JPS5929437B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative laminate, and more particularly to a method for manufacturing a synchronous embossed decorative laminate having an uneven pattern that is synchronized with a pattern.

Conventionally, there are roughly two methods for imparting unevenness that matches the pattern on the surface of a thermosetting resin decorative board.

The first method is called the direct embossing method,
Typical examples include a method in which an embossing plate that matches the pattern is used to directly create irregularities on the decorative board using a flat plate press, and a method in which an embossing roll is used to directly create irregularities on the surface of the decorative board.

However, with this method, it is expensive to manufacture the embossing plate and embossing roll, and it is difficult to register the design of the decorative board with the uneven pattern of the embossing plate and embossing roll, which takes time to manufacture, resulting in cost problems. It was hot. The second method is generally called the chemical embossing method, in which a pattern is formed on the base paper for resin impregnation using ink containing a resin polymerization inhibitor to create a difference in the curing speed of the resin on the surface of the decorative board. , a method that utilizes this difference to form an embossed pattern on the surface, or a method that forms a pattern on the base paper for resin impregnation with ink containing a substance that has a repellent effect on resin,
There is a method of repelling the resin on the ink area during coating or impregnation to form an embossed pattern. These methods are extremely advantageous in terms of matching the design and the embossed pattern, but in the case of the former, it takes time for the resin to harden and only the volumetric shrinkage of the resin is used, so it is difficult to form depressions. This naturally limits the width, making it impossible to form a recess with a deep floor of arbitrary width, and thermosetting resins molded under heat and pressure, such as urea resin, melamine resin, and tap resin, are not very effective. do not have.

On the other hand, various experiments were conducted on the latter, but the repelling effect alone was not sufficient.
There was a problem in that a sufficient embossing effect could not be achieved with heat and pressure molding type resins. The present invention overcomes the above-mentioned drawbacks and in a relatively simple and therefore low cost manner.
Moreover, the object is to manufacture an embossed decorative board that can be applied to thermosetting resins of heat-pressing molding type.

In other words, the present invention provides a method for applying a pattern to a decorative paper using an ink containing a resin that is releasable to the thermosetting resin to be impregnated and a substance that foams, decomposes, evaporates, or sublimates when heated and pressurized. , the entire surface of the decorative paper including the pattern was impregnated with a thermosetting resin and dried to produce an impregnated paper, and then the impregnated paper was placed on a base material and heated and pressurized to harden the thermosetting resin. The gist of the present invention is to provide a method for manufacturing a decorative board, which is characterized in that the cured resin on the pattern is then removed to form a recess. Hereinafter, the above-mentioned present invention will be explained in detail.

First, the explanation based on →l using a principle diagram is as follows. As shown in FIG. 1, the decorative paper 1 has a texture pattern,
Print using regular ink or a paint composition with a wood grain pattern as a base pattern, or directly impregnate the decorative paper only in the areas where you want the painted surface to be depressed, such as wood grain patterns or abstract patterns. After the pattern 2 is provided with an ink containing a resin that is releasable to the curable resin and a substance that foams, decomposes, evaporates, or sublimates under heat and pressure molding conditions, it is dried.

Next, as shown in the second figure, the printed paper is coated with or impregnated with a thermosetting resin 3, and after drying, an impregnated decorative paper is obtained.

Next, as shown in Figure 3, impregnated paper is placed on top of the base material 4 with the pattern 2 on the surface, and then a molded plate or film 5 such as a metal plate or plastic film is placed on top of the paper and heated by normal means. Apply pressure. By this heating and pressurization, the thermosetting resin is cured as shown in the fourth figure.

At this time, the hardened portion 6 on the pattern 2 not only has a poor affinity with the removable resin in the pattern 2, but also has a hardened part 6 on the pattern 2 due to the influence of foaming, decomposition, evaporation, or sublimated substances contained in the pattern 2. Peeling occurs from the interface. On the other hand, the hardened portion 7 other than the pattern 2 is firmly adhered to the decorative paper 1. In the above, the substances that foam, decompose, evaporate, or sublimate act during heating and pressure molding, apply force to the thermosetting resin film on the top of the pattern layer, and cause molecular cohesive failure between the thermosetting resins. It is thought that this causes the thermosetting resin film only on the upper part of the pattern layer to be completely released from the mold. Next, as shown in Figure 5, when the molded plate or film 5 is peeled off, the resin of the cured portion 6 corresponding to the pattern 2 adheres and is peeled off.
Alternatively, although not shown, the impregnated paper may be layered on the base material, the impregnated resin may be cured by applying heat and pressure by ordinary means, and then the cured resin above the pattern layer may be removed by hubbing or brushing. In this way, a decorative board having an uneven pattern that matches the pattern 2 is obtained. In the present invention, the decorative paper may be paper such as titanium paper, thin paper, or kraft paper, cloth such as cotton cloth or glass cloth, or nonwoven fabric.

