JP3002422B2 - Decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative panel, and more particularly to a decorative panel used for a wall panel of a unit bath or the like, in which the design of the surface layer is made more transparent and deep and has excellent quality. The present invention relates to a decorative board having an effect.

[0002]

2. Description of the Related Art Conventionally, a vinyl chloride steel plate is generally used as a decorative plate mainly used for a wall of a unit bath or the like. In recent years, with the spread of unit baths for detached houses (hereinafter referred to as system baths), silk printing or transfer printing is performed on the surface of an inorganic base material such as a calcium silicate plate or the like, which has a more luxurious feel. Has been used, and wall panels have been used as decorative panels painted on them.

In some cases, natural marble, natural granite, or the like is used as a higher-grade wall material. However, due to the weight and the like, these natural materials use a standard panel of 800 mm × 2200 mm or the like as a single plate. There are few cases, always 8
It is common to form a large panel using three to four medium plates, such as 00 mm x 550 mm. In this case, the joint between the plates is finished by embedding a caulking material as a joint, but a colored caulking material such as light gray is generally used for the purpose of the design effect.
Other high-quality wall materials for system baths include large design ceramic tiles. In this case, the joints between the tiles are generally finished by applying light-colored caulking.

[0004]

On the other hand, with the advancement of the consumer market in recent years, there has been a trend in this field to supply products having better design and quality at an appropriate price, and in particular, the area is particularly large. The development of large and conspicuous wall panels has become an important theme in the industry. In addition to using a bathroom in a small space of about 1 tsubo every day, as well as a place to relax, the design of the wall needs to be deeper with a higher texture and a clearer and cleaner one. It has become.

[0005] However, the wall panels currently on the market are not only vinyl chloride steel sheets, but also the latest inorganic decorative boards, the surface of which has a printed layer of 10 μm to 30 μm on the design surface.
Most of the panels are simply painted lightly, and no panels with a deep texture that meets the above needs have emerged. These panels have a thin surface layer (0.1 mm to 0.3 m).
m), there is a problem in that joint cutting is impossible and high-quality image expression cannot be achieved in terms of design.

On the other hand, natural stones such as marble and granite, large ceramic tiles and the like have a luxurious feeling and are free from joint processing, and are excellent in design, but are expensive and heavy. Since the processing cost is relatively expensive, it is used only by a very limited number of users and is not common. Under such circumstances, development of a wall panel for a system bus which has a high-quality and deep texture and is suitable for joint processing has become an issue.

SUMMARY OF THE INVENTION The present invention has been made in view of the above description. A first object is to express a deep texture, and a second object is to enable joint processing. The third problem is to ensure a satisfactory quality as a bathroom wall panel, and the fourth problem is to supply it at an appropriate price.

[0008]

As a means for expressing a design with a deep texture, which is the first problem, the first tried formulation is to laminate a clear layer of a fixed thickness on a printing layer. It is a method of painting on the surface. Even with this formulation, a considerably deeper texture can be obtained compared to the conventional product, but the present inventors aimed at a further effect and decomposed the printed layer into two layers, and expressed one design with two printed layers. I focused on doing.

For example, when one pattern is composed of three plates, a clear film is used for the outermost print layer, a pattern consisting of a concealed portion and a transparent portion is printed for one plate, and a relatively thick intermediate layer is formed. A film (pattern layer) on which the remaining two plates are printed is laminated via a certain (thickness: 0.2 to 0.5 mm) clear film, that is, by sandwiching the clear film, and an upper printed pattern and a lower layer are laminated. By integrating the printed pattern and the three layers via a clear film, a deep design expression can be realized. In this case, it is desirable to use a colored film as the film to be printed to form the picture layer.

As a second object, a means for obtaining a decorative board capable of joint processing is to laminate a sheet having a thickness that allows the depth of joint processing under a design layer (composite sheet expressing a design). Further, the problem can be solved by using a sheet colored in accordance with a predetermined design design.
For example, as shown in FIG. 2, when the depth of the joint is 0.8 mm, if the thickness of the surface design layer is 0.35 mm and the thickness of the colored sheet laminated thereunder is 0.8 mm, the coloring is performed. The joint is cut to a position of 0.45 mm from above the sheet layer. In addition, if the coloring sheet is colored with a preset joint color, it is possible to express a joint of a predetermined color without coloring (painting) the joint portion later.

