JP2004160708A - Decorative plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative plate which has excellent surface hardness, damage resistance and water resistance sufficiently usable as a floor material, etc., which does not increase in weight with a simple constitution and which can be simply manufactured. <P>SOLUTION: The decorative plate is obtained by laminating a decorative sheet 1 on a base plate 3 via an adhesive layer 2 having a hardness exceeding the hardness of the plate 3. It is desirable to use a one-liquid moisture curing type hot-melt adhesive or an electron beam curing type adhesive in the layer 2. Groove working 4 or chamfering working 5 of the depth not reaching the plate 3 from the surface of the sheet 1 reaching in the layer 2 may be performed. The water resistance is not lowered by the working. If the layer 2 is previously colored in a color tone similar to the sheet 1, it is not necessary to color the working part later. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a decorative panel used for interior materials such as wall materials and floor materials in buildings such as houses, furniture and furniture, and is particularly suitable for applications such as indoor floor surfaces and stair treads. The present invention relates to a decorative board having excellent surface hardness and scratch resistance.
[0002]
[Prior art]
As for the existing veneer flooring, a type in which a veneer having a thickness of about 0.1 mm to 3 mm is adhered to a base plate made of a wooden material having a thickness of about 5 mm to 15 mm and a surface coating is applied with a transparent paint is mainstream. . However, since the veneer is a natural material, the color variation is large, it takes time for toning, it has poor weather resistance, it is easy to tan, it has poor water resistance, and it easily swells when immersed in water , Low hardness (durometer hardness of about 40 to 50), and easy damage.
[0003]
In order to solve these problems, instead of using veneer, a decorative sheet made of synthetic resin with excellent water resistance is used, and between the base plate and the decorative sheet, a hard thermoplastic resin is used to provide surface hardness. There is a proposal of a decorative plate with a resin plate interposed (Patent Document 1). However, since this decorative board has a resin plate attached to the back of the decorative sheet with an adhesive, and then the base plate is attached to the back of the resin plate with an adhesive, the product configuration becomes multilayer, and the There are problems that the process becomes complicated and the weight of the product increases.
[0004]
[Patent Document 1] JP-A-2001-191454 [0005]
[Problems to be solved by the invention]
The present invention solves the above-mentioned problems of the prior art, has excellent surface hardness, scratch resistance, and water resistance that can be sufficiently used as a floor material, etc., has a simple structure, does not increase the weight, and is easily manufactured. The purpose is to provide a possible decorative board.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the decorative board of the present invention is a decorative board in which a decorative sheet is laminated on a base plate via an adhesive layer, wherein the hardness of the adhesive layer is lower than the hardness of the base plate. It is characterized by exceeding.
[0007]
Further, in the above decorative board, the base plate is made of a wood-based material.
[0008]
Further, in the above decorative board, the adhesive layer is made of a one-component moisture-curable hot-melt adhesive or an electron beam-curable adhesive.
[0009]
In the above decorative board, the thickness of the adhesive layer is 50 μm or more.
[0010]
Further, in the decorative plate described above, the adhesive layer has a durometer hardness of 50 to 80.
[0011]
Further, in the above decorative board, the adhesive layer is colored.
[0012]
Further, in the decorative plate, groove processing and / or chamfering processing that does not reach the base plate are performed from the decorative sheet surface to the adhesive layer.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
The decorative board of the present invention will be described with reference to the drawings. As shown in FIG. 1, a decorative sheet 1 is laminated on a base plate 3 with an adhesive layer 2 interposed therebetween. 2 is higher than the hardness of the base plate 3.
[0014]
The base plate 3 is similar to that of a conventional decorative board, and is generally made of a wood-based material such as a normal plywood, a medium fiber board (MDF), a hard fiber board (HDF), and a particle board. Things are used. Although the thickness is arbitrary according to the use and the like, it is generally 3 to 30 mm, and among them, the one having a thickness of 5 to 15 mm is most widely used.
[0015]
The hardness of the base plate 3 made of such a wood-based material is generally about 50 in durometer hardness (JIS K 7215), so that the hardness (after hardening) of the adhesive layer 2 is usually set to durometer hardness. It must be at least 50 or more. It is more preferable to use an adhesive having a durometer hardness of 60 or more, more preferably 65 or more, and a durometer hardness higher than that of the base plate 3 by at least 5 or more. However, if it is too hard, it loses flexibility and becomes brittle, easily breaking or cracking due to impact. Therefore, the durometer hardness is preferably not more than 80.
[0016]
The type of the adhesive used for the adhesive layer 2 is not particularly limited. However, a general solvent-type adhesive or a woodworking emulsion adhesive often cannot obtain sufficient hardness. It is desirable to use.
