JP2009233942A - Method for producing decorative plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To produce a decorative plate which is excellent in caster resistance, injury resistance, and decoration properties and suppresses the occurrence of a veneer splitting phenomenon. <P>SOLUTION: An adhesive layer 2 having elasticity in a cured state is formed on the surface of a woody substrate 1. While the adhesive layer 2 is semi-cured, a woody thin veneer 5 having an air dry water content or a high water content is laminated/unified on/with its surface through a paper layer 3. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a decorative board having excellent caster resistance.

Conventionally, as shown in, for example, Patent Document 1, as a method of manufacturing a flooring material in which a surface finishing material is attached to one side of a wooden board via an adhesive, a rubber adhesive and a resin are provided on one side of the wooden board. A method is known in which a mixed adhesive mixed with a system adhesive is subbed and dried, and then a surface finishing material is placed on the upper surface and adhered. When manufactured by this method, since a rubber adhesive is used, it is effective to prevent the floor board from being damaged when a chair or furniture with casters is moved.
JP 2003-21420 A

  However, in that case, when a wood thin veneer with a moisture content higher than the air dry moisture content (about 5 to 7%) is attached as a surface finish by a hot press, the single plate itself contracts due to shrinkage. There is a problem that cracks occur. This phenomenon is particularly prominent when a high moisture content wood veneer having a grain pattern is used.

  In addition, it is possible to form an adhesive layer with a uniform thickness by using a material with a substantially uniform surface, such as MDF, as the base material. However, a material with uneven surface or uneven suction, such as plywood, can be used. When used, the thickness of the adhesive layer under the thin wood veneer varies depending on the location due to unevenness of the surface and uneven suction, especially when the caster is used in the thinned adhesive layer Single plate peeling tends to occur.

  The present invention has been made in view of such points, and its purpose is to provide excellent caster resistance and a single plate cracking even when a material having uneven surface or uneven suction is used as a base material such as plywood. This is to obtain a decorative board excellent in scratch resistance and cosmetic properties in which the above phenomenon hardly occurs.

  In order to achieve the above object, according to the present invention, an adhesive layer having elasticity in a cured state is provided on the surface of a wooden substrate, and the surface of the adhesive layer is semi-cured, and the paper is applied to the surface. Air-dry moisture content or high moisture content wood thin veneer was laminated and integrated through the layers.

  Specifically, in the invention of claim 1, as a method for producing a decorative board in which a wood thin veneer is laminated and integrated on a surface of a wood substrate by a hot press through an adhesive, An adhesive layer forming step for forming a semi-cured adhesive layer by applying a base-side adhesive having elasticity in a cured state and semi-curing the surface, and a thin paper on the semi-cured adhesive layer A paper layer laminating step for placing and laminating paper layers, a single plate side adhesive applying step for applying a single plate side adhesive on the paper layer, and the wood thin veneer on the single plate side adhesive And laminating and integrating the laminate by hot-pressing the laminate, and the thickness of the adhesive layer is 30 μm or more and 75 μm or less, and the hardness of the adhesive layer is The hot-press press process to obtain a cosmetic base material of 30 ° or less with a type A durometer, and this cosmetic base Characterized in that it comprises a cosmetic process step for decorative processing on the surface of the.

  In the invention of claim 2, as a method for producing a decorative board in which a wood thin veneer is laminated and integrated by a hot press through an adhesive on the surface of the wood substrate, the surface of the wood substrate is cured. The adhesive layer forming process for forming a semi-cured adhesive layer by applying an elastic base material side adhesive and semi-curing, and applying the paper adhesive on the semi-cured adhesive layer And a paper layer laminating step in which thin paper is placed on the paper adhesive and laminating a paper layer, a single plate side adhesive applying step for applying a single plate side adhesive on the paper layer, and this single plate By laminating the wood thin single plate on the side adhesive to obtain a laminate, and by laminating and integrating the laminate by hot pressing, the thickness of the adhesive layer is 30 μm or more and 75 μm or less. And a decorative base material having a hardness of the adhesive layer of 30 ° or less with a type A durometer And Runetsu圧 pressing step, characterized in that it comprises a cosmetic process step for decorative processing on the surface of the decorative substrate.

