JPS5923258B2 - Decorative board and its manufacturing method - Google Patents

Description

[Detailed description of the invention] The present invention provides a three-dimensional synthetic resin pattern layer on the surface of an organic or inorganic board such as wood fiberboard, mineral fiberboard, plywood, gypsum board, calcium silicate board, etc. This invention relates to a decorative board and its manufacturing method.

In recent years, there has been a growing trend for architectural decorative laminates to have innovative, high-class, and complex designs. Conventionally, an uneven rough surface is formed on the surface of a plate by spray painting or a forming device such as an embossing roll, and the uneven rough surface imparts a unique texture to the surface of the plate. Patterns are formed by printing etc. on However, when performing gravure printing or flexographic printing on the surface of a plate-like object with such an uneven rough surface, unlike when printing on a smooth plate-like object surface, the printing ink is applied to the uneven surface. There was a problem in that the printed pattern was only attached to the top and not sufficiently attached to the bottom of the recess, and as a result, the printed pattern became discontinuous in the recess, making the entire pattern unclear and having a poor pattern pattern.

One way to eliminate these problems is to use a screen printer to apply a large amount of printing ink thickly in a pattern on the uneven surface of a plate-like object. However, on the other hand, it is possible to apply sufficient printing ink to the paper and there is no need to worry about the pattern becoming discontinuous.
Compared to gravure printing, flexographic printing, etc., the work efficiency is extremely low, and this has the disadvantage of reducing the productivity of decorative laminates.

In order to eliminate such drawbacks, the present invention forms an uneven rough surface on the surface of a plate-like object by appropriate means, applies a viscous liquid to the convex portions of the surface in a pattern, and then applies the viscous liquid to the convex portions of the surface. After attaching particles made of hot-melting synthetic resin to the liquid surface, these synthetic resin particles are heated and melted, and a part of them flows into the recess.
The object of the present invention is to provide a decorative board in which a continuous pattern-like synthetic resin coating layer from the convex top to the concave bottom is formed on the uneven rough surface of a plate-like object by residence, and a method for manufacturing the same.

The embodiments of the present invention will be explained with reference to the drawings.
As shown in the figure, granular paint is applied almost uniformly to the entire surface of a wood fiberboard, plywood, gypsum board, or other plate-like object 1 by spray painting, and then dried to form convexities caused by the granular paint. A concave portion 2 is formed between the convex portions 2a and 2a adjacent to the portion 2a.
An uneven rough surface 2 having a shape of b is formed.

However, the method of the present invention is not limited to the method using spray paint as described above as a method for forming the uneven rough surface 2 on the surface of the plate-like object 1. For example, sand or other granular decorative materials may be used. The present invention can also be applied by pasting the attached decorative paper onto the surface of a plate to provide an uneven rough surface, or by forming an uneven rough surface over the entire surface of the plate using a shaping device such as an embossing roll. This can be fully satisfied, and an appropriate method may be selected and adopted in view of the purpose of the decorative board and its design.

The viscous liquid 3 is applied to the uneven rough surface 2 of the plate-shaped article 1 thus formed in a desired pattern by gravure printing, flexographic printing, or other suitable printing method.

At this time, the viscous liquid 3 adheres only to the top surface of the convex portions 2a of the uneven rough surface 2, and a discontinuous pattern is formed on the uneven rough surface 2. The viscous liquid 3 used is specifically printing ink, paint, or adhesive, and may be a viscous synthetic resin liquid, synthetic resin emulsion, or other viscous liquid.

Next, while the applied viscous liquid 3 is not dry, a large number of granules 4 made of hot-melting synthetic resin are almost uniformly sprinkled on the surface of the plate-like object 1 to adhere to the viscous liquid 3, When the unattached particulate matter is removed by suction using a suitable suction device, as shown in FIG. A discontinuous raised pattern is formed.

Thereafter, when the heat-melting synthetic resin particles 4 are heated and melted, the convex portions 2afI. The K-attached granules 4 melt and connect with each other, flow along the uneven rough surface 2, and part of it flows into the recess 2b and stays there, resulting in friendly thermal melting as shown in FIG. A continuous resin coating layer 5 is formed in a pattern on the uneven rough surface 2 using the synthetic resin.

That is, the discontinuous pattern created by the viscous liquid 3VC applied to the top surface of the convex portions 2a of the uneven rough surface 2 of the plate-like object 1 forms the resin coating layer 5f1C.
As the resin coating layer 5VC is coated more continuously, a pattern pattern formed by the resin coating layer 5VC appears on the uneven rough surface 2.

In this way, the peripheral edge of the pattern formed on the uneven rough surface 2 penetrates into the recess 2b and continues between adjacent recesses to form the outline of the pattern, and the uneven parts 2a,
2b is entirely coated with synthetic resin to form a three-dimensional ridged pattern, and in this state is cooled and hardened to obtain a decorative board.

