JP5116036B2 - Composite decorative board - Google Patents

Description

  The present invention relates to a composite decorative board, and more particularly, to a heat-resistant composite decorative board that does not cause warping and protrusion of a surface end portion of the composite decorative board by heating.

In recent years, composite decorative boards that have a pattern layer on the back surface of a transparent resin plate-like body and have a deep pattern layer that can be seen through the transparent resin are attracting attention. A general configuration is shown in FIG . A composite decorative board 1a having a composite structure of a core material 2a made of a wood material and a transparent resin plate 6a on the front surface and a resin plate 8a that does not require special transparency on the front surface, the thermal expansion of the resin plate and the transparent resin plate and the core material 2a Since the coefficients of thermal expansion differ greatly, the composite decorative board having a large area is formed in such a shape that the edge band 5a around the end face holds down the front and back surfaces of the composite decorative board. In such a shape, the joint Fa of the edge band can be seen from the front side of the composite decorative board and lacks in design. 7a is a pattern layer and 9a is an adhesion adjusting layer. FIG. 7 shows a configuration for compensating for these drawbacks and improving the appearance. The composite decorative board 1b has edge bands 5b attached to the four circumferences of the core material 2b made of wood material, and the transparent resin plate 6b on the front surface and the resin plate-like body 8b on the back surface are bonded so as to cover the edge band and the corners are chamfered The edge band seam is not visible from the front. However, when a heat resistance test is performed at 60 ° C. or 70 ° C. for 4 hours, the front and back resin face materials expand due to heat. For example, in the case of an acrylic resin plate or ABS resin plate, about 1 to 3 m jumps out about 1.5 to 3 mm on one side. Will occur and the appearance will be damaged. When it is severe, the pattern layer 7b may be cut or peeled off. One of the causes is that the resin plate-like bodies on the front and back surfaces are bonded so as to cover and cover the edge band, so that they cannot be stopped at the ends and freely extend. However, after the extended front and back materials are cooled, the adhesive also cools and remains stretched as it shrinks to the original dimensions. Thereafter, even if the heat resistance test is performed again at 60 ° C. and 70 ° C., there is almost no change in dimensions. The inventors focused on this phenomenon and reached the present invention after trial and error. Although the following gazette is mentioned as a prior art, the elastic adhesive which follows this even if the resin plate-like body expands and contracts is used, and the edge sticking material covers the thickness surface of the surface material at the corner. Are sequentially positioned. In addition, a joining method for improving the yield at the stage of manufacturing the composite plate is described.
JP 2003-269048 A Japanese Patent Laid-Open No. 2005-74805

  Provided is a composite decorative board which is improved in heat resistance of a composite decorative board in which a resin plate-like body and a wood-based core material are combined, and has no warp and end protrusion at an atmospheric temperature of 70 ° C. or lower.

  The composite decorative board of the present invention uses a wood-based material such as plywood, particle board, MDF (Medium Density FIBERBOARD) as a core material, and a transparent resin plate-like body including a pattern layer is provided on one surface via an adhesive. In addition, in the composite decorative board provided with the resin plate-like body having the adhesion adjusting layer on the other surface via an adhesive, the resin plate-like body used for the front and back surfaces is preheated to be in the vicinity of the desired heat-resistant temperature. The adhesive is applied in a stretched state, and the force to shrink when the temperature returns to room temperature is allowed to remain as stress inside the resin plate. The transparent resin plate is a transparent resin plate and a state in which a pattern layer is formed by printing or painting on the transparent resin plate. The resin plate is a resin plate that does not require special transparency. A state in which a coated surface having the same physical properties and adhesion as the pattern layer is formed is a plate-like body. The pattern layer has a concealing property and covers the edge band and the seam (adhesive surface) between the edge band and the core material, thereby improving the design and further cutting the end surface portion of the transparent resin plate by diamond cutting. Provide a composite decorative board with a high design view by providing a surface.

  In addition, the use of a polyurethane-based hot-melt adhesive that has an early appearance of initial strength during bonding and is less softened by heat after reaction hardening as an adhesive, stressed by the force to shrink the resin plate on the front and back surfaces at room temperature It was made to remain so that when it was heated, it was released from the stress, but not as stretched.