[0017]
The reaction-curable adhesive includes, for example, a two-component curable urethane-based adhesive, a moisture-curable urethane-based adhesive (particularly, a one-component moisture-curable hot-melt adhesive), a two-component curable or one-component curable epoxy. Adhesives, urea adhesives, melamine adhesives, phenolic adhesives, resorcinol adhesives, cyanoacrylate adhesives, ultraviolet curable adhesives, electron beam curable adhesives, and the like.
[0018]
Among them, it can be quickly bonded at room temperature without causing thermal deterioration of the base plate 3 and the decorative sheet 1, has both hardness and toughness after hardening, and can be hardened without any trouble even when sandwiched between opaque bodies. It is most desirable to use a one-part moisture-curable hot melt adhesive or an electron beam-curable adhesive.
[0019]
In order to stably maintain the durometer hardness of 50 or more in the adhesive layer 2, it is preferable that the thickness of the adhesive layer 2 be at least 50 μm or more. However, if the thickness is too large, it is uneconomical, and the adhesive strength may be reduced or the impact resistance may be deteriorated. Therefore, the thickness is preferably about 1 mm or less.
[0020]
The adhesive layer 2 may be colorless and transparent, but may be colored in any color tone. If the adhesive layer 2 is colored to a color tone similar to the color tone of the design pattern of the decorative sheet 1, if the decorative sheet 1 has insufficient concealing properties, the color tone of the base plate 3 may be uneven or uneven. In addition, there is an advantage that the color tone variation and unevenness of the design pattern of the decorative board viewed from the surface are suppressed, and the design quality of the decorative board is stabilized. This effect is more remarkable when a colored and opaque adhesive is used than when it is colored or translucent.
[0021]
Further, a groove 4 and a chamfer 5 are often applied to the surface and the peripheral edge of the decorative board. In such a case, the adhesive layer 2 is colored in advance and shown in FIG. As described above, the groove processing 4 and the chamfer processing 5 are performed from the decorative sheet 1 surface to the adhesive layer 2 but to a depth that does not reach the base plate 3, so that the groove processing 4 and the chamfer processing 5 are performed. There is also an advantage that the color tone is stabilized, and it is not necessary to apply a coloring treatment such as painting to these portions later.
[0022]
Coloring agents used for coloring the adhesive layer 2 are the same as those used for ordinary decorative board paints, printing inks, and the like, and include, for example, titanium oxide, zinc oxide, iron oxide (red iron oxide, yellow oxide). Inorganic pigments such as iron and iron black), carbon black and cobalt blue, organic pigments such as anthraquinone, quinacridone, isoindolinone, quinophthalone, perylene, dioxazine and phthalocyanine; metal powder pigments such as aluminum powder and bronze powder; fish scale powder And pearlescent pigments such as bismuth acid chloride, mica coated with titanium oxide and mica coated with iron oxide.
[0023]
In order to enhance the hiding power of the adhesive layer 2, it is desirable to use at least an inorganic pigment, a metal powder pigment and / or a pearlescent pigment, which is a pigment having a high hiding power, among the various pigments described above. In particular, when at least a metal powder pigment and / or a pearlescent pigment are used, the light reflection effect thereof gives a shining feeling similar to that of natural wood, so that the decorative sheet 1 has some transparency, This is suitable for design, for example, when the adhesive layer 2 is exposed at the processing 4 portion or the chamfering 5 portion.
[0024]
The decorative sheet 1 is for imparting a desired design to the surface of the decorative material by a desired pattern, surface embossing, or the like. In some cases, veneer or patterned paper is used, but the decorative sheet 1 is required for decorative boards such as flooring materials. Considering the water resistance, it is desirable to use the decorative sheet 1 made of a thermoplastic resin.
[0025]
The decorative sheet 1 made of a thermoplastic resin has a pattern layer provided by printing or the like on the surface of an opaque base sheet made of a thermoplastic resin, or a back and / or front surface of a transparent base sheet made of a thermoplastic resin. May be a decorative sheet of a single layer structure such as those provided with a pattern layer, those provided with a surface protective layer on their surface, or a pattern layer on a base sheet made of a transparent or opaque thermoplastic resin The decorative sheet may have a multilayer structure in which a transparent thermoplastic resin layer is laminated through the layer.
[0026]
Examples of the thermoplastic resin constituting the decorative sheet 1 include polyolefin resins such as polyethylene and polypropylene, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ethylene- (meth) acrylate copolymer, and the like. Olefin copolymer resins such as ethylene-unsaturated carboxylic acid copolymer metal neutralized products (ionomer resins), polyester resins such as polyethylene terephthalate, polybutylene terephthalate, 1,4-cyclohexanedimethanol-modified polyethylene terephthalate, and polycarbonate , An acrylic resin such as polymethyl methacrylate, a styrene resin such as polystyrene, acrylonitrile-butadiene-styrene copolymer (ABS), and the like. It may be a body or the like.
