JPS595427B2 - Decorative material manufacturing method - Google Patents

Description

Detailed Description of the Invention The present invention relates to a method for producing a decorative material having an embossed pattern on the surface, in which a desired pattern is provided on a base paper made of a mixture of heat-resistant synthetic pulp and wood pulp, and the pattern is A method for producing a decorative material, which comprises applying a synthetic resin to the entire surface of the paper, applying embossing to produce a decorative paper, and then adhering the decorative paper to a base material via an adhesive. It is something.

Conventionally, laminated decorative boards with embossed patterns on the surface are made by heating and softening a vinyl chloride sheet, synthetic paper made mainly of olefin resin, or backing paper coated with vinyl chloride paste, which has convex parts. It is known that an embossed pattern is formed by continuously applying pressure between a cooled gold roll and a rubber roll, and then laminated to a base material via an adhesive.

However, since it uses a synthetic film, it is expensive, and the surface lacks solvent resistance, making it unsuitable for use as an interior material. As another method, paper can be made from a mixed pulp of kraft pulp and sulfide pulp with a basis weight of 309/77.
Printed paper of approximately 1" is laminated to a base material via adhesive, the entire surface of the printed paper is coated with synthetic resin paint, and both the base material and the base material are embossed using a mold roll.

However, in order to emboss something that is integrated with the base material,
Embossing of deep or rough patterns is difficult, and embossing reproducibility varies depending on the quality of the base material. The present invention eliminates these conventional drawbacks and
To provide a method for producing a decorative material having an embossed surface on its surface at low cost and in which the embossed pattern is unlikely to disappear or decrease.

The present invention will be explained in more detail with reference to the drawings.

FIG. 1 is a diagram showing the state before embossing of the decorative paper used for manufacturing the decorative material according to the present invention, in which an arbitrary pattern 2 is formed on the surface of the base paper 1 made of a mixture of synthetic pulp and wood pulp. Furthermore, synthetic resin 3 is applied to the entire surface including the pattern 2.
It is coated with

The synthetic pulp contained in the base paper 1 may be polystyrene-based, aromatic nylon-based, polyester-based, acrylic-based, or other synthetic pulp that is heat resistant to heat of 100°C or higher and has heat softening properties. good. Polyolefin-based synthetic pulp such as polyethylene has a low melting point and therefore has a problem in terms of heat resistance, so it is not included in the present invention. The mixing ratio of synthetic pulp is preferably about 30 to 40%, but it is not limited to these as it varies depending on the type of synthetic pulp, purpose of use, etc. The pattern 2 can be provided by any means using ordinary ink, such as gravure printing, offset printing, letterpress printing, screen printing, transfer printing, and the like.

As the synthetic resin 3, alkyd resin, urethane resin, acrylic resin, vinyl resin, polyester resin, urea resin, phenol resin, epoxy resin, etc. can be used, and 7 to 109/Trl (dry) coating is applied to the entire surface including any pattern 2. do. If the finished product is required to have cellophane tape removability, it is necessary to add silicone resin, wax, etc. as a slip agent.

As the coating method, conventional methods such as roll coating, gravure coating, bar code, air knife coating, flow coating, dip coating, spray coating, and blade coating are used. Embossing methods include the so-called paper embossing method, which involves continuously passing between a metal embossing roll and a urun roll made from a reverse mold of the same under pressure, and applying pressure to form an embossed pattern. Any conventional embossing method may be used, such as a hot embossing method in which the material is softened in a preheater and passed between a metal embossing roll and a rubber back roll, or a method in which a metal embossing plate is used instead of the metal embossing roll. Fig. 2 is a partially enlarged view showing the embossing process using the paper embossing method, in which the metal embossing roll 4 and the urun roll 5 are placed in front and rotated idly without passing the decorative paper through and pressurized. 4 is formed, and by passing decorative paper between the metal embossing roll 4 and the urun roll 5 and applying pressure, an embossed pattern is continuously formed.

For the metal embossing roll, a temperature sufficient to soften or melt the synthetic pulp is selected, but for styrene synthetic pulp, a temperature of about 1700C to 180C is optimal.

When it is desired to make the concave portions of the formed embossed pattern transparent, the temperature is preferably about 220° C. to 240° C. for styrene synthetic pulp. When the concave portion is made transparent in this way, when it is attached to a base material, the aesthetic effect can be enhanced in conjunction with the color or pattern of the base material or adhesive.

Furthermore, a metallic reverse plate can also be used instead of the Urun Roll 5. Also, when using the heat embossing method, the third
As shown in the figure, embossing is performed by passing decorative paper between a metal embossing roll 4 and a rubber roll 6.

FIG. 4 shows an example of continuous embossing using a hot embossing method, in which the decorative paper 20 that has left the unwinding section 7 comes into contact with a heat drum 8 and is softened by a far-infrared heater 9. The material is pressed by passing between the rubber roll 6 and the metal embossing roll, the embossed pattern is fixed by the cooling roll 10, and the material is wound up into the winding section 11.

