JP5235391B2 - Method for producing decorative board having uneven pattern - Google Patents

Description

  The present invention relates to a method for producing a decorative board having a concavo-convex pattern excellent in design, which can be suitably used for a wall material or a floor material of a building.

  A decorative board having a concavo-convex pattern on its surface is used as a wall material or floor material of a building. And as for such a decorative board, as shown to patent document 1 or patent document 2, an uneven | corrugated pattern is engraved by the embossing type | mold board etc. on the surface of the base material, and the paint finish is given to this surface .

  That is, in Patent Document 1, an undercoat paint is applied to the surface of a substrate on which an uneven pattern is formed by an embossed mold, and after drying, an overcoat paint different from the undercoat paint is applied, and the top coat paint of the convex portion is scraped off and dried. A method for manufacturing an uneven decorative board is disclosed.

Further, in Patent Document 2, an embossed recess restoration layer made of a synthetic resin is provided on a wood fiberboard-based substrate having a concavo-convex pattern, embossed from above, and a colored paint layer and a protective layer are further formed thereon. It is disclosed that a layer can be provided.
JP 58-170573 A Japanese Patent Laid-Open No. 10-323942

  However, according to such a method, since the paint is applied after embossing the substrate surface, a low-viscosity paint accumulates in the recesses 22a of the uneven pattern 22 as shown in FIG. The uniform transparent coating layer 30 cannot be formed on the entire surface 22. In addition, there is a problem that the sharp embossing feeling disappears due to the paint accumulated in the recess 22a, and the design appearance of the uneven pattern is impaired.

  The present invention was made in view of such conventional problems, and was excellent in wear resistance, stain resistance, load resistance, etc. applicable to floor materials used in hard environments as well as wall materials. It is an object of the present invention to provide a method for producing a decorative board having an uneven pattern having a high design property having a sharp emboss feeling and having physical properties.

In order to solve the above problems, a manufacturing method of a decorative sheet having an uneven pattern of the present invention, according to the invention of claim 1, an ultraviolet curable transparent coating material is applied to the surface of the substrate is irradiated with ultraviolet rays heating After the deformable first transparent coating layer is formed, an ultraviolet curable transparent coating is applied on the first transparent coating layer, and the second transparent coating can be heated and deformed by irradiating ultraviolet rays. By forming a film layer, a heat-deformable transparent coating layer comprising the first and second transparent coating layers is formed, and then the transparency comprising the first and second transparent coating layers . The surface of the coating layer is embossed by hot pressure to form a concavo-convex pattern on the surface of the substrate, and the transparent coating layer is heated and deformed along the concavo-convex pattern.

According to the invention of claim 2, in the method for producing a decorative board having a concavo-convex pattern according to claim 1 , after forming a heat-deformable transparent coating layer, the entire surface of the transparent coating layer Is then sanded, and then the surface of the transparent coating layer is hot-press embossed.

Moreover, according to invention of Claim 3 , in the manufacturing method of the decorative board which has an uneven | corrugated pattern of Claim 1 or Claim 2 , a base material is on the surface of the wood fiber board of specific gravity 0.4-1.0. A decorative veneer having a thickness of 0.15 to 0.4 mm is attached.

Furthermore, according to the invention of claim 4 , the transparency of the thin film is formed on the surface of the decorative board having the concavo-convex pattern obtained by any one of the manufacturing methods of claims 1 to 3 by the ultraviolet curable transparent paint. A finish coating is applied and a transparent finish coating layer is provided.

According to the first aspect of the present invention, the heat-deformable transparent coating film comprising the first and second transparent coating layers by applying an ultraviolet curable transparent coating on the surface of the substrate and irradiating with ultraviolet rays. Layer is formed, and then the surface of the transparent coating layer is hot-pressure embossed, so that the transparent coating layer that has not yet been completely cured by irradiation of ultraviolet rays is softened by the heat during hot-pressure embossing. At the same time, it is deformed by heating along the concavo-convex pattern formed on the substrate surface, and the concavo-convex pattern is intimately adhered to the concavo-convex pattern. A decorative board having an uneven pattern having a high design property can be produced.