Furthermore, as a method for applying base patterns such as cloth grain patterns and wood grain patterns, and patterns for areas to be recessed, to these decorative papers, there are conventional printing methods such as letterpress printing, offset printing, gravure printing, or screen printing. It can be formed by printing, drawing, or painting by a hand-drawing method, a normal painting method, or the like. Next, in the present invention, the ink or coating composition for applying the base pattern is a known one, for example, a coloring agent such as a dye or pigment is added to an ink or coating vehicle, and further, for example, a plasticizer, a stabilizer, etc. agent, wax/grease,
Use an ink or coating composition prepared by adding optionally known additives such as desiccants, auxiliary desiccants, curing agents, thickeners, dispersants, fillers, etc., and thoroughly kneading them with solvents, diluents, etc. can do.

In the above ink or coating composition, the vehicle may be a known one, such as various oils and fats such as linseed oil, soybean oil, or synthetic drying oil, or natural resins such as rosin, copal dammar, hardened rosin, rosin ester, or polymerized rosin. and synthetic resins such as processed resins, rosin-modified phenolic resins, 100% phenolic resins, maleic acid resins, alkyd resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, amino alkyd resins, Cellulose derivatives such as nitrocellulose and ethylcellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, as well as glue, casein, dextrin, and zein can be used.

Next, among the constituent components of the ink composition used to provide the pattern formed in the recesses in the above, first, as a resin that has releasability to the thermosetting resin to be impregnated, thermal Plastic resins or thermosetting resins such as melamine resins, urea resins, silicone resins, etc. are used.

In particular, when using a reactive type resin as the thermosetting resin to be impregnated, it is preferable to use a resin that has a type of releasability different from the curing reaction of the thermosetting resin to be impregnated. For example, condensation type silicone resins or melamine resins are suitable as release resins for diallyl phthalate resins. Next, substances that foam, decompose, evaporate, or sublimate under the thermosetting resin molding conditions are particularly important when the impregnated thermosetting resin is urea resin, melamine resin, acetoguanamine resin, benzoguanamine resin, diallyl phthalate resin, etc. It is effective for the type of resin that is molded under heat and pressure, and since the molding conditions differ depending on each resin, the substances suitable for addition and the amounts applied thereof also differ. For example, if the target thermosetting resin is diallyl phthalate resin, the molding conditions are 140°C, 10k9/
(-In the case of -Fll 8 minutes, substances that foam, decompose, evaporate, or sublimate are likely to act particularly near 13'C, such as calcium phosphate, ammonium phosphate, calcium sulfate (gypsum), atropine, 2-amino-P-cresol. , P-xyquinone, oxypyridine, P-oxybenzaldehyde, P-quinone, 2-aminoquinoline, P-
Isopropylbenzoic acid, 6-methylbenzenecarboxylic acid
Examples include 1,3-oxindolecarboxylic acid-2, azodicarbonamide type, para-toluenesulfonylhydrazide, benzenesulfonylhydrazide, and the like. The above ink composition has the above two types of substances as main components of the vehicle,
Coloring agents such as dyes and pigments are added to the mixture, optionally necessary additives are added, and the mixture is sufficiently kneaded with a solvent, diluent, etc.

Next, in the present invention, the method of applying resin treatment to the printing paper includes, for example, a method of immersing the printing paper in a solution type or emulsion type resin liquid and drying it, or a method of applying the resin treatment to the printing paper. Coating or applying the resin liquid as above,
This can be done by a drying method or the like.

As the resin liquid in the above, for example, one or two thermosetting resins such as urea resin, melamine resin, acetoguanamine resin, benzoguanamine resin, unsaturated polyester resin, diallyl phthalate resin, or initial condensates thereof. A resin liquid containing the above as main components can be used.

In this case, the amount of resin attached to the impregnated paper is 5 in terms of solid content.
Although the object of the present invention can be achieved if the amount is 0 to 150%/a, it is preferable to use a resin adhesion amount of 60 to 80%.

Further, base materials applicable to the present invention include plywood, particle board, flexible board, calcium silicate board, pulp cement, and resin-impregnated laminated core paper.

In the present invention, during hot-pressure molding, a metal plate such as a duralumin plate or a stainless steel plate, or a plastic film such as polypropylene or vinylon can be used as the molding plate or film, as described above.

As is clear from the above description, in the method of the present invention, the pattern formed in the recesses contains a removable resin and a substance that foams, decomposes, evaporates, or sublimates under the molding conditions. The thermosetting resin is extremely easy to peel off, resulting in sharp recesses.