  In these inventions of claim 1 or 2, the base material side adhesive is applied to the surface of the wooden base material to form a semi-cured adhesive layer, and the paper adhesive is applied directly or on the semi-cured adhesive layer. After the paper layer is laminated, the veneer side adhesive is applied, and the thin wood veneer is further laminated, and the laminated body is hot-pressed to be laminated and integrated to obtain a cosmetic base material. A decorative process is performed on the surface of the substrate to obtain a decorative board. At that time, since the base material side adhesive is in a semi-cured state, the base material side adhesive is prevented from seeping into the thin wood veneer.

  Moreover, the adhesive layer has a thickness of 30 μm or more and 75 μm or less and a hardness of 30 ° or less with a type A durometer, that is, a base material side adhesive in which the cured product is in such a state is used. In addition, since the paper layer and the thin wood veneer are laminated on the semi-cured adhesive layer, a sufficiently large thickness of the adhesive layer can be ensured. For this reason, a decorative board in which an adhesive layer having sufficient thickness and flexibility can be obtained, and peeling of the thin wood veneer is suppressed even when the caster is used for a long time.

  In the method for producing a decorative board according to claim 3, a semi-cured adhesive layer is formed by applying a base material-side adhesive having elasticity in a cured state and semi-curing the surface of the wooden substrate. An adhesive layer forming step, a paper layer laminating step of applying a paper adhesive on the semi-cured adhesive layer and placing a thin paper on the paper adhesive to laminate the paper layer; The thickness of the adhesive layer is 30 μm or more and 75 μm or less, and the hardness of the adhesive layer is 30 ° or less with a type A durometer. The first hot-pressing step, the single-plate-side adhesive applying step for applying the single-plate-side adhesive on the paper layer that has undergone the first hot-pressing step, and the wood thin unit on the single-plate-side adhesive. A laminating process for laminating plates to obtain a laminate, and laminating and integrating the laminate by hot pressing It is a second hot pressing step of obtaining a decorative substrate, characterized in that it comprises a cosmetic process step for decorative processing on the surface of the decorative substrate.

  In this invention of Claim 3, the base material side adhesive agent is apply | coated to the woody base material, and the adhesive layer of a semi-hardened state is formed, and a paper layer is formed on this semi-hardened state adhesive layer via a paper sticking adhesive. These are laminated, these are hot-pressed and laminated and integrated, and an adhesive layer is formed between the wood base material and the paper material by the base material side adhesive. Further, the veneer side adhesive is applied on the paper layer to laminate the thin wood veneer, and these are laminated and integrated again by hot-pressing to obtain a decorative base material. Processing is performed to obtain a decorative board. At that time, since the base material side adhesive is in a semi-cured state, the base material side adhesive is prevented from seeping into the woody thin single plate. Moreover, a semi-cured adhesive layer is formed on the wood substrate, and a paper layer and a thin wood veneer are laminated on the semi-cured adhesive layer, so that an adhesive layer having sufficient thickness and flexibility can be obtained. An interposed decorative board can be obtained, and peeling of the thin wood veneer is suppressed even when the caster is used for a long time.

  In invention of Claim 4, the wooden base material by the manufacturing method of the decorative board of any one of the said Claims 1-3 shall be plywood.

  In this invention of claim 4, since the semi-cured adhesive layer is formed on the plywood as the wood substrate, and the paper layer and the wood thin veneer are laminated on the semi-cured adhesive layer, the surface is uneven. Even if it is a plywood with uneven suction, the thickness of the adhesive layer can be sufficiently secured, and peeling of the thin wood veneer when using casters can be suppressed.

  According to a fifth aspect of the present invention, in the method for manufacturing a decorative board according to the first or second aspect, the surface of the wood thin veneer is formed by shot blasting after the hot-pressing step and before the decorative processing step. It further includes a float processing step of performing a float processing to a depth from the back of the wood thin single plate to the depth of the single plate side adhesive.

  In the invention of claim 6, in the method for manufacturing a decorative board according to claim 3, the surface of the wood thin veneer is formed by shot blasting after the second hot-pressing step and before the decorative processing step. In addition, the method further includes a float processing step of performing a float processing to a depth from the back of the wood thin single plate to the depth of the above-mentioned single plate side adhesive.

  In other words, in the floating process by the shot blasting method, the portion of the wood thin veneer that has oozed the adhesive becomes difficult to be ground. According to the above configuration, the depth of unevenness of the floating process is adjusted by adjusting the amount of soaking of the adhesive on the veneer side by applying the float process to the wood sheet veneer where the veneer side adhesive has soaked. Is determined.

