JPS59391B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel method for manufacturing embossed decorative laminates.

Conventional embossed decorative boards include a physical embossing method using an embossing plate or the like, and a chemical embossing method that involves promoting and suppressing curing and foaming.

The method using an embossing plate is a method in which the embossing is physically applied using a metal or plastic mold or sheet with unevenness. It has its drawbacks. On the other hand, the chemical embossing method is a method of applying embossing by controlling the foaming of the resin and the curing speed of the resin, but this method has drawbacks such as limitations on the resin and the difficulty in controlling the embossing. have. Moreover, in the conventional method, the unevenness of the base material is not expressed at all, but only different unevenness is provided. The decorative laminate manufacturing method according to the present invention is a completely new method that eliminates the above-mentioned drawbacks, and is capable of stably manufacturing embossed decorative laminates by expressing the irregularities of the base material as they are.

That is, the present invention places a surface forming layer that deforms at least when heated and pressurized on the surface of a base material having unevenness, and further includes:
An embossing sheet formed by laminating a layer of a substance that deforms when heated and pressurized and a layer of a substance that does not deform when heated and pressurized is placed so that the layer of the deformable substance is in contact with the surface forming layer to form a laminate. The gist of the present invention is a method for manufacturing a decorative board, which is characterized in that after forming, the laminate is heated and pressurized, and then the embossing sheet is peeled off. The above-mentioned present invention will be explained in detail below.

First, the manufacturing method of the present invention will be explained using the drawings. 1 to 4 are cross-sectional views schematically showing each step of the method for manufacturing a decorative laminate according to the present invention. In the present invention, first, as shown in FIG. 1, a surface forming layer 2 is placed on the surface of a base material 1 having irregularities, and an embossing sheet 3 is placed on top of the surface forming layer 2 to form a laminate. Here, the embossing sheet 3 is made by laminating a layer 4 of a material that deforms when heated and pressurized (hereinafter referred to as a deformable layer) and a layer 5 of a material that does not deform when heated and pressurized (hereinafter referred to as a support layer). The deformable layer 4 is placed so as to be in contact with the surface forming layer 2. Next, as shown in FIG. 2, the laminate shown in FIG. 1 is heated and pressed by heating and pressing devices 6 and 7. Thereafter, the laminate is taken out of the apparatus and the embossing sheet 3 is peeled off as shown in FIG. 3 to obtain an embossed decorative board as shown in FIG. 4. In the present invention, the above method can be used if only to obtain an embossed decorative board that makes use of the fabric of the base material, but if a pattern other than the fabric of the base material is to be provided, the following method may be used. An example is a method in which a base coat layer and/or a pattern layer is provided on the surface of a base material having irregularities or on the surface of a surface forming layer on the base material side before being placed on the base material.

According to this method, an embossed decorative board having a pattern layer 8 as shown in FIG. 5 can be obtained. (The base coat layer is not shown.) In this case, it goes without saying that the surface forming layer 2 is required to be transparent. Also, before placing it on the surface of the base material, a base coat layer and/or a pattern layer may be provided on the surface of the surface forming layer opposite to the base material, or
After placing the surface forming layer on the surface of the base material, it is also possible to provide a scot layer and/or a pattern layer on the surface of the surface forming layer, in which case a pattern as shown in FIG. An embossed decorative board having layer 8 is obtained. (Note that the base coat layer is not shown.) In the above invention, the base paper 9 is provided with a pace coat layer and/or a pattern layer 8 as a surface forming layer, and then coated or impregnated with the resin 10. It is particularly preferable to use a composite sheet from the viewpoint of adhesion to the base material and surface protection, and when such a composite sheet is used, an embossed decorative board as shown in FIG. 7 can be obtained.

(The base coat layer is not shown.) In the above manufacturing method, if the adhesion between the base material and the surface forming layer is not sufficient during heating and pressing, an adhesive may be applied to the base material and/or the surface forming layer. It doesn't matter if you apply it.