In addition, as a third problem, the inventors of the present invention have conducted intensive studies in order to obtain a product which does not pose a problem in terms of quality even when used as a bathroom wall panel. Is an acrylic resin film, that is,
An acrylic clear film was adopted. At present, most of the printed films for decorative boards are made of vinyl chloride resin, and clear films composited with these are also often made of vinyl chloride resin. Therefore, it is practical to use a vinyl chloride resin as a material of a film used for a surface layer for obtaining a deep design effect which is the first problem. However, the vinyl chloride film has a problem in heat resistance. In the case of a clear film, there is a problem that the film is easily whitened with respect to warm water exceeding 60 ° C., and the quality is poor when used as a surface material of a wall panel for a bathroom. Not preferred.

On the other hand, an acrylic film has the following characteristics as compared with a vinyl chloride film. (1) High heat resistance (vinyl chloride film is whitened by hot water at 60 ° C, but acrylic clear film is not whitened to 85 ° C). (2) Excellent in weatherability (vinyl chloride film is continuously exposed to sunshine weather meter. (3) High transparency (total light transmittance, vinyl chloride film 72%, acrylic clear film 93)
%), (4) Excellent in stain resistance. From the above, it is understood that the acrylic film is an appropriate material in consideration of the characteristics of the surface layer material of the bathroom wall panel.

The fourth problem, supply at an appropriate price, has been solved as follows. The drawbacks of the acrylic clear film are that there are problems that (1) the cost is relatively high and (2) there is no colored film having concealing properties compared to the vinyl chloride film. The following means has been adopted as means for solving this problem. The problem (1) was solved by reducing the thickness of the clear film used (because the acrylic clear film has high transparency, the thickness of the intermediate clear layer is 0.5 mm in the case of a vinyl chloride film). 0.15m when necessary
m gives equivalent texture). The problem (2) has been solved by using a vinyl chloride film as a colored film for forming a picture layer.

[0014] First, since the colored vinyl chloride film can contain a large amount of additives such as pigments and various stabilizers, there is no problem in quality such as heat resistance and weather resistance. Since the film and the vinyl chloride film are chemically compatible, thermal lamination etc. are easy,
A composite of a vinyl chloride film and an acrylic clear film can be formed by the same processing recipe as the vinyl chloride film. As a result, problems in terms of cost and production processing have been solved, and the problem of supply at an appropriate price can be cleared.

[0015]

FIG. 1 is a cross-sectional view showing a layer structure of a decorative plate according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view of a portion which has been subjected to joint processing for forming joint grooves. Show. (1) Preparation of Acrylic Print Film A An acrylic print film A was formed by printing a pattern 2 on one side of the front side of the acrylic clear film 1 by printing using a concealable paint. In this example, the acrylic clear film 1 has a thickness of 50 μm and a width of 91, for example.
The thing of 0 mm was used. In addition, the pattern 2 is a 1st pattern of a stone pattern composed of 3 plates (a transparent portion 2 for a printed portion 1).
Percentage) was printed. (2) Formation of Picture Layer C The picture layer 4 was printed on one side of the surface of the colored vinyl chloride film 3 to form the picture layer C. Colored vinyl chloride film 3
In the case of this example, for example, a thickness of 100 μm and a width of 910 m
m. For pattern 4, the remaining two plates of the three-plate stone pattern were printed. The pattern layer C may be printed with an independent pattern that is not necessarily linked to the pattern of the acrylic print film A. Another design effect can also be obtained by using a single-color colored vinyl chloride film 3 on which no pattern 4 is printed as the pattern layer C. (3) Preparation of composite sheet D The acrylic print film A of (1) above is used as an upper layer, and the picture layer C of (2) above is used as a lower layer, and prepared in advance in an intermediate layer between the acrylic print film A and the picture layer C. The acrylic clear film B thus obtained is laminated, and three layers are thermally laminated to form a composite sheet D. The acrylic clear film B has a thickness of about 0.1 mm to 0.5 mm. In the case of this example, the thickness is 150 μm and the width is 910 mm. (4) Preparation of Surface Material F The coloring sheet E is made of a vinyl chloride resin, and is formed by forming a vinyl chloride resin mixed with an inorganic filler and mixed with an inorganic filler into a sheet by a calender rolling method. . The colored sheet E has a thickness of 0.8 mm and a width of 910 mm, for example. This colored sheet E
The composite sheet D is stacked on the sheet, laminated by thermocompression bonding, and cut into a predetermined size to form a front material F. (5) Adhesion to base material H Surface material F is overlapped on base material H which has been subjected to sealer treatment in advance via an adhesive G such as an epoxy-based adhesive. As the substrate H, a substrate generally used in a bathroom, such as a water-resistant plywood, an inorganic substrate, and a galvanized steel sheet, is used. Substrate H
A specific example is a so-called autoclave flexible board. This autoclave flexible board is an autoclave curing board of a flexible board, and the flexible board is a kind of inorganic substrate, which is distinguished from a natural curing board, and pressurized, heated,
It is humidified and cured in a short time. The characteristics of the autoclave curing board are that the rate of dimensional change is smaller than that of the natural curing board, and there is an advantage that deformation (warpage) is less likely to occur. You. For example, the thickness of the substrate H is 4 m.
m, a width of 800 mm and a height of 2200 mm are used. (6) Coating After bonding the base material H and the surface material F, the surface of the acrylic print film A of the surface material F is coated with an acrylic UV paint to a thickness of about 60 μm by a film method, and is cured by UV and top-coated. The coating film I is formed to obtain a desired decorative board. (7) Joint processing As described above, for example, as shown in FIG.
After obtaining a decorative board having a height of 2200 mm and a height of 2200 mm, a surface having a width of, for example, 3 mm and a depth of 0.8 mm is provided at intervals of, for example, 550 mm.
The joint wall of mm was cut by an NC router, and joint processing for forming the joint groove 5 was performed to prepare a bathroom wall panel.

