JP2005288861A - Method for manufacturing thin decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a thin decorative material which can be actually processed and has a required actual strength even when it is an ultrathin decorative material with a thickness of 2-4 mm. <P>SOLUTION: Both faces of a semi-cured mat molded so that only an actual forming part becomes thick, are respectively coated with a flexible resin water solution with a resin ratio of 10-60% at a ratio of ≥300 g/m<SP>2</SP>, and it is consolidation-pressed by flat plates under a high temperature and high pressure condition. An actual part is formed at a part with a higher specific gravity among a resin-reinforced fiberboard with the specific gravity of 1.2-1.7 and a thickness of 2-4 mm. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a thin plate decorative material, and more particularly to a method for manufacturing a thin plate decorative material having a strengthened real part.

  In general, a decorative material used for a wall material, a floor material or the like is generally subjected to actual processing on a joint portion. In this case, cutting is performed with a saw or the like on the end face of the inorganic plate formed to have a uniform thickness, and the fruit is formed. However, if a rock wool compacted plate or the like is a base material, the strength of the real part is significantly lowered by the cutting of the saw, and therefore, reinforcement such as applying a resin only to the real part is performed.

  However, when used as a flooring material, a continuous load is applied to the real part due to the bending of the ground caused when a load is applied, and therefore breakage easily occurs. In order to solve such problems, the present applicant has proposed a flooring material having a specific gravity higher than that of the conventional inorganic mat by impregnating the entire inorganic mat with a large amount of an aqueous soft resin solution and performing compaction pressing. Patent Documents 1 and 2).

  However, the soft water-soluble resin is not impregnated in all layers, and is mainly present in the front and back layers. Therefore, attempts have been made to add a penetrant to the water-soluble resin liquid in order to impregnate the water-soluble resin liquid up to the center layer, or to impregnate the resin liquid into an inorganic mat having a hole. However, even if these measures were taken, the resin reinforcement was inclined such that most of the resin was present in the front and back layers and the center layer was small. For this reason, there is no problem as long as the actual shape is a shape that makes use of the surface layer such as the overlapped shape, but in the real part of the actual shape, the front and back layers that are reinforced with resin are deleted by cutting. It becomes a real structure with low strength. In order to solve this, it is conceivable to press the entire layer at a higher density with a higher pressure.

However, when adjusting to the target thickness, it is necessary to stack more mats, and parts that do not need to be reinforced are reinforced, which is wasteful. Further, in order to increase the overall specific gravity, it is necessary to apply a large amount of an aqueous soft resin solution. For this reason, in order to consolidate to a desired thickness, a very large pressure is required, and there is a manufacturing problem that equipment is large and puncture is likely to occur.
Japanese Patent Application No. 2003-95444 Japanese Patent Application No. 2003-116975

  In view of the above problems, the present invention efficiently increases the specific gravity only by increasing the specific gravity of the part to be actually processed, and this actual processing is possible even for ultra-thin cosmetic materials of 2 to 4 mm. An object of the present invention is to provide a method for producing a thin plate decorative material having a desired actual strength.

Means for Solving the Problems and Effects of the Invention

According to the method for manufacturing a thin decorative sheet according to the present invention, a soft resin aqueous solution having a resin rate of 10 to 60% is applied to 300 g / m ² on both sides of a semi-cure mat formed so that only the actual forming part is thick. It is applied at a ratio, and is pressed with a flat plate under high temperature and high pressure conditions, and is adjusted to a specific gravity of 1.2 to 1.7 and a thickness of 2 to 4 mm. It consists of a process of forming fruit.

  According to the present invention, it is possible to efficiently increase only the specific gravity of only the actual forming part and to obtain a thin plate decorative material having only the actual forming part having sufficient strength. For this reason, the manufacturing effect that it becomes difficult to generate | occur | produce puncture without requiring a large sized installation like a prior art example is also acquired.