In the above manufacturing method, in order to more easily peel off the embossing sheet from the surface forming layer after heating and pressing, the surface of the embossing sheet in contact with the surface forming layer,
That is, it is desirable that the surface of the deformable layer be matted or coated with a mold release agent, and it is particularly desirable that the surface of the deformable layer be matted and then coated with a mold release agent.

In the above, in order to apply the base coat layer, adhesive, and mold release agent, ordinary coating methods such as roll coating, gravure coating, barcode coating, screen coating, spray coating, and brush coating can be used.

To provide the above-mentioned pattern layer, a conventional printing method such as an offset printing method, a gravure printing method, a letterpress printing method, a screen printing method, or a transfer printing method can be used. Alternatively, printing can also be used.

As the above-mentioned heating and pressing device, a conventional device such as a hot flat press or a hot pressure roll press can be used.

In the above-mentioned invention, the base material having projections and depressions may be any material that already has projections and depressions or can be provided with projections and depressions by some method, such as various veneers, various plywoods, particle boards, hardwood boards, etc. Examples include wood plates such as boards, various metal plates such as iron plates, aluminum plates, and copper plates, inorganic plates such as plastic plates, glass plates, stone, gypsum boards, and concrete plates, and paper. Methods for imparting unevenness include physical methods such as brushing, uneven roll pressing, uneven flat pressing, hitting, chemical methods such as etching, electrochemical methods such as plating, printing methods, etc. It is also possible to place something thereon, or to provide an opening by punching or the like, and any method may be used as long as it can be made uneven.

Next, in the above-mentioned present invention, the ink or coating composition for applying the base coat layer and/or pattern layer to the substrate or surface forming layer is a known ink or coating composition, for example, an ink or coating vehicle that is colored with a dye or pigment, etc. Add the agent,
Furthermore, for example plasticizers, stabilizers, waxes. An ink or coating composition prepared by adding optionally known additives such as grease, desiccant, auxiliary desiccant, curing agent, thickener, dispersant, filler, etc., and sufficiently kneading with a solvent, diluent, etc. 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 rosin, rosin ester, or polymerized rosin. 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, synthetic resins such as amino alkyd resins cellulose derivatives such as nitrocellulose and ethylcellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, etc.
Glue, casein, dextrin, zein, etc. can be used.

Next, in the above-mentioned invention, the surface forming layer must at least deform when heated and pressed to follow the irregularities of the base material.

As such a coating film, sheet or composite sheet as described below is used. First, the paint for forming the coating film uses a vehicle such as a resin, and contains colorants, fillers, plasticizers, desiccants, curing agents, dispersants, etc.
It is possible to use a paint that has been sufficiently kneaded with a solvent, a diluent, etc. with addition of other known additives. As the resin for the vehicle, those listed above as the vehicle for the ink or coating composition can be used. In addition, plastic films or sheets can be used as the sheet, and examples of known materials include cellophane, acetate, polyethylene, polypropylene, polyester, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polyamide, polyvinyl alcohol, polystyrene, hydrochloric acid rubber, A film or sheet of ionomer, polyurethane, etc. can be used.

Furthermore, the composite sheet includes a multilayer sheet of plastic films or sheets, a laminated sheet of a plastic film or sheet and paper or metal, a resin-impregnated sheet, a resin-coated sheet, and the like. As the base paper for the resin-impregnated sheet, any sheet-like material that can be impregnated with resin can be used, such as synthetic paper such as titanium paper, overlay paper, and tissue paper. Here, as the resin for the resin-impregnated sheet, thermosetting resins such as melamine resins, tap resins, guanamine resins, polyester resins, phenol resins, urea resins, urethane resins, alkyd resins, polyamide resins, and epoxy resins are used. Can be used. Furthermore, thermoplastic resins, such as vinyl chloride resins, vinylidene chloride resins, acrylic resins, olefin resins, vinyl butyral resins, styrene resins, vinyl alcohol resins, and other homopolymer or copolymer resins, nitrocellulose, Cellulose derivatives such as ethyl cellulose, rubber derivatives such as chlorinated rubber, cyclized rubber, etc. can be used. Further, modified resins of the above resins, and further resins mixed with the above resins can also be used. Further, as the base paper for the resin-coated sheet, a sheet-like material that is permeable to resin can be used, and the same material as the base paper for the resin-impregnated sheet can be used.