[0016]

As described above, according to the present invention, an acrylic print film having a pattern composed of a transparent portion and a concealed portion printed on one of the front and back surfaces of the acrylic clear film is used as the outermost surface side, and the acrylic print film is formed on the back surface side. An acrylic clear film is laminated, a pattern layer obtained by applying a pattern to a vinyl chloride film or colored is laminated on the back side of the acrylic clear film, and the above-mentioned acrylic printing film, acrylic clear film and a pattern layer are laminated and integrated. Since the composite sheet was used for the surface layer, it was possible to express a deep texture by integrating the upper layer pattern and the lower layer pattern via a clear film,
Moreover, by using an acrylic clear film, the heat resistance is high, the weather resistance is excellent, the transparency is high, and the quality that does not cause any problem as a bathroom wall panel can be secured, and the outermost layer side is an acrylic clear film, By using a vinyl chloride film on the picture layer side, it is possible to reduce the use of an expensive acrylic clear film and supply it at an appropriate price.

Further, in the invention according to claim 2 of the present invention, since a surface material in which a colored sheet is laminated and integrated on the back side of the picture layer of the composite sheet is used for the surface layer, the joint groove is processed by the joint processing. Then, the coloring sheet can be perforated to expose the color of the coloring sheet, and joint grooves having an appropriate depth can be formed and an appropriate joint color can be exposed.

In the invention according to the third aspect of the present invention, the thickness of the colored sheet is set to 0.3 mm or more and the joint groove is cut to the portion of the colored sheet. A joint groove having a depth can be formed to expose an appropriate joint color.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a layer configuration of a decorative board according to an example of an embodiment of the present invention.

FIG. 2 is a cross-sectional view of a portion where joint processing for forming the joint groove is performed.

FIG. 3 is a front view of the decorative board for explaining a position where a joint groove is formed in the same.

[Explanation of symbols]

 A Acrylic printing film B Acrylic clear film C Picture layer D Composite sheet E Colored sheet 1 Acrylic clear film 2 Picture 3 Colored vinyl chloride film 4 Picture 5 Joint groove

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-62-55134 (JP, A) JP-A-3-257250 (JP, A) JP-A-63-170231 (JP, U) (58) Survey Field (Int.Cl. ⁷ , DB name) B32B 1/00-35/00 E04F 13/00-13/18

Claims (3)

(57) [Claims] An acrylic printed film having a pattern consisting of a transparent portion and a concealed portion printed on one of the front and back sides of the acrylic clear film is the outermost layer side, and an acrylic clear film is laminated on the back side of the acrylic printed film.
A composite sheet obtained by laminating a pattern layer obtained by applying a pattern or coloring to a vinyl chloride film on the back side of the acrylic clear film and laminating and integrating the three layers of the acrylic printing film, the acrylic clear film and the pattern layer as a surface layer. A decorative plate characterized by being used. 2. The decorative board according to claim 1, wherein a surface material obtained by laminating and integrating a colored sheet on the back side of the picture layer of the composite sheet is used for the surface layer. 3. The decorative board according to claim 2, wherein the thickness of the colored sheet is 0.3 mm or more, and the joint groove is cut to a portion of the colored sheet.