  According to a seventh aspect of the present invention, in the method for manufacturing a decorative board according to the fifth or sixth aspect, in the decorative processing step, the wooden thin veneer subjected to the floating process is heated and floated on the wooden thin veneer. A transparent impregnating resin is applied, impregnated, and cured so as not to fill the recessed portion that has been processed. In this way, a decorative board having excellent scratch resistance and cosmetic properties can be obtained. Then, a colored filling resin is filled in the recesses, a surface uniform sander is applied, and a transparent coating film layer is formed on the surface, thereby obtaining a decorative plate having excellent surface surface scratch resistance and cosmetic properties. it can.

  As described above, according to the method for producing a decorative board of the present invention, an adhesive layer is provided on the surface of the wooden substrate, and the thin wooden board is laminated and integrated on the surface of the semi-cured adhesive layer via the paper layer. As a result, even if the base material is plywood, a stable and sufficient adhesive layer is ensured and caster resistance is excellent. A decorative veneer is obtained.

  Hereinafter, the best embodiment of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.

  FIG. 1 shows a process of a decorative board manufacturing method according to an embodiment of the present invention, and FIG. 2 shows a decorative board P manufactured by the manufacturing method. The decorative board P is used as a flooring. is there.

(Decorative board)
That is, in FIG. 2, 1 is a wood base material, 2 is an adhesive layer made of a base material side adhesive having elasticity in a cured state formed on the surface of the wood base material 1, and 3 is laminated on the adhesive layer 2 4 is a single plate side adhesive layer formed on the paper layer 3, and 5 is a wood thin single plate laminated on the single plate side adhesive layer 4. A decorative base 6 is formed, and a cosmetic process is applied to the surface of the decorative base 6.

(1) Wood base material The wood base material 1 may be, for example, wood, a wood fiber board such as an insulation board, MDF, or hard board, or a plywood or particle board.

  It is desirable that at least the surface of the wooden substrate 1 is hard. As a strengthening method for strongly reinforcing the surface of the wooden substrate 1, the surface layer may be simply impregnated with melamine resin, phenol resin, epoxy resin, urethane resin or isocyanate resin, or melamine resin. A reinforcing layer made of various resin-impregnated paper such as impregnated paper or phenol resin-impregnated paper may be provided on the surface layer. Also, instead of resin-impregnated paper, hard artificial resin wood mainly made of wood powder, wood fiber, wood slices, etc., and kneaded and molded with various resins, or hard wood fiber boards such as MDF, hardboard, etc. The surface may be reinforced with a wooden substrate.

  Moreover, you may stick hard wooden base materials, such as MDF and a hard board, on the surface, such as a plywood. In this case, the MDF, the hard board and the like may be reinforced with resin impregnation.

  In any case, the surface of the soft wooden substrate 1 needs to be strengthened so that it can withstand long-term and continuous use of casters.

(2) Adhesive layer The adhesive layer 2 is composed of a cured product of a soft base-side adhesive having a thickness of 30 to 75 μm and a hardness of 30 ° or less with a type A durometer. Thus, when the adhesive layer 2 has sufficient thickness and elasticity, peeling of the thin wood veneer 5 can be suppressed even for a long-term and continuous load of the caster.

  Examples of the base material side adhesive to be the adhesive layer 2 include acrylic resins, vinyl acetate resins, latex resins, rubber resins, vinyl urethane resins, urethane resins and modified products thereof, and these resins. And a mixture of urea melamine resin, epoxy resin, phenol resin, isocyanate resin and the like are preferably used.

  Furthermore, in order to increase the application amount of the base-side adhesive and form an appropriate adhesive layer, it is preferable to add various thickeners and extenders to increase the viscosity. As the thickener, for example, flour or poval is used. As the extender, calcium carbonate, alumina, titanium oxide or the like is used. Moreover, you may accelerate | stimulate sclerosis | hardenability by adding a hardening | curing agent suitably to a base material side adhesive agent. As the curing agent, a thermal reaction type or moisture curing type reaction initiator is appropriately added.

  Moreover, in order to improve the concealing property of the woody base material 1, various pigments may be added and colored to the base material side adhesive.

(3) Paper layer As the paper layer 3, the base-side adhesive oozes out easily on the surface of the paper layer by pressing without impeding the impregnation of the base-side adhesive and the single-plate-side adhesive described below. Paper having a thickness and weight per unit area that does not streak can be used. The paper layer 3 suppresses the penetration of the base material side adhesive into the woody thin veneer 5, and the paper layer 3 is impregnated and strengthened by the base material side adhesive and the veneer side adhesive. It has become.

