JPS6054866B2 - Manufacturing method of three-dimensional decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a decorative board made of a thermosetting resin, particularly a melamine resin, which has fine irregularities on its surface and has an excellent three-dimensional effect.

Until now, methods such as roller embossing and template embossing have been used to impart textured patterns such as wood grain patterns and abstract patterns to thermosetting resin decorative materials such as melamine decorative boards.

However, with these conventional methods, it is extremely difficult to completely synchronize the pattern pattern and the embossed pattern, and there are also problems in that the manufacturing cost of the embossed plate increases. The present inventor conducted research in search of a method for manufacturing a three-dimensional decorative board that forms unevenness that perfectly matches the pattern and does not require an embossing plate, and as a result of research, the inventor found that the curing of the thermosetting resin can be partially suppressed. He came up with the idea of adding unevenness to the decorative surface, and succeeded in realizing this using printing technology.

The method for producing a three-dimensional decorative board of the present invention includes providing a regular printing layer with a desired pattern on a decorative base paper using a regular printing ink, and then using a printing ink containing a thermosetting resin curing inhibitor. A decorative base paper provided with a hardening inhibiting printing layer and provided with the above two types of printing layers is impregnated with a thermosetting resin and dried to form an impregnated paper, and this impregnated paper is overlapped with a base material to form a decorative surface of the impregnated paper. A mirror plate is applied to the mirror plate and heated and pressurized, and as the pressure is released, incompletely cured resin adheres to the mirror plate side and is removed, thereby obtaining a J decorative surface having unevenness. Consisting of

To explain with reference to the drawings, first, as shown in Figure 1,
A normal printing layer 12 with an arbitrary pattern is provided on a suitable decorative base paper 11 using normal ink, and a hardening suppressing printing layer 13 is provided thereon using an ink containing a hardening inhibitor.

Printing can be done by any commonly used method such as gravure, gravure offset, silk screen, and flexo printing. As a hardening inhibitor, an alkaline substance is useful when the thermosetting resin is a melamine resin.

Inorganic bases such as caustic soda, soda carbonate, and borax, or organic bases such as triethanolamine, pyridine, and guanidine carbonate are useful, and it is of course possible to use a mixture of these. Next, the decorative base paper with the two types of printing described above is impregnated with a thermosetting resin liquid such as melamine resin, and dried to produce an impregnated paper 2 as shown in FIG. 2.

Impregnation and drying of the thermosetting resin liquid may be performed according to techniques known in the production of impregnated paper for decorative laminates. Thereby, the impregnated paper 2 is obtained in which the uncured thermosetting resin 21 is present on the printed surface and the back surface of the decorative base paper 11. This impregnated paper 2 is laminated with a suitable base material 3 such as core paper, particle board, plywood, etc., and heated and pressed to harden the resin.

Conditions such as heating temperature, pressure, and treatment time are selected according to the curing characteristics of the thermosetting resin used and the mode of action of the curing inhibitor. Appropriate conditions may be readily determined, again based on established techniques for manufacturing thermoset decorative laminates. The heating and pressurization is performed by applying a mirror plate 4, that is, a mirror-finished stainless steel plate or a chrome-plated steel plate, to the decorative surface.

Since the uncured resin 21 of the impregnated paper 2 in the hardening suppressing printed layer 13 remains incompletely cured, as shown in FIG. When the specular plate 4 is released, the deposit 32 on that side will peel off, and the part where it was applied will remain as a minute depression. Even if it does not adhere to the mirror plate, it can be removed by spraying fluid on it or scrubbing it with a brush, if necessary.
The other parts have a smooth surface. According to the method of the invention,
By the above-described mechanism, concave portions are formed in accordance with the pattern of the first-curing suppression-containing printed layer 13.

