JPS5951435B2 - Method for manufacturing decorative board with uneven wood grain pattern - 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, and more specifically, the present invention relates to a method for manufacturing a decorative board having an uneven wood grain pattern, and more specifically, an uneven pattern having a texture that perfectly matches the autumn wood portion of a wood grain pattern printed paper and has a wood texture similar to that of natural wood. A decorative board with an uneven wood grain pattern that can reproduce the natural wood texture by using a molding board that has both the same type of wood grain printing paper and a natural wood conduit pattern that does not cause any discomfort. The purpose is to obtain.

Conventionally, when manufacturing a decorative board with an uneven wood grain pattern, as described in Japanese Patent Publication No. 46-3600, a photograph of a wood grain pattern printed paper is taken and the wood grain pattern printed paper is placed on a metal plate such as an aluminum plate or a stainless steel plate. The same pattern is obtained by an etching method to make a mother plate, and paper or cloth impregnated with thermosetting resin such as phenol resin is placed on this mother plate via a release sheet and heated and pressed to form a mold plate. There is a method of making a wood pattern and matching it with woodgrain pattern printing paper impregnated with thermosetting resin.

Since this method involves etching a metal plate, the uneven wood grain pattern is not rounded, and it is technically very difficult to faithfully reproduce the delicate uneven wood grain and conduit parts of the surface of natural wood. Obtaining a decorative board with wood skin is determined by the type of light rays. The base plate 7 thus obtained was etched with an etching solution suitable for the type of substrate, for example, in the case of an aluminum plate, a ferric chloride solution was used to obtain an etched plate 8 as shown in FIG.

On the other hand, as shown in FIG. 4, a veneer laminated plywood board 11 is obtained by laminating a natural wood veneer 9 of the same type as the used woodgrain pattern printing paper or a natural wood that does not give a sense of discomfort on a plywood 10.

Next, as shown in FIG.
Place the pressure 10 to 30 kg/C using a normal press.
A matrix board 13 as shown in FIG. 6 was obtained by heat-pressing at a temperature of 100 to 150 DEG C. for a time of 10 to 30 minutes, on which the uneven wood grain pattern of the etching board 8 was transferred onto the veneer laminated plywood 11.

In this way, the uneven pattern on the etching board, which had an acute-angled uneven pattern, changes to a round uneven pattern due to the cushioning properties of the veneer laminated board 11.

Next, as shown in FIG. 7, a release film 12 such as polypropylene is placed on the mother mold plate 13, and on top of the release film 12 impregnated with a thermosetting resin such as melamine resin or phenol resin.
3 mils overlay paper 14 and weighing is usually 100g/M
2 to 190 g/M2 of kraft paper 15 was placed, and a normal press was used at a pressure of 15 to 25 kg/Cm2 and a temperature of 14
By heating and pressing at 0 to 160°C for 10 to 20 minutes, as shown in Figs. 16
A forming plate 17 was obtained on which the image was transferred.

At this time, the reason why overlay paper is used is that impregnated overlay paper is usually thin, so it is easy to increase the amount of thermosetting resin relative to the weight of the paper, that is, the impregnation rate. Therefore, since the amount of resin is large, the wood grain conduit grooves 16 of the natural wood veneer 9 can be faithfully transferred onto the shaping board, and it also serves to protect the surface of the shaping board. Next, as shown in Fig. 10, a base material using multiple sheets of paper or cloth impregnated with a thermosetting resin such as melamine resin or phenol resin in a conventional manner and dried, or a base material such as plywood, hardboard, particle board, etc. An overlay paper 14 impregnated with a thermosetting resin of the same type as the woodgrain pattern printing paper 19 impregnated with a thermosetting resin such as melamine resin or diallyl phthalate resin and dried is placed on top of the paper 18, and a release film 1 such as polypropylene is placed on top of the paper 18.
2, so that the register mark 4 of the forming plate 17 obtained in the previous step and the register mark of the wood grain pattern printing paper 19 match, that is, the wood grain pattern of the forming plate 17 and the wood grain pattern of the wood grain pattern printing paper 19. After matching the temperature, place the
70℃, pressure 10-90kg/Cm・, time 5-50
The desired decorative board was obtained by heating and pressing under the conditions of 10 minutes.