  The design layer provided on the resin plate on the front and back surfaces, the adhesion strength of the adhesion adjustment layer to the resin plate is a flexible property that can follow expansion and contraction against changes in heat from room temperature to 70 ° C. It is necessary that the coating film has an adhesion strength that does not peel off.

  It is also effective to install an infrared heater and / or a hot air generator near the position immediately before the press roll in order to control the surface temperature of each resin plate-like body immediately before the press bonding to 50 ° C. to 70 ° C.

  In addition, it is easy to keep the pre-applied heat until the time of joining with the core, and the backup roll of the roll coater is warmed so that each resin plate does not warp when passing through the roll coater to which the hot melt adhesive is applied. Use a roll coater. As a method for heating the roll, a heater is attached in the roll or heat rays are irradiated from the outside of the roll.

  The composite decorative board according to the present invention is a highly decorative composite decorative board in which the joint of the edge band is not visible when viewed from the front of the door, but the environment up to 70 ° C. is higher than the cold repeated C test of special plywood JAS. There is no warpage in the test, and no gaps or protrusions due to temperature changes occur on the four sides of the edge band and highly-designed surface member, so the appearance is not impaired.

The composition of the composite decorative board of the present invention comprises the following elements.
1) The composite decorative board is composed of wood-based material such as particle board, MDF, and plywood as a core material, an acrylic resin board as a surface material, an acrylic resin board as a back material, and acrylonitrile-butadiene-styrene copolymer resin. (Hereinafter, referred to as ABS), high impact polystyrene (hereinafter, referred to as HIPS), or the like having a substantially equal linear expansion coefficient is preferably used.
2) It is desirable that the front and back face materials have the same thickness.
3) It is desirable that the adhesive on the back surface has the same composition. The pattern layer and the adhesion adjusting layer provided on the front and back resin plate-like bodies are preferably the same type of paint or ink, the surface wettability is 35 dynes / cm 2 or more, and the back side is a single resin plate-like body. In this case, the wettability is the same as that of the pattern layer by polishing, corona discharge, or primer treatment, and is 35 dynes / cm 2 or more.
4) The adhesive is preferably a hot melt adhesive that has a high initial strength and a high strength, and the strength after curing is difficult to be thermoplastic and the heat resistance is high, and PUR. H. M.M. Is mentioned. PUR. H. M.M. Is an abbreviation for moisture-curing polyurethane hot melt adhesive. The initial strength is manifested by hot melt, and the isocyanate is gradually cured by moisture in the material and moisture in the air.
5) The temperature of the resin plate-like body is expanded near the desired heat-resistant temperature, applied with an adhesive, and crimped to the core material in an expanded state. It is desirable that the adhesive is applied in an atmosphere of 20 ° C. to 25 ° C., the roll application temperature is 100 ° C. to 150 ° C., and the back roll is also heated to the same temperature.
6) The bonding environment is 20 ° C. to 25 ° C., and the adhesive has an open time as short as possible to prevent the temperature of the resin plate from being lowered. The temperature of the core material is suitably 15 ° C to 20 ° C. The plate temperature of the resin plate was swept from 30 ° C. to 70 ° C. under conditions of room temperature of 20 ° C. and core material plate temperature of 17 ° C., and the pre-adhesion temperature and the temperature during pressure bonding were measured to give a heat load of 70 ° C. The warp and peeling of the time were observed, and it was found that the plate temperature at the time of pressure bonding was 50 ° C to 70 ° C. The results are shown in Table 1.

  FIG. 1 is a partial cross-sectional view showing a configuration of a composite decorative board 1 of the present invention. 2 is a core material using a wood-based material. Reference numeral 3 denotes a transparent resin plate-like body which is composed of a pattern layer 7 printed or painted on the transparent resin plate 6 and adhered to the core material. Reference numeral 4 denotes a resin plate-like body which is composed of an adhesion adjusting layer 9 painted on the resin plate 8 and bonded to the core material.

  First, a procedure for producing the transparent resin plate-like body 3 will be described. A 2 mm thick transparent acrylic resin plate (Mitsubishi Rayon, trade name: Acrylite S) is cut to 455 mm x 695 mm, and cream-based acrylic urethane resin-based enamel paint (made by Toupe, trade name: Refine) 2K) was adjusted at a ratio of 9: 1: 35 of the main agent, curing agent, and thinner, and was applied at a rate of 165 g / m 2 with a curtain coater, and placed in a shelf for natural drying. The drying time was 12 hours at a room temperature of 20 ° C. to obtain a monochromatic pattern layer 7. The coating means is appropriately selected from curtain coater, roll coater, and spray.