The crack-resistant thin paper generally used has a thickness of about 30 to 60 μm and a weight per unit area of about 25 to 40 g / m ² , has directionality, and the fiber direction is parallel to the longitudinal direction. Yes. In this case, in order to prevent general cracks (surface cracks), the fiber direction is directed in a direction orthogonal to the base material 1 made of plywood. However, when a long decorative board having a longitudinal direction of 3 m or 4 m is manufactured, paper having such a width cannot be obtained.

Therefore, using a paper with increased thickness, the fiber directions are parallel. In this case, it is preferable to use a paper having a low directionality produced by long net-type papermaking. Since such a paper with less directionality has a lower strength than paper with directionality, a certain amount of thickness and weight per unit area are required. Furthermore, it is more preferable to mix chemical fiber with pulp. Specifically, a paper produced by long net-making with a ratio of pulp to rayon of about 7: 3 or 5: 5, a thickness of about 70 to 120 μm, and a basis weight of about 30 to 50 g / m ^2. Preferably used.

(4) Veneer side adhesive layer A hard veneer side adhesive is applied on the paper layer 3 to firmly adhere the paper layer 3 and the thin wood veneer 5 to the veneer side. It is preferable that the agent layer 4 is formed and the paper layer 3 and the wood thin veneer 5 are joined and integrated by the veneer side adhesive layer 4.

  The above single veneer-side adhesive is capable of realizing a desired strength when the laminated body in which the wood base material 1, the paper layer 3, and the wood thin veneer 5 are laminated by hot pressing. preferable.

  Specifically, as the single plate side adhesive, for example, acrylic resin, vinyl acetate resin, latex resin, rubber resin, vinyl urethane resin, urethane resin and their modified resins, urea melamine resin, Epoxy resins, phenol resins, isocyanate resins, etc., and mixtures of these resins are used. In order to effectively suppress cracking of the veneer due to dry and wet conditions when using the decorative board P, an adhesive having a hardened product such as urea melamine-based resin or isocyanate-based resin as a main veneer side adhesive is used as a main agent. It is preferable to use as. Moreover, you may accelerate | stimulate sclerosis | hardenability by adding a hardening | curing agent suitably to a veneer-side adhesive like a base material side adhesive.

  The amount of the single-plate adhesive applied is preferably the minimum amount necessary to prevent the wood thin single plate 5 from spreading. That is, it is preferable that the amount of stain on the wood thin veneer 5 of the veneer side adhesive is 50% or less of the thickness of the wood thin veneer 5, and by controlling the amount of stain in this way, a shot to be described later Floating process by the blast method can be performed effectively.

  The entire paper layer 3 is impregnated and strengthened by impregnating the base material side adhesive and the veneer side adhesive from both the front and back sides.

(5) Wood thin veneer As the wood thin veneer 5, a natural wood material or a thin slice obtained by slicing these laminates can be used. As the natural wood material, any material such as conifers, broad-leaved trees, so-called fast-growing trees can be used. Moreover, what sliced the laminated body of natural wooden material is what is called an artificial veneer.

  In addition, the wood thin veneer 5 can be a dry veneer or a raw veneer (so-called wet veneer). If the thickness of the wood thin veneer 5 is too thick, not only will it become hard, but the resistance to dry cracking of the veneer 5 itself will deteriorate, so the thickness of the wood thin veneer 5 is 0.15 to 1.0 mm. The degree is preferable, and the thickness of about 0.25 to 0.6 mm is more preferable in consideration of the subsequent floating process.

(Production method)
Next, the manufacturing method of the decorative board which concerns on embodiment of this invention is demonstrated. As shown in FIG. 1, this manufacturing method includes an adhesive layer forming step, a paper layer laminating step, a veneer side adhesive applying step, a laminating step, a hot press process, a float forming step, and a cosmetic processing step. .

(1) Adhesive layer formation process First, the base material side adhesive agent is apply | coated on the said wooden base material 1, The adhesive layer 2 of a semi-hardened state is formed by semi-hardening the base material side adhesive agent. As a means for applying the substrate side adhesive, a flow coater or a roll coater is preferably used. It applies so that the adhesive layer 2 of 30-75 micrometers thickness may be formed with this base material side adhesive agent.