It is extremely easy to synchronize this with the pattern of the normal printed layer 12 below it, since both are printed. Therefore, as shown in the example below, for example, by providing a wood grain pattern in the normal printing layer and providing a conduit part in the hardening inhibitor-containing layer, the conduit part is recessed and a matte surface is formed. Therefore, it is possible to obtain a three-dimensional decorative board that realistically reproduces the feel of the actual wood surface. However, it goes without saying that the uneven pattern provided by the printed layer containing a hardening inhibitor does not need to be aligned with the pattern of the printed layer, and the out-of-synchrony should be adjusted to suit the design of the three-dimensional decorative board to be manufactured. All you have to do is choose.

Example 1 A wood grain pattern was printed by gravure printing on the surface of a colored decorative base paper with a weight of 80 y1 d using an ordinary ink having the composition shown below.

However, the solvent is the following mixed solvent.

On top of this wood grain pattern, a conduit pattern completely in sync with the wood grain pattern was provided by gravure printing using an ink containing a hardening inhibitor having the following formulation. In addition, cellulose acetate is
N. V. = 5%, the degree of acetylation is 56-60%, and contains cyclohexanone and MEK as a solvent. Next, the printed decorative base paper was impregnated with a resin liquid in a dry amount of 90 y1 of melamine resin using a commonly used impregnating device, and dried to obtain an impregnated paper.

This impregnated paper was layered on four sheets of core paper, a mirror plate was applied to the decorative surface, and the melamine resin was cured by heating and pressing at a pressure of 100k91Cfi1 temperature of 135°C for 2 hours.
The resin in the conduit part, which is in tune with the wood grain pattern, adheres to the mirror plate while being incompletely cured and is removed.As a result, fine dents are formed, resulting in a synchronized embossed high-pressure melamine decorative board with a rich three-dimensional effect. Ta.

Example 2 The decorative base paper with two types of printing layers prepared in Example 1 was
A fast-curing melamine resin "Santopp M-700" (manufactured by Nissan Chemical Industries, Ltd.) was impregnated at a ratio of 120yI and dried to obtain an impregnated paper.

This impregnated paper was layered on a particle board with a thickness of 15 wun, and a mirror plate was applied thereto, followed by heating and pressurizing to shape.

However, the conditions were: pressure 20k9 d1 temperature 150°C 1 hour 5 minutes. In this case as well, a low-pressure melamine decorative board with synchronized embossing and excellent stereoscopic illusion was produced.

[Brief explanation of drawings]

The drawings are schematic cross-sectional views for explaining the steps of the method for producing a three-dimensional decorative board of the present invention, and FIG. 1 shows a normal printing layer and a printing layer containing a curing inhibitor on a decorative base paper Figure 2 shows the stage in which the decorative base paper provided with the two types of printing layers described above is impregnated with thermosetting resin to form impregnated paper, and Figure 3 shows the stage in which impregnated paper is formed based on the impregnated paper. This shows how the decorative board was manufactured by stacking the resin over the wood and applying heat and pressure to harden the resin. 1... Three-dimensional decorative board, 2... Impregnated paper, 3
... Base material, 11 ... Decorative base paper, 13.
...Printed layer containing a curing inhibitor, 21...
... Thermosetting resin (uncured), 31... Cured resin.

Claims (1)

[Scope of Claims] 1. A normal printing layer with a desired pattern is provided on a decorative base paper using a normal printing ink, and then a hardening inhibiting printing layer is formed using a printing ink containing a hardening inhibitor of a thermosetting resin. The decorative base paper provided with the two types of printing layers described above is impregnated with a thermosetting resin and dried to form impregnated paper, and this impregnated paper is overlapped with the base material to form a mirror plate on the decorative surface of the impregnated paper. A three-dimensional decorative board that is made by applying heat and pressure, and when the pressure is released, incompletely cured resin adheres to the mirror plate side and is removed, thereby creating a decorative surface with unevenness. manufacturing method. 2. The method for producing a three-dimensional decorative board according to claim 1, wherein the thermosetting resin is a melamine resin and an alkaline substance, particularly an inorganic or organic base, is used as a curing inhibitor. 3. The method for producing a three-dimensional decorative board according to claim 1, wherein the pattern of the printing layer using a printing ink containing a curing inhibitor is made to match the pattern of the printing layer using a normal printing ink.