JPS5936600B2 - Mokumeoutotsumoyouoyuusurukeshiyoubanno Seizouhouhou - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board having an uneven wood grain pattern, which can faithfully represent the condition of the skin of a natural wood board.
The present invention relates to a method for manufacturing a decorative board that has a three-dimensional appearance extremely similar to that of a natural wood board due to differences in color tone and gloss between concave and convex parts.

Various attempts have been made to make decorative boards look like natural wood, and this type of decorative board includes a matching embossed decorative board with an uneven pattern that perfectly matches the pattern of the decorative paper, and a embossed decorative board that has an uneven pattern that perfectly matches the pattern of the decorative paper. There are non-synchronized embossed decorative boards etc.

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, the molding boards used for decorative boards with wood grain patterns to give the appearance of natural wood have traditionally been stainless steel boards, duralumin boards,
A thermosetting resin mold plate obtained using an embalming plate obtained by etching a desired uneven pattern on an aluminum plate etc. with an embalming solution, and an original plate made from natural wood with a uniform thickness. After applying a mold release agent and pouring silicone rubber to a uniform thickness, it is cured and peeled off from the surface of the original plate to obtain a concave mold, and then epoxy resin is poured into this mold.
A mold plate is obtained by placing paper or cloth impregnated with a thermosetting resin and drying it through a thermoplastic release sheet on a convex mold reinforced with glass fiber cloth, etc., and heating and pressing it. be. The present inventors aimed to make the conventional natural wood-like decorative boards using these molded boards more similar to natural wood boards, in other words, to reduce the unique gloss difference and color tone difference between the spring and autumn wood parts of natural wood boards. In order to reproduce this, we investigated using the above-mentioned forming plate and found a method using a gravure offset roll.

However, since the mold plate obtained by the former method is obtained by ordinary pressing, there is almost no unevenness in its thickness, and the base plate with an uneven pattern obtained by the same press using the mold plate 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 obtained by curving a natural wood board, or the delicate parts of a natural wood board. The latter method can faithfully transfer the texture of the grain of a natural wood board, but it is not possible to make a version from the original board using silicone rubber, or from a silicone rubber version using epoxy resin. Because silicone rubber or epoxy resin is poured by hand onto the plate to be removed, 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. appears.

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, pour epoxy resin into the unfilled recesses and the entire surface.
To reinforce this plate, one or two sheets of glass fiber cloth are placed on top of it, 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 the female molding plate from the male epoxy resin plate by heating and pressurizing it with thermosetting resin-impregnated paper, the uneven thickness of the epoxy resin plate will be transferred as is. The resulting molded plate also has uneven thickness. Furthermore, as shown in Fig. 1, uneven thickness appears in the base plate 1 of the decorative board obtained using the forming plate, and when coloring and painting only the convex portions with the gravure offset roll 2, uneven coloring and coating 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, and in other words, part a where the wood grain lines are cut appears, which makes it difficult to use as a product. This has the disadvantage of lowering its value, and it has not been possible to obtain a decorative board with an uneven wood grain pattern similar to a natural wood board, which is the goal of the present invention.
However, in order to complete the purpose of the present invention, the inventor has
We were able to complete this by discovering a new method for manufacturing a molding plate. In other words, by injecting and polymerizing and hardening vinyl monomers into the original board that has been subjected to the concave processing, the material is reinforced with plastic (referred to as WOOd Plastic CombinatiOn, hereinafter abbreviated as WPC). By changing the quality of the original plate, it is possible to eliminate the reduction in compression of the original plate during heating and pressurization and increase the number of times of repeated use, and it is also possible to obtain a uniform product directly from an original plate of uniform thickness.