Furthermore, as the resin for the resin-coated sheet, the same resin as that for the resin-impregnated sheet can be used.

If these resin-impregnated sheets or resin-coated sheets are provided with a base coat layer and/or a pattern layer before being impregnated with or coated with a resin as described above, an extremely excellent decorative board can be produced.

In the above, the adhesive applied to the base material or surface forming layer may be a known adhesive, such as a phenol resin, a furan resin, a urea resin, a melamine resin, a polyester resin, a polyurethane resin, or an epoxy resin. , silicone resins, other thermosetting resins, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyvinyl butyral, poly(meth)acrylic resins, nitrocellulose, polyamides, other thermoplastic resins, butadiene-atari Those containing one or more of lonitrile rubber, neoprene, other rubber derivatives, glue, zein, natural resin, sodium silicate, casein, starch, dextrin, gum arabic, etc. as main components are used. Next, the embossing sheet according to the present invention will be explained.

The embossing sheet basically consists of a deformable layer and a support layer, and has a layered structure of two or more layers. It is used to promote deformation of the surface forming layer when the deformable layer is heated and pressurized, and is also required to have releasability since it is peeled off from the surface forming layer after heating and pressurizing. Furthermore, in order to improve the releasability as described above, it is desirable to perform matte processing or apply a mold release agent such as silicone resin. The support layer is for supporting the deformable layer and smoothing the surface of the surface forming layer corresponding to areas other than the uneven portions of the base material, and must not be deformed by heating and pressing. Each of the deformable layer and the support layer constituting the embossing sheet may be a laminate of two or more layers. Therefore, embossing sheets can be classified into three types depending on the number of layers: 2-layer structure, 3-layer structure, and 4-layer structure or more. 2-layer structure refers to the total of 1 deformable layer and 1 supporting layer. It is composed of two layers, and a coating film or a sheet-like material can be used as the deformable layer. The coating film can be formed by applying almost all synthetic resins such as thermoplastic resins and thermosetting resins, polyethylene glycol, wax, etc. to a support layer by a conventional coating method, extrusion coating, etc. Further, the sheet-like material can be formed by fusing or simply overlapping a thin plastic film or sheet with a support layer having a low softening temperature and a thickness of about 100 .mu.m or less. In addition, as a support layer, polyester, hard polyvinyl chloride, polypropylene, etc. have a high softening temperature, and 50μ
plastic films or sheets, paper, iron plates, aluminum plates, metal plates such as duralumin plates,
A glass plate or the like can be used. A three-layer structure consists of two deformable layers and one support layer, or one deformable layer and two support layers.
In the former case, one of the deformable layers is a thin plastic film or sheet (first deformable layer) with a low softening temperature and a thickness of about 100 μm or less, and the other layer is the plastic film or sheet. Deformation of the first deformable layer, which is a material (second deformable layer) interposed between the supporting layer and is made of a thin plastic film or sheet that exhibits fluidity when heated and pressurized, has a low softening temperature, and has a thickness of about 100μ or less. Almost all synthetic resins such as thermoplastic resins and thermosetting resins, polyethylene glycol, wax, etc. are coated on either or both of the support layer and the first deformable layer by a normal coating method. A three-layer embossing sheet can be formed by applying the above-mentioned two together using a conventional laminating method or simply overlapping them.

At this time, the support layer can be exactly the same as the two-layer structure described above. In the latter case, the deformable layer can be made of the same material as the two-layer structure described above, and the support layer can be made into two layers by appropriately combining the same materials as the two-layer structure described above. A supporting layer can be formed.