The decorative board thus obtained was a decorative board that was completely in sync with the woodgrain pattern printed paper used and was also able to perfectly reproduce the wood texture of natural wood.

The greatest feature of the present invention is that any paper with a wood grain pattern can be made into the decorative laminate, which is the object of the present invention, and it is completely symmetrical, which could not be obtained with the prior art, and also has the characteristics of natural wood. It has been successfully reproduced using a simple and inexpensive manufacturing method. [Example] The light and shade of oak patterned woodgrain pattern printing paper with register marks is photographed using a plate-making camera to obtain a film that allows light to pass through the portion corresponding to the autumn wood portion.

On the other hand, when we pre-impregnated woodgrain pattern printing paper with melamine resin and examined the dimensional change after drying, we found that it was 0.0% smaller in the longitudinal direction than before impregnation.
It was found that it elongated by 90% and by 1.44% in the lateral direction. Therefore, the film is stretched based on the horizontal magnification of 1.44%, and the extra vertical magnification of 0.54% is cut off at a place where the wood grain pattern is inconspicuous to match the vertical magnification of 0.90%. A negative film corrected to the same dimensions as the printing paper after dipping and drying is produced. Next, a photosensitive resin "Fujisper Resist" manufactured by Fujifilm Co., Ltd. was coated on a 2 mm thick aluminum plate at a rate of 20 g/shaku' and dried. A negative film was placed on top of this and fixed in close contact. A light beam from a carbon arc was irradiated for 20 minutes at a position 500 mm away from the negative film surface.

Thereafter, the negative film was removed, and the uncured portion corresponding to the spring material portion was washed with warm water and dried at a temperature of about 50° C. to obtain a base plate. This base plate was etched with a ferric chloride solution to obtain an etched plate having an uneven wood grain pattern. On the other hand, the etching obtained in the previous step was placed on a 4 mm plywood board made of a 0.2 mm thick oak veneer, which is a veneer made of the same type of natural wood as this woodgrain pattern printing paper, through a 20 μ thick polypropylene film. The plates could not be stacked together and the press pressure could not be increased to 20°C. Furthermore, as described in Japanese Patent Publication No. 49-12684, woodgrain pattern printing paper with the same dimensions as natural wood is made from natural wood using the gravure printing method, and molded plates are made from the natural wood using electroforming and thermosetting. There is a method of synchronizing the woodgrain pattern printing paper that has been impregnated with a synthetic resin and dried.

Since this method uses natural wood as the prototype, the wood species and grain patterns are limited, so it is not easy to obtain the desired natural wood, and furthermore, because it uses electroforming, The disadvantage is that the equipment is large-scale and the cost of the forming plate is also high. However, the present inventors have completely eliminated the above-mentioned conventional drawbacks and have accomplished the object of the present invention.

In other words, a film made by photographing woodgrain pattern printing paper with register marks is used in the final process to overlap the register marks on the forming board and the register marks on the woodgrain pattern printing paper to match the respective wood grain patterns. Taking into account the dimensional changes in the woodgrain pattern printing paper used in the final process, we corrected it to the desired size and created a negative that allows light to pass through the area corresponding to the wood grain area of the woodgrain pattern. Make a film.