  As a method of semi-curing the substrate side adhesive, for example, when a thermosetting adhesive is used, heating means such as infrared rays or a ventilating dryer is used. Further, for example, when an ultraviolet curable adhesive is used, a moisture curable or thermosetting reaction initiator is used in combination, and a semi-cured state is obtained by ultraviolet irradiation.

  The semi-cured state is a state where curing has progressed to the extent that no liquid adhesive is present, for example, only the surface of the adhesive is film-cured and there is an uncured liquid adhesive. Does not include state. It means a state in which the entire gelation of the adhesive has been completed and the surface thin wood veneer 5 can be bonded by a hot press process.

  For example, in the case of semi-curing by heat, the temperature is appropriately adjusted depending on the heating temperature and the heating time. For example, in the case of semi-curing by ultraviolet irradiation, the amount is appropriately adjusted depending on the ultraviolet irradiation amount and the ultraviolet irradiation time.

  If the curing is insufficient, an appropriate thickness of the adhesive layer 2 cannot be ensured, resulting in a decorative board having inferior caster resistance. Moreover, when hardening progresses too much, adhesion | attachment with the contact bonding layer 2 and the thin wood board 5 will be bad, and various malfunction will generate | occur | produce by a caster-proof test and a heat-resistant drying test.

(2) Paper Layer Laminating Step Next, a thin paper is placed on the semi-cured adhesive layer 2 to laminate the paper layer 3. The paper layer 3 can also be laminated by applying a paper adhesive on the semi-cured adhesive layer 2 and placing thin paper on the paper adhesive.

  Further, after the paper layer laminating step, the wood substrate 1, the adhesive layer 2 and the paper layer 3 may be preliminarily hot-pressed to be laminated and integrated (first hot-pressing step). There are various hot pressing methods such as a general roll press and a flat plate press, and a flat plate press is preferably used. The hot press is performed for 30 to 90 seconds at 100 to 130 ° C. and 0.2 to 1.0 MPa. Thereby, the base material side adhesive is completely cured, the thickness of the adhesive layer 2 is 30 μm or more and 75 μm or less, and the hardness of the adhesive layer 2 is 30 ° or less with a type A durometer. After the first hot press process, it is desirable to cool and cure.

(3) Single-plate-side adhesive application step A single-plate-side adhesive layer 4 is formed by applying a single-plate-side adhesive on the paper layer 3. The application means for applying the veneer side adhesive is not particularly limited. What is necessary is just to select the application | coating method according to the application quantity of the target single-plate side adhesive agent, for example, a roll coater, a flow coater, a spray etc. are suitable.

(4) Lamination process Next, the thin wood veneer 5 is laminated | stacked on the veneer side adhesive bond layer 4, and a laminated body is obtained. The wood thin veneer 5 placed may be temporarily fixed. As a method for temporary fixing, a method in which moisture in the temporarily fixed portion is blown off by high frequency or the like and the single plate side adhesive is solidified is preferably used.

(5) Hot-pressing step Further, the laminate is hot-pressed and laminated and integrated to obtain a decorative base 6. Even after the paper layer laminating step, the wood base material 1, the adhesive layer 2 and the paper layer 3 are hot-pressed and laminated and integrated (when the first hot-pressing step is performed), the veneer side adhesive is also used. Then, after the wood thin veneer 5 is laminated, hot pressing is performed again (second hot pressing process). The method of hot pressing is the same as the method described above. Thereby, the base material side adhesive and the veneer side adhesive are completely cured.

  At this time, the stain on the wood thin veneer 5 of the veneer side adhesive is 50% or less of the thickness of the wood thin veneer 5.

(6) Floating process Next, the surface of the decorative base 6 is subjected to a floating process by shot blasting to the depth from the back of the wood sheet veneer 5 of the veneer side adhesive to the part that has penetrated. . The shot blasting process is a process in which a hard and fine blasting abrasive is made to collide with the surface of the thin wood veneer 5 to make fine scratches on the surface. Thereby, the soft part of the wood thin veneer 5 is ground, a hard part remains, and the decorative base material 6 which has an unevenness | corrugation on the surface can be obtained.

  As abrasives for blasting, glass beads, glass powder, inorganic particles such as silicon, metal particles such as alumina, hard organic particles pulverized with walnuts and peach seeds, or dry ice particles pulverized with dry ice Is used. Such an abrasive for blasting is ejected from the nozzle and is made to collide with the surface of the decorative substrate 6 to carry out a floating process. Note that the decorative base 6 does not necessarily have to be floated.