Note that the heat-melting synthetic resin particles 4 used in the method of the present invention may be formed from synthetic resin appropriately colored in view of the design of the decorative board, and the size of the particles 4 may be Although the size is not particularly limited, it is preferably 20 to 50 meshes in size. If granules with a size of 20 mesh or more are used, the synthetic resin tends to spread due to the flow after heating and melting, making it difficult to form a delicate pattern. If a material with a size smaller than a mesh is used, even if it is heated and melted, the amount of movement of the synthetic resin due to its flow will be small, making it difficult to sufficiently retain it in the concave bottom of the uneven rough surface 2. This is because it is difficult to form a continuous synthetic resin coating layer.

However, the size of the granular material 4 is appropriately determined and used depending on the shape of the uneven rough surface 2 on the surface of the plate-like object and the desired pattern pattern. If a large pattern is to be formed, granules of 20 or more mesh sizes may be mixed and used.

In addition, in the method of the present invention, it is not necessary to completely melt the hot-melting synthetic resin granules 4; instead, only the surface portion thereof is heated and melted, and the molten portion flows into the concave portions of the uneven rough surface 2. Next, specific examples of the present invention will be shown.

Example: Apply 5000c to the entire surface of the wood fiberboard coated with base coat B.
Using a spray gun, spray paint a white vinyl acetate paint prepared to PS in small particles approximately uniformly with an average particle diameter of 2 to 4 Tm and a raised height of 0.2 to 0.3 m. The coated layer is then dried to form an uneven surface, and then a translucent acrylic ink with a tackiness of 3000 cps is applied to the top of the uneven surface using a flexo printing machine to form a desired pattern. It was applied to.

Next, granules (melting point: 110°C,
20 to 50 mesh) was uniformly spread onto the uneven surface using a scattering device to adhere to the ink layer, and the unattached particulate matter was removed by suction using a suction device. The plate-like material with the granules adhered to the surface in a pattern is sent to a dryer, and the synthetic resin granules are heated and melted at 200°C for 2 minutes, then taken out from the dryer and allowed to cool to room temperature. The molten synthetic resin was cooled and hardened.

As a result, a part of the yellow-green colored synthetic resin stays at the bottom of the concave and convex rough surfaces, and a continuous synthetic resin film layer is formed on the surface of the printing ink applied in a pattern on the convex tops. A decorative board on which a continuous pattern of yellow-green synthetic resin appeared was obtained.

As described above, in the present invention, an uneven rough surface is formed almost uniformly on the entire surface of a plate-like object by an appropriate method, and then a viscous liquid is applied in a pattern to the convex portions of the uneven rough surface. After that, particles of a hot-melting synthetic resin are attached to the surface of the viscous liquid, and then the granular hot-melting synthetic resin is heated and melted, and a part of it flows into the recesses of the uneven rough surface and hardens. Since this method forms a continuous synthetic resin pattern layer, unlike conventional printing methods, the pattern does not become discontinuous at the concave portions of the uneven surface, but instead forms a series of clear patterns along the uneven surface. A pattern created by the synthetic resin layer can be obtained, and the viscous liquid can be applied to the convex portions of the uneven surface using a cylindrical printing plate such as gravure or flexo printing. Unlike the case of thick coating, the production efficiency of decorative laminates is improved, and by appropriately determining and using the size of the granules to be attached to the viscous liquid,
It is possible to form a pattern with a synthetic resin layer having a raised height that could not be obtained by conventional printing force methods. The decorative board obtained in this way has a synthetic resin pattern layer with a rich variety of surface shapes, and the pattern is rich in three-dimensional effect, and it has a beautiful decorative surface that compares favorably with the uneven rough surface of the board-shaped object surface. Moreover, it is possible to create patterns with different colors and lightness depending on the uneven rough surface and the difference in the thickness of the synthetic resin coating layer covering the concave and convex portions.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, and Fig. 1 is a front view showing a state in which a viscous liquid is attached in a pattern to the convex portions of an uneven rough surface, and Fig. 2 is a top view showing a state in which a viscous liquid is attached to a convex portion of a rough surface. FIG. 3 is a sectional view showing a state in which granules are melted and hardened to form a continuous pattern. 1... Plate-shaped object, 2... Uneven rough surface, 2a
...Convex part, 2b...Concave part, 3...
・Viscous liquid layer, 4... Heat-melting synthetic resin granules,
5...Synthetic film layer.

Claims (1)

[Scope of Claims] 1. A heat-melting synthetic resin layer melted by heating is provided over a part of the entire surface of the convex portion of the surface of the plate-like article provided with the rough surface and into the concave portion adjacent to the convex portion, A decorative board characterized in that the synthetic resin layers are provided at multiple locations on the surface of a plate-like object, and a desired pattern is formed by these synthetic resin layers. 2. A roughly uniform roughened surface is formed on the entire surface of the plate-like object by an appropriate method, and then a viscous liquid is applied in a pattern to the convex portions of the roughened surface, and then a viscous liquid is applied to the surface of the viscous liquid. Particles of heat-melting synthetic resin are attached, and then the heat-melting synthetic resin particles are heated and melted, and a portion of the heat-melting synthetic resin particles flow into the concave portions of the uneven surface and harden to form a continuous synthetic resin pattern layer. A method for producing a decorative board, characterized by forming a decorative board. 3. The method for producing a decorative board according to claim 2, wherein the heat-melting synthetic resin granules are colored in an arbitrary color.