CA1056289A - Process for manufacturing a decorative panel impressed with a permanent embossed pattern - Google Patents
Process for manufacturing a decorative panel impressed with a permanent embossed patternInfo
- Publication number
- CA1056289A CA1056289A CA210,240A CA210240A CA1056289A CA 1056289 A CA1056289 A CA 1056289A CA 210240 A CA210240 A CA 210240A CA 1056289 A CA1056289 A CA 1056289A
- Authority
- CA
- Canada
- Prior art keywords
- decorative
- emulsion
- embossed pattern
- mount
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/08—Moulding or pressing
- B27N3/10—Moulding of mats
- B27N3/14—Distributing or orienting the particles or fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/10—Next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/06—Embossing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
- B32B2262/067—Wood fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
Landscapes
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Wood Science & Technology (AREA)
- Manufacturing & Machinery (AREA)
- Forests & Forestry (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Adhesives Or Adhesive Processes (AREA)
Abstract
PROCESS FOR MANUFACTURING A DECORATIVE PANEL IMPRESSED
WITH A PERMANENT EMBOSSED PATTERN
ABSTRACT OF THE INVENTION
A process for manufacturing a decorative panel with a perma-nently embossed pattern is provided in which a rough fibrous texture is provided on the surface of a fibrous mount, the textured surface is im-pregnated with a solution or an emulsion of a thermosetting high-mole-cular weight substance and, without hardening, only the solvent in the solution or emulsion is substantially evaporated, then, a decorative thin veneer or a decorative, impregnated paper is overlaid on the mount with an adhesive applied therebetween, and before the impregnated substance and adhesive become hardened, the overlaid decorative veneer or decorative impregnated paper are heat-pressed into contact with an embos-sed patterned surface of a metal mould to impress the pattern on the panel.
WITH A PERMANENT EMBOSSED PATTERN
ABSTRACT OF THE INVENTION
A process for manufacturing a decorative panel with a perma-nently embossed pattern is provided in which a rough fibrous texture is provided on the surface of a fibrous mount, the textured surface is im-pregnated with a solution or an emulsion of a thermosetting high-mole-cular weight substance and, without hardening, only the solvent in the solution or emulsion is substantially evaporated, then, a decorative thin veneer or a decorative, impregnated paper is overlaid on the mount with an adhesive applied therebetween, and before the impregnated substance and adhesive become hardened, the overlaid decorative veneer or decorative impregnated paper are heat-pressed into contact with an embos-sed patterned surface of a metal mould to impress the pattern on the panel.
Description
~0562&~9 BACKGROUND OF T~IE INVENTION
The present invention relates to the manufacture of a decorative panel, more specifically, of a decorative panel impressed with a permanently embossed pattern.
Known is the manufacture of a so-called moulded panel which is used as a decorative means for luxurious furniture, doors, cabinets,side-boards, book-shelves, etc., by applying to the surface of the material machine tools such as three-face or four-face automatic planningmachines, single-spindle or double-spindle chamfering machines or milling machines, together with handicraft work, according to the desired scheme. However in applying such conventional machining techniquesto produce an embossed pattern in accordance with a desired scheme, not only are the kinds of wood used restricted, but also the value of the machined wood may be deprecia-ted by the finishing which follows the machining, depending upon the kinds of wood used. Moreover, when an intricate embossed pattern is to be created by shaping the amount of handicraft in the job increases and since ¦ this demands a high degree of skill, the work becomes extremely inefficient.
The present invention therefore provides a technically easy, and economical process of manufacturing a decorative panel bearing a sedate, tasteful, intricate embossed pattern such as seen on conventional panel, by the simple means of pressing under a pattern mould, instead of resorting to the conventional complicated handicraft which calls for high skill thereby, eliminating the difficulty and inconvenience of conventional machining.
mus the present invention provides a process for manufacturing a decorative panel having a permanently embossed pattern on a surface comprising the steps of:
providing a mount of fibrous material having a water content of 8-13%
by weight with a rough, fibrous textured surface and selected from particle board, composite wood, hard fibre board, non-woven cloth and compressed felting; impregnating said surface to a depth of 1-3 mm with . .
/ ~
10562~9 a solution of a thermosetting high molecular weight substance; forming a provisional lamination of a thin decorative layer comprising a slice of cooked wood having a water content of 8-50% by weight with a grain pattern on said rougll impregnated surface using an adhesive therebetween applied at a rate of 80-200 g/m2 and having a solids content of 40-50%, the adhesive being selected from polyvinyl acetate emulsion, vinyl acetate copolymer emulsion and polymeric acetate emulsion compound with the decorative side out; and heat-pressing said provisional lamination with the decorative side in contact with a mould surface bearing the required embossed pattern, before said impregnating material and said adhesive harden.
' .
.i la-.
$
lOS62~9 ¦ According to another aspect of the present invention, the pro-cess for manufacturing a decorative panel impressed with a permanently embossed pattern as described above with respect to the one aspect of the invention, further comprises a step of treating the decorative sur-face with a surface-treating agent prior to the step of heat-pressing the provisional lamination.
