JPS588988B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board with a concavo-convex pattern formed thereon by applying or impregnating a thermosetting resin under heat and pressure, and making it easier to peel off the resin after hardening the impregnated paper. Form the desired pattern using effective ink,
A method for producing a synchronized embossed decorative board having an uneven pattern synchronized with the printed ink area by using resin-impregnated paper and peeling and removing the thermosetting resin on the ink area by puffing or brushing after heating and pressing. be.

Conventionally, there are two methods for providing unevenness that matches the design on the surface of a thermosetting resin decorative board, depending on the type of dog.

The first method is called the direct embossing method,
Typical methods include a method in which an embossing plate that matches the pattern is used to directly create irregularities on the decorative board using a flat plate press, and a method in which an embossing roll is used to directly create irregularities on the surface of the decorative board.

However, with this method, it is expensive to manufacture the embossing plate and embossing roll, and it is difficult to register the design of the decorative board with the uneven pattern of the embossing plate and embossing roll, which takes time to manufacture, resulting in cost problems. was there.

The second method is generally called the chemical embossing method, in which a pattern is formed on the base paper for resin impregnation using ink containing a resin polymerization inhibitor to create a difference in the curing speed of the resin on the surface of the decorative board. This is a method that utilizes this difference to form an embossed pattern on the surface.

However, although this method is extremely advantageous in terms of matching the design and the embossed pattern, it takes time for the resin to harden, and because it only uses the resin's idle accumulation, the width of the depressed recess is This naturally causes limitations and makes it impossible to form deep recesses of any desired width.Also, since a polymerization inhibitor is used, uncured parts remain inside the resin, resulting in poor surface hardness. There was a problem of low wear resistance.

The object of the present invention is to eliminate the above-mentioned drawbacks, and to efficiently produce embossed decorative laminates with good physical properties using a relatively simple method and therefore at low cost.

That is, the present invention provides a resin-impregnated patterned paper in which a pattern is provided on a patterned paper using an ink that is releasable to a thermosetting resin, and the entire surface of the patterned paper including the pattern is coated or impregnated with a thermosetting resin. A decorative board characterized in that it is stacked on a base material, and then heated and pressurized to cure the resin, thereby removing the hardened resin on the ink that is made easy to peel off by puffing or brushing to form recesses. The gist is the manufacturing method.

As shown in Figure 1, a fabric pattern, wood grain pattern, etc. is printed on a decorative paper such as titanium paper, thin paper, or non-woven fabric using a regular ink or paint composition as a base pattern, or directly onto the decorative paper. , print etc. with releasable ink 2 only on the areas where you want the coating surface to be depressed, such as matching patterns, abstract patterns, etc.
dry or harden.

Next, the printing paper is coated or impregnated with a thermosetting resin 3, and after drying, it is made into an impregnated decorative paper, which is then layered on a base material 4 such as plywood with the ink layer on the surface, and then a metal such as a duralumin plate or a stainless steel plate. The plate 5 is placed as a release plate and molded under heat and pressure.

In such an integrated decorative board, the ink layer having releasability causes the resin coating film on the ink layer to peel off from the ink layer interface as shown in FIG.

Next, this hardened and easily peeled thermosetting resin coating is removed by puffing or brushing to form a concave pattern that perfectly matches the pattern shown in Figure 3 to obtain the desired decorative board. .

In the present invention, as the decorative paper for the patterned paper, papers such as titanium paper, tissue paper, and kraft paper, cloths such as cotton cloth and glass cloth, and nonwoven fabrics can be used.

Furthermore, as a method for applying base patterns such as cloth grain patterns, wood grain patterns, and patterns for areas to be recessed to these decorative papers, there are conventional printing methods such as letterpress printing, offset printing, gravure printing, or screen printing. It can be formed by printing, drawing, or painting by a hand-drawing method, a normal painting method, or the like.

Next, in the present invention, the ink or coating composition for applying the base pattern is a known one, for example, a coloring agent such as a dye or pigment is added to an ink or coating vehicle, and further, for example, a plasticizer, a stabilizer, etc. Ink made by adding optionally known additives such as drying agent, wax/grease, drying agent, auxiliary drying agent, curing agent, thickener, dispersing agent, filler, etc., and thoroughly kneading with solvent, diluent, etc. or paint compositions can be used.