[0027]
The pattern layer in the decorative sheet 1 is formed using a conventionally known printing ink or paint by an appropriate printing method such as a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, an inkjet printing method, or the like. You. When the picture layer is a solid layer or includes a solid layer, in addition to the various printing methods described above, for example, a roll coating method, a gravure coating method, a rod coating method, a knife coating method, an air knife coating method, and a die coating method. A coating method such as a spray coating method or a spray coating method may be employed.
[0028]
The type of the picture is, for example, a wood grain pattern, a stone grain pattern, a cloth grain pattern, an abstract pattern, a geometric pattern, a character or a symbol, or a combination thereof. In order to stabilize the design, it is desirable to use an opaque base sheet and / or to provide an opaque solid layer made of an opaque printing ink or paint on the back side of the picture layer. Further, in order to further improve the design of the decorative sheet 1, the surface is embossed, the concave portion of the emboss is filled with a coloring agent by a wiping method or the like, and the surface is glossed using a gloss ink or a matte ink. A mat pattern may be formed.
[0029]
In order to manufacture the decorative board of the present invention, an adhesive is applied to the upper surface of the base plate 3 and / or the back surface of the decorative sheet 1, and then the base plate 3 and the decorative sheet 1 are overlapped and the adhesive is cured. Just fine. The method of applying the adhesive is arbitrary, such as a roll coating method, a gravure coating method, a die coating method, a lip coating method, a comma coating method, a knife coating method, a flow coating method, and the like.
[0030]
When a one-component moisture-curable hot melt adhesive is used, an adhesive that has been heated and melted in a sealed state is applied on the base plate 3 and / or the back surface of the decorative sheet 1 and before the adhesive is cooled and solidified. If the base plate 3 and the decorative sheet 1 are overlapped and left to cool as they are, they are fixed by cooling and solidifying the adhesive, and thereafter, the action of moisture absorbed from the air during the period from the application of the adhesive to the overlapping. Cures and adheres completely. If the air is dry and the curing is slow, measures such as spraying water vapor between the application of the adhesive and the superposition may be taken. This adhesive has considerable adhesive strength when it is fixed by cooling and solidification, without waiting for complete curing, so it can be transported, stacked, and post-processed as it is, which is convenient in terms of productivity. Is good.
[0031]
When using an electron beam-curable adhesive, an adhesive is applied on the base plate 3 and / or the back surface of the decorative sheet 1 and the base plate 3 and the decorative sheet 1 are overlapped. The adhesive may be cured by irradiating an electron beam from the surface side of the adhesive. Since this adhesive is completely cured almost instantly by irradiation with an electron beam, a curing step for reactive curing of the adhesive is not required at all. Further, the curing treatment by electron beam irradiation is usually possible at a high speed of several tens to several hundreds of meters per minute, so that the production efficiency is extremely high.
[0032]
As shown in FIG. 2, the decorative plate of the present invention can be subjected to groove processing 4 and / or chamfer processing 5. If the depth of the groove processing 4 and the chamfering processing 5 is set to a depth from the surface of the decorative sheet 1 to the inside of the adhesive layer 2 but not to the base plate 3, the surface of the decorative plate may be wet with water. Even if there is, the water does not seep into the base plate 3 and the swelling or peeling of the decorative surface does not occur. In this manner, there is an advantage that a decorative plate having a three-dimensional design by the groove processing 4 and the chamfering processing 5 and also having excellent water resistance can be obtained.
[0033]
Further, when the adhesive layer 2 is colored in a color tone similar to that of the decorative sheet 1, the color tone of the adhesive layer 2 exposed at the portion where the groove processing 4 or the chamfering processing 5 is performed is different from the color tone of the decorative sheet 1. Since there is no sense of incongruity in comparison, there is an advantage that a decorative plate excellent in design can be easily obtained without necessitating a new coloring treatment such as painting on the four grooved portions and the chamfered five portions.
[0034]
As the cross-sectional shape of the grooved portion 4 and the chamfered portion 5, the same shape as that used in the same type of decorative board of the related art can be arbitrarily adopted. For example, as the cross-sectional shape of the four grooved portions, a V-shaped, U-shaped, semi- (elliptical) or a V-shaped groove with a corner between the inclined surface and the upper surface formed as a curved surface convex upward. (A so-called R groove) and the like, and the five chamfering portions have a slope shape (C chamfering), an upwardly convex curved surface shape (R chamfering) and the like. As a processing method of the groove processing 4 and the chamfering processing 5, a cutting method using a cutting tool such as a plane, a chisel, a saw, a file, and a router is generally used.