According to still another aspect of the present invention, -the process for manufacturing a decorative panel impressed with a perma-nently embossed pattern as described above with respect to the first aspect of the invention, further comprises a step of enveloping at least the whole surface of the provisional lamination in a thermoplastic film prior to the step of heat-pressing the provisional lamination.
The foregoing as well as the characteristic features of the present invention will become more apparent and more readily understandable from the following description and the appended claims.
The process for manufacturing a decorative panel impressed with a permanently embossed pattern according to the present invention is proposed in an effort to overcome the difficulty and inconvenience of conventional shaping practices. In this proposed process, a decorative veneer or a decorative impregnated paper overlaid on a fibrous mount is utilized without losing the beauty of the natural wood of the veneer or without losing the intricate, beautiful pattern of the decorative im-pregnated paper, and only by heat-pressing under a pattern mould can an embossed pattern of a desired scheme be exactly reproduced to thereby successfully offer a novel decorative panel.
In one embodiment of the present invention, a rough fibrous texture is presented on a surface of a fibrous mount, the surface is im-pregnated with a solution or an emulsion of a thermosetting high-molecular weight substance, and only the solvent in the solution or emulsion is substantiaily evaporated without allowing the thermosetting high-molecular i ~3 - 2 ---- 1056Z8~3 weight substance to harden, then a decorative thin veneer or a decorative impregnated paper is overlaid on the thermosetting high-molecular weight i substance impregnated surface, with an adhesive inserted therebetween, and this laminated product with its decorative side in contact with a pattern mould bearing an embossed pattern is heat-pressed under the mould, prior to hardening of the impregnation and the adhesive.
The mount whlch forms the material of the decorative panel, upon which the embossed pattern is to be reproduced, is mainly selected from boards such as particle board, composite wood or from fibrous moulded products such as hard fibreboard, non woven cloth and compressed felting. There is no limitation on the thickness, but generally speaking, 10 - 20 mm would be preferable, be-cause it would facilitate the subsequent step of heat-pressing and would widen the scope of applicability for the final product.
The fibrous mount to be used has its surface coarsened, in other words, short, fine fibres are frmed on the surface. Thus the fibrous moulded products described above by way of example, which are originally rough on the surface, may be employed as they are, but the less coarse boards tescribed by way of example prior to the fibrous moulded products, would have to be submitted to a coarsening process to expose short, fine fibres, such as by scraping the relatively smooth surface. Even the fibrous moulded products might need such a treatment if the surface has to be coarser.
The moisture ln such a mount is a factor governing the value of the decorative panel of the invention and it is preferably adjusted to 8 - 13 ~ by weight.
According to the present invention, the surface layer of the mount is preliminarily impregnated with a solution or an emulsion of a thermosetting high-molecular weight substance.
As an example urea-formaldehyde resin, melamine-formaldehyde resin, thermosetting acrylic resin, phenolic resin, epoxy resin, diallylphth-alate resin, natural rubber, styrene-butadiene rubber, and butadiene-acryloni-trile rubber can be used singly or in combinations as the high molecular 10562~9 weight substance.
Impregnatlon with a solution or an emulsion of such a high-molecular weight substance is done by brushing, spraying, or by means of a roll-coater, a spreader,etc.
Special technical attention should be paid in this impregnation to the tepth of impregnation into the surface layer. Such is dependent on the depth and profile of the embossment of the pattern on the metal mould bearing the embossed pattern and to be used for subsequent heat-pres-sing, but generally impregnation has to be done carefully so that the impregnated substance may be evenly distributed over only the surface layer in a depth of 1 - 3 mm.
Still more important, the solution or emulsion of the thermoset-ting high-molecular weight substance thus impregnated into the surface layer of the mount should, without immediately thermosetting, be allowed to stay as is for 30 minutes to 48 hours at a temperature within the range of room temperature up to 50C so that the solvent or water in the solution or emulsion may be substsntially evaporated.
According to the present invention, thereafter, a decorative veneer of a decorative impregnated paper is provisionally adhered by means of an adhesive, to the mount with its surface layer impregnated with a non-cured high-molecular weight substance. Then the provisionally adhered assembly is left as it is at an ambient temperature for 20 minutes to three hours, during which it becomes dry to the finger touch.
The adhesive may be, for example, polyvinyl acetate emulsion or a composition obtained by mixing polyvinyl acetate emulsion with sty- -rene-butadiene latex, synthetic rubber, such as chloroprene, epoxy resin, an emulsion of a melamine-formaldehyde pre-condensate or a urea-formaldehyde pre-condensate and a composition obtained by mixing a homo-polymer emulsion of vinyl acetate or a copolymer emulsion of vinyl acetate with ethylene or acrylic ester and so on with the second component having functional groups such as unsaturated carboxylic acid, for example, maleic acid or acrylic acid, alkyl ester of unsaturated carboxylic acid or amide of unsaturated carboxylic acid, the amount of adhesive applied b~lng desirab~ 80 - 200 .
':
~ .:
gr/m2 ln terms of 40 - 50 % solids.