In addition, a four-layer structure or more means two or more deformable layers and two or more support layers.
The deformable layer is composed of two deformable layers in the three-layer structure described above, and a second deformable layer is provided between the second deformable layer and the support layer in order to promote deformation of the second deformable layer. The third deformable layer is selected appropriately from those similar to those that can be used as the second deformable layer, and the third deformable layer is formed using the same method as the second deformable layer. A fourth or similar number of deformation layers can be provided.

In addition, two or more supporting layers can be formed by appropriately combining the same supporting layers as those used in the three-layer structure. In this way, embossing sheets can be classified into three types depending on the number of layers, but it is desirable to use one that matches the degree of unevenness of the base material, the type and thickness of the surface forming layer, heating and pressing conditions, etc. .

As is clear from the above description, the present invention is a method for manufacturing an embossed decorative board extremely easily and inexpensively, and the embossing can also be easily controlled.

Further, the embossing sheet used in the present invention can be used repeatedly. This is because the deformable layer that makes up the embossing sheet has an unevenness that is the opposite of the unevenness on the surface of the base material after the sheet is used, but when it is reused, the heat and pressure will change the unevenness on the next base material. This is because it has the property of being able to freely deform according to the requirements. According to the manufacturing method of the present invention, a delicate three-dimensional effect can be expressed due to the difference in gloss caused by the unevenness of the surface of the decorative board.

For example, when producing a decorative board with a wood grain pattern, a product that closely resembles natural wood is obtained. In particular, when the base material is a wood board such as plywood, the unevenness of the wood board can be expressed as is, resulting in an extremely excellent product. At this time, if the soft parts of the wood are removed by brushing the surface of the wood board as described above, the unevenness will be more clearly expressed. Conventional embossed decorative boards are made by first sealing the base material, a wooden board such as plywood, to eliminate surface irregularities, and then applying a printing layer or the like on top of that, which has no relation to the irregularities of the base material. Compared to conventional boards that provide unevenness, the decorative board obtained by the present invention can express the unevenness of the base material as it is, and because it uses naturally occurring conduits, a natural feel can be obtained, and the effect is tremendous. There is something. Furthermore, if you use a transparent or transparent material as the surface forming layer, you can achieve the same shine as a completely natural wood surface with improved surface properties. A decorative board with depth and new grain can be obtained. The decorative laminate obtained by the method of the present invention is suitable for various uses, for example, as a material for ceilings, floors, walls, or interior decoration of buildings, vehicles, ships, etc., or as materials for furniture and fittings,
It can be used as a material for tables, musical instruments, cabinets, etc.

The present invention will be described in more detail below with reference to Examples.

Example 1 A composite sheet made of 237/d tissue paper impregnated with tap resin and printed with a wood grain pattern that harmonizes with the conduit of the base material was layered on a lauan plywood board with conduit holes dug out by brushing. Furthermore, an embossing sheet consisting of a 3-layer structure consisting of a 50μ vinylon matte film as the first deformable layer, a synthetic rubber adhesive as the second deformable layer, and a 200μ polyester film as the support layer was layered at 160°C and 25kg/C.
After shaping with a flat press for 5 minutes at step d, the embossing sheet was peeled off to obtain a beautiful tap-embossed decorative board with shine and depth similar to that of natural wood.

Example 2 The base material was plywood with concave portions in the conduit holes, and a 507/d colored transparent paper (507/d) impregnated with melamine resin was printed with a wood grain pattern that harmonized with the conduit of the base plywood with transparent organic pigment ink. 137 impregnated with melamine resin on top of Kojin TKS)
/d overlay paper on the composite sheet, the first
30μ polypropylene film as the deformation layer, PVC-vinyl acetate copolymer resin as the second deformation layer, 100μ polypropylene film as the support layer
By stacking an embossing sheet consisting of a 4-layer laminate consisting of a μ polyester film and a mirrored stainless steel plate, and forming it by flat press at 150°C and 70k9/Cd for 7 minutes, the embossing sheet was peeled off. A deep melamine embossed decorative board that allows the wood surface of the base plywood to be seen through was obtained.