Here, the transparent coating layer irradiated with ultraviolet rays is cured even if it is not completely cured, and is in a state where it can be heated and deformed. Furthermore, even after forming the concavo-convex pattern by hot-pressure embossing, the curing proceeds with time even without a drying operation with a ventilating dryer or the like, so that it is possible to manufacture efficiently with a short manufacturing process. Furthermore, since an ultraviolet curable transparent paint is used, there is little evacuation of VOC due to a condensation reaction of an organic solvent or a thermosetting resin.

  And the transparent coating layer provided uniformly on the surface of the concavo-convex pattern has physical properties such as excellent wear resistance, surface hardness, stain resistance, load resistance, etc. It can be suitably used for applications.

Further, since the transparency coating layer is formed by coating two layers of the first transparent coating layer and the second transparent coating layer, while securing excellent design property, the entire surface A uniform coating film can be formed, and a decorative board having a concavo-convex pattern having even more excellent physical properties can be produced.

According to the invention described in claim 2 , since the transparent coating layer is formed and then ground and hot-press embossed, a thinner transparent finish coating is applied to the surface of the decorative board having the uneven pattern obtained. When forming a film layer, the adhesiveness of a transparent coating-film layer and a transparent finish coating-film layer can be improved. Furthermore, the decorative board which has the uneven | corrugated pattern which was further excellent in the design property in which the fine damage | wound at the time of hot-press embossing is not conspicuous can be manufactured.

The invention according to claim 3 shows a most preferable example as a base material, and by forming a concavo-convex pattern up to the inside of the wood fiber board, a hot pressure for forming a concavo-convex pattern on the transparent coating film layer. When embossed, the substrate is provided with a concavo-convex pattern, and the wood veneer is laminated and integrated along the concavo-convex pattern, and the wood texture has a transparent coating layer laminated and integrated with the wood veneer. Moreover, the decorative board which has the uneven | corrugated pattern which was further excellent in the designability can be manufactured.

According to invention of Claim 4 , as above-mentioned, the decorative board which has the uneven | corrugated pattern which was further excellent in the design property in which the fine damage | wound at the time of hot press embossing is not conspicuous can be manufactured.

  Below, the manufacturing method of the decorative board 10 is demonstrated based on FIG. 2 about one of the most suitable Examples. In the “decorative plate manufacturing method” of this example, “(A) lamination step”, “(B) lamination integration step”, “(C) transparent coating film formation step”, “(D) concavo-convex pattern formation” Steps are performed in this order.

  In the “lamination process”, as shown in FIG. 2A, a decorative veneer 14 made of a natural wood material having a thickness of 0.15 to 0.40 mm is laminated on the surface of the wood fiber board 12 via an adhesive layer 13. To obtain a laminate.

  The wood fiber board 12 preferably has a specific gravity of about 0.4 to 1.0 and a thickness of about 0.8 to 6.0 mm. The wood fiber board 12 is integrally formed with the decorative veneer 14 to reinforce the veneer veneer 14, and the uneven pattern 22 is stable. Used as a base material for manufacturing. In this case, a general medium wood fiber board (hereinafter referred to as “MDF”) or a hard wood fiber board (hereinafter referred to as “HDF”) is used.

  “MDF” and “HDF” include “U type” using urea melamine resin as a binder, “M type” using melamine resin as a binder, “P” using phenolic resin as a binder. In addition to “type”, a wood fiber board using an isocyanate resin or a polyol resin is used. Furthermore, there are those using “hardwood wood fibers” and “conifer wood fibers”, and these wood fibers and a binder can be used in any combination. In order to realize excellent “morphological stability”, it is preferable to use “hardwood fiber” as the woody fiber other than “U type” as the binder.

The specific gravity of the wood fiber board 12 is selected in consideration of “scratch resistance” , “load resistance” , “embossability”, and the like. Specifically, the wood fiber board has a specific gravity of 0.4 to 1.0. And a wood fiberboard having a specific gravity of 0.6 to 0.8 is preferably selected. When the specific gravity is less than 0.4, the decorative board is inferior to “scratch resistance” and “load resistance”, and when the specific gravity is greater than 1.0, the “embossability” is inferior.