Since a female forming plate is obtained using a normal press, there is no reason for the uneven thickness of the forming plate, and therefore, by converting the original plate with a uniform thickness into WPC, it is easy to use. We were able to obtain an inexpensive molding plate using this method. and,
The base plate for decorative laminates obtained using this molding board could faithfully transfer the condition of the skin of the natural wood board, and had no uneven thickness, no uneven coloring on convex parts, and no uneven coating. below,
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 convex portions of the obtained original plate 4 were the adjusted thickness b. Vinyl monomers such as methyl methacrylate, styrene, unsaturated polyester, etc. are injected into this original plate, but in order to facilitate this injection, the original plate is usually heated to a moisture content of 8 to 9%. Adjust with dryer. Furthermore, put this in a vacuum pressurized container and use 5 to 20 mols per field for 30 ml.
After degassing for 1 to 2 hours, the monomer is introduced and pressurized at normal pressure for 1 to 2 hours to achieve an injection rate of 60 to 90%. From then on,
When carrying out polymerization, it is preferable to wrap the monomer-injected original plate in a packaging material such as aluminum foil in order 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 using the electron beam irradiation polymerization method to apply 200 megavolts of electrons to the monomer-injected original plate. The material was polymerized and cured by irradiation with 20 mecarats using a line accelerator to obtain the original plate 5 shown in FIG. Thereafter, as shown in FIG. 4, a thermosetting resin such as melamine resin, guanamine resin, phenolic resin, diallyl phthalate resin, etc. is usually applied to the original plate 5, with its 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 to be impregnated and dried by the above method are placed and heated and pressurized at a temperature of 110 to 160°C, a pressure of 10 to 60 kg/Cd, and a time of 10 to 40 minutes to form the material shown in Fig. 5. Template 8 was obtained. At this time, there was almost no reduction in compression of the original sheet made into WPC, and it was possible to use it repeatedly. Next, as shown in FIG. 5, using an ordinary laminator, a colored base paper 11 corresponding to the spring material is applied to the surface of a base material 9 selected from plywood or hardboard, etc. using an adhesive 10 such as vinyl acetate resin. A base plate bonded with urethane resin or the like is made, and the wood grain pattern surfaces of the forming plate 8 obtained above are superimposed at a temperature of 120 to 140°C and a pressure of 15 to 20 kf! /
The base plate 12 shown in FIG. 6 was obtained by heating and pressing at a Cdl time of 10 to 20 minutes.

Next, as shown in FIG. 6, since the color tone corresponding to the spring wood portion of the base plate 12 is provided in the color base paper, printing ink 13 having a color tone corresponding to the fall wood portion is applied using a gravure offset roll. Print only on the raised areas. Further, a matte clear resin paint 14 corresponding to the spring wood part is applied to the entire surface using a roll coater and dried, and then a glossy clear resin paint 15 corresponding to the autumn wood part is applied and dried to obtain the desired decorative board. Ta. The decorative board thus obtained has the delicate grain, color tone, and luster of a natural wood board, and is a novel method that does not use printing paper. Examples of the present invention will be described below.

〔Example〕

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

Next, the original plate adjusted with a hot air dryer to have a moisture content of 8 to 9% was placed in a vacuum tank and heated for 2 hours under a vacuum of 511 mHg.
After degassing for a period of time, 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 irradiated with 20 mechalat using a 200 mechavolt electron beam accelerator to harden it. Next, a 20-micron thick polypropylene sheet and 10 sheets of phenol resin-impregnated paper (weighing 1809/A) were sequentially placed on the original plate with the uneven 5-patterned surface facing up, and the whole was inserted into a molding press at a temperature of 130 µm.
It was molded by heating and pressing at a temperature of 20 kg/CIL for 20 minutes at a temperature of 20 kg/CIL to obtain three mold plates of uniform thickness. Next, 23f!
/7T? A base plate is obtained by printing colored base paper on the entire surface of thin paper with printing ink of a color matching the spring wood part of the cedar board and pasting it to plywood using a vinyl acetate emulsion resin adhesive.

The wood grain patterned surface of the molded plate obtained above was superimposed on this surface and heated and pressed at a temperature of 120° C. and a pressure of 20 kg/d for 1 hour and 10 minutes to obtain a base plate. Next, use a gravure offset roll to apply printing ink with a color tone corresponding to the autumn wood part of the cedar board only to the convex parts of this base plate, and after drying, roll urethane resin paint corresponding to the spring wood part to the entire surface. 30 at coater
~50f! /ml and dry. Further, the desired decorative board could be obtained by applying a urethane resin paint corresponding to the autumn wood part only to the convex parts using a gravure offset roll and drying it.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing a state in which a convex portion of a base plate is coated with a gravure offset roll.

Claims (1)

[Claims] 1 The undulating pattern is emphasized by polishing the original board with the desired wood grain pattern, such as brushing, 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 process of obtaining a thermosetting resin molding plate, pasting the pre-colored color base paper and the base material via adhesive, overlapping the wood grain pattern surfaces of the molding plate obtained in the previous process, and heating. A step of applying pressure to obtain a base plate having an uneven wood grain pattern, a step of applying printing ink to the convex portions of the base plate obtained in this manner, a further step of applying and drying a matte clear resin paint over the entire surface, and a step of further applying the convex portions to the convex portions. A method for manufacturing a decorative board having an uneven wood grain pattern, which combines the steps of applying and drying a glossy clear resin paint on the chisel.