In this case, the temperature of the thermal drum 8 and the surface temperature of the far-infrared heater 9 may be adjusted in the same manner as the temperature applied during paper embossing.

In this hot embossing method, better results can be obtained if the metal embossing roll 4 is cooled.

The rubber roll 6 used has a rubber hardness of 40 to 60 degrees, and the lower the rubber hardness, the better the embossed pattern will be. The decorative paper with the embossed pattern thus produced is laminated onto a base material via an adhesive.

As the adhesive, phenolic resins, urea resins, epoxy resins, vinyl acetate resins, acrylic resins, polyvinyl resins, starch resins, and the like can be used.

These adhesives may be in any form such as emulsion, solvent, adhesive, film type, etc.

Materials used as base materials include wood base materials such as natural wood, plywood, particle board, and hardboard; inorganic base materials such as asbestos, cement board, calcium silicate board, special asbestos board, rock wool board, and homocement board; iron plate, zinc plate,
Metal base materials such as aluminum plates, base materials such as synthetic resin plates, etc. can be used.

<Example 1> Patterns were printed by gravure printing using ink with nitrocellulose resin as a vehicle on 309/I base paper Topka 0P-30 (manufactured by Topka Co., Ltd.), which was made by mixing 30% styrene-based synthetic pulp with natural pulp. was applied.

Next, the entire printed surface was coated with a synthetic resin paint mainly composed of a urethane resin of the following composition at a ratio of 109/I (dry) using a gravure roll having a plate depth of 1301/Inchl7Oμ.

Acrylic urethane resin (UR-203 manufactured by Toyo Ink Co., Ltd.) 100 parts by weight Silicone resin (slip agent) 3.3 Isocyanate
23〃 The decorative paper thus obtained was heated to 180°C using a metal embossing roll and 701<
Pressure embossing molding of 9/(1-JMoV1) was performed, and then urea resin was applied to the plywood at a ratio of about 40 f!/I (wet) using a roll coater, and laminated using a continuous laminator.

The plywood thus obtained was a beautiful laminated decorative plywood without destroying the embossed pattern.

Also, apply the above adhesive to the back side of the base paper using a roll coater.
09/A (wet) coating and manufactured using a continuous laminator that wraps around the sides has a much better design effect because the edges after application are also clean. As mentioned above, in the present invention, polyethylene (melting point 8
Because we use a base paper made from a mixture of heat-resistant synthetic pulp such as polystyrene (melting point 240°C) and wood pulp, rather than polyolefin-based synthetic pulp such as
The embossed pattern will not fade.

In addition, when using polyolefin-based synthetic pulp such as polyethylene, the adhesiveness is weak, so it is necessary to use a two-component type adhesive or to treat the back side, which increases costs.However, the method of the present invention According to the study, decorative materials can be produced at low cost because common emulsion-type adhesives can be used to bond to base materials such as plywood, and polystyrene-based synthetic pulp has hydrogen bonds with natural wood pulp. Because polyethylene synthetic pulp is only entangled with natural pulp, it has higher interlaminar strength than natural pulp.

Furthermore, when embossing is performed at a temperature above the melting point of synthetic pulp using the method of the present invention, the recesses become transparent or translucent, allowing the surface of the base material or adhesive to be seen through, creating a unique design. It is also possible to obtain decorative materials that have effects.

[Brief explanation of drawings]

Figure 1 is a partially enlarged view showing the state of the decorative paper used in the present invention before embossing, and Figures 2 and 2 are partially enlarged views showing the embossing process using the paper embossing method and the heat embossing method, respectively. The enlarged view and FIG. 4 are general views showing one embodiment of an embossing process using a hot embossing method. 1...Base paper, 2...Picture, 3...
...Synthetic resin, 4...Metal embossing roll, 5
...Urun roll, 6...Rubber roll, 7...Unwinding section, 8...Heat drum,
9... Far infrared heater, 10... Cooling roll, 11... Winding section, 20...
・Cosmetic paper.

Claims (1)

[Scope of Claims] 1 A desired pattern is provided on base paper made by mixing heat-resistant synthetic pulp and wood pulp, and then a synthetic resin is applied to the entire surface including the pattern, and then embossing is applied to make decorative paper. 1. A method for producing a decorative material, which comprises producing a decorative paper and then adhering the decorative paper to a base material via an adhesive. 2. The method according to claim 1, wherein the embossing is performed at a temperature below the melting point of the synthetic pulp. 3. The method according to claim 1, wherein the recesses are made transparent or translucent by embossing at a temperature equal to or higher than the melting point of the synthetic pulp. 4. The method according to claim 3, which uses a colored adhesive. 5. The method according to claim 3 using a transparent adhesive.