JPS5810215B2 - Manufacturing method of cushioning board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a cushioning board, and more particularly, to a method for manufacturing a board having cushioning properties using a foamable synthetic resin and having a printed pattern.

For example, floorboards commonly used in residential construction are made of decorative plywood for most of the exposed parts, with the exception of the floorboards placed at the bottom of tatami mats, and ordinary wood or plywood is used, with carpets etc. laid on top. I was trying to keep it that way.

In recent years, cushioning floorboards with abstract patterns have been developed in place of wooden floorboards that are made of thick plywood as a substrate and mosaiced with small pieces of wood grain pattern. As shown in , a foamable vinyl chloride resin solution is applied to the surface of a noncombustible material 1 such as asbestos paper, and heated and dried at about 120°C to 150°C to form a synthetic resin layer 2. A pattern is printed on the surface with ink, and a transparent vinyl chloride resin solution 4 is applied to the printed surface 3, and heated in an oven at about 220° C. for about 2 to 4 minutes to foam the foamable synthetic resin 2. The thus-manufactured sheet 5 having cushioning properties was adhered to a floor substrate 6 such as plywood.

Although the floorboard manufactured in this way has cushioning properties, the manufacturing cost is high, and the sheet 5 attached to the substrate 6 is exposed to high temperature during the foaming process and stretches, but the printed pattern is deformed due to this, so the pattern does not change. Distortion and misalignment of patterns occur when connecting floorboards.

Further, there is a problem that asbestos paper as the noncombustible material 1 on the back surface of the sheet 5 is likely to cause delamination.

For this purpose, the sheet 5 is made of glass fiber as the non-combustible material 1.
The method of forming the same has disadvantages such as low dimensional accuracy, patterns that do not match when attached to the substrate 6, and high cost.

The sheet 5 in which the foamable synthetic resin layer 2 is foamed in this way expands and contracts during the foaming process, resulting in low dimensional accuracy and distortion of the printed pattern, and is expensive and has not been put to practical use.

The present invention was developed in view of the above-mentioned drawbacks, and involves forming a foamed synthetic resin layer directly on a substrate, and pasting an impregnated sheet with a pre-printed pattern on this synthetic resin layer, thereby eliminating the risk of misalignment of the pattern. A method of manufacturing a cushioning board is provided.

Next, the configuration of an embodiment of the present invention will be explained with reference to FIGS. 2 and 3.

Reference numeral 10 denotes a hard substrate such as thick plywood or iron plate having a thickness of 10 mm or more, and the substrate 10 is undercoated with adhesive 1 such as vinyl acetate resin emulsion or vinyl chloride resin emulsion using a roll coater 11 or the like. , dried in a dryer 12 to form an adhesive layer 13 as shown in FIG.
Then, with a roll coater 14 etc., the
A foamable synthetic resin layer 15 is formed by applying a foamable synthetic resin solution such as foamable vinyl chloride resin to a thickness of about m as thick as possible.

Line 1 of the substrate 10 to which the foamable synthetic resin solution is applied
6 and another line 17, an impregnated sheet having a printed pattern surface 18 on which a pattern is printed with normal ink and an ink containing a foaming inhibitor having the property of suppressing foaming of the foamable synthetic resin. Rolled glass paper as
9 is rewound, this glass paper 19 is superimposed on the upper surface of the foamable synthetic resin layer 15, and the foamed synthetic resin solution is used as an adhesive to adhere the glass paper 19 using a rubber roll 20.

Then, the glass paper 19 is attached to the paper 200.
It is heated and foamed in a foaming furnace 21 at a temperature of .degree. C. to 250.degree.

Further, the surface of the glass paper 19 adhered to the surface of the foamable synthetic resin layer 15 of the substrate 10 is coated with a transparent synthetic resin solution such as transparent vinyl chloride resin sol to a thickness of about 0.1 to 3 mm using a niflow coater 22. Apply to a thickness of 120
It is dried in a dryer 23 at a temperature of 150°C to 150°C to form a transparent synthetic resin layer 24 on the surface.

In this way, a platform board with an uneven pattern is produced.

Then, make this thick floor board, for example, 1800mm long and 30mm wide.
Cut to 0 mm with cutter 25, and cut the four sides with Honjitsu processing machine 2.
In step 6, actual processing is performed to form a floor plate 27 having cushioning properties.

In such a process, an adhesive layer 13 is provided on the surface of the rigid substrate 10 to improve adhesion of the foamable synthetic resin layer 15 to the non-impregnated substrate 10, and a pattern is printed in advance. The glass paper 19 is impregnated with the applied foamable synthetic resin solution and bonded, and then heated to foam the foamable synthetic resin layer 15. Due to the dimensional stability of the glass paper 19 against heat, the pattern is distorted. Misalignment can be eliminated.