Furthermore, the thickness of the wood fiber board 12 is set in consideration of “embossability”, specifically, a wood fiber board of 0.8 to 6.0 mm is selected, preferably 0.8 to 3 A wood fiber board of about 0 mm is selected. When the thickness is less than 0.8 mm, only the decorative veneer 14 is crushed during embossing, and it is difficult to form a desired uneven pattern 22 on the wood fiber board 12. When the thickness exceeds 6.0 mm, only the wood fiber board 12 is preferentially compressed in the thickness direction, and it becomes difficult to form a desired uneven pattern 22.

  And the decorative veneer 14 is laminated and integrated on the surface of the wood fiber board 12 through the adhesive layer 13. At this time, as an adhesive, a general wood adhesive is used. For example, urea melamine resin, vinyl acetate resin, latex resin, aqueous vinyl urethane resin, melamine resin, phenol resin, Isocyanate resins and their modified products are used alone or in combination.

  In the “lamination integration step”, as shown in FIG. 2B, the laminate is hot-pressure integrated by a hot press machine, and the base material is laminated and integrated to obtain a laminate. The hot-pressing conditions used in the laminating and integrating step are set in order to reliably laminate and integrate the wood fiber board 12 and the decorative projecting board 14, the pressing temperature is 100 to 130 ° C., and the pressing pressure is 0.8 to 1. The pressure is preferably set to 30 to 90 seconds.

  In the “transparent coating film forming step”, as shown in FIG. 2C, an ultraviolet curable transparent paint having at least an ultraviolet curable property is applied to the surface of the laminate obtained in the previous step by a roll coater or a flow. After being applied by a coater, spray, or the like, the transparent coating layer 30 having a substantially uniform thickness is formed on the surface of the laminated plate by being irradiated with ultraviolet rays.

These transparent coating layers 30 are made of a general ultraviolet curable transparent paint used for wood surface coating. These UV-curable transparent paints are undercoat paints (corresponding to “first transparent paint film layer 32” in the present invention), intermediate paints (corresponding to “second transparent paint film layer 34” in the present invention), It is generally composed of a top coating (corresponding to “transparent finish coating layer (not shown)” in the present invention). The undercoat paint seals the veneer and improves the adhesion between the decorative veneer 14 and the intermediate paint. The intermediate coating has a predetermined thickness, thereby contributing to “stain resistance” , “load resistance” , “improvement of surface hardness”, and the like, and contributes to the substantial performance of the transparent coating layer. The top coat imparts smoothness to the surface and adjusts the gloss to improve the “designability”.

As the ultraviolet curable transparent paint, for example, a solvent-free acrylate resin or methacrylate resin monomer or oligomer is preferably used as the resin. An appropriate amount of a photoinitiator is added to these resins and used as an ultraviolet curable transparent paint. As the ultraviolet curable transparent paint, a solventless type is preferably used. When adjusting the viscosity at the time of coating, a monomer component such as an acrylate monomer or a methacrylate monomer is used instead of the organic solvent .

Preferably, as shown in FIG. 4, the transparent coating layer 30 is formed of a first transparent coating layer 32 and a second transparent coating layer 34. The first transparent coating film layer 32 is formed by irradiating with ultraviolet rays after applying an undercoat paint having general ultraviolet curing properties at a coating amount of about 1.5 g to 5.0 g / scale ² . For the second transparent coating layer 34, an intermediate coating or top coating having general ultraviolet curing properties is used. In this case, specifically, the second transparent coating film layer 34 is formed by applying ultraviolet rays after applying a coating having general ultraviolet curing properties at a coating amount of about 2.0 g to 15.0 g / scale ^2. Is done.

  When the ultraviolet curable transparent resin is irradiated with ultraviolet rays, radicals are generated from the photoinitiator, the resin undergoes a radical reaction, cures instantaneously, and the resin is cured to such an extent that it can be handled. However, the radical reaction continues after the resin is cured, and the transparent coating layer 30 is gradually cured even after irradiation with ultraviolet rays. In general, under normal temperature (25 ° C.) conditions, it takes about 1 week to 10 days until the coating film is completely cured. Accordingly, the hot-pressure embossing is preferably performed as soon as possible after the ultraviolet irradiation, and is preferably performed within 2 to 3 days, and most preferably within 24 hours.

  In addition to the acrylate-based resins and methacrylate-based resins exemplified in this embodiment, the transparent coating layer formed by ultraviolet irradiation can be used in the same manner as in this embodiment for the heat-deformable coating layer. Is possible. In particular, in the case of providing a transparent finish coating layer, which will be described later, it is an indispensable condition that the concavo-convex pattern 22 formed by the transparent coating layer 30 after hot-press embossing and the transparent finish coating layer are in close contact with each other.

  Furthermore, it is preferable to add a small amount of a thermosetting resin such as an isocyanate resin or a polyol resin to the undercoat paint used for the first transparent coating film layer 32. Thereby, after forming the 1st transparency coating film layer 32 and the 2nd transparency coating film layer 34, hot pressure embossing is given with a hot pressure embossing machine, and the first transparent film is heated by the heat when forming the concavo-convex pattern 22 on the surface. The heat-resistant coating layer 32 is completely heat-cured, and the decorative veneer 14 and the second transparent coating layer 34 can be firmly laminated and integrated.

In addition, talc and various pigments are generally appropriately added to the first transparent coating film layer 32 in order to improve the sealing property.

  Furthermore, before providing the transparent coating layer 30 on the decorative veneer 14, the decorative veneer 14 may be colored with a colorant such as a color pigment or dye. In this case, it is preferable to add a small amount of a thermosetting resin such as an isocyanate resin or a polyol resin to the colorant. Thereby, the colorant is completely thermoset by heat at the time of hot-press embossing that forms the uneven pattern 22 on the surface, and the decorative veneer 14 and the transparent coating film layer 30 can be firmly laminated and integrated.

1 and 3 are sectional views showing a decorative board 10 manufactured by a reference manufacturing method, and FIG. 4 is a sectional view showing the decorative board 10 to which the manufacturing method of the present invention is applied. This decorative board 10 has a highly designed concavo-convex pattern having excellent physical properties such as wear resistance, stain resistance, and load resistance that can be applied not only to wall materials but also to floor materials used in hard environments. A decorative board having

  In the “concave / convex pattern forming step”, as shown in FIG. 2 (D), hot press embossing is performed from the surface of the transparent coating film layer 30 with a hot press machine having a concave / convex embossed surface to a depth of 0.15. A concavo-convex pattern 22 of ~ 0.40 mm is formed, and the decorative board 10 is obtained.

  In this case, it is preferable that the moisture content is adjusted before the “uneven pattern forming step”. In the production method of the present invention, the moisture content is preferably 7 to 20%, more preferably 10 to 15%, when the embossed pattern is formed into a hot press machine. This moisture content adjustment may be a “curing method” or a “water absorption method”.

  The “curing method” is, for example, from the “white birch with a thickness of 0.18 mm” to the wood fiber board 12 made of “MDF having a specific gravity of 0.7 and a thickness of 2.7 mm” which is the most preferred embodiment of the present invention. In the embodiment in which the decorative veneer 14 is combined and a transparent coating layer is provided on the surface, it is confirmed that the moisture content is 12% when cured at a temperature of 23 ° C. and a humidity of 53% for 2 days. Yes.

  In the “water absorption method”, water is applied to the back surface of the wood fiber board 12 by means such as spraying or roll coating to absorb water. Also by this method, the water content which was “3 to 5%” can be increased to “7 to 20%”.

  If the moisture content is lower than 7%, the processability at the time of hot-press embossing is inferior, and not only a beautiful uneven pattern cannot be formed, but also the formed uneven pattern is inferior in “morphological stability” due to moisture or wetness. Can only get. On the other hand, if the water content exceeds 20%, puncture (steam explosion) is likely to occur during hot-pressure embossing.