As an embodiment of the present invention, a semi-cure mat is a wet papermaking slurry containing 35 to 70% by weight of mineral fiber, 25 to 55% by weight of an inorganic powder, and 5 to 25% by weight of a binder as essential components. Then, the wet mat obtained by dehydration may be semi-cured by hot pressing and then dried to obtain a water content of 10% or less and a specific gravity of 0.3 to 0.9.
According to this embodiment, continuous production is possible by wet papermaking, and a thin plate decorative material with high productivity is obtained.

As another embodiment of the present invention, a molding plate having at least one notch portion at a lower end edge is installed in the vicinity of the papermaking exit where the slurry is placed on the long net, and the molding plate is formed when the slurry is subjected to wet papermaking. By passing through, at least one ridge which becomes the actual forming portion may be formed on the surface of the wet mat.
According to this embodiment, the protrusion which becomes a real formation part can be continuously manufactured simultaneously with papermaking on the surface of a wet mat, and the manufacturing method of a thin-plate decorative material with higher productivity is obtained.

As another embodiment of the present invention, cutting is performed on the surface of a semi-cured mat that is uniformly manufactured, and the protrusions that are the actual forming portions are formed on the surface of the semi-cured mat. Even when surface uniform compaction is performed, a portion that becomes an actual forming portion can be manufactured with high dimensional accuracy.

As a new embodiment of the present invention, a soft resin aqueous solution having a resin ratio of 10 to 60% is applied to both sides of a semi-cured mat at a rate of 300 g / m ² or more, and then a part of the semi-cured mat is thickened. A soft resin aqueous solution having a concentration higher than that of the soft resin aqueous solution may be applied only to the formed portion, and consolidation pressing may be performed with a flat plate under high temperature and high pressure conditions.
According to this embodiment, since the specific gravity of the part used as an actual formation part becomes still higher, the thin sheet | seat decorative material whose actual intensity | strength is still higher is obtained.

In another embodiment of the present invention, an actual formation portion having a high specific gravity may be colored.
According to this embodiment, there is an effect that it becomes a mark of actual processing at the time of post-processing such as mounting or makeup processing, and the position of actual processing is easy to understand.

The manufacturing method of the thin-plate decorative material concerning this invention is a case where it applies to a flooring, and is manufactured in the following procedures.
That is, a soft resin aqueous solution having a resin ratio of 10 to 60% is applied to both sides of a semi-cure mat formed so that only the actual forming part is thick, and is applied at a rate of 300 g / m ² or more. In the resin-reinforced fiberboard obtained by performing compaction pressing and adjusting to a specific gravity of 1.2 to 1.7 and a thickness of 2 to 4 mm, fruit is formed in a portion having a high specific gravity.

In particular, a semi-cured mat formed so that only the actual formed portion is thick is manufactured by the following procedure.
Put mineral fiber, inorganic powder and binder into water, add additives such as water repellent, antifoaming agent and pigment to this, stir, then add auxiliary additives such as flocculant, solid content A slurry with a rate of several percent is obtained. And a semi-cure mat is obtained by dehydrating the wet mat obtained by making the slurry with a long-mesh type or a round net-type machine, and drying it with a hot-air ventilation dryer. However, if temporary pressing (80 to 110 ° C., 5 to 77 kg / cm ² , 30 to 150 seconds sec) is performed before drying, the rigidity of the semi-cured mat is increased and handling properties are improved.

  Examples of mineral fibers include rock wool, slag wool, mineral wool, glass wool, and glass fiber, and these are used alone or in combination. The amount of mineral fiber added is preferably 35 wt% to 70 wt%, particularly 45 to 60 wt%. This is because if the mineral fiber is less than 35%, the bending strength of the obtained semi-cured mat becomes very weak, and the handling property of the semi-cured mat becomes very poor. Moreover, when the mineral fiber exceeds 70% by weight, the amount of inorganic powder added relatively decreases, and water or a resin diluted with water is applied to the semi-cured mat, and the compaction press is performed again. This is because it is difficult to increase the density.