The pattern printed on the glass paper 19 is formed into an uneven shape by expanding due to the foaming of the foamable synthetic resin layer 15 or by suppressing the foaming of the foamable synthetic resin layer 15 by the foaming suppressing ink. Foaming agents that impart foaming properties include substituted nitroso compounds, substituted hydrazide compounds, and substituted azo compounds that decompose at high temperatures to generate inert gases such as nitrogen. Foaming inhibitors include maleic acid An organic acid such as, an organic acid anhydride such as maleic anhydride, etc. is used, and an organic acid anhydride such as maleic anhydride is used, which lowers the foaming temperature by contact with the foaming agent.

Note that the glass paper 19 is made of glass fiber and has many pores, but rayon paper may be used instead of the glass paper 19. In this case, the substrate 10
A foamable synthetic resin layer 15 is formed on the material, rayon paper is pasted thereon, a transparent synthetic resin liquid is applied thereto, and then the foamable synthetic resin layer 15 is foamed in a foaming furnace 21.

Also, instead of the glass paper 19 or rayon paper, a nonwoven fabric with a high porosity may be used.

According to the present invention, since the foamable synthetic resin layer is formed and foamed by directly applying the foamable synthetic resin solution to the substrate, there is no risk of delamination of the foamable synthetic resin layer.

Also, since adhesive was applied to non-impregnated substrates,
The adhesive strength of the foamable synthetic resin layer is large and there is no possibility of peeling.

An impregnated sheet with a pattern printed on it is attached to the surface of this foamable synthetic resin layer, so the surface is decorated and can be used as is as a board for decorative floorboards. Coupled with the fact that the adhesive is bonded using a lever solution, the manufacturing process is small, only the decorative pattern position is required, and a floorboard with excellent cushioning properties against a hard substrate can be obtained.

In particular, since the pattern is printed on the impregnated sheet in advance and pasted on afterwards, the dimensional stability of the sheet is good, so even in the foaming process after pasting, the pattern will not be in the same position. There is no deviation.

Therefore, the occurrence of defective products due to, for example, inconsistency in the pattern of the floorboards is reduced, contributing to cost reduction.

Furthermore, at least a portion of the impregnated sheet is printed with a pattern using a foam-suppressing ink that suppresses the foaming of the foamable synthetic resin.
The foaming of the foamable synthetic resin layer corresponding to the foaming-suppressing ink is suppressed 1, and an uneven pattern is formed on the surface, which can enhance the cosmetic effect.

[Brief explanation of the drawing]

Fig. 1 is a sectional view of a conventional floorboard, Fig. 2 is a sectional view of a floorboard as a board according to the present invention, Fig. 3 is a perspective view thereof, and Fig. 4 is a sectional view of a conventional floorboard.
The figure is a side view thereof, and FIG. 5 is an explanatory view of the manufacturing process showing one embodiment of the present invention. DESCRIPTION OF SYMBOLS 10... Rigid substrate, 13... Adhesive layer, 15... Foaming synthetic resin layer, 18... Print pattern surface, 19... Glass paper as an impregnated sheet, 24... Transparent synthetic resin layer.

Claims (1)

[Claims] 1. A foamable synthetic resin layer is formed by applying a foamable synthetic resin liquid to the surface of a rigid substrate, and an impregnated sheet having a printed pattern surface is attached to this foamable synthetic resin layer. A method for manufacturing a cushioning board, characterized in that a transparent synthetic resin layer is formed on the impregnated sheet before or after foaming the foamable synthetic resin layer. 2. The method for manufacturing a cushioning board according to claim 1, wherein at least a part of the printed pattern surface of the impregnated sheet is printed with an ink containing a foaming inhibitor. 3. The method of manufacturing a cushioning board according to claim 1 or 2, wherein the substrate is a non-impregnated substrate and an adhesive layer is interposed between the substrate and the foamable synthetic resin layer. 4. Claims 1 to 4, characterized in that the transparent synthetic resin layer is formed by impregnating a glass paper as an impregnated sheet with a foamable synthetic resin liquid, foaming the foaming synthetic resin layer, and then coating it. Method 5 for manufacturing a cushioning board according to any one of Item 3: After coating and forming a transparent synthetic resin layer on rayon paper as an impregnated sheet impregnated with a foamable synthetic resin liquid, the foamable synthetic resin layer is foamed. A method for manufacturing a cushioning board according to any one of claims 1 to 3, characterized in that: