JPS5821580B2 - How do you know what to do? - Google Patents

Description

[Detailed description of the invention] The present invention is a method for manufacturing a decorative board having an uneven wood grain pattern.

This law relates to a method for manufacturing decorative boards that can faithfully represent the wood tone of natural wood boards, and that exhibits a three-dimensional effect that is extremely similar to natural wood boards due to differences in color tone and gloss between concave and convex parts. be.

Previous attempts have been made to make decorative boards look like natural wood.

Various kinds of decorative boards are available, and examples of this type of decorative laminate include a synchronous embossed decorative laminate with a concavo-convex pattern that perfectly matches the pattern of the decorative paper, and a non-synchronized embossed laminate that does not match the pattern.

However, the main purpose of these methods is only to impart an uneven pattern to the decorative surface, and as for the surface finish, the gloss of the concave and convex parts is the same, and the spring wood and autumn wood of natural wood boards have the same gloss. No attempt has been made to reproduce the unique differences in gloss and color tone of the parts.

In addition, as a mold board used for decorative boards with wood grain patterns to give a natural wood look, conventional methods have been used in which the desired pattern is etched onto stainless steel plates, duralumin plates, aluminum plates, etc. using an embalming solution. A mold release agent was applied to the thermosetting resin mold plate obtained using the obtained embalming plate and a base plate made of natural wood with uniform thickness, and silicone rubber was applied to the plate to make it uniform in thickness. After the resin is cured and peeled off from the surface of the original plate to obtain a concave mold, epoxy resin is poured into this mold, reinforced with glass fiber cloth, etc., and a thermoplastic release sheet is placed over the convex mold obtained. Impregnated with thermosetting resin
There is a mold plate obtained by placing paper or cloth to be dried and heating and pressurizing it.

The inventors of the present invention aimed to improve the unique gloss difference between the spring and autumn wood parts of natural wood boards in order to make them more similar to natural wood boards than the conventional 9 natural wood-like decorative boards using these shaped boards. In addition, as a result of studies using the above-mentioned forming template for the purpose of reproducing color tone differences, a method using a gravure offset roll was discovered.

However, since the molded board made by the former method is obtained by ordinary pressing, there is almost no unevenness in its thickness, and the plywood with an uneven pattern obtained by the same pressing using the molded board is
Since a uniform thickness can be obtained, if colored and glossy paint is applied only to the convex portions, the coating can be done evenly and evenly, but the former type of forming plate technically requires the shape and depth of the etching. Since the height is constant, it is not possible to express the depth and slope of concave parts from the varying convex parts that can be obtained by twisting and applying force to a natural wood board, or the delicate parts of a natural wood board.

The latter method can faithfully transfer the condition of a natural wood board, but when making a silicone rubber version from the original board, or when making an epoxy resin version from a silicone rubber version, both methods are difficult to create. Because silicone rubber or epoxy resin is poured by hand onto the plate to be coated, if the surface after pouring is not made uniform, that surface will become the back side of the plate to be obtained, resulting in uneven thickness of the plate itself. appear.

For example, when obtaining an epoxy resin plate from a silicone rubber plate, place the female silicone rubber plate obtained from the original plate on a horizontal table, place the epoxy resin on the uneven surface that has faithfully transferred the unevenness of the original plate, and use a spatula to Push it into the recess.

After curing, epoxy resin is poured into the unfilled recesses and the entire surface, one or two sheets of glass fiber cloth are placed on top of it to reinforce the plate, and after curing, epoxy resin is applied again.

Because the work is done with a spatula, and the viscosity of the epoxy resin is high, it is difficult to obtain a plate with a constant thickness.

Therefore, when removing a female molding plate by heating and pressing thermosetting resin-impregnated paper (cloth) from the male epoxy resin plate obtained, the uneven thickness of the epoxy resin plate is transferred as is. Therefore, the resulting molded plate also has uneven thickness.

Furthermore, the base plate 1 of the decorative board obtained using the molding board shown in Figure 1 also has uneven thickness. It appears unevenly, and as shown in Figure 2, all of the convex parts corresponding to the autumn wood parts are not colored or coated with paint, resulting in areas 9 where the wood grain lines are cut, resulting in poor quality as a product. There is a disadvantage that the value decreases, and it has not been possible to obtain a decorative board with an uneven wood grain pattern that closely resembles a natural wood board, which is the object of the present invention.

However, in order to accomplish the object of the present invention, the present inventors have completed a novel method for manufacturing a shaping plate.

In other words, vinyl-based single plate is used on the original board that has been processed with swirls.

Wood P 1astic Combinatio
n, hereinafter abbreviated as WPC) 1-) By changing the quality of the sparse wood into dense processed wood,
The purpose is to eliminate the reduction in compression of the original plate during heating and pressing, thereby increasing the number of times it can be used repeatedly, and to obtain a uniform product directly from the original plate of uniform thickness.

There is no example of a factor that causes the thickness unevenness of the forming plate to obtain a female forming plate with a normal punch. By this method, we were able to obtain an inexpensive molding plate.

The plywood for decorative laminates obtained using this molded board was able to faithfully transfer the condition of the natural wood board, and had no uneven thickness, no uneven coloring on convex parts, and no uneven coating. .

Hereinafter, the present invention will be explained in more detail based on the drawings.

In FIG. 3, a natural wood board is adjusted to have a uniform thickness b using an electric planer or the like, and a curving process is performed using a "graining machine" equipped with an ordinary wire brush to obtain an original board 4.

All the thicknesses of the curved portions of the obtained original plate 4 were the adjusted thickness b.

Vinyl monomers such as methyl ivy acrylate, styrene, unsaturated polyester, etc. are injected into this original plate.To facilitate this injection, the original plate is usually
Use a dryer to adjust the moisture content to 9%.

Furthermore, this was placed in a vacuum pressurized container and heated to 5 to 20 mm Hg.
After degassing for 30 minutes to 2 hours, the monomer was introduced and the mixture was heated at normal pressure for 1 hour.
Pressurize for ~2 hours to inject to an injection rate of 60-90.

Thereafter, when carrying out the polymerization, it is preferable to wrap the monomer-injected original plate in a packaging material such as foil to prevent the monomer from volatilizing and escaping.

As the polymerization method, a heating polymerization method or an electron beam irradiation polymerization method is used.

Here, the heating polymerization method involves placing the monomer-injected original plate in a water bath heated to 70 to 80°C and heating and polymerizing it for 4 to 7 hours, or applying an electron beam irradiation polymerization method to the monomer-injected original plate at 200 mechavolts. The material was polymerized and cured by irradiation with 20 Megarat using an electron beam accelerator to obtain the original plate 5 shown in FIG.

Thereafter, as shown in FIG. 4, the original plate 5 is placed with the uneven patterned surface facing upward through a thermoplastic release sheet 6 made of polypropylene or the like.
A plurality of sheets of paper or cloth 7 impregnated with a thermosetting resin such as melamine resin, guanamine resin, phenol resin, diallylphta v-) resin, etc. in a conventional manner and dried are placed and heated to a temperature of 11.
0-160 cardiac pressure 10-60 to 9/crrI2, time 1
The mold plate 8 shown in FIG. 5 was obtained by heating and pressing for 0 to 40 minutes.

At this time, there was almost no decrease in compression of the original plate converted to W2C,
Repeated use was also possible.

Next, as shown in FIG. 5, the thermosetting resin-impregnated paper or cloth 1
0 was placed, and then a release sheet 6 was applied, and the wood grain pattern surface of the mold plate 8 obtained above was superimposed, and the temperature was 120 to 140°C, the pressure was 15 to 20°C, 9/'2 was applied, and the time was 10 to 20°C. The base plate 11 shown in FIG. 6 was obtained by heating for 20 minutes.

Next, as shown in FIG. 6, a color enamel paint 12 having a tone and gloss corresponding to the spring material portion of the base plate 11 is applied over the entire surface using a roll coater or a flow coater and dried.

Furthermore, a color enamel paint 13 with a tone and gloss corresponding to the autumn wood portion was applied only to the convex portions using a gravure offset roll to obtain the desired decorative board.

The convex portions of the thus obtained decorative board were evenly coated, and a decorative board having the delicate wood grain, color tone, and gloss of a natural wood board was obtained.

Examples of the present invention will be described below.

EXAMPLE A cedar board with a desired wood grain pattern is made uniform in thickness using a planer or the like, and then brushed and polished to give it an undulating finish to produce an original board with an uneven pattern that can be molded.

Next, the original plate adjusted to a water content of 8 to 9 by using a hot air dryer is placed in a vacuum tank and degassed for 2 hours under a vacuum of 5 mmHg, after which methyl methacrylate monomer is injected.

After this was left for one hour at normal pressure, it was taken out and wrapped in aluminum foil to suppress the volatilization of the monomer.

This is cured by irradiating it with 20 megavolts using a 200 megavolt electron beam accelerator.

Next, with the uneven pattern side of the original plate facing up, a 20 micron thick polypropylene sheet and phenolic resin impregnated paper (weighing 1
80&/cm") were placed one after another, the whole was inserted into a molding press, and the temperature was 130℃ and the pressure was 20℃.
/.

It was molded by heating and pressing at crn2 for 20 minutes to obtain a mold plate with a uniform thickness.

Next, phenol resin-impregnated paper is placed on the surface of the plywood, and the wood grain patterned surface of the mold board obtained in the previous step is superimposed via a 20 micron thick polypropylene sheet, and the whole is inserted into a molding press. Then, the temperature was 130℃ and the pressure was 20℃.
Plywood was obtained by heating and pressing under the conditions of (m2, time 15 minutes).

Next, apply 50 to 70 g of enamel paint on the entire surface of this plywood using a roll coater in a color and gloss that corresponds to the spring wood of the cedar board.
Paint m2 and dry.

Furthermore, the desired wood grain pattern is faithfully transferred by applying an enamel paint with a color and gloss corresponding to the convex parts, that is, the autumn wood part of the cedar board, using a gravure offset roll and drying. We were able to obtain decorative plywood with different colors and glosses.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing a state in which convex portions of plywood are coated with a gravure offset roll. Here, 1 is a plywood having an uneven pattern, 2 is a gravure offset roll, and 3 is a presser roll. FIG. 2 is a perspective view of FIG. 1. Here, a indicates a portion that is not painted due to uneven thickness of the base plate. FIG. 3 is a cross-sectional view of a natural wood board that has been curved, and the thickness of each convex portion is constant. Here, 4 is the original plate obtained by the swirling process. FIG. 4 is a cross-sectional view of a structure in which a forming plate is obtained from a WPC original plate. Here, 5 is a WPC original plate, 6 is a release sheet,
7 is a plurality of sheets of thermosetting resin-impregnated paper or cloth. FIG. 5 is a cross-sectional view of a structure in which decorative plywood is obtained from a forming board. Here, 8 is a forming plate, 9 is a base material, and 10 is paper or cloth impregnated with a thermosetting resin. FIG. 6 is an enlarged cross-sectional view of the decorative board painted on the plywood obtained in FIG. 5. Here, 11 is the base plate 12, the enamel layer appearing in the recess, 1
3 is an enamel layer painted on the convex portion.

Claims (1)

[Claims] 1 The undulating pattern is emphasized by brushing or other polishing on the original board with the desired wood grain pattern, and the undulating pattern is faithfully transferred from the so-called plastic-reinforced undulating pattern original board, which is made by injecting and polymerizing vinyl monomer and hardening it. A step of obtaining a thermosetting resin forming plate, and applying a thermosetting resin impregnated paper or cloth and a substrate onto the wood grain pattern surface via a plastic release sheet using the thus formed forming plate. A process of placing the materials one after another and applying heat and pressure to obtain plywood with the undulating pattern transferred to it, and a process of applying enamel to the surface of the plywood obtained in this way to change the gloss and color tone of the concave and convex areas. A method for manufacturing a decorative board having an uneven wood grain pattern consisting of.