The decorative veneer mentioned in the present invention refers preferably to thin sllces about 0.2 - 0.7 mm or preferably 0.25 - 0.35 mm thick, with quarter sawn grain, flat sawn grain or mixed grain or knurls, of wood such as "nara (a type of oak)", "Nire (a type of elm)", "Sakura (cherry)", "shio~i ~Fraxinus Spaethiana)" or of imported wood such as teak walnut, rosewood, zebrawood, mahogany. The allowable water content of the decorative veneer depends on the type of impregna-tion of the mount and on the type of athesive applied to the mount. When the impregnation is by epoxy resin, the value of allowable water content is about 50% and when it is diallylphthalate, the value should be set at about 10 %. Generally speaking, a low water content in the range of 8 - 50 % is deemed one of the factors assuring good and fa~thful repro-duction of a pattern on the veneer.
The decorative impregnated paper which may be substituted for the decorative veneer may be a patterned paper with a wood grain or a pattern printed thereon, which consists of a base of sulphite pulp or rayon pulp impregnated with a thermosetting synthetic resin or a composition of a thermosetting synthetic resin and a thermoplastic synthetic resin; one which is commercially available with a fat content of 45 - 70 % and thick-ness of 2 - 5 mills may be employed.
It is known that phenolic resin, diallylphthalate resin, mel-amine resin, unsaturated polyester resin, epoxy resin, guanamine resin, thermosetting acrylic resin, methacrylic acid ester, etc. are available for impregnation in the commercial production of the decora-tive impregnated paper. If i* is necessary to faithfully reproduce an intricate embossed pattern in the subsequent step of heat-pressing under a metal mould bearing an embossed pattern, the ob~ect will be attained successfully by adopting a base impregnated with diallylphthalate resin 8S compounded with a thermosetting acrylic resin (a copolymer of methylol methacrylic amide or methylol amide which gives a functional side chain to styrene, methacrylic acid ester, acrylic acid ester or acrylonitrile) such that the fat content may be 75 - 80 %.
The provisionally adhered laminatlon of the mount and the decor-1056Z~39 atlve impregnated paper is placed, prior to the hardening of the impreg-nating material and the adhesive, upon a metal mould bearing a deslrable embossed pattern, with the decorative side directly in contact with the mould, and then the lamination is heat-pressed against the mould.
The conditions of heat-pressing depend on the type of impreg-nated substance, but the common standard conditions are: 90 - 170C, 70 -250 kg/cm2, 1 - S minutes.
By such heat-pressing, a decorative panel with a permanently embossed pattern according to the present invention can be obtained successfully, with the embossed pattern faithfully reproduced on the decorative veneer or decorative impregnated paper.
The following is one embodiment of the present invention.
A particle board 15 mm thick with a water content of 12 % was used as the mount. The surface of the mount was scraped to expose rough clusters of short, fine fibres. The surface layer of the mount to a depth of ~ mm was repeatedly impregnated with the following resin compounds by means of a spreader:
Impregnated resin compound ~Example 1~
~ Diallylphthalate prepolymer ......... 100 parts by weight Diallylphthalate monomer ............ 10 parts by weight Benzoyl peroxide .................... 3 parts by weight Tricholoroethylene .................. 50 parts by weight Impregnated resin compound ~Example 2) Bisphenol A-type epoxy resin......... 100 parts by weight Amine type hardening agent .......... 8 parts by weight Methyl ethyl ketone ................. 35 parts by weight Toluene ............................. 15 parts by weight Following the impregnation, the mount was left for about 30 minutes to allow the solvent to evaporate, after which an adhesive com-posed of polyvinyl acetate emulsion, 100 parts by weight; urea resin,10 parts by weight; and wheat flour, 5 parts by weight; was applied to the surface of the mount at a rate of 150 gr/m in terms of solids by means of a glue spreader or a hand roller and the water content was allowed .
.
` 1056Z89 to evaporate. Next the mount with an overlay of a decorative veneer 0.3 mm thick shaved from a mahogany wood with water content adjusted to 13 % was left, provisionaly adhered together with the first mount at room temperature for three hours. Instead of leaving at room temperature, a hot press may be used for 40 seconds at 130C and 10 kg/cm for the purpose of provisional adhering.
The provisional lamination of the mount and the decorative veneer was placed in a hot press, with the decorative side in direct contact with a metal mould bearing a desired embossed pattern provided on the hot press, and then heat-pressed under the conditions of 130C, 100 kg/cm , for 3 minutes, thereby producing a decorative panel with a permanently embossed pattern reproduced thereon, characterized by excel-lence in resistance to water, humitity, weather, heat, wear and chemicals.
A second embodiment of the present invention is generally the same as the first one except for the following point. Namely, the surface of the provisional lamination of the mount and the decorative veneer of impregnated paper is coated with a surface-treating agent mainly composed of polyethylene glycol or a copolymer of ethylene and vinyl acetate.
The surface-treating agent applied for this purpose is a compound mainly composed of polyethylene glycol or a coplymer of ethylene and vinyl acetate which is applied by means of a spreader or by brushing.
The effect of this coating in the case of a decorative veneer is that the agent whlch penetrates the fibre voids and capillaries softens the ve~
neer itself, helps the slipping and sticking of fibres and facilitates demoulding in heat-pressing, thereby assuring uniform finishing of the pro-ducts. In the case of a decorative paper the effect is similar to the above, the slipping and sticking of the paper surface being improved.