In the above ink or coating composition, the vehicle may be a known vehicle, such as various oils and fats such as linseed oil, soybean oil, or synthetic drying oil, rosin, copal dammar, hardened gin, rosin ester, or polymerized gin. Synthetic resins such as natural resins and processed resins, rosin-modified phenolic resins, 100% phenolic resins, maleic acid resins, alkyd resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, amino alkyd resins, etc. , cellulose derivatives such as nitrocellulose and ethylcellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, as well as glue, casein, dextrin, zein, and the like can be used.

Next, as for the ink composition having releasability in the above, for example, one or more types of silicone resin or silicone-based resin are used as the main components of the vehicle, coloring agents such as dyes and pigments are added to this, and the required amount is further added. A composition prepared by adding optional additives and thoroughly kneading with a solvent, diluent, etc. can be used.

Next, in the above-mentioned present invention, the method of applying resin treatment to the patterned paper includes, for example, a method of immersing the patterned paper in a solution type or emulsified resin solution and drying it, or a method of applying the resin treatment to the patterned paper as described above. This can be done by coating or applying a resin liquid and drying it.

As the resin liquid in the above, for example, one type of thermosetting resin such as urea resin, melamine resin, acetoguanamine resin, penzoguanamine resin, unsaturated polyester resin, diallyl fucrate resin, or an initial condensate thereof. Alternatively, a resin liquid containing two or more types as main components can be used.

In this case, the amount of resin attached to the impregnated paper is 5 in terms of solid content.
Although the object of the present invention can be achieved with a resin adhesion amount of 0 to 150%/m2, preferably a resin adhesion amount of 60 to 80% is used.

In addition, the base materials applicable to the present invention include plywood, particle board, flexible board, calcium silicate board,
The material may be pulp cement, resin-impregnated laminated core paper, or a single material such as Motomura.

In the present invention, the peeling resin can also be removed by stacking plastic films or the like and applying pressure, but this method has the disadvantage that the plastic film cannot be used repeatedly and is expensive. Therefore, it cannot be used in industrial production at all.

On the other hand, in the case of using puffing or brushing as in the present invention, the recess forming step can be easily incorporated into the conventional manufacturing process, and manufacturing can be performed at extremely low cost.

Therefore, the decorative board obtained by the method of the present invention is suitable for various uses, such as decorative boards for building materials, doors,
It can be used for wall materials, furniture, kitchens, etc.

Next, the present invention will be explained in more detail with reference to Examples.

"Parts" in the following text indicate "parts by weight."<Example1> A wood grain pattern was gravure printed on 80 g/m 2 titanium paper using a normal gravure ink, and a conduit portion was printed using a gravure printing machine using the following releasable ink.

(Ink formulation) Silicone resin 15 parts Pigment 5 parts Tonolene
30.
Impregnated.

(Resin blend) Diaryl phthalate polymer 188 parts Diaryl phthalate monomer 12 Penzoyl peroxide
12〃Lauric acid
0.6 methyl ethyl ketone 150 toluene 50 The impregnated liquid is dried at 80°C for 10 minutes to obtain impregnated paper.

Next, layer the impregnated paper on 3% plywood with the ink side facing up.
A polished duralumin plate was placed thereon with the mirror surface facing downward, and pressed at 130° C. and 1Q kg/cm 2 for 5 minutes.

When the duralumin plate was released from the mold after pressing, the resin only in the conduit part hardened and easily peeled off because it had poor affinity with the conduit part.

By feeding the resulting decorative board under a rotating nylon brush with a belt facing upward, the resin on the conduit portion of the decorative board was easily peeled off and a sharp and deep tone-embossed decorative board was obtained. .

Example 2> A wood grain pattern was gravure printed on a 55 y/m2 titanium paper using ordinary gravure ink, and then a conduit portion was printed using a gravure printing machine using the same ink as in Example 1, and then 120 y/m2 of titanium paper was printed. Dry at ℃ for 1 minute to harden the ink on the conduit.
The solid content was 35g/m using the same impregnating resin liquid as in Example 1.
2. The impregnated liquid was dried at 80° C. for 10 minutes to obtain impregnated paper.

