JPS5940114B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board in which colors appear in the concave portions of an embossed pattern.

Decorative boards made by embossing a plate with a paper overlay on the surface or a painted plate have been known for some time, but deep embossing is difficult because the paper or coating film is not flexible enough. When attempting to create a pattern, the strength of the paper or coating film decreases, resulting in damage to the paper or peeling of the coating film, and the uneven pattern tends to become shallower due to springback of the base material after manufacturing. There is.

In order to eliminate this problem, it is possible to perform embossing at a high temperature, but if the temperature is too high, there is a risk of carbonization on the surface of the base material, so there is a limit to the processing temperature. In order to create an embossed pattern, it was necessary to carry out heat and pressure treatment for a long time. The present invention provides a method for manufacturing a decorative board that eliminates these drawbacks and allows a variety of colors to appear in the concave pattern.

That is, in the present invention, a colored layer and a paper layer mixed with thermoplastic resin fibers are sequentially and integrally provided on the surface of an appropriate substrate to form an intermediate base material, and the surface of this intermediate base material is coated with the thermoplastic resin fibers. By pressing with an embossed pattern plate having a temperature higher than the melting point, an uneven pattern is formed on the surface of the intermediate base material, and the thermoplastic resin fibers are melted on the bottom of the recessed pattern, thereby causing the thermoplastic resin fibers to be mixed. The feature is that the color of the colored layer provided on the lower side of the paper appears on the surface. The intermediate base material used in the method of the present invention is
It may be formed by sequentially adhering colored paper and paper mixed with thermoplastic resin fibers to the surface of the substrate, or it may be formed by adhering these colored papers and mixed paper to the surface of the substrate, with the colored paper as the lower layer. Alternatively, it may be formed by applying a colored layer to the surface of the substrate by painting and then pasting the mixed paper with an adhesive.

Also, instead of a colored layer by painting, a colored adhesive may be used to attach the mixed paper to the surface of the substrate, but in order to make the decorative board display sufficient color with this colored adhesive, It is preferable to adjust the viscosity etc. so as to form a relatively thick adhesive layer.

Furthermore, as an intermediate base material, paper mixed with thermoplastic resin fibers whose back side has been colored in advance may be adhered to the substrate.
In this case, unevenness tends to appear in the thickness of the colored layer, and as a result,
During hot pressing using an embossed pattern board, etc., colors may appear in undesired areas other than the concave pattern formed on the intermediate base material, so depending on the pattern depth of the embossed pattern board, etc., colors may appear only in designated areas. It is necessary to adjust so that the colors appear.

On the other hand, paper mixed with thermoplastic resin fibers is made by mixing synthetic fibers such as polyethylene, polypropylene, acrylic, etc. with general pulp in a ratio of 10:90 to 90:10 (wt%), and adding size and filler. things are used, but
The reason for blending general pulp is that problems arise in terms of product price, size, filler yield, etc., and if these problems can be solved, there will be no hindrance to the method of the present invention even if the paper is made only of thermoplastic resin fibers. There is no. This type of paper uses thermoplastic resin in the form of fibers, so it cannot be seen through, but when heated to a temperature higher than the melting temperature of the thermoplastic resin fibers, the fibers melt and form a film. Because it is shaped like this, the back side can be seen through.

The present invention takes advantage of such properties of mixed paper, and therefore, the embossing pattern plate or embossing roll that is pressed onto the surface of the intermediate base material mentioned above is heated to a temperature higher than the melting point of the thermoplastic resin fiber. I need to be there.

In addition, in the present invention, since the embossed pattern board or the like is pressed against the intermediate base material to simultaneously form the concave and convex pattern, the convex portions of the embossed pattern are pressed with sufficient pressure to form the concave and convex pattern on the intermediate base material. It is necessary to do so.