The desirable amount of application ls in the case of a copoly-mer of ethylene and vinyl acetate 50 - 150 gr/m2 in terms of i2% solids.
In the same way as in the first embodiment the provisional lamination of the mount and the decorative veneer or impregnated paper thus surface-treated is placed and heat-pressed in the hot press, with -56Z~9 the decorative side in direct contact with the metal mould bearing an embossed pattern.
The surface-treating agent may be applied as above after pro-visional lamination, as the veneer or paper to which the agent has been preliminarily applied may be overlaid on the member and then provision-ally adhered together.
Except for the step of applying the surface-treating agent, the second embodiment comprises the same steps as the first one. In the second embodiment the provisional lamination is obtained in the same manner as in the first one. Thereafter ethylene-vinyl acetate emulsion 12 % solids is brushed on the surface of the decorative veneer at a rate of 120 gr/m . Next, in a way similar to the first embodiment, the provisional lamination of the mount and the decoratlve veneer or paper to which has been applied the surface-treating agent, is placed in a hot press, with the decorative side in direct contact with the metal mould bearing the desired embossed pattern; and then heat-pressPd under the conditions of 130C, 100 kg/m and 3 minutes, thereby producing a decorative panel with a permanently embossed pattern reproduced thereon, characterized by excellence in resistance to water, humidity, weather, heat, wear and chemicals.
A third embodiment of the present invention follows generally the same process as the first one except for the following step. Namely the step i~ added of enveloping at least the whole surface of the provi-sional lamination of the mount and the decorative veneer or impregnated paper obtained in the manufacturing process of the first embodiment in a thermoplastic substance which can form a film in the subsequent step of heat-pressing. The added step has the effect of giving a moulded product a high fidelity of reproducing a ~pecific pattern of the mould as well as improving the cushioning, slipping and demouldability of the lamination against the metal mould, and facilitating the step of heat-pressing. The envelopment of the lamination in the thermoplastic film may be done by means of an adhesive.
Thereafter the lamination is placed and heat-pressed in a A
.
.
~` 1056289 hot preas, with the decorative side in direct contact with the metal mould bearing an embossed pattern.
Except for the step of applying the thermoplastic film, the third embodiment is the s8me as the irst one.
: ~ .
In this case the provlsional lamination obtained in the same way as in the first embodiment is enveloped in a coat of adhesive in a polyethylene ilm; placed in a hot press, with the decorative side in direct contact with the metal mould bearing the desired embossed pattern;
andthen heat-pressed under the conditions of 130C, 100 kg/m2, for 3 minutes, thereby producing a decorative panel with a permanently em-bossed pattern reproduced thereon, characteri~ed by excellence in resis- ~:
tance to water, humidity, weather, heat, wear and chemicals.
The present invention relates to the manufacture of a decorative panel, more specifically, of a decorative panel impressed with a permanently embossed pattern.
Known is the manufacture of a so-called moulded panel which is used as a decorative means for luxurious furniture, doors, cabinets,side-boards, book-shelves, etc., by applying to the surface of the material machine tools such as three-face or four-face automatic planningmachines, single-spindle or double-spindle chamfering machines or milling machines, together with handicraft work, according to the desired scheme. However in applying such conventional machining techniquesto produce an embossed pattern in accordance with a desired scheme, not only are the kinds of wood used restricted, but also the value of the machined wood may be deprecia-ted by the finishing which follows the machining, depending upon the kinds of wood used. Moreover, when an intricate embossed pattern is to be created by shaping the amount of handicraft in the job increases and since ¦ this demands a high degree of skill, the work becomes extremely inefficient.
The present invention therefore provides a technically easy, and economical process of manufacturing a decorative panel bearing a sedate, tasteful, intricate embossed pattern such as seen on conventional panel, by the simple means of pressing under a pattern mould, instead of resorting to the conventional complicated handicraft which calls for high skill thereby, eliminating the difficulty and inconvenience of conventional machining.
mus the present invention provides a process for manufacturing a decorative panel having a permanently embossed pattern on a surface comprising the steps of:
providing a mount of fibrous material having a water content of 8-13%
by weight with a rough, fibrous textured surface and selected from particle board, composite wood, hard fibre board, non-woven cloth and compressed felting; impregnating said surface to a depth of 1-3 mm with . .
/ ~
10562~9 a solution of a thermosetting high molecular weight substance; forming a provisional lamination of a thin decorative layer comprising a slice of cooked wood having a water content of 8-50% by weight with a grain pattern on said rougll impregnated surface using an adhesive therebetween applied at a rate of 80-200 g/m2 and having a solids content of 40-50%, the adhesive being selected from polyvinyl acetate emulsion, vinyl acetate copolymer emulsion and polymeric acetate emulsion compound with the decorative side out; and heat-pressing said provisional lamination with the decorative side in contact with a mould surface bearing the required embossed pattern, before said impregnating material and said adhesive harden.
' .
.i la-.
$
lOS62~9 ¦ According to another aspect of the present invention, the pro-cess for manufacturing a decorative panel impressed with a permanently embossed pattern as described above with respect to the one aspect of the invention, further comprises a step of treating the decorative sur-face with a surface-treating agent prior to the step of heat-pressing the provisional lamination.