Below, a duralumin mirror plate was used under the same conditions as in Example 1.
By placing impregnated paper on a /m plywood and heating and pressurizing it, releasing the duralumin board and brushing the decorative board, the easily peeled resin is easily removed, resulting in an embossed decorative board with perfectly synchronized recesses and patterns. Got the board.

<Example 3> A wood grain pattern was gravure printed on 80 g/m2 titanium paper using a regular gravure ink, and a conduit portion was printed using a gravure printing machine using the following ink composition.

(Ink formulation) Silicone resin 20 parts Pigment 5 Thonoleene 4
5〃Xylene 30〃The printing press was dried at 120° C. for 1 minute to harden it, and the solid content was impregnated with sog 7 m 2 of the primary resin mixture.

(Resin blend) Diallylfucrate prepolymer 120 parts Unsaturated polyester 40 Benzoyl peroxide 12 Lauric acid 0.6 Methyl ethyl ketone 150 Toluene
5Q〃Dry the impregnated liquid at 80℃ for 10 minutes, layer the impregnated paper on a 3m/m plywood board with the ink side facing up, and then place a 20% matte duralumin board on top, with the matte side facing downward. The sample was placed so as to be heated and pressurized under the same conditions as in Example 1.

After pressing, the duralumin board was released from the mold and the resin on the conduit portion was removed by brushing to obtain a sharp and deep tone-embossed decorative board.

<Example 4> A wood grain pattern was gravure printed on the titanium paper of 809/door 2 using ordinary gravure ink, and a conduit portion was printed using a gravure printing machine using the same ink composition as in Example 3.

After printing, dry at 120℃ for 1 minute to impregnate melamine-formaldehyde resin with solid content of 5097m2.
It was dried at ℃ for 5 minutes to obtain impregnated paper.

Next, the impregnated paper was layered on 3% plywood, and 13 g/m
2 Overlay paper was coated with a mixed resin solution containing melamine-formaldehyde resin and penzoguanamine-formaldehyde resin at a solid content ratio of 8:2.
Impregnated paper impregnated with 0 g/m2 and dried was layered, and a polished stainless steel metal plate was placed thereon with the mirror surface facing downward and press-molded.

After pressing, the melamine-formaldehyde resin and overlay paper layer on the conduit portion were easily removed by brushing to obtain a tone-embossed decorative board.

<Example 5> A wood grain pattern was gravure printed on 55g7m2 of titanium paper using ordinary gravure ink, and a conduit portion was printed by screen printing using the following ink composition.

(Ink formulation) Silicone resin 15 parts Pigment 5 Ethyl cellulose 1Q Toluene
25 parts xylene 45 1 part of the printing paper
It was dried at 20°C for 1 minute and impregnated with a solid content of 4097 m2 using the same resin mixture as in Example 1. After drying, the impregnated paper was layered on a 4 m/m plywood board, and a polished duralumin board was placed on top of it. Place it so that the mirror surface is on the bottom and heat it at 130℃, 2
The molding was performed by force heating and pressure for 5 minutes at 0 kg/C every 2 minutes.

After molding, the duralumin board was released from the mold, and the resin on the conduit portion was removed by rolling to obtain a tuned embossed decorative board.

[Brief explanation of the drawing]

FIGS. 1 to 3 are cross-sectional views schematically showing steps for manufacturing a decorative board by the method of the present invention. Explanation of the symbols representing the main parts of the diagram, 1...Patterned paper, 2
...Ink layer having releasability to thermosetting resin, 3...
...Thermosetting resin, 4...Base material, 5...Metal plate.

Claims (1)

[Claims] 1 A pattern is provided on a patterned paper using an ink that is releasable to a thermosetting resin, and the entire surface of the patterned paper including the pattern is coated or impregnated with a thermosetting resin, and the resin-impregnated patterned paper is used as a base material. A method for producing a decorative board, which comprises stacking, and then heating and pressurizing the resin to cure it, thereby removing the cured resin on the ink, which is made easy to peel, by puffing or brushing to form recesses. .