In addition, if a molded plate or film is used during molding, if the resin attached to the plate or film is removed and the next molding is performed after it is peeled off, it will be integrated with the thermosetting resin and the resin will be integrated with the thermosetting resin. Since it does not affect the decorative laminate in any way, it does not need to be removed during each decorative laminate manufacturing process, so the decorative laminate can be manufactured extremely efficiently. The decorative board obtained by the method of the present invention is suitable for various uses, and can be used, for example, as decorative boards for building materials, such as doors, wall materials, furniture, kitchens, etc.

Next, the present invention will be explained in more detail with reference to Examples.

"Parts" in the following text indicate "parts by weight." [Example 1]
A wood grain pattern was gravure printed on 809/A titanium paper using a regular gravure ink, and a conduit portion was printed using a gravure printing machine using the following releasable ink.

(Ink formulation) The printing paper was dried at 120°C for 1 minute to harden the silicone ink on the conduit part, and the solid content was 80% with the following resin formulation.
9/A Impregnated.

(Resin formulation) The impregnated liquid was dried at 80°C for 10 minutes to obtain impregnated paper.

Next, layer the impregnated paper on the plywood from step 3 with the ink side facing up,
A polished duralumin plate was placed on top of it with the mirror surface facing downward, and pressed at 140° C. with a 10 kg weight for 8 minutes. When the duralumin plate is released from the mold after pressing, the resin only on the conduit part has poor affinity with the conduit part, and the resin on the conduit part has become brittle due to the foaming effect of the conduit part, so the resin is mixed with the duralumin Z board. Transferred and obtained a matching embossed decorative board.

[Example 2] A wood grain pattern was gravure printed on a 559/I titanium paper using normal gravure ink, and then a conduit portion was printed using a gravure printing machine using the same ink as in Example 1, and then 1
Dry at 20°C for 1 minute to harden the ink on the conduit part, impregnate with the same impregnating resin liquid as in Example 1 at a solid content of 609/I, and dry the impregnated impregnating liquid at 80°C for 10 minutes to impregnate. It was made into paper.

Below, using a duralumin mirror plate under the same conditions as in Example 1, 4~
Place an impregnated finger on the plywood, heat and pressurize it, release the duralumin board, and then brush the decorative board to remove the easily peeled resin, resulting in an embossed decorative board with perfectly synchronized patterns with the recesses. I got it.

[Example 3] A wood grain pattern was gravure printed on 809/m'' titanium paper using a regular gravure ink, and a conduit portion was printed using a gravure printing machine using the following releasable ink.

(Ink formulation) The printed paper was dried at 120° C. for 1 minute to harden the silicone ink on the conduit portion, and was impregnated with the same resin mixture as in Example 1 at a solid content of 909/m.

The impregnated liquid was dried at 8°C for 10 minutes to obtain impregnated paper. Next, the impregnated paper was stacked on the plywood from step 3 with the ink side facing up, and the vinylon film was placed on top of it with the matte side facing down for 5 minutes at 130°C and 101<9/d. Pressed. After pressing, the vinylon film was released from the mold, and the resin on the conduit portion was transferred to the vinylon film, yielding a sharp and deep tone-embossed decorative board.

[Example 4] A wood grain pattern was gravure printed on 559/I titanium paper using a normal gravure ink, and a conduit portion was printed using a gravure printing machine using the same ink composition as in Example 8.

After printing was completed, the paper was dried at 120° C. for 1 minute, impregnated with the same resin as in Example 1 at a solid content of 609/wl, and dried at 100° C. for 2 minutes to obtain an impregnated paper. Next, the impregnated paper was layered on the plywood from No. 3 to 3, and the polypropylene film was placed thereon with the matte side facing downward, and heated and pressurized under the same conditions as in Example 3. After pressing was completed, the polypropylene film was released from the mold, and the resin on the conduit portion was transferred to the polypropylene film, yielding a tone embossed decorative board.

[Brief explanation of drawings]

1 to 5 are cross-sectional views schematically showing an example of the process of manufacturing a decorative board by the method of the present invention. Explanation of the symbols representing the main parts of the figure, 1... Decorative paper, 2... Pattern, 3... Thermosetting resin, 4... Base Material, 5... Molded board or film, Dan... Decorated board.

Claims (1)

[Claims] 1 After creating a pattern on decorative paper using an ink containing a resin that has releasability to the thermosetting resin to be impregnated and a substance that foams, decomposes, evaporates, or sublimates when heated and pressurized, the pattern is included. Impregnated paper is produced by impregnating the entire surface of the decorative paper with a thermosetting resin and drying it.Then, the impregnated paper is stacked on a base material and heated and pressurized to harden the thermosetting resin. 1. A method for manufacturing a decorative board, which comprises forming recesses by removing a cured resin.