According to still another aspect of the present invention, -the process for manufacturing a decorative panel impressed with a perma-nently embossed pattern as described above with respect to the first aspect of the invention, further comprises a step of enveloping at least the whole surface of the provisional lamination in a thermoplastic film prior to the step of heat-pressing the provisional lamination.
The foregoing as well as the characteristic features of the present invention will become more apparent and more readily understandable from the following description and the appended claims.
The process for manufacturing a decorative panel impressed with a permanently embossed pattern according to the present invention is proposed in an effort to overcome the difficulty and inconvenience of conventional shaping practices. In this proposed process, a decorative veneer or a decorative impregnated paper overlaid on a fibrous mount is utilized without losing the beauty of the natural wood of the veneer or without losing the intricate, beautiful pattern of the decorative im-pregnated paper, and only by heat-pressing under a pattern mould can an embossed pattern of a desired scheme be exactly reproduced to thereby successfully offer a novel decorative panel.
In one embodiment of the present invention, a rough fibrous texture is presented on a surface of a fibrous mount, the surface is im-pregnated with a solution or an emulsion of a thermosetting high-molecular weight substance, and only the solvent in the solution or emulsion is substantiaily evaporated without allowing the thermosetting high-molecular i ~3 - 2 ---- 1056Z8~3 weight substance to harden, then a decorative thin veneer or a decorative impregnated paper is overlaid on the thermosetting high-molecular weight i substance impregnated surface, with an adhesive inserted therebetween, and this laminated product with its decorative side in contact with a pattern mould bearing an embossed pattern is heat-pressed under the mould, prior to hardening of the impregnation and the adhesive.
The mount whlch forms the material of the decorative panel, upon which the embossed pattern is to be reproduced, is mainly selected from boards such as particle board, composite wood or from fibrous moulded products such as hard fibreboard, non woven cloth and compressed felting. There is no limitation on the thickness, but generally speaking, 10 - 20 mm would be preferable, be-cause it would facilitate the subsequent step of heat-pressing and would widen the scope of applicability for the final product.
The fibrous mount to be used has its surface coarsened, in other words, short, fine fibres are frmed on the surface. Thus the fibrous moulded products described above by way of example, which are originally rough on the surface, may be employed as they are, but the less coarse boards tescribed by way of example prior to the fibrous moulded products, would have to be submitted to a coarsening process to expose short, fine fibres, such as by scraping the relatively smooth surface. Even the fibrous moulded products might need such a treatment if the surface has to be coarser.
The moisture ln such a mount is a factor governing the value of the decorative panel of the invention and it is preferably adjusted to 8 - 13 ~ by weight.
According to the present invention, the surface layer of the mount is preliminarily impregnated with a solution or an emulsion of a thermosetting high-molecular weight substance.
As an example urea-formaldehyde resin, melamine-formaldehyde resin, thermosetting acrylic resin, phenolic resin, epoxy resin, diallylphth-alate resin, natural rubber, styrene-butadiene rubber, and butadiene-acryloni-trile rubber can be used singly or in combinations as the high molecular 10562~9 weight substance.
Impregnatlon with a solution or an emulsion of such a high-molecular weight substance is done by brushing, spraying, or by means of a roll-coater, a spreader,etc.
Special technical attention should be paid in this impregnation to the tepth of impregnation into the surface layer. Such is dependent on the depth and profile of the embossment of the pattern on the metal mould bearing the embossed pattern and to be used for subsequent heat-pres-sing, but generally impregnation has to be done carefully so that the impregnated substance may be evenly distributed over only the surface layer in a depth of 1 - 3 mm.
Still more important, the solution or emulsion of the thermoset-ting high-molecular weight substance thus impregnated into the surface layer of the mount should, without immediately thermosetting, be allowed to stay as is for 30 minutes to 48 hours at a temperature within the range of room temperature up to 50C so that the solvent or water in the solution or emulsion may be substsntially evaporated.
According to the present invention, thereafter, a decorative veneer of a decorative impregnated paper is provisionally adhered by means of an adhesive, to the mount with its surface layer impregnated with a non-cured high-molecular weight substance. Then the provisionally adhered assembly is left as it is at an ambient temperature for 20 minutes to three hours, during which it becomes dry to the finger touch.
The adhesive may be, for example, polyvinyl acetate emulsion or a composition obtained by mixing polyvinyl acetate emulsion with sty- -rene-butadiene latex, synthetic rubber, such as chloroprene, epoxy resin, an emulsion of a melamine-formaldehyde pre-condensate or a urea-formaldehyde pre-condensate and a composition obtained by mixing a homo-polymer emulsion of vinyl acetate or a copolymer emulsion of vinyl acetate with ethylene or acrylic ester and so on with the second component having functional groups such as unsaturated carboxylic acid, for example, maleic acid or acrylic acid, alkyl ester of unsaturated carboxylic acid or amide of unsaturated carboxylic acid, the amount of adhesive applied b~lng desirab~ 80 - 200 .
':
~ .:
gr/m2 ln terms of 40 - 50 % solids.
