JPS5923249B2 - Method for manufacturing embossed decorative sheet and decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention can reduce equipment costs and the number of processes in manufacturing embossed decorative sheets and decorative laminates, and can easily produce embossed decorative sheets and decorative laminates with various surface finishes using thermosetting resin. This is a method that can produce

Conventionally, embossed decorative sheets have been produced using a method of forming using an embossed film, a method of post-embossing with a roll, a method of chemically embossing, and a method of forming embossing sheets using an embossed sheet, an embossed film, etc. as a decorative sheet. Methods of molding are known. However, in the conventional method of producing an embossed decorative sheet, the method using an embossed film has the disadvantage that there is a limit to the depth and restrictions are imposed on heating, pressure, etc.

Also, post-emboss processing is often used for thermoplastic resins, but
It has drawbacks that make it difficult to apply to thermosetting resins. Furthermore, although chemical embossing can be synchronized with patterns, it has the drawbacks of deteriorating the physical properties of the embossed area and being unsuitable for embossing abstract patterns. Furthermore, embossed decorative boards also have the same drawbacks as mentioned above. The present invention was developed as a result of extensive research into embossed decorative sheets and decorative boards, and was developed using metal foils, synthetic resin sheets, or composite materials thereof (hereinafter referred to as foils).
We aim to overcome the drawbacks of conventional embossed decorative sheets and decorative board manufacturing methods by embossing, surface-treating, resin-processing, and transfer-molding the resin onto the surface of the decorative base material. Based on this finding, the present invention has been accomplished.

In the present invention, foils are embossed in advance, a thermosetting resin with a B stage is coated on one or both sides of the foil, the coated resin is transferred to a decorative base material, and one or two molded products are produced at the same time. This is a method for producing a thermosetting resin embossed decorative sheet and a decorative board, which is characterized by obtaining the following.

The metal foils used in the present invention include aluminum, copper, iron, etc. foils with a thickness of about 7μ to 100μ, and the synthetic resin sheets include polypropylene, polyester, nylon, polycarbonate, polychloride, etc. vinyl,
A single film such as polystyrene, or a film whose heat resistance is improved by a filler such as an inorganic substance can be used.

In addition to foils, laminates of metal foil and paper and synthetic resin sheets and paper can also be used.

In either case, the surface can be treated for mold release or the like. Embossing of foils can be done at room temperature or up depending on the material to be embossed.
200℃, pressurization 1-100V4/c! Continuously processed as appropriate with a double-sided embossing roll or a single-sided embossing roll in the range of n, and pressurized at room temperature to 200℃ 1 to 100K9
There is a sheet processed into a single sheet under the conditions of /d.

A resin is applied to one or both sides of the foil after embossing, and this resin is a thermosetting resin that easily obtains the so-called B stage, such as polyester resin (including diallyl ctrate resin), melamine resin, It is an epoxy resin, etc., and fillers etc. are added as necessary.

After applying the resin to one or both sides of the resin embossed foil to such an extent that almost no embossment irregularities appear on the surface (after drying), dry or preheat depending on the type of resin and proceed to the B stage for curing. Depending on the press format, it can be cut or wound into a continuous sheet.

At this time, the appropriate amount of coating applied to the embossing foil is 5 to 200 microns in film thickness after drying.

The molding conditions can be within or slightly lower than the manufacturing conditions for decorative laminates by the general press method.

For example, polyester resin is 100℃~150℃, 1~
60V4/d1 time depends on the base material. 1 for melamine resin
20℃~160℃, 5~100! /d1 time depends on the base material. For epoxy resin, 130℃~180℃, 5~60K
The f/Cfl time depends on the substrate. The configuration method during molding is
In the case of high-pressure melamine decorative board, the melamine overlay by the conventional method is omitted, and the embossed foil coated with melamine resin is placed on the patterned paper impregnated with melamine resin, and the core layer is made of kraft paper impregnated with phenolic resin, and the embossed foil is coated with melamine resin by the conventional method. Heat and pressure mold.