In addition, when 1 to 15% by weight of heat-resistant organic fiber having a length of 1.0 to 15 mm is mixed in place of the mineral fiber, it is very effective in improving cracks and chips during cutting of a thin decorative sheet. is there. Here, the heat-resistant organic fiber is a fiber that does not melt even when heated at 150 to 200 ° C., for example, nylon, tetron, polyamide, polypropylene, polyethylene terephthalate, polyurethane, various rubber fibers, composites thereof, or wood fibers. Conceivable.
The addition amount of the heat-resistant organic fiber is preferably 0.5% by weight to 15% by weight. This is because if the amount added is less than 0.5% by weight, the effect of improving the strength is hardly observed. In addition, if the addition amount exceeds 15% by weight, not only does it cause a cohesion failure during papermaking, it becomes a semi-cured mat with non-uniform density, but the specific gravity does not increase when the semi-cured mat is pressed again. This is because the strength decreases.
Further, the length of the heat resistant organic fiber is preferably 1.0 to 15 mm. If the length is less than 1.0 mm, there is almost no effect of improving the strength. If the length exceeds 15 mm, a cohesive failure occurs during the paper making, resulting in a semi-cured mat with non-uniform density. is there.
The thinner the heat-resistant organic fiber is, the smaller the thickness becomes, and the uniform dispersion at the time of papermaking becomes possible. Generally, the thickness is 500 μm or less, preferably 300 to 100 μm.

  Examples of the inorganic powder include shirasu foam, silica flour, glass foam, calcium carbonate, aluminum oxide, vermiculite and the like, and these are used alone or in combination. The added amount of the inorganic powder is preferably 35 to 50% by weight.

Examples of the binder include melamine resin, phenol resin, epoxy resin, isocyanate resin, polyvinyl alcohol, acrylic emulsion or vinyl acetate emulsion or modified products thereof, starch, corn starch, soybean flour, wheat flour, etc. Used alone or in combination. The polyvinyl alcohol, vinyl acetate emulsion or modified products thereof, starch, corn starch, soy flour, wheat flour, etc. are desirably 5% by weight or less because the water resistance of the finally obtained flooring material becomes worse when the amount added is increased. . Also, for example, binders with excellent water resistance such as melamine resin, phenol resin, and epoxy resin are not completely cured by heat at 80 ° C. to 110 ° C. during semi-cure, and are pressed at a high temperature and high pressure of 150 to 250 ° C. The floor material finally obtained exhibits excellent water resistance by being completely cured. Furthermore, these water-resistant resins are very expensive, and it is not desirable to add more than 20% by weight of resin.
For the above reasons, at least two types of binders are used in combination: a binder that has the effect of improving the handleability of the inorganic mat and a binder that has the effect of improving the water resistance of the finally obtained flooring. It is desirable. From the viewpoint of cost and water resistance, it is not preferable to add a total amount exceeding 25% by weight at the maximum. However, phenolic resins can contribute to any of the aforementioned properties and are a preferred binder.

  As a method for forming the protrusions that are the actual forming portions on the surface of the semi-cured mat, for example, when making the slurry, a forming plate having a notch at the lower end edge is installed near the slurry outlet. And you may provide the protrusion which becomes an actual formation part by allowing the said shaping | molding board to pass through a wet mat | matte, and leaving a slurry component thickly only in the part which passes the said notch part.

  In addition, the surface of the semi-cured mat having a specific gravity of 0.3 to 0.9, which has been wet-made and uniformly dehydrated, semi-cured, and dried, is cut only in the actual forming portion. You may shape | mold so that the thickness of may become thicker than the thickness of another part. Cutting can also be performed by a machine such as a planer that can regulate the thickness or by a saw.

The obtained wet mat is hot-pressed and semi-cured. The semi-cure is performed under hot press conditions of 3 to 7 kg / cm ² and 60 to 120 ° C. for about 40 seconds to 5 minutes. The press used for semi-cure may be a single-stage or multi-stage batch press, or a continuous hot-press belt press, but preferably a continuous hot-press belt press. used.