Example 3 307/ in which the base coat layer was printed with a wood grain pattern that harmonized with the conduit of the base plywood by gravure printing.
d After laminating the thin paper with a plywood board having concave portions in the conduit holes using an ethylene-vinyl acetate emulsion type adhesive, an amino alkyd resin is roll coated over the thin paper.

After that, a 30μ polyethylene film was used as the first deformation layer, a urethane resin was used as the second deformation layer, and a 20μ polyethylene film was used as the support layer.
The embossing sheet consisting of three layers of μ polyester film is stacked and heated and pressed using a roll press at a temperature of 120°C and a pressure of 15k9/Cd to completely cure the amino alkyd resin, and then the embossing sheet is peeled off to create an embossed decorative board. Obtained. Example 4 The base material was plywood with concave portions in the conduit holes, and a urethane adhesive was applied with a roll coater to the printed surface of an 80μ transparent PVC film printed with a wood grain pattern that harmonized with the conduit of the base material, and then the plywood was coated with a roll coater. On top of this, a 50μ vinylon pine film treated with silicone is used as the first deformation layer, a urethane adhesive is used as the second deformation layer, and a 200μ vinylon film is laminated as the support layer.
Layering the embossing sheet consisting of three layers of aluminum plates,
After molding with a flat press at 150° C. and 25k9/Crli for 5 minutes, the embossing sheet was peeled off to obtain a PVC embossed decorative board that took advantage of the shine and depth of the base material.

Example 5 The base material was 2m/m thick cardboard with an uneven pattern printed on it by screen printing, and acrylic emulsion type adhesive was applied to the printed surface of a 40μ transparent nylon film printed with a pattern that harmonized with the uneven pattern on the base material. After applying the agent with a roll coater, it is laminated with the base paper, and on top of this, a 30μ polyester mat film as the first deformable layer, a synthetic rubber adhesive as the second deformable layer, and a 3.0 m/m thickness as the support layer. An embossing sheet consisting of three layers of mirrored stainless steel plates is stacked and formed by flat press at 150℃ and 10k9/Cd for 3 minutes, and then the embossing sheet is peeled off to create an embossed decorative board that matches the printed pattern. Obtained.

Example 6 A 1 m/m iron plate with an uneven pattern formed by etching was used as the base material, and after coating and baking a primer made of phenol epoxy resin, a pattern that harmonized with the unevenness of the base iron plate was printed.507/ d A composite sheet made of titanium paper impregnated with tap resin is stacked, and an embossing sheet is made of three layers: a 30 μ polypropylene film as the first deformable layer, an amino alkyd resin as the second deformable layer, and a 200 μ polyester film as the support layer. After stacking and forming by flat press at 120° C. and 25k9/Cd for 5 minutes, the embossing sheet was peeled off to obtain a tap embossed decorative board.

Example 7 The base material was a 1 m/m thick aluminum plate with a concave-convex pattern formed by hot pressing using an embossing plate, and the printed surface of a 100μ transparent PVC film was printed with a pattern that harmonized with the concave-convex pattern of the base material. After applying the chloroprene adhesive, it is laminated with the base material, and on top of this, a 30μ polyester film is applied as the first deformable layer, and a synthetic rubber adhesive is applied as the second deformable layer.
As a support layer, an embossing sheet consisting of three layers of 200μ polyester film was layered and heated at 150℃, 30K9/
After hot flat pressing with Cd for 5 minutes, the embossing sheet was peeled off to obtain an embossed decorative board with aluminum luster.

Example 8 1rf punched round hole with diameter 3m/m by punching machine
The base material is a sheet of m-thick paper laminated with plywood using a vinyl acetate adhesive.After laminating this with a 100μ colored PVC film coated with a vinyl acetate adhesive, a 50μ vinylon film is applied as the first deformable layer on top of this. Film, 2nd
Embossing sheets consisting of three layers, acrylic resin as the deformable layer and 200 μm polyester film as the support layer, are stacked together, heat-flat pressed at 150°C and 20k9/CriL for 5 minutes, and then the embossing sheet is peeled off to color. An embossed decorative board protected and decorated with a PVC film was obtained.