(7) Cosmetic processing step Finally, various decorative processings are applied to the surface of the decorative base 6 with or without the float processing to obtain a decorative board. For example, the surface that has been float-processed may be colored, and a uniform transparent coating layer may be provided on the surface that is thin enough not to fill the unevenness by the float-process.

  Furthermore, as another method, the wood thin veneer 5 is coated and impregnated with a permeable resin on the wood veneer 5 that has been improved in impregnation by the shot blasting method, and then cured by ultraviolet curing, electron beam curing, heat curing, or the like. The resin may be impregnated and cured, and a uniform transparent coating layer may be provided on the surface with a thin film that does not fill the surface with unevenness by floating.

  As another method, the wood thin veneer 5 is made by applying and impregnating a permeable resin to the wood thin veneer 5 having improved impregnation property by the shot blasting method, followed by ultraviolet curing, electron beam curing, heat curing or the like. The resin is impregnated and cured. Further, a transparent colored filling resin is filled to such an extent that the surface is filled with unevenness processing by floating processing, and the surface is made uniform by ultraviolet curing, electron beam curing, heat curing or the like. A uniform transparent coating film layer with a thin film may be provided on the uniform surface by a transparent resin.

  In these cases, the permeable resin, the transparent colored filling resin, the transparent resin, etc. include acrylic, urethane, epoxy, polyester, vinyl urethane, vinyl acetate, urea-melamine, phenol, isocyanate. System resins and their modified products and mixtures are used.

  In particular, as a transparent colored filling resin subjected to a float process, it is preferable to add moisture curing properties and ultraviolet curing properties by adding a photoinitiator or an isocyanate moisture curing resin to them.

(Effect of embodiment)
Thus, according to the manufacturing method according to the embodiment of the present invention, the manufactured decorative board P has a thickness of 30 μm or more and 75 μm or less, and a hardness of 30 ° or less with a type A durometer. Since it has elasticity, the adhesive layer 2 that is flexible and has a sufficient thickness is interposed between the wood base material 1 and the wood thin veneer 5. In addition, when the decorative board P is manufactured, the semi-cured adhesive layer 2 is formed on the wooden substrate 1, and the paper layer 3 and the thin wood veneer 5 are laminated on the semi-cured adhesive layer 2. Even if the wooden substrate 1 is a plywood having irregularities and suction unevenness on the surface, the thickness of the adhesive layer 2 can be sufficiently ensured. As a result, even if the decorative board P uses a caster for a long period of time, the stress is dispersed and the peeling of the wood thin veneer 5 can be effectively suppressed.

  Further, by providing the paper layer 3 between the adhesive layer 2 and the wood thin veneer 5, the paper layer 3 is impregnated with the base material side adhesive to be the adhesive layer 2, and the wood thin veneer 5 is obtained. Suppression of the base material side adhesive can be suppressed.

  In addition, since the paper layer 3 and the wood thin veneer 5 are joined and integrated by the veneer-side adhesive, the paper layer 3 and the wood thin veneer 5 are firmly bonded, and the paper layer 3 is based on the whole. The material side adhesive and the veneer side adhesive are impregnated and reinforced.

  In addition, while suppressing the spread of the base material side adhesive to the woody thin veneer 5 and taking into account the suppression of the veneering of the veneer side adhesive to the woody thin veneer 5, this decorative board is shot. When the floating process is performed by the blast method, unevenness hardly occurs and the decorative board P having excellent design properties can be obtained.

  Moreover, the stain of the veneer side adhesive on the surface of the wood thin veneer 5 is made less than 50% of the thickness of the wood thin veneer 5 by making the stain on the veneer thin veneer 5 less than 50% of the thickness of the wood veneer 5 Not only is there no rise, but also the occurrence of unevenness can be more reliably suppressed during the float-making process by the shot blast method, and a decorative board P that is more excellent in design can be obtained.

  Furthermore, the depth of unevenness of the float-making process is determined by adjusting the amount of soaking of the adhesive on the veneer side by applying the float process to the wood sheet veneer 5 where the veneer-side adhesive has spread. Therefore, it is possible to effectively carry out floating processing.

  Next, specific examples will be described.