  After semi-curing, drying with a hot air dryer or the like set to about 80 to 250 ° C., and adjusting the moisture content to 10% or less, a semi-cured mat having a specific gravity of 0.3 to 0.9 is obtained. .

  Since the amount of the mat placed on only a part of the portion where the fruit is formed is large, only the part of the actual formation becomes a plate having a high specific gravity even if semi-cured with a flat plate. However, since the spring back is strong only in the actual forming part, even when semi-curing with a flat plate, only the actual forming part can be a slightly thicker plate.

  Uniform surface resin by applying a soft resin aqueous solution to the front and back surfaces of the semi-cure mat formed so that the actual forming part is thick, and pressing the plate under high temperature and high pressure conditions using a flat plate hot plate. A reinforced fiberboard is obtained. At this time, a surface-uniform plate having a high specific gravity around the actual forming portion can be obtained. In this case, even if the specific gravity is increased by 2 to 3%, there is an effect. However, it is preferable that the specific gravity is preferably increased by 5% or more.

  A soft resin aqueous solution diluted with water is applied to the front and back surfaces of the above-mentioned semi-cured mat, and is pressed again under higher temperature and pressure conditions than when semi-cured, and has an average specific gravity of 1.2 to 1.7 and a thickness of 2 Adjust to ~ 4mm resin reinforced inorganic board.

  As the soft resin aqueous solution, any water-soluble resin can be used. For example, vinyl urethane, acrylic emulsion, vinyl acetate emulsion or latex emulsion and modified products or mixtures thereof are preferable. In particular, latex emulsion is preferably used by being mixed with a small amount (about 5 to 25%) of another resin liquid in order to give the resin reinforced fiber board a great effect of improving bending strength. However, as the amount of latex increases, the suitability of the sander deteriorates. Therefore, it is not preferable to add more than 25% by weight in the total resin ratio. Moreover, in order to improve the sander suitability, a small amount (5 to 25%) of a hard resin such as a melamine resin, a phenol resin, or an epoxy resin may be added. This is because if these hard resins are added in an excessive amount, the floor material becomes hard and brittle, which is not preferable. And it is preferable to dilute with water so that the resin ratio of the aqueous soft resin solution is 10 to 60% by weight, particularly 15 to 40% by weight. This is because if the resin ratio is less than 10% by weight, the effect of improving the dimensional stability and scratch resistance by the impregnating resin cannot be expected. Further, if the resin ratio exceeds 60%, the permeability of the resin liquid is deteriorated.

Semi-cure mats exhibit a certain level of water repellency due to the semi-cure of the adhesive, so in order to increase the permeability of the resin, the surface tension of the resin diluted with water is a kind of surfactant. Lowering the drug and increasing the permeability). In addition, when the resin diluted with water is impregnated, burrs (water and resin containing excess resin impregnated in the semi-cured mat at the time of pressing flow out of the mat at the time of hot pressing under high temperature and high pressure. , A state of curing around the resin-reinforced fiberboard) occurs. For this reason, it is necessary to apply | coat the quantity according to thickness and specific gravity. For example, in the case of a semi-cured mat having a thickness of 6 mm and an average specific gravity of 0.4, if the total amount of resin impregnated from the front and back surfaces exceeds 800 g / m ² , burrs start to occur, and if it exceeds 1200 g / m ² , A large amount of burr is generated. For this reason, in the case of a semi-cured mat having a thickness of 6 mm and an average specific gravity of 0.4, it is desirable to apply the resin to the front and back surfaces by 400 to 500 g / m ² (total 800 to 1000 g / m ² ). At this time, the formation of burrs can be significantly suppressed by providing a recess or a through-hole leading to the front and back surfaces in at least one of the front and back surfaces. In addition to the penetrant, a small amount of an antifoaming agent or a release agent may be added.

  A high-concentration soft resin aqueous solution to which a penetrant is added may be further applied only to the actual formation portion. The high concentration means a 40 to 80% soft resin aqueous solution, and a soft water-soluble resin having a resin ratio of 45 to 60% can be preferably used in consideration of permeability. Examples of the coating method include linear coating with a nozzle or the like, coating with a roll coater, and the like.