Example 9 A 200μ thick aluminum plate embossed with a hairline using a steel brush was used as a substrate, 237/d thin paper impregnated with tap resin was layered on this, and a 40μ vinylon film was further added as a first deformation layer, and a second deformation layer was applied. A 4-layer embossing sheet consisting of a synthetic rubber adhesive as a support layer, a 100μ polyester film and a stainless steel mirror plate as a support layer was layered at a temperature of 130℃ and a pressure of 15K.
9/Crii. After applying heat and pressure using a roll press, the embossing sheet was peeled off to obtain a hairline embossed decorative board whose surface was protected with tap resin.

Example 10 A plywood base material with concave portions in the conduit holes was coated with an emulsion type adhesive mainly composed of ethylene monovinyl acetate copolymer resin, and then a wood grain pattern that matched the conduit of the base material was applied. Printed 507/77? Laminate the titanium paper with the base plywood.

Thereafter, polyester resin was applied onto the titanium paper using a roll coater, and on top of this, an embossing sheet consisting of a 40μ vinylon matte film as the first deformable layer, a 100% alkylphenol resin as the second deformable layer, and a 200μ polyester film as the support layer was formed. were superimposed and heated and pressed using a roll press at a temperature of 150° C. and a pressure of 15k9/Cd. After the resin was completely cured by further heating, the embossing sheet was peeled off to obtain a polyester embossed decorative board. Example 11 The base material was plywood with a concavity in the conduit hole portion and a wood grain pattern directly printed on it, the base material was coated with urethane resin, and a 50μ nylon film was coated on top of this as a first deformation layer.
Synthetic rubber adhesive as the second deformable layer, 20% as the support layer
Embossing sheets made of 0μ polyester films were stacked together and flat pressed at 150° C. and 20k9/cm for 3 minutes to obtain an embossed decorative board whose surface was protected by urethane resin.

Example 12 A punching machine made countless round holes with a diameter of 2~ to a thickness of 1w.
The base material is a piece of yellow cardboard of 500mm thick laminated with white cardboard of the same thickness using an adhesive mainly composed of ethylene-vinyl acetate copolymer. Apply Bisol with a roll coater.

Furthermore, on top of this, a 50μ vinylon film was used as the first deformation layer, an acrylic resin was used as the second deformation layer, and a 200μ vinylon film was used as the support layer.
An embossed decorative board was obtained by stacking embossing sheets consisting of three layers of μ polyester film and performing roll pressing at a temperature of 150° C. and a pressure of 12k9/Cd.

[BRIEF DESCRIPTION OF THE DRAWINGS] FIGS. 1 to 4 are cross-sectional views schematically showing each step of the method for manufacturing a decorative laminate according to the present invention, and FIGS. It is a sectional view showing one embodiment of the decorative board obtained. Explanation of the symbols representing the main parts of the figure: 1... Base material having unevenness, 2... Surface forming layer, 3...
...Sheet for embossing, 8...Pattern layer.

Claims (1)

[Scope of Claims] 1. A surface forming layer that deforms at least when heated and pressurized is placed on the surface of a base material having irregularities, and further includes a layer of a substance that deforms when heated and pressurized, and a layer of a substance that exhibits fluidity when heated and pressurized. After forming a laminate by placing an embossing sheet formed by sequentially laminating a layer of a substance and a layer of a substance that does not deform when heated and pressurized so that the layer of the deformable substance is in contact with the surface forming layer, A method for manufacturing a decorative board, which comprises heating and pressing the laminate and then peeling off the embossing sheet. 2. The method for manufacturing a decorative laminate according to claim 1, which uses a base material having an uneven surface having a pattern layer. 3. The method for manufacturing a decorative board according to claim 1, wherein the surface forming layer is a layer having a pattern layer. 4. The method for manufacturing a decorative board according to claim 1, wherein the surface forming layer is a layer obtained by providing a pattern layer on base paper and then impregnating the entire surface with resin.