The decorative veneer mentioned in the present invention refers preferably to thin sllces about 0.2 - 0.7 mm or preferably 0.25 - 0.35 mm thick, with quarter sawn grain, flat sawn grain or mixed grain or knurls, of wood such as "nara (a type of oak)", "Nire (a type of elm)", "Sakura (cherry)", "shio~i ~Fraxinus Spaethiana)" or of imported wood such as teak walnut, rosewood, zebrawood, mahogany. The allowable water content of the decorative veneer depends on the type of impregna-tion of the mount and on the type of athesive applied to the mount. When the impregnation is by epoxy resin, the value of allowable water content is about 50% and when it is diallylphthalate, the value should be set at about 10 %. Generally speaking, a low water content in the range of 8 - 50 % is deemed one of the factors assuring good and fa~thful repro-duction of a pattern on the veneer.
The decorative impregnated paper which may be substituted for the decorative veneer may be a patterned paper with a wood grain or a pattern printed thereon, which consists of a base of sulphite pulp or rayon pulp impregnated with a thermosetting synthetic resin or a composition of a thermosetting synthetic resin and a thermoplastic synthetic resin; one which is commercially available with a fat content of 45 - 70 % and thick-ness of 2 - 5 mills may be employed.
It is known that phenolic resin, diallylphthalate resin, mel-amine resin, unsaturated polyester resin, epoxy resin, guanamine resin, thermosetting acrylic resin, methacrylic acid ester, etc. are available for impregnation in the commercial production of the decora-tive impregnated paper. If i* is necessary to faithfully reproduce an intricate embossed pattern in the subsequent step of heat-pressing under a metal mould bearing an embossed pattern, the ob~ect will be attained successfully by adopting a base impregnated with diallylphthalate resin 8S compounded with a thermosetting acrylic resin (a copolymer of methylol methacrylic amide or methylol amide which gives a functional side chain to styrene, methacrylic acid ester, acrylic acid ester or acrylonitrile) such that the fat content may be 75 - 80 %.
The provisionally adhered laminatlon of the mount and the decor-1056Z~39 atlve impregnated paper is placed, prior to the hardening of the impreg-nating material and the adhesive, upon a metal mould bearing a deslrable embossed pattern, with the decorative side directly in contact with the mould, and then the lamination is heat-pressed against the mould.
The conditions of heat-pressing depend on the type of impreg-nated substance, but the common standard conditions are: 90 - 170C, 70 -250 kg/cm2, 1 - S minutes.
By such heat-pressing, a decorative panel with a permanently embossed pattern according to the present invention can be obtained successfully, with the embossed pattern faithfully reproduced on the decorative veneer or decorative impregnated paper.
The following is one embodiment of the present invention.
A particle board 15 mm thick with a water content of 12 % was used as the mount. The surface of the mount was scraped to expose rough clusters of short, fine fibres. The surface layer of the mount to a depth of ~ mm was repeatedly impregnated with the following resin compounds by means of a spreader:
Impregnated resin compound ~Example 1~
~ Diallylphthalate prepolymer ......... 100 parts by weight Diallylphthalate monomer ............ 10 parts by weight Benzoyl peroxide .................... 3 parts by weight Tricholoroethylene .................. 50 parts by weight Impregnated resin compound ~Example 2) Bisphenol A-type epoxy resin......... 100 parts by weight Amine type hardening agent .......... 8 parts by weight Methyl ethyl ketone ................. 35 parts by weight Toluene ............................. 15 parts by weight Following the impregnation, the mount was left for about 30 minutes to allow the solvent to evaporate, after which an adhesive com-posed of polyvinyl acetate emulsion, 100 parts by weight; urea resin,10 parts by weight; and wheat flour, 5 parts by weight; was applied to the surface of the mount at a rate of 150 gr/m in terms of solids by means of a glue spreader or a hand roller and the water content was allowed .
.
` 1056Z89 to evaporate. Next the mount with an overlay of a decorative veneer 0.3 mm thick shaved from a mahogany wood with water content adjusted to 13 % was left, provisionaly adhered together with the first mount at room temperature for three hours. Instead of leaving at room temperature, a hot press may be used for 40 seconds at 130C and 10 kg/cm for the purpose of provisional adhering.
The provisional lamination of the mount and the decorative veneer was placed in a hot press, with the decorative side in direct contact with a metal mould bearing a desired embossed pattern provided on the hot press, and then heat-pressed under the conditions of 130C, 100 kg/cm , for 3 minutes, thereby producing a decorative panel with a permanently embossed pattern reproduced thereon, characterized by excel-lence in resistance to water, humitity, weather, heat, wear and chemicals.
A second embodiment of the present invention is generally the same as the first one except for the following point. Namely, the surface of the provisional lamination of the mount and the decorative veneer of impregnated paper is coated with a surface-treating agent mainly composed of polyethylene glycol or a copolymer of ethylene and vinyl acetate.
The surface-treating agent applied for this purpose is a compound mainly composed of polyethylene glycol or a coplymer of ethylene and vinyl acetate which is applied by means of a spreader or by brushing.