The compaction press under high temperature and high pressure to which the resin is applied is performed at a press schedule of 150 to 250 ° C., 10 to 30 kg / cm ² and about 3 to 30 minutes. In this case, before applying the high-temperature and high-pressure press, temporary pressing is performed at a pressure of about 0 to 5 kg / cm ² for several tens of seconds to 1 to 2 minutes, and after sufficient steam is blown, 15 to 20 kg / cm ² This pressing (main pressure) is effective in suppressing the generation of burrs. In this case, even when a large amount of resin exceeding 1200 g / m ² on one side is applied, almost no burrs are generated. When temporary pressing is performed, even if a large amount of resin of 1200 to 1800 g / m ² is placed, a suitable press that hardly generates burrs is possible. A batch-type single-stage or multi-stage hot-pressing machine is used because a long press with a uniform surface is required. In this consolidation press, a flat plate-shaped press plate is always used, and a plate obtained by this consolidation press is a plate having a uniform surface. However, according to the present invention, the average specific gravity at the periphery of the actual formation portion is 5% or more higher than the specific gravity of the other portions.

Moreover, it is preferable that the actually strengthened part is colored. Even when a flat surface plate is obtained by compaction pressing under high temperature and high pressure conditions, if the part with high density is colored, it will serve as a mark for the actual processing position, and the actual processing position will be known. It is because it becomes easy.
As a coloring method, when a semi-cured mat is continuously formed, it may be after papermaking and dehydration, or after semi-curing. Further, it may be before impregnating with the soft resin aqueous solution or after impregnating the soft resin aqueous solution. For example, when coloring a semi-cured mat produced from a slurry, a white pigment or the like is applied only to the portion that passes through the notch portion of the wet mat in accordance with the position of the notch portion of the molding plate provided with the notch portion. It may be colored by spraying a very small amount of the dispersed aqueous solution in the form of a mist. And, for example, when a semi-cured mat is wet-made and semi-cured after being dehydrated, only a very small amount of an aqueous solution in which a white pigment or the like is dispersed is sprayed only in the actual forming part after semi-curing. The portion adjusted to increase the density becomes easy to understand. In addition, for example, when a semi-cured mat is wet-made, dehydrated, semi-cured, and dried, and then a portion other than the actual forming portion is cut so that only the actual forming portion becomes thick, only the actual forming portion is colored. May be. Further, when a high concentration soft resin aqueous solution is applied only to the actual forming portion, the high concentration soft resin aqueous solution may be colored with a pigment or the like.

  And the decorative process is given to the single side | surface of the resin reinforced fiber board obtained in this way. For example, a sheet-like decorative material is affixed. Examples of the sheet-like decorative material include veneer, paper, resin-impregnated paper, and olefin sheet. Moreover, you may apply | coat on the above-mentioned sheet-like decorative material as another makeup | decoration process. Examples of the coating include urethane coating and UV coating.

  Furthermore, actual processing, groove processing, chamfering processing, and the like may be performed on the above-described sheet-shaped decorative material. For example, a 0.25 mm thick veneer is pasted, the surface is sanded, colored and UV-coated, and then a width-decision cutting, a four-round chamfering process and a mounting process are simultaneously performed with a saw. The actual machining at this time is performed on a portion whose specific gravity has been previously increased. In general, actual processing is carried out in phase, but with the present invention, it is possible to perform actual processing, particularly actual processing, even with a thin sheet decorative material of 4 mm or less, and sufficient Has real strength.