This negative film with a wood grain pattern is placed on a base material coated with a photosensitive resin and irradiated with light to harden only the autumn wood portion of the wood grain pattern, thereby revealing the wood grain pattern on the base material. Next, after obtaining a base plate from which the uncured photosensitive resin has been removed, the surface of the base plate is etched to obtain an etched plate having the same pattern as the woodgrain pattern printed paper. Next, select a veneer of natural wood that is the same type as this woodgrain pattern printing paper or that does not cause any discomfort, and bond the veneer to plywood using a conventional method to obtain a veneer-laminated plywood board. The etched plate described above is placed with a film interposed therebetween and heated and pressed to obtain a master plate in which the uneven pattern of the etched plate is transferred onto the veneer laminated board. As a result, the sharp irregularities, which are a drawback of the conventional etching method, are rounded, and together with the grain conduit grooves of natural wood, it is possible to obtain a master board having an irregular woodgrain pattern surface that is closer to that of natural wood. after that,
Thermosetting resin-impregnated paper or cloth is placed on the mother plate with a release film interposed therebetween and heat-pressed to form a pattern between the uneven wood grain pattern of the etched plate and the wood grain conduit groove portion of the laminated veneer board. After obtaining a transferred forming plate, the forming plate and a woodgrain pattern printing paper impregnated with a thermosetting resin are matched with each other by their respective register marks, and then heated and pressed, thereby eliminating the drawbacks of the conventional method. As a result, a decorative board having a wood grain unevenness pattern that is perfectly synchronized and that can easily reproduce the natural skin of natural wood, which is the object of the present invention, can be obtained. below,
The present invention will be explained in more detail based on the drawings.

In Figure 1, the dimensions of a film made by photographing a woodgrain-patterned printed paper with register marks are obtained after the woodgrain-patterned printing paper is impregnated with any thermosetting resin such as melamine resin or diallyl phthalate resin and dried. A negative film 1 that has been corrected to a desired size taking into account the changes, and has a register mark 4 that allows light to pass through a portion 2 corresponding to the fall wood portion and prevents light from passing through the portion 3 that corresponds to the spring wood portion. Create.

The reason for modifying the film is that wood grain printing paper has the property of stretching both vertically and horizontally by impregnating it with a thermosetting resin and drying it. The elongation rate varies depending on the type of base paper of the woodgrain pattern printing paper used, and dimensional changes must be taken into consideration for each woodgrain pattern printing paper.
That is, this is to ensure that the wood grain patterns of the impregnated wood grain printing paper and the imprinting plate are completely matched in the final step of superimposing the wood grain patterns of the impregnated wood grain pattern printing paper and the imprinting plate using register marks that serve as alignment marks. Generally, the elongation rate is greater in the horizontal direction than in the vertical direction. The elongation rate differs depending on the type of base paper manufactured by the base paper manufacturer, but if the base paper used for the woodgrain pattern printing paper is constant, then the so-called impregnation process, which involves impregnating and drying a thermosetting resin such as melamine resin or diallyl phthalate resin, will increase the elongation rate. If the impregnating conditions such as the impregnating speed of the machine and the impregnating temperature are kept constant, they will not vary from one manufacturing rod to another. Next, as shown in Figure 2,
After applying the photosensitive resin 6 to the surface of the base material 5, it was covered with the negative film 1 obtained in the first step, and a light beam was irradiated from above to harden the transparent part corresponding to the autumn wood part 2. Thereafter, a base plate 7 is obtained from which the uncured photosensitive resin of the light-shielding portion corresponding to the spring material portion 3 is removed.

Here, the base material 5 is a metal plate such as an aluminum plate, a duralumin plate, or a stainless steel plate, and an aluminum plate is preferable from the viewpoint of cost and ease of etching. As the photosensitive resin 6, a normal photosensitive resin for metal etching is used. The light beam used is a carbon arc light beam or an ultraviolet lamp.

The irradiation time was the photosensitive resin used in Kg/Cm2, the pressing temperature was 140° C., and the pressing conditions were 10 minutes under heat and pressure to obtain a mother plate. Next, 8 sheets of 2 mils overlay paper pre-impregnated with melamine resin and 8 sheets of 190 g/M2 kraft paper impregnated with phenol resin were sequentially placed on top of the mother plate through a polypropylene film with a thickness of 20 μm, and press pressure was applied. 20kg/Cm2, press temperature 1
The molded plate was heat-pressed at 45° C. for 15 minutes to obtain a molded plate having both the uneven pattern on the mother plate and the wood grain conduit grooves of the straight-grained oak veneer. Next, register marks on the woodgrain pattern printing paper are placed on the decorative laminate component material, which is a combination of 6 sheets of phenol resin impregnated paper, melamine resin impregnated oak pattern woodgrain pattern printing paper, and melamine resin impregnated overlay paper, through a polypropylene film. Place the mold plate with the register marks aligned and insert it into a normal press at a press pressure of 80 kg/cm2 and a press temperature of 160°C.
, heated and pressed under press conditions with a press time of 25 minutes, and
After cooling for a minute, it is taken out and the wood grain pattern of the wood grain pattern printing paper and the wood grain pattern of the forming plate are completely in sync, and it also has oak straight grain wood grain conduit grooves, and the oak pattern is comparable to the natural wood surface of oak. It was possible to obtain a decorative board having an uneven wood grain pattern.