The effect of this coating in the case of a decorative veneer is that the agent whlch penetrates the fibre voids and capillaries softens the ve~
neer itself, helps the slipping and sticking of fibres and facilitates demoulding in heat-pressing, thereby assuring uniform finishing of the pro-ducts. In the case of a decorative paper the effect is similar to the above, the slipping and sticking of the paper surface being improved.
The desirable amount of application ls in the case of a copoly-mer of ethylene and vinyl acetate 50 - 150 gr/m2 in terms of i2% solids.
In the same way as in the first embodiment the provisional lamination of the mount and the decorative veneer or impregnated paper thus surface-treated is placed and heat-pressed in the hot press, with -56Z~9 the decorative side in direct contact with the metal mould bearing an embossed pattern.
The surface-treating agent may be applied as above after pro-visional lamination, as the veneer or paper to which the agent has been preliminarily applied may be overlaid on the member and then provision-ally adhered together.
Except for the step of applying the surface-treating agent, the second embodiment comprises the same steps as the first one. In the second embodiment the provisional lamination is obtained in the same manner as in the first one. Thereafter ethylene-vinyl acetate emulsion 12 % solids is brushed on the surface of the decorative veneer at a rate of 120 gr/m . Next, in a way similar to the first embodiment, the provisional lamination of the mount and the decoratlve veneer or paper to which has been applied the surface-treating agent, is placed in a hot press, with the decorative side in direct contact with the metal mould bearing the desired embossed pattern; and then heat-pressPd under the conditions of 130C, 100 kg/m and 3 minutes, thereby producing a decorative panel with a permanently embossed pattern reproduced thereon, characterized by excellence in resistance to water, humidity, weather, heat, wear and chemicals.
A third embodiment of the present invention follows generally the same process as the first one except for the following step. Namely the step i~ added of enveloping at least the whole surface of the provi-sional lamination of the mount and the decorative veneer or impregnated paper obtained in the manufacturing process of the first embodiment in a thermoplastic substance which can form a film in the subsequent step of heat-pressing. The added step has the effect of giving a moulded product a high fidelity of reproducing a ~pecific pattern of the mould as well as improving the cushioning, slipping and demouldability of the lamination against the metal mould, and facilitating the step of heat-pressing. The envelopment of the lamination in the thermoplastic film may be done by means of an adhesive.
Thereafter the lamination is placed and heat-pressed in a A
.
.
~` 1056289 hot preas, with the decorative side in direct contact with the metal mould bearing an embossed pattern.
Except for the step of applying the thermoplastic film, the third embodiment is the s8me as the irst one.
: ~ .
In this case the provlsional lamination obtained in the same way as in the first embodiment is enveloped in a coat of adhesive in a polyethylene ilm; placed in a hot press, with the decorative side in direct contact with the metal mould bearing the desired embossed pattern;
andthen heat-pressed under the conditions of 130C, 100 kg/m2, for 3 minutes, thereby producing a decorative panel with a permanently em-bossed pattern reproduced thereon, characteri~ed by excellence in resis- ~:
tance to water, humidity, weather, heat, wear and chemicals.
Claims (6)
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for manufacturing a decorative panel having a permanently embossed pattern on a surface comprising the steps of:
providing a mount of fibrous material having a water content of 8-13%
by weight with a rough, fibrous textured surface and selected from particle board, composite wood, hard fibre board, non-woven cloth and compressed felting; impregnating said surface to a depth of 1-3 mm with a solution of a thermosetting high molecular weight substance; forming a provisional lamination of a thin decorative layer comprising a slice of cooked wood having a water content of 8-50% by weight with a grain pattern on said rough impregnated surface using an adhesive therebetween applied at a rate of 80-200 g/m2 and having a solids content of 40-50%, the adhesive being selected from polyvinyl acetate emulsion, vinyl acetate copolymer emulsion and polymeric acetate emulsion compound with the decorative side out; and heat-pressing said provisional lamination with the decorative side in contact with a mould surface bearing the required embossed pattern, before said impregnating material and said adhesive harden.
providing a mount of fibrous material having a water content of 8-13%
by weight with a rough, fibrous textured surface and selected from particle board, composite wood, hard fibre board, non-woven cloth and compressed felting; impregnating said surface to a depth of 1-3 mm with a solution of a thermosetting high molecular weight substance; forming a provisional lamination of a thin decorative layer comprising a slice of cooked wood having a water content of 8-50% by weight with a grain pattern on said rough impregnated surface using an adhesive therebetween applied at a rate of 80-200 g/m2 and having a solids content of 40-50%, the adhesive being selected from polyvinyl acetate emulsion, vinyl acetate copolymer emulsion and polymeric acetate emulsion compound with the decorative side out; and heat-pressing said provisional lamination with the decorative side in contact with a mould surface bearing the required embossed pattern, before said impregnating material and said adhesive harden.
2. The process of claim 1, comprising an additional step of coating the thin decorative layer with a surface-treating agent mainly composed of polyethylene glycol or a copolymer of ethylene and vinyl acetate before heat-pressing.
3. The process of claim 1, comprising an additional step of enveloping at least the whole surface of said provisional lamination in a thermoplastic film before heat-pressing.