Example 1
50% by weight of rock wool as mineral fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch as binder, and 7% by weight of powdered phenol resin are put into water to obtain a slurry with 5% solid component. A small amount of an antifoaming agent was added thereto and stirred. This slurry was made with a long net paper making machine to obtain a wet mat. However, in the vicinity of the mat outlet where the wet mat is discharged, a molding plate having a lower end edge portion located at a depth of 1 cm from the mat surface and having a notch portion having a depth of 1 cm and a width of 2 cm in the middle is disposed. For this reason, when the wet mat passes through the molded plate, many slurry components remain only in the portions where the cutout portions are provided, and the wet mat becomes thick. The wet mat was dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. This wet mat was hot-pressed with a press schedule of 1 minute at 90 ° C. and 7 kg / cm ² to obtain a pre-semi-cure mat. This pre-semi-cured mat was cut into a size of an angle with a water cutter and further dried with a hot air dryer adjusted to 220 ° C. to obtain a semi-cured mat having a water content of 5%. The semi-cured mat had a thick portion of 6.5 mm and a thin portion of about 6.0 mm.

Then, a soft resin aqueous solution in which 1% by weight of a penetrating agent, 0.05% by weight of an antifoaming agent and 5% by weight of a release agent is added to an acrylic emulsion having a resin ratio of 35% diluted with water is used as the semi-cure mat. It applied to the front and back of this by the flow coater in the ratio of 60 g / scale angle. Next, a 3.0mm distance bar placed on both sides was sandwiched, and hot pressing was performed at 190 ° C and 5kg / cm ² for 1 minute, then at 190 ° C and 20kg / cm ² for 20 minutes. A 3.3 mm resin reinforced fiber board was obtained.

  The resin reinforced fiber board was sanded on both sides to obtain a 3.0 mm uniform resin reinforced fiber board. Further, an adhesive mixed with vinyl acetate emulsion and isocyanate was applied to the surface of the resin reinforced fiber board, and a 0.25 mm cover wet veneer was attached. Then, UV coating was applied to the surface of the cover wet veneer to obtain a thin plate decorative material. Subsequently, a groove having a length of 1.5 mm and a width of 2.5 mm was formed from the decorative surface in the middle of the thin sheet decorative material. And the part which forms the bottom of this groove | channel was cut out by the length of 2.0 cm, and the test body of thickness 1.7mm was obtained. The bending strength and specific gravity of this test body were measured. The measurement results are shown below.

Example 2
50% by weight of rock wool as mineral fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch as binder, and 7% by weight of powdered phenol resin are put into water to obtain a slurry with 5% solid component. A small amount of an antifoaming agent was added thereto and stirred. This slurry was made with a long net paper machine and dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. This wet mat was hot-pressed with a press schedule of 1 minute at 90 ° C. and 7 kg / cm ² to obtain a pre-semi-cure mat. This pre-semi-cured mat was cut into a size of an angle with a water cutter and dried with a hot air dryer adjusted to 220 ° C. to obtain a semi-cured mat having a water content of 5% and a thickness of 7.0 mm.

Cutting was performed at a depth of 1 mm from the surface so that a protrusion forming an actual forming portion having a width of 2.5 cm and a height of 1 mm remained in the middle of the surface of the semi-cured mat. Then, on the front and back surfaces of the cut semi-cure mat, a 1% by weight penetrant, 0.05% by weight defoaming agent, 5% by weight release agent in an acrylic emulsion with a resin ratio of 35% diluted with water The soft resin aqueous solution to which the agent was added was applied at a rate of 60 g / scale angle with a flow coater. Then, a 3.0mm distance bar placed on both sides is sandwiched, and hot pressing is performed at 190 ° C, 5kg / cm ² for 1 minute, and then at 190 ° C, 20kg / cm ² for 20 minutes. A 3.3 mm resin reinforced fiber board was obtained.

  The resin reinforced fiber board was sanded on both sides to obtain a 3.0 mm uniform resin reinforced fiber board. Further, an adhesive mixed with vinyl acetate emulsion and isocyanate is applied to the surface of the resin reinforced fiber board, a 0.25 mm cover wet veneer is pasted, and UV coating is applied to the surface side, and a thin plate decorative material Got. Next, a groove having a depth of 1.5 mm, a width of 2.5 mm, and a length was dug from the decorative surface in the middle of the thin sheet decorative material. And the part which forms the bottom of the said groove | channel was cut out by the length of 2.0 cm, and the test body of thickness 1.7mm was obtained. The specimen was measured for bending strength and specific gravity. The measurement results are shown below.

