ethylene vinyl acetate adhesive, and the latter with a urethane adhesive.

[0018] This flush door is made using a warp-resistant, soundproof, and heat-insulating MDF board in which a laminated sheet made of reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper in that order is attached to both sides of the MDF with a urethane-based adhesive, or a warp-resistant, soundproof, and heat-insulating MDF board in which a laminated sheet made of reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper in that order is attached to one side of the MDF with a urethane-based adhesive and a melamine decorative board or polyolefin decorative board is attached to the other side with an adhesive.

[0019] MDF is used in residential construction materials such as flooring (base material), moldings, baseboards, window and door frames, ceiling panels, counters, bathroom vanities, system kitchen doors, and shelves, as well as furniture doors, side panels, and shelves. The aluminum foil laminated sheet-bonded MDF board of this invention can be effectively used in these applications. [Effects of the Invention]

[0020] MDF boards made by bonding layers of reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper in that order, are attached to both sides of the MDF with a urethane adhesive, or by bonding one side of the MDF with a urethane adhesive and then a melamine or polyolefin decorative board with adhesive on the other side, inhibit moisture migration and prevent warping. They also have soundproofing and heat insulation effects. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a schematic perspective view of an aluminum foil laminated sheet double-sided adhesive MDF board according to the present invention. [Figure 2] 1 is a schematic perspective view of an aluminum foil laminated sheet single-sided adhesive MDF board according to the present invention. [Figure 3] 1 is a cross-sectional view of a laminated sheet of aluminum foil, polyethylene film, and paper according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0022] Examples of the present invention are given below, but the present invention is not limited to the following examples. [Example]

[0023] FIG. 1 is a schematic perspective view of an aluminum foil laminated sheet double-sided adhesive MDF board (1) of the present invention. The MDF board (1) is warp-resistant, soundproof, and heat-insulating, and is made by laminating MDF (4), paper, polyethylene film, and aluminum foil together in the following order: reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper. The laminated sheet (2) is attached to both sides of the MDF (4) with a urethane adhesive (3). The urethane adhesive (3) used was Bond CVC300M (mixture, vinyl copolymer resin emulsion adhesive, urethane dispersion type) / hardener NV (mixture, crosslinking agent for water-based adhesive (polyisocyanate), hexamethylene diisocyanate) manufactured by Konishi Co., Ltd. [Example]

[0024] FIG. 2 is a schematic perspective view of the aluminum foil laminated sheet single-sided adhesive MDF board (5) of the present invention. A laminated sheet (2) of MDF (4), paper, polyethylene film, and aluminum foil, in the order of reinforced paper, polyethylene film with hot melt adhesive, aluminum foil, polyethylene film with hot melt adhesive, and reinforced paper, is attached to one side of the MDF (4) with a urethane-based adhesive (3), and a melamine decorative board or polyolefin decorative board is attached to the other side with an ethylene vinyl acetate adhesive to the former and a urethane-based adhesive to the latter, to form a warp-resistant, soundproof, and heat-insulating MDF board (5). [Example]

[0025] Figure 3 is a cross-sectional view of a laminated sheet of aluminum foil (9), polyethylene film (8), and paper (7) according to the present invention. In the laminate of paper (7), polyethylene film (8), and aluminum foil (9), the laminated sheet (6) is made by bonding reinforced paper (7), polyethylene film (8) with hot melt adhesive, aluminum foil (9), polyethylene film (8) with hot melt adhesive, and reinforced paper (7) in this order.

[0026] The above describes the invention of an MDF board bonded with an aluminum foil laminated sheet, but performance can be improved by making small improvements to each part. [Industrial Applicability]

[0027] As mentioned above, laminated sheets made of reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper in that order are attached to both sides of MDF with a urethane adhesive, or to one side with a urethane adhesive and the other side with a melamine or polyolefin decorative panel. This prevents moisture migration and warping, and also provides soundproofing and heat insulation. The aluminum foil laminated sheet-bonded MDF board of this invention can be used in building materials such as wall materials, floor materials, and building fixtures to provide warp resistance, soundproofing, and heat insulation. [Explanation of symbols]

[0028] 1. Aluminum foil laminated sheet, double-sided adhesive MDF board 2. Aluminum-polyethylene laminated sheet 3. Urethane adhesive 4 MDF base material 5 Aluminum foil laminate sheet, single-sided adhesive MDF board 6. Cross section of laminated sheet of aluminum foil, polyethylene film, and paper 7 Reinforced paper for building materials 8 Polyethylene film 9. Aluminum foil

Claims

1. This warp-resistant, soundproof, and heat-insulating MDF board is characterized by having a laminate of MDF, paper, polyethylene film, and aluminum foil, with laminate sheets bonded in the following order: reinforced paper, polyethylene film, aluminum foil, polyethylene film, and reinforced paper, attached to both sides of the MDF with a urethane adhesive.

2. A warp-resistant, soundproof and heat-insulating MDF board characterized by a laminate of MDF, paper, polyethylene film and aluminum foil, in which a laminate sheet made by bonding reinforced paper, polyethylene film with hot melt adhesive, aluminum foil, polyethylene film with hot melt adhesive and reinforced paper in that order is attached to one side of the MDF with a urethane-based adhesive, and a melamine decorative board or polyolefin decorative board is attached to the other side, the former with an ethylene vinyl acetate adhesive and the latter with a urethane-based adhesive.

3. A flush door, characterized in that it is made using the warp-resistant, soundproof and heat-insulating MDF board according to claim 1 or 2.

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