If the base material to be coated with low-pressure melamine resin is plywood, particle board, inorganic board, etc., embossed foil coated with melamine resin is placed on top of the unimpregnated patterned paper laminated to the base material, and then the embossed foil coated with melamine resin is placed on top of the base material and pasted with unimpregnated patterned paper. Either mold it or prepare the patterned paper to be used that has been impregnated with resin to the extent that it can be bonded to the base material, and then place the resin-impregnated patterned paper and then the embossed foil coated with melamine resin on the base material in order, and then simultaneously It can be molded.

Decorative boards can also be molded using polyester resin, epoxy resin, etc. in a similar manner.

Also, continuous decorative boards and sheets can be molded in the same way.

According to the method of the present invention, the manufacturing cost is lower than that of the embossed backing plate used in the production of embossed decorative laminates, the manufacturing conditions are comparable to those of non-embossed decorative laminates, and there is no fear of damage to the embossed decorative laminate. The surface finish can also be easily changed.

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

However, it is not necessarily limited to this embodiment.
Example 1 Using an embossing roll, wood grain embossing was applied to a glossy aluminum foil with a thickness of 50μ at room temperature under the condition of a linear pressure of 1 kg/i, and melamine resin was applied to the surface of this embossed foil after drying.
A sample was prepared by coating and drying so that it became 0.

Rice scale 190g/Ri? 4 sheets of phenol-impregnated paper with a resin content of 50% on kraft paper, then a 100g/R wood grain pattern impregnated paper with a melamine resin content of 40%, and then a patterned paper with the coated surface of the embossed foil coated with the melamine resin mentioned above. These structures were placed so that they were on the sides, and cushion materials were used on the top and bottom of these structures to press them into a flat plate.

The pressing conditions were a temperature of 140°C, a pressure of 80V4/i, and a heat-pressing time of 30 minutes, and the sample was taken out after cooling. The resulting veneer is extremely clear as there is no melamine impregnated overlay.
It had a beautiful appearance with aluminum foil edges and embossing, and due to the transferred melamine resin, the surface properties were the same as those using a regular overlay. Example 2 In the same manner as in Example 1, a 50 μm double-sided glossy aluminum foil was given a satin finish embossing.

Tap resin was applied to both surfaces so that the dry coating thickness was 50 μm. Next, use a rice scale of 100 on a 5.5m thick plywood board.
g/Ri? 2 pieces of unimpregnated patterned paper with abstract patterns pasted together
I prepared one.

The paper-laminated plywood was placed on top J centering around the tap-resin embossed foil so that the paper-laminated surface of the paper-laminated plywood became a tap-resin embossed foil, and flat plate press molding was performed. The pressing conditions were a temperature of 130° C., a pressure of 12 odor/Cfli molding time of 15 minutes, and the sample was taken out using a hot-hot cycle. As a result of the above, two sheets of satin embossed and tapped resin decorative plywood could be molded at the same time.

The surface of the obtained decorative plywood had the physical properties of the transferred tap resin. Example 3 In the same manner as in Example 2, a matte embossed foil coated with tap resin on both sides was continuously made into a roll.

Next, add 2 pieces of unimpregnated wood grain pattern paper weighing 80g of rice in a continuous roll.
I prepared one. Three layers were installed above and below the resin-coated embossed foil so that the printed surface of the woodgrain pattern paper became the resin-coated embossed foil, and the molding temperature was 140 using a belt-type continuous molding machine.
After molding at ℃, molding pressure 5Kf/Cdl molding time 40 seconds,
The three layers were wound one by one.

The tap resin was transferred and cured on the surfaces of both the upper and lower wood grain patterns obtained, and the paper had an excellent appearance with a satin embossed wood grain pattern, making it suitable for applications such as wallpaper. Moreover, the embossed foil rolled up after molding could be used repeatedly.

Claims (1)

[Claims] 1 Metal foils, synthetic resin sheets, or composites thereof are embossed in advance, a thermosetting resin with a B stage (resin hardening level) is applied to this, and the applied resin is applied to the surface of the decorative base material. 1. A method for producing a thermosetting resin embossed decorative sheet and decorative board, which comprises transferring and molding the decorative sheet.