Example 3
50% by weight of rock wool as mineral fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch as binder, and 7% by weight of powdered phenol resin are put into water to obtain a slurry with 5% solid component. A small amount of an antifoaming agent was added thereto and stirred. This slurry was made with a long net paper machine and dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. This wet mat was hot-pressed with a press schedule of 1 minute at 90 ° C. and 7 kg / cm ² to obtain a pre-semi-cure mat. This pre-semi-cured mat was cut into a size of an angle with a water cutter and further dried with a hot air dryer adjusted to 220 ° C. to obtain a semi-cured mat having a water content of 5% and a thickness of 7.0 mm. . Further, cutting was performed at a depth of 1 mm from the surface so that a protrusion forming an actual forming part having a width of 2.5 cm and a height of 1 mm remained in the middle of the surface of the semi-cured mat.

On the front and back surfaces of the semi-cure mat that has been cut, 1% by weight penetrant, 0.05% by weight antifoaming agent, 5% by weight in acrylic emulsion with a resin ratio of 35% diluted with water using a flow coater A soft resin aqueous solution to which a release agent was added was applied at a rate of 60 g / angle. Furthermore, only 1% by weight of penetrant, 0.05% by weight of antifoaming agent and 10% by weight of release agent are added to 50% resin emulsion diluted with water only on the ridges that will be the actual forming part. 10 g of the high concentration soft resin aqueous solution was uniformly applied. Then, a 3.0 mm distance bar placed between both sides is sandwiched, and hot pressing is performed with a press schedule of 190 ° C. and 5 kg / cm ² for 1 minute, and further at 190 ° C. and 20 kg / cm ² for 20 minutes. A 3.3 mm resin reinforced fiber board was obtained.

  The resin reinforced fiber board was sanded on both sides to obtain a 3.0 mm uniform resin reinforced fiber board. And the adhesive agent which mixed vinyl acetate emulsion and isocyanate is apply | coated to the surface of the said resin reinforced fiber board, a 0.25 mm cover wet veneer is stuck, UV coating is given to the surface side, and it is a thin-plate cosmetics Got. A groove having a length of 1.5 mm and a width of 2.5 mm was dug in the middle of the thin decorative material. The portion forming the bottom of the groove was cut into a width of 2.0 cm and a length to obtain a test body having a thickness of 1.7 mm. The bending strength and specific gravity of this test body were measured. The measurement results are shown below.

Comparative Example 1
50% by weight of rock wool as mineral fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch as binder, and 7% by weight of powdered phenol resin are put into water to obtain a slurry with 5% solid component. A small amount of an antifoaming agent was added thereto and stirred. This slurry was made with a long net paper machine and dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. This wet mat was hot-pressed with a press schedule of 1 minute at 90 ° C. and 7 kg / cm ² to obtain a pre-semi-cure mat. This pre-semi-cured mat was cut into a size of an angle with a water cutter and dried with a hot air dryer adjusted to 220 ° C. to obtain a semi-cured mat having a water content of 5% and a thickness of 6 mm.

On the front and back surfaces of the semi-cured mat, a 1% by weight penetrant, 0.05% by weight antifoaming agent, and 5% by weight release agent are added to a 35% resin emulsion diluted with water using a flow coater. The added soft resin aqueous solution was applied at a rate of 60 g / angle. Then, a 3.0 mm distance bar placed between both sides is sandwiched, and hot pressing is performed with a press schedule of 190 ° C. and 5 kg / cm ² for 1 minute, and further at 190 ° C. and 20 kg / cm ² for 20 minutes. A 3.3 mm resin reinforced fiber board was obtained.