  Next, the resin plate-like body 4 is created. Mixing ratio of main agent, curing agent and thinner with cream-based acrylic urethane resin enamel paint (trade name: Refine 2K) on one side of 2mm thick ABS resin plate (trade name Toughace, manufactured by Sumitomo Bakelite) Was adjusted at a ratio of 10: 1: 35, applied with a curtain coater at a ratio of 165 g / m 2, and placed in a shelf for natural drying. The drying time was 12 hours at a room temperature of 20 ° C. to form the adhesion adjusting layer 9. The coating means is appropriately selected from curtain coater, roll coater, and spray.

  Next, an edge band is bonded to the end surface of the core member 2 around the periphery. A 15 mm thick particle board was cut to -4 mm with respect to the composite decorative board size. That is, when making a composite decorative board of 445 mm × 695 mm, it is cut into 441 mm × 691 mm, and a 2 mm thick edge band (made by Panefuri Industry, product name: Acrylic Marblet) 5 is hot melt adhesive (Daikyo) Co., Ltd., trade name: Imelt W-1600) is applied and bonded at a rate of 100 g / m2. The thickness of the core material 2 and the width of the edge band 5 are adjusted to be flush with each other. These bonding operations can be performed accurately when treated with a Holzher Triathlon Edge Bander.

  Next, the process of creating a laminate will be described. Adhesive application and pressure bonding are performed in a room whose room temperature is adjusted to 20 to 25 ° C. As described above, a resin plate-like body using an acrylic resin plate or ABS resin plate painted in advance is cured for 30 minutes in a constant temperature room at 60 ° C. When the plate temperature was measured, it was kept at 60 ° C. The core material 2 having the edge band 5 attached around the four sides is cured in a room at 20 ° C. for 30 minutes. In this case, it is confirmed that the temperature is maintained at 15 ° C. As a hot melt adhesive, PUR. H. M.M. (Kreb Chemie, product name: Kliberit 706.0) is used and melted at a roll temperature of 100 ° C. to 150 ° C. on a roll coater for hot melt shown in FIG. By heating the backup roll of the roll coater, the decrease in the plate temperature of the resin plate can be delayed, and the warp of the resin plate passing therethrough can be prevented. PUR. Molten on the painted surface of a transparent resin plate using a transparent acrylic resin plate. H. M.M. Is applied at a rate of 60 ± 5 g / m 2 to form the adhesive layer 16. Similarly, PUR. Molten on the painted surface of a resin plate-like body using an ABS resin plate. H. M.M. Is applied at a rate of 60 ± 5 g / m 2. A special jig is used so that the four rounds jump out by 0.5 mm, and the edge band is set on the front and back surfaces of the core material stuck on the four rounds. Thereafter, using a roll press machine shown in FIG. 3, the roll interval is reduced by 0.25 to 0.5 mm from the total thickness including the transparent resin plate, the resin plate, and the core, and the rubber hardness is 70 degrees. The roll is passed at a speed of 5 to 7 m / min and pressed. At this time, the material temperature of the transparent resin plate and the resin plate at the time of roll pressing is controlled to 50 ° C to 70 ° C. In order to maintain the material temperature of each resin plate, the infrared heater 21 emits heat rays to maintain the material temperature. In addition, using multiple roll press machines, incorporating a heater into the roll of the first roll press machine, managing the roll temperature between 50 ° C and 70 ° C, and maintaining the material temperature of the transparent resin plate and resin plate Better results can be obtained by crimping to.

  Curing is performed in a room at 20 ° C for 30 minutes or more after the roll press. After that, chamfering is performed on the upper and lower sides using a chamfering device.