At this time, if the entire surface of the concave part of the embossed pattern is pressed until it comes into contact with the surface of the intermediate base material, the color of the colored layer will appear on the entire surface of this intermediate base material, which is not preferable. If the structure is configured so that it is in contact with the surface of the intermediate base material, the lower colored layer will partially appear in the convex pattern of the resulting decorative board due to the melting of the thermoplastic resin fibers, and the decorative board will A light color pattern corresponding to the dark color of the concave pattern can be obtained, and a beautiful pattern can be formed. Next, examples of the present invention will be shown.

Example 97 A copolymer emulsion adhesive of vinyl acetate and arylate ester was applied to the surface of a 1tm thick wood fiberboard.
70 weight polyethylene fibers coated at a ratio of /wl and colored paper pasted on the back side on the adhesive. After gluing mixed paper containing I reprinted the pattern.

As a result, the maximum depth is 1.0m7! A decorative board having an uneven pattern in which an L-shaped recess pattern was formed and the color of the colored paper appeared on the entire bottom of the recess pattern was obtained. As described above, in the present invention, a colored layer and a paper layer mixed with thermoplastic resin fibers are sequentially and integrally provided on the surface of a substrate to form an intermediate base material, and then the temperature is raised to a temperature equal to or higher than the melting point of the thermoplastic resin fibers. By pressing the convex pattern part of an embossed pattern board or the like with an appropriate pressure against the surface of the intermediate base material, an uneven pattern is formed on the surface of the intermediate base material, and at the same time, the color by the colored layer is displayed on the bottom surface of the concave pattern. Since it is related to a method for producing a decorative board characterized by causing the thermoplastic resin fibers to melt, the thermoplastic resin fibers are melted at the same time as the depressions are formed on the surface of the intermediate base material by heat pressure using the convex pattern parts of the embossed pattern board or the like. The paper layer becomes transparent, and the color of the colored layer provided on the back side of the paper layer appears on the surface, forming a beautiful pattern. Through a simple process, the concave pattern and color can be perfectly matched. It is possible to easily obtain a decorative board that is in tune with the above, and furthermore, the thermoplastic resin fiber shows almost no decrease in strength even when the base material is softened by water hammering, etc., and has high tensile strength. Therefore, even if a deep uneven pattern is formed, there is no risk of the surface tearing or cracking, and therefore the decorative effect will not be impaired. Since a molded body corresponding to the pattern is formed, it is possible to prevent the recessed portion from restoring due to spring back of the base material. Furthermore, according to the method of the present invention, by coloring the surface of the paper mixed with thermoplastic resin fibers in a color different from that of the colored layer, a decorative board with a rich variety of colors in which the convex pattern and the concave pattern are different can be obtained. It is also possible to further emphasize the three-dimensional effect of the uneven pattern.

Claims (1)

[Claims] 1. A colored layer and a paper layer mixed with thermoplastic resin fibers are sequentially and integrally provided on the surface of the substrate to form an intermediate base material, and then heated to a temperature equal to or higher than the melting point of the thermoplastic resin fibers. By pressing the convex pattern part of an embossed pattern board, etc., onto the surface of the intermediate base material with appropriate pressure, a concave and convex pattern is formed on the surface of the intermediate base material, and at the same time, the color due to the colored layer is displayed on the bottom surface of the concave pattern. A method for manufacturing a decorative board, which is characterized by: 2. The method for manufacturing a decorative board according to claim 1, wherein the colored layer is made of colored paper. 3. The method for manufacturing a decorative board according to claim 1, wherein the colored layer is made of paint. 4. The method for manufacturing a decorative board according to claim 1, wherein the colored layer is made of a colored adhesive. 5 By forming the pattern depth so that the bottom of the concave pattern of the embossed pattern board etc. comes into contact with the surface of the intermediate base material, an intermediate color made of the colored layer can be created on the convex pattern provided on the intermediate base material. 5. A method for manufacturing a decorative laminate according to claim 1, wherein the decorative laminate is made to come out.