Example 1
A substrate plywood having a thickness of 11.5 mm, in which a plurality of single plates were stacked so as to be orthogonal to each other and the surface single plates were arranged in the longitudinal direction, was cut into a rectangle of 310 × 1850 mm. After applying 100 g / m ² of an ethylene vinyl based soft base adhesive to the surface of this base plywood, it is ventilated with a dryer at a temperature of 60 ° C. for 10 minutes and semi-cured to form an adhesive layer. did. This is cooled, 77 g / m ² of melamine paper adhesive is applied to the surface of the adhesive layer, and a thin paper with a basis weight of 25 g / m ² is placed thereon. As a coating, 77 g / m ² of a melamine-based hard adhesive was applied.

  On top of this, a wood grain thin veneer of rice bran having a thickness of 0.25 mm and an air dry moisture content (7%) is placed, and bonded by a hot press (120 ° C., 50 seconds, 0.8 MPa). The cosmetic base material was obtained.

  When this decorative base material surface was observed, there was no single plate cracking and it was in a good situation. A water-based colorant was applied to the surface, and after drying, a transparent coating layer having a uniform surface was formed on the surface with an acrylic ultraviolet curable coating.

  When a caster resistance test was performed on this surface, the amount of dents on the surface of the decorative board was about 0.1 mm, and there was no major problem. Furthermore, peeling of the veneer after the test was not observed. Moreover, when the heat-resistant drying test (80 degreeC * 24 hours) was done, there was no problem at all.

(Example 2)
The decorative base material obtained in Example 1 was subjected to shot blasting, and the soft part of the surface was ground to carry out floating processing. A transparent coating layer of a thin film with a uniform surface was provided on the surface with an acrylic UV-curing paint to such an extent that the surface was not filled with irregularities due to the floating process.

  A caster resistance test was performed on this surface. Since the float process was performed, the amount of dents could not be measured, but defects such as peeling of the veneer after the test were not observed. Moreover, when the heat-resistant drying test (80 degreeC * 24 hours) was done, there was no problem at all.

(Example 3)
The decorative base material obtained in Example 1 was subjected to shot blasting, and the soft part of the surface was ground to carry out floating processing. The decorative substrate was adjusted so that the surface temperature was 40 ° C., and 100 g / m ² of transparent penetrating resin was applied and impregnated on the surface. This transparent penetrating resin comprises 40 parts by weight of epoxy acrylate, 30 parts by weight of tripropylene glycol diacrylate, 30 parts by weight of 2-hydroxypropyl methacrylate, 20 parts by weight of hexamethylene diisocyanate, 10 parts by weight of polyol, 0.5 parts by weight of dye, 2-hydroxy-2-methyl-1-phenyl-propan-1-one (3 parts by mass) is blended.

  Then, it was allowed to stand for 60 seconds, and after all the impregnating resin had permeated, it was irradiated with ultraviolet rays to cure the resin in the single plate. Furthermore, after coating with a rubber coater to the extent that the irregularities due to the float process were filled, the surface was made uniform by filling with a transparent colored filling resin to the extent that the surface was uniform with an iron reverse coater. This transparent colored filler resin comprises 30 parts by weight of epoxy acrylate, 40 parts by weight of tripropylene glycol diacrylate, 5 parts by weight of acryloylmorpholine, 5 parts by weight of hexamethylene diisocyanate, 0.7 parts by weight of dye, bisacylphosphine 0 0.7 parts by mass and 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one.

  This surface was irradiated with ultraviolet rays to cure the transparent colored filling resin. Furthermore, after the surface uniform sander was given to the whole surface, the transparent coating layer of the thin film with a uniform surface was provided in this surface.

  When this surface was subjected to a caster resistance test, the dent amount was 0.08 mm, and there was no problem. In addition, defects such as peeling of the single plate after the test were not observed. Moreover, when the heat-resistant drying test (80 degreeC * 24 hours) was done, there was no problem at all.

(Comparative Example 1)
In the said Example 1, the cosmetic base material was obtained on the same conditions except not using a paper sticking adhesive and a thin paper.

  When the surface of this decorative base material was observed, the adhesive oozed out from the surface of the thin wood veneer, and on the other hand, the veneer cracks (cracks) occurred in some places. The layer was exposed.

  A water-based colorant was applied to the surface of this decorative substrate, and after drying, a transparent coating layer having a uniform surface was provided on the surface with an acrylic ultraviolet curable coating. In this case, it was only possible to obtain a decorative material with poor design, in which the adhesive layer was exposed in some parts from the part where the single plate was broken.