  FIG. 2 is a schematic cross-sectional view for explaining that the hot melt adhesive 11 is melted and uniformly applied onto the coated surfaces of the transparent resin plate 3 and the resin plate 4 using a roll coater 10 for hot melt. FIG. Reference numeral 12 denotes an application roll. A heater 13 is installed inside the roll, and the roll is heated by energization. No. 14 is a doctor roll that adjusts the roll gap to adjust the amount of hot melt adhesive 11 that has been melted. Reference numeral 15 denotes a backup roll, which is similarly provided with a heater 13. Each roll surface temperature can be adjusted to 100 ° C. to 150 ° C. by energization to heat the transparent resin plate and the resin plate. Although not particularly shown, heat rays may be irradiated from the outside of the roll instead of the heater. Each resin plate that has passed through the roll coater forms an adhesive layer 16. Reference numeral 17 denotes a belt conveyor.

  FIG. 3 is a schematic cross-sectional view for explaining the pressing of the transparent resin plate-like body 3 and the resin plate-like body 4 provided with the adhesive layer 16 on the front surface and the back surface side of the core material 2 using the roll press machine 18. is there. Each of the pair of press rolls 19 is provided with a rubber layer 20, and the rubber hardness is preferably 70 degrees. However, when it is necessary to push in the adhesive due to the smoothness and roughness of the core material, a higher rubber hardness is required and 80 degrees is required. Further, when smoothness is particularly required, an iron roll is used. On the other hand, if the surface quality of the core material is high and the surface properties are dense, the rubber hardness is preferably low, and even if it is as low as 50 degrees, it can be used without any problem. The transparent resin plate-like body 3 is disposed in close contact with the front surface side of the core material 2 via the adhesive layer 16, and the resin plate-like body 4 is disposed in close contact with the back surface side through the adhesive layer 16. Passing and pressing a press roll having a rubber hardness of 70 degrees with a roll interval of 0.25 to 0.5 mm narrower than the total thickness including the transparent resin plate, the resin plate, and the core at a speed of 5 to 7 m / min. To do. At this time, the material temperature of the transparent resin plate and the resin plate at the time of roll pressing is controlled to 50 ° C to 70 ° C. 22 is a roller conveyor.

  In the configuration of Example 1, a composite decorative board was prepared in the same manner as in Example 1 except that an adhesion adjusting layer was formed on the back surface using a 2 mm thick HIPS resin board instead of the ABS resin board.

The composite decorative board produced in Examples 1 and 2 was subjected to a heat resistance test and a cold heat repetition test in the following manner.
(Heat resistance test 1) The composite decorative board was allowed to stand at 20 ° C for 7 days, heated in a constant temperature room at 60 ° C for 24 hours, and then cooled at room temperature, and then warped, peeled off, and the front and back materials did not protrude.
(Heat resistance test 2) The composite decorative board produced in this example was heated at 50 ° C for 1 hour, 60 ° C for 1 hour, 70 ° C for 1 hour, and further at 70 ° C for 3 hours, and then cooled at room temperature. There was no warping, peeling, or jumping out of the front and back surfaces.
(Cold Heat Repeat C Test) A JAS standard cold heat repeat C test of special plywood was conducted, and an environmental test from -20 ° C. to 60 ° C. was conducted to confirm durability.

(Drilling test for hinge installation)
About the composite decorative board manufactured in Examples 1 and 2 above, a hole 23 having a diameter of 35 mm and a depth of 13 mm from the ABS resin plate or HIPS resin plate side is seated so that the side wall surface thereof is located 5 mm from the side surface of the composite decorative plate. Drilled with a drill with a feeding cutter, the shape was observed. FIG. 4 shows the cross-sectional shape of the hole, and it was confirmed that no cracks or the like occurred in the resin plate.

  The composite decorative board 1 is obtained through the same configuration and steps as in the first embodiment. Indoor curing is performed in an atmosphere at 20 ° C. for 30 minutes or more after the roll press. Thereafter, a single crystal diamond blade is attached to the chamfering machine, and the chamfering shown in FIG. 5 is performed. The chamfering is finished to a cut-like glossy surface of crystal glass, and the cut surface 30 is formed on all four sides. The angle of the cut surface is not particularly limited, but an angle of 15 ° to 35 ° with respect to the surface of the transparent resin plate 6 is preferable. The edge of the composite decorative board 1c obtained in this way has a structure in which the joint between the edge band 5 and the core material is obstructed by the pattern layer 7 from the front side, so the edge band color and pattern are unique. Therefore, it is possible to provide a composite decorative board with high design properties. Further, by making the edge band 5 the same as the material of the surface, the seam can not be seen from the surface, and the surface and the mouth end can be seen integrally, and a composite decorative board with a higher design can be obtained.