  As another example, “lamination process”, “lamination integration process”, “transparency coating film formation process”, “sanding process”, “uneven pattern formation process”, “transparency coating film formation process” May be performed in this order. In the “sanding step”, a general wide belt sander or a hand sander is preferably used, and has an effect of improving the adhesiveness of the transparent coating layer composed of multiple layers.

  Further, a transparent finish coating film layer may be provided on the surface of the decorative board 10 obtained in this way by a “transparency finish coating process”. For example, after the second transparent coating layer 34 is formed on the base material by the “lamination step”, “lamination integration step”, and “transparency coating step”, the entire surface is uniformly sanded with a wide belt sander or the like. Then, after that, the concave / convex pattern 22 is formed by the “concavo-convex pattern forming step”, and a transparent finish coating film layer of a thin film is provided on at least the convex portion 22b of the surface by transparent finish coating. Thereby, the decorative board which has the uneven | corrugated pattern which was further excellent in the design property in which the fine damage | wound at the time of hot-press embossing is not conspicuous can be manufactured.

In this case, the transparent finish coating layer is a thin film, and a general top coating is used. Specifically, the coating amount is generally about 0.6 to 1.0 g / scale ² to form a transparent coating layer.

  On the other hand, when the decorative board 10 to which the present invention is applied is used as a decorative board requiring bending strength such as being used by being bridged between joists, for example, as shown in FIG. The material 40 may be used by being laminated and integrated.

  As the other woody base material 40, a woody base material such as a general plywood, MDF, or particle board is used. These woody base materials 40 are laminated on the back surface of the decorative board 10 via an adhesive, and are laminated and integrated by hot pressing or cold pressing. In this case, a light specific gravity plywood or fiberboard having a specific gravity of about 0.2 to 0.4 can be used as the wood base material 40, which is a more preferable usage form from the viewpoint of substituting the South Sea wood.

Cross-sectional view of a decorative board obtained by a reference manufacturing method Process drawing (A)-(D) which shows the manufacturing method of the Example of this invention Expanded cross-sectional view of a decorative board obtained by a reference manufacturing method Enlarged sectional view of the resulting reduction粧板by the production method of the embodiment of the present invention Expanded cross-sectional view of a decorative board used by being laminated and integrated with other woody substrates Conventional decorative board obtained by a conventional manufacturing method

DESCRIPTION OF SYMBOLS 10 Decorative board 12 Wood fiber board 13 Adhesive layer 14 Decorative veneer 22 Uneven pattern 22a Concave part 22b Convex part 30 Transparent coating layer 32 First transparent coating layer 34 Second transparent coating layer 40 Other wooden substrate

Claims (4)

An ultraviolet curable transparent paint is applied to the surface of the substrate, and after forming a first transparent coating layer that can be heated and deformed by irradiating ultraviolet rays, an ultraviolet curable type is applied on the first transparent coating layer. A heat-deformable transparent coating layer comprising the first and second transparent coating layers by applying a transparent paint and irradiating ultraviolet rays to form a heat-deformable second transparent coating layer. Form the
Next , the surface of the transparent coating layer composed of the first and second transparent coating layers is embossed by heat and pressure to form a concavo-convex pattern on the substrate surface, and the transparent coating layer is formed into the concavo-convex pattern. A method for producing a decorative board having a concavo-convex pattern, wherein the decorative board is heat-deformed along the surface . After forming a heat-deformable transparent coating layer,
Sanding the entire surface of the transparent coating layer,
2. The method for producing a decorative board having a concavo-convex pattern according to claim 1 , wherein the surface of the transparent coating layer is hot-press embossed. Substrate, according to claim 1 or claim, characterized in that the surface of the wood fiber board of the specific gravity 0.4 to 1.0, is obtained by attaching a decorative veneer thickness 0.15~0.4mm A method for producing a decorative board having the uneven pattern according to 2 . A transparent finish coating film is applied to the surface of the decorative board having the concavo-convex pattern obtained by any one of the manufacturing methods according to claim 1 with a UV-curable transparent paint. A method for producing a decorative board having a concavo-convex pattern, comprising providing a layer.

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