[0035]
【Example】
Example 1
A 170 μm thick polyolefin-based resin-coated wood-patterned decorative sheet is coated with a opaque one-pack moisture-curable hot-melt adhesive (J-6574, manufactured by Nippon Fuller Company) having a similar color to the decorative sheet. It was applied at 135 μm, adhered to the surface of a base plate made of a medium fiberboard (MDF) having a thickness of 5.5 mm, cooled and solidified, and then cured and cured at room temperature. Thereafter, from the surface of the decorative sheet, a V-shaped groove having a depth of 220 μm was cut and formed with a router so as to reach the adhesive layer but not to the base plate. Was prepared.
[0036]
In the decorative plate, the adhesive layer exposed in the grooved portion was colored in the same color as the decorative sheet, and the base plate was not seen through, so that no design defect was felt. Further, the durometer hardness of the surface of the decorative plate and the base plate before the decorative sheet was bonded was measured with a hardness tester (DD2, manufactured by Kobunshi Keiki Co., Ltd.). The decorative board of the invention was superior in surface hardness. Further, 5 cc of water droplets were dropped on the grooved portion on the surface of the decorative plate, covered with a watch glass to prevent drying, and allowed to stand for 24 hours. However, there was no evidence that water had penetrated the base plate. No swelling or peeling of the sheet occurred.
[0037]
Example 2
In Example 1 above, instead of the one-component moisture-curable hot-melt adhesive, an opaque electron beam-curable adhesive (manufactured by BASF: LR8555) having a similar color to the decorative sheet was used. Immediately after lamination, the decorative sheet of the present invention was produced in the same manner as in Example 1 except that the decorative sheet was irradiated with an electron beam (4 MRad) from the front side and cured. The design and the water resistance of this decorative board were the same as those of the decorative board of Example 1 described above, and there was no problem at all, and the durometer hardness of the surface was 72.
[0038]
Comparative Example 1
In Example 1 above, a non-colored urethane-modified vinyl acetate copolymer-based aqueous emulsion adhesive (manufactured by Konishi Co., Ltd .: CVC555) was applied to a thickness of 30 μm after drying instead of the one-component moisture-curable hot melt adhesive. Otherwise, a decorative board was produced in the same manner as in Example 1 above. In this decorative plate, the base plate was exposed at the bottom of the grooved portion, and the color tone of the exposed base plate and the adhesive layer was different from the color tone of the decorative sheet, so that the design was uncomfortable. In addition, the durometer hardness of the surface was 58, which was lower than that of the medium fiberboard (62) as the base plate, the scratch resistance was insufficient, and the water resistance test was performed in the same manner as in Example 1 above. In addition, water seeped into the base plate, swelling occurred near the grooved portion, and peeling of the decorative sheet from the base plate was also observed from the cut surface of the decorative sheet in the grooved portion.
[0039]
【The invention's effect】
As described above, the decorative board of the present invention can be manufactured by a simple process of simply bonding the base plate and the decorative sheet with an adhesive, and does not require auxiliary materials such as a hard resin board, so that the weight is reduced. It is a decorative board that is not bulky and has excellent surface hardness and scratch resistance, and can be used as a floor material or a stair tread. Furthermore, even if groove processing or chamfering processing is performed, if the depth is set to a level that does not reach the base plate, the water resistance does not decrease, and the adhesive is appropriately colored so that the groove can be formed. The present invention has various excellent effects, such as that a processed board or a chamfered section does not need to be subjected to a coloring treatment such as painting later, and that a decorative board having a design-like uncomfortable feeling can be easily manufactured.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view of an example of a decorative board according to the present invention.
FIG. 2 is a schematic cross-sectional view of an example of the decorative board of the present invention.
[Explanation of symbols]
1 Base plate 2 Adhesive layer 3 Decorative sheet 4 Groove processing 5 Chamfering processing

Claims (7)

A decorative board comprising a decorative sheet having a decorative sheet laminated on a base plate via an adhesive layer, wherein the hardness of the adhesive layer is higher than the hardness of the base plate. The decorative board according to claim 1, wherein the base plate is made of a wooden material. The decorative board according to claim 1, wherein the adhesive layer is made of a one-component moisture-curable hot melt adhesive or an electron beam-curable adhesive. The decorative board according to any one of claims 1 to 3, wherein the adhesive layer has a thickness of 50 µm or more. The decorative board according to any one of claims 1 to 4, wherein the adhesive layer has a durometer hardness of 50 to 80. The decorative board according to any one of claims 1 to 5, wherein the adhesive layer is colored. The decorative plate according to any one of claims 1 to 6, wherein a groove process and / or a chamfer process that does not reach the base plate is performed from the decorative sheet surface to the adhesive layer.

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