[Comparative Example 1]
In Example 1, the laminating operation was performed in a room in a winter room at a room temperature of 10 ° C. in a state where the plate temperature of the transparent resin plate and the ABS resin plate was 10 ° C. and the plate temperature of the particle board was 7 ° C. PUR. H. M.M. After laminating at a temperature of 100 ° C. to 150 ° C. and heating only one side, lamination was performed in the same manner as in Example 1, and after standing at 20 ° C. for 7 days, a heat resistance test 1 was conducted. Protruded about 1 mm on both sides on the 695 mm side in the longitudinal direction. In addition, cracks occurred in the pattern layer, the acrylic resin plate was peeled off, the back surface was warped, and appearance and poor adhesion occurred.

[Comparative Example 2]
In Example 1, the adhesive used for lamination was laminated using a thermoplastic EVA hot melt adhesive (ethylene vinyl acetate) (trade name: W-1600, manufactured by Daikyo). All except the adhesive was the same as in Example 1. After curing for 7 days at 20 ° C., heat resistance tests 1 and 2 were performed. In either case, no warpage or peeling occurred, but the front and back resin plate-like bodies were reduced by 0.5 mm from the end, resulting in poor appearance.

  The composite decorative board in which the front and back surfaces of the woody material of the present invention are covered with a resin plate is warped in a wide temperature environment, peeled off, and does not jump out of the front and back boards, and does not impair the appearance. Not only for doors for system kitchens, but can be widely provided for face materials such as bathroom vanities, storage furniture doors, and partition panels.

It is a schematic cross section of the composite decorative board of the present invention. Example 1 It is a schematic cross section of a roll coater for hot melt adhesive. Example 1 It is a schematic cross section of a roll press. Example 1 It is a schematic cross section of a hinge mounting hole test piece. It is another embodiment of a composite decorative board. (Example 3) It is a schematic cross section of the conventional composite decorative board. It is a schematic cross section of the conventional composite decorative board.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Composite decorative board 2 Core material 3 Transparent resin plate-like body 4 Resin plate-like body 5 Edge tape 6 Transparent resin plate 7 Picture layer 8 Resin plate 9 Adhesion adjustment layer 10 Roll coater 11 Hot melt adhesive 12 Application roll 13 Heater 15 Backup Roll 16 Adhesive layer 18 Roll press 19 Press roll 20 Rubber layer 21 Infrared heater 23 Hole 30 Cut surface

Claims (6)

  A wood-based board is used as the core, and a transparent resin plate including a pattern layer is provided on one surface via a moisture-curable polyurethane hot melt adhesive (hereinafter abbreviated as PUR.HM). , PUR. H. M.M. In a composite decorative board provided with a resin plate-like body having a coating film having adhesiveness similar to that of the picture layer (hereinafter referred to as an adhesion adjusting layer), the adhesive layer is used for the one surface and the other surface. The transparent resin plate and the resin plate are preliminarily warmed and bonded to the core member in a state of being stretched in the vicinity of a desired heat-resistant temperature, and the force to shrink when the temperature returns to room temperature A composite decorative board which remains as stress in the inside of the body and does not appear as an elongation until the environmental temperature reaches the desired heat resistance temperature.   Assuming that the hottest atmospheric temperature in summer is 70 ° C., the elongation of the resin plate is within the stress range even when the ambient temperature rises from room temperature to 70 ° C., and the transparent resin plate and The composite decorative board according to claim 1, wherein the resin plate-like body is pressure-bonded while being controlled at a temperature of 50C to 70C.   The composite decorative board according to claim 1 or 2, wherein the composite decorative board has a strength to suppress thermal expansion of a resin board to which the pattern layer and the adhesion adjusting layer are in close contact.   2. The adhesive strength of an adhesive that adheres the pattern layer and the adhesion adjusting layer to the core has a strength to suppress thermal expansion or contraction of the transparent resin plate and the resin plate. The composite decorative board of any one of -3.   The composite decorative board according to any one of claims 1 to 4, wherein the pattern layer and the adhesion adjusting layer are made of paint or ink made of acrylic urethane resin.   The composite decorative board according to any one of claims 1 to 5, wherein a cut surface is formed at a four-circumferential end face portion of the transparent resin plate-like body.

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