  The resin reinforced fiber board was sanded on both sides to obtain a 3.0 mm uniform resin reinforced fiber board. Further, an adhesive mixed with vinyl acetate emulsion and isocyanate is applied to the surface of the resin reinforced fiber board, and a 0.25 mm cover wet veneer is pasted, and UV coating is applied to the surface side of the sheet decorative material. Obtained. A groove having a length of 1.5 mm and a width of 2.5 mm was dug in the middle of the thin decorative material. Next, the portion forming the bottom of the groove was cut out to a width of 2.0 cm and a length to obtain a test body having a thickness of 1.7 mm. The bending strength and specific gravity of this test body were measured. The measurement results are shown below.

Measurement result Bending strength (Number of specimens N = 3 average)
Example 1: MOR 65.8N / mm ² , MOE 7.1kN / mm ²
Example 2: MOR 64.2 N / mm ² , MOE 7.2 kN / mm ²
Example 3: MOR 78.5N / mm ² , MOE 8.3kN / mm ²
Comparative Example 1: MOR 29.1N / mm ² , MOE 3.9kN / mm ²
MOR represents the maximum bending fracture strength, and MOE represents the bending Young's modulus.

Specific gravity (number of specimens N = 3 average)
Example 1: 1.57 (11.3% up compared to Comparative Example 1)
Example 2: 1.55 (up 9.9% compared to Comparative Example 1)
Example 3: 1.62 (up 14.9% compared to Comparative Example 1)
Comparative Example 1: 1.41

  Example 1 which is a thin plate decorative material in which an actual forming part is formed during wet papermaking, Example 2 which is a thin plate decorative material in which the actual forming part is formed by cutting during semi-cure mat, and only the actual forming part in Example 2 In Example 3 in which a high-concentration soft resin aqueous solution with a resin ratio of 60% was applied to all, the resin reinforcement as a whole was performed, but from Comparative Example 1 which is a thin plate decorative material that does not reinforce the actual forming part Was also found to have a large bending strength. In particular, it was revealed that Example 3 in which a high-concentration soft resin aqueous solution was applied to the actual forming portion had the largest bending strength.

The method for producing a thin decorative sheet according to the present invention can be used not only for flooring but also for walling.

Claims (6)

On both surfaces of the molded semi-cured mat so that only the actual forming portion is increased, the resin ratio 10% to 60% of the soft resin solution was applied respectively 300 g / m ² or more percentage of consolidation in the flat plate at high temperature and high pressure conditions Production of thin sheet decorative material characterized by forming a fruit in a high specific gravity portion of a resin reinforced fiber board obtained by pressing and adjusting to a specific gravity of 1.2 to 1.7 and a thickness of 2 to 4 mm. Method.   Semi-cure mat wet-forms a slurry containing 35 to 70% by weight of mineral fiber, 25 to 55% by weight of inorganic powder, and 5 to 25% by weight of binder, followed by dehydration. The thin plate makeup according to claim 1, wherein the wet mat obtained is semi-cured by hot pressing and then dried to have a water content of 10% or less and a specific gravity of 0.3 to 0.9. A method of manufacturing the material.   The surface of the wet mat is formed by placing a molding plate having at least one notch at the lower edge near the exit of the papermaking where the slurry is placed on the long mesh, and allowing the slurry to pass through the paper when wet forming the slurry. The method for producing a thin sheet decorative material according to claim 2, wherein at least one ridge forming an actual forming part is formed on the sheet.   4. The surface of a semi-cured mat that is manufactured to have a uniform surface is subjected to a cutting process to form protrusions that form actual forming portions on the surface of the semi-cured mat. Manufacturing method for thin sheet decorative material. After applying a soft resin aqueous solution having a resin ratio of 10 to 60% on both sides of the semi-cured mat at a rate of 300 g / m ² or more, only the portion where the semi-cured mat becomes thicker than the soft resin aqueous solution. 5. The method for producing a thin plate decorative material according to claim 1, wherein a high-concentration soft resin aqueous solution is applied and compaction pressing is performed with a flat plate under high temperature and high pressure conditions. The method for producing a thin decorative sheet according to any one of claims 1 to 5, wherein an actual formed portion having a high specific gravity is colored.