[Brief explanation of drawings]

Figure 1 was obtained by photographing a woodgrain pattern printed paper. FIG. 3 is a plan view of the film. Reference numeral 1 is a negative film modified in consideration of dimensional changes, 2 is a portion corresponding to the fall wood portion through which light can pass, 3 is a portion corresponding to the spring wood portion through which light cannot be transmitted, and 4 is a register mark. FIG. 2 is an enlarged vertical sectional view of the base plate after the photosensitive resin on the base material is cured using a negative film and the uncured photosensitive resin is removed. 5 is a base material, 6 is a photosensitive resin, and 7 is the obtained base plate. FIG. 3 is an enlarged longitudinal sectional view of an etched plate obtained by etching the base plate 7. FIG. 8 is the etched plate obtained. FIG. 4 is an enlarged longitudinal cross-sectional view of a natural wood veneer laminated board. 9 is a veneer obtained from natural wood, 10 is plywood, and 11 is the obtained veneer laminated plywood. FIG. 5 is a longitudinal sectional view of the configuration for obtaining a master plate. 12 is a release film. FIG. 6 is an enlarged longitudinal cross-sectional view of the obtained master plate. 13 is the obtained master template. FIG. 7 is a longitudinal sectional view of the configuration for obtaining a forming plate. 14 is an overlay paper, and 15 is a thermosetting resin-impregnated kraft paper. FIG. 8 is a plan view of the obtained forming plate. 4' is a register mark, 16 is a wood grain conduit groove transferred from a laminated veneer board, and 17 is the obtained mold board. FIG. 9 is a longitudinal cross-sectional view of the obtained forming plate. FIG. 10 is a longitudinal cross-sectional view of a structure in which a decorative board is obtained using the obtained forming plate. 18 is a base material, and 19 is woodgrain pattern printing paper impregnated with a thermosetting resin and dried.

Claims (1)

[Claims] 1 A film made by photographing a woodgrain pattern printed paper with arbitrary register marks is corrected to the desired size taking into account the dimensional change after the woodgrain pattern printing paper is impregnated with a thermosetting resin and dried. The first step is to make a negative film that allows light to pass through the part corresponding to the area, and after coating the surface of the base material with a photosensitive resin, it is covered with the negative film obtained in the first step and the light beam is transmitted from above. A second step of obtaining a base plate from which the light-transmitting part corresponding to the autumn wood part is cured by irradiation, and the photosensitive resin that is the final hardening of the light-shielding part corresponding to the spring wood part is removed; A third step of etching the surface obtains an etched board, and then a fourth step of obtaining a natural wood veneer laminated board that is the same type as the woodgrain pattern printing paper used in the first step or does not cause any discomfort; The etched plate obtained in the third step is placed on the surface of the veneer-laminated plywood obtained in the fourth step with a release film interposed therebetween, and heat-pressed to create an uneven wood grain pattern on the etched board. The fifth step is to obtain a master plate which has been transferred onto the etched plate, and a thermosetting resin-impregnated paper or cloth is placed on the master plate via a release film and heat-pressed to improve the uneven wood grain of the etched plate. a sixth step of obtaining a molded board onto which the pattern and the wood grain conduit groove portions of the veneer laminated plywood are transferred;
Place woodgrain pattern printing paper with register marks impregnated with thermosetting resin and dry on the base material, and match the register mark of the woodgrain pattern printing paper and the register mark of the forming plate obtained in the 6th step through a release film. A method for manufacturing a decorative board having an uneven wood grain pattern, characterized by comprising a seventh step of placing a forming board so as to have a pattern and heating and pressing it.