4. The process of claim 1, wherein the step of impregnating the rough surface with a solution or emulsion of a thermosetting high molecular weight substance and then substantially evaporating only the solvent from the solution or emulsion without allowing the impregnated substance to harden.
5. The process of claim 1, wherein said high molecular weight substance includes one or more selected from the group consisting of urea formaldehyde resin, melamine formaldehyde resin, thermosetting acrylic resin, phenolic resin, epoxy resin, diallylphthalate resin, natural rubber, styrene-butadiene rubber, and butadiene-acrylonitrile rubber.
6. The process of claim 1, wherein the mount of fibrous material is subjected to a coarsening process to expose short, fine fibres prior to impregnation with the solution of the thermosetting high molecular weight substance.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP11002273A JPS5643848B2 (en) | 1973-09-29 | 1973-09-29 | |
| JP48110020A JPS5060558A (en) | 1973-09-29 | 1973-09-29 | |
| JP48110021A JPS5060559A (en) | 1973-09-29 | 1973-09-29 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1056289A true CA1056289A (en) | 1979-06-12 |
Family
ID=27311619
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA210,240A Expired CA1056289A (en) | 1973-09-29 | 1974-09-27 | Process for manufacturing a decorative panel impressed with a permanent embossed pattern |
Country Status (5)
| Country | Link |
|---|---|
| CA (1) | CA1056289A (en) |
| DE (1) | DE2446307C3 (en) |
| FR (1) | FR2245495B1 (en) |
| GB (1) | GB1472629A (en) |
| IT (1) | IT1022413B (en) |
Families Citing this family (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB8417704D0 (en) * | 1984-07-11 | 1984-08-15 | Secr Defence | Laminate materials |
| FR2568164B1 (en) * | 1984-07-27 | 1987-09-04 | Ostermann Michel | PROCESS FOR PRODUCING DECORATIVE PRODUCTS FROM FRAGMENTS OR PIECES OF WOOD AND PRODUCTS OBTAINED |
| IT1246084B (en) * | 1990-01-30 | 1994-11-14 | Ordinan Trading Ltd | PROCEDURE FOR THE FORMATION OF A COATING ELEMENT PARTICULARLY FOR VEHICLE INTERIORS AND COATING ELEMENT REALIZED WITH THE SAID PROCEDURE |
| US6379786B1 (en) * | 1997-11-28 | 2002-04-30 | Bridgestone Corporation | Ligneous finishing material |
| DE19754420C1 (en) * | 1997-12-08 | 1999-03-04 | Daimler Benz Ag | Method of improvement of veneer appearance |
| WO1999059787A1 (en) * | 1998-05-20 | 1999-11-25 | Eduard Küsters Maschinenfabrik GmbH & Co. KG | Method and installation for improving the usability of panel materials |
| SE516696C2 (en) | 1999-12-23 | 2002-02-12 | Perstorp Flooring Ab | Process for producing surface elements comprising an upper decorative layer as well as surface elements produced according to the method |
| GB2370013B (en) * | 2000-12-15 | 2004-06-30 | Fine Irish Pine Res Ltd | Furniture |
| SE0101620D0 (en) | 2001-05-10 | 2001-05-10 | Pergo Ab | Embossed decorative boards |
| SE525681C2 (en) * | 2001-12-07 | 2005-04-05 | Pergo Ab | Structured panels with matched surface |
| SE526728C2 (en) | 2003-12-11 | 2005-11-01 | Pergo Europ Ab | A method of making panels with a decorative surface |
| RU2446044C2 (en) * | 2010-07-08 | 2012-03-27 | Государственное образовательное учреждение высшего профессионального образования "Воронежская государственная лесотехническая академия" | Method of gluing wood materials |
| CN104029551B (en) * | 2014-06-17 | 2016-08-24 | 营口西尔伯曼钢琴有限公司 | Casing of piano coating resin mill base handwritten drawings production technology |
| CN106393384A (en) * | 2016-09-09 | 2017-02-15 | 福建农林大学 | Method for producing zero-formaldehyde bamboo flakeboard by using unsaturated polyester resin |
| CN106393385A (en) * | 2016-09-09 | 2017-02-15 | 福建农林大学 | Method for producing zero-formaldehyde light fiberboards through unsaturated polyester resin |
| CN106272862A (en) * | 2016-09-21 | 2017-01-04 | 福建农林大学 | A kind of production method of aldehyde-free environment-friendly floor base material particieboard |
-
1974
- 1974-09-11 GB GB3966274A patent/GB1472629A/en not_active Expired
- 1974-09-24 FR FR7432092A patent/FR2245495B1/fr not_active Expired
- 1974-09-27 DE DE2446307A patent/DE2446307C3/en not_active Expired
- 1974-09-27 IT IT27838/74A patent/IT1022413B/en active
- 1974-09-27 CA CA210,240A patent/CA1056289A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| IT1022413B (en) | 1978-03-20 |
| FR2245495B1 (en) | 1978-07-13 |
| FR2245495A1 (en) | 1975-04-25 |
| DE2446307C3 (en) | 1980-10-30 |
| GB1472629A (en) | 1977-05-04 |
| DE2446307A1 (en) | 1975-04-10 |
| DE2446307B2 (en) | 1980-03-06 |
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