  This surface was subjected to a caster resistance test. The amount of dents on the decorative plate surface was about 0.1 mm, and there was no major problem. Moreover, when the heat-resistant drying test (80 degreeC * 24 hours) was conducted, the crack (coating film crack) had generate | occur | produced in the places of the transparent coating-film layer surface.

(Comparative Example 2)
In Example 1, the base material adhesive is not semi-cured (cured for 10 minutes by ventilation at 60 ° C. and then semi-cured and then cooled, and 77 g / m ² of melamine-based paper adhesive is applied to the surface of the adhesive layer. A cosmetic base material was obtained under the same conditions except that the coating process was not performed. When the surface of this decorative base material was observed, a decorative base material having a suitable design appearance could be obtained.

  A water-based colorant was applied to the surface of this decorative substrate, and after drying, a transparent coating layer having a uniform surface was provided on the surface with an acrylic ultraviolet curable coating.

  Moreover, when the heat-resistant drying test (80 degreeC * 24 hours) was done, there was no problem at all.

  However, when a caster resistance test was conducted on this surface, peeling was observed on the veneer surface. When the cross section of the peeled portion was observed, only 15 μm was formed where the adhesive layer was the thinnest.

  INDUSTRIAL APPLICATION This invention is very useful in the manufacturing method of a decorative board utilized as a flooring excellent in caster resistance, and its industrial applicability is high.

FIG. 1 is a process diagram showing a method for manufacturing a decorative board according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of a decorative board to be manufactured.

Explanation of symbols

P veneer 1 wood substrate 2 adhesive layer 3 paper layer 4 veneer side adhesive layer 5 wood thin veneer 6 veneer substrate

Claims (7)

A method for producing a decorative board, in which a wood thin veneer is laminated on a surface of a wood substrate by a hot press through an adhesive,
An adhesive layer forming step for forming a semi-cured adhesive layer by applying a semi-cured base material side adhesive having elasticity in a cured state to the surface of the wooden substrate;
A paper layer laminating step of placing a thin paper on the semi-cured adhesive layer and laminating the paper layer;
A veneer side adhesive application step of applying a veneer side adhesive on the paper layer;
A laminating step of laminating the wood thin veneer on the veneer side adhesive to obtain a laminate;
A decorative base material in which the thickness of the adhesive layer is 30 μm or more and 75 μm or less, and the hardness of the adhesive layer is 30 ° or less with a type A durometer, by hot-pressing the laminate and integrating the layers. And hot press press
A method for producing a decorative board, comprising: a cosmetic processing step of performing cosmetic processing on the surface of the decorative base material. A method for producing a decorative board, in which a wood thin veneer is laminated on a surface of a wood substrate by a hot press through an adhesive,
An adhesive layer forming step for forming a semi-cured adhesive layer by applying a semi-cured base material side adhesive having elasticity in a cured state to the surface of the wooden substrate;
A paper layer laminating step of applying a paper adhesive on the semi-cured adhesive layer and placing a thin paper on the paper adhesive to laminate the paper layer;
A veneer side adhesive application step of applying a veneer side adhesive on the paper layer;
A laminating step of laminating the wood thin veneer on the veneer side adhesive to obtain a laminate;
A decorative base material in which the thickness of the adhesive layer is 30 μm or more and 75 μm or less, and the hardness of the adhesive layer is 30 ° or less with a type A durometer, by hot-pressing the laminate and integrating the layers. A hot press process to obtain
A method for producing a decorative board, comprising: a cosmetic processing step of performing cosmetic processing on the surface of the decorative base material. An adhesive layer forming step for forming a semi-cured adhesive layer by applying a semi-cured base material side adhesive having elasticity in a cured state on the surface of the wooden substrate;
A paper layer laminating step of applying a paper adhesive on the semi-cured adhesive layer and placing a thin paper on the paper adhesive to laminate the paper layer;
The wood substrate, the adhesive layer, and the paper layer are laminated together by hot pressing, so that the thickness of the adhesive layer is 30 μm or more and 75 μm or less, and the hardness of the adhesive layer is 30 with a type A durometer. A first hot-pressing step of less than or equal to °;
A single-plate-side adhesive application step of applying a single-plate-side adhesive on the paper layer that has undergone the first hot-pressing step;
A laminating step of laminating a thin wood veneer on the veneer side adhesive to obtain a laminate;
A second hot-pressing step of obtaining a decorative base material by hot-pressing the laminated body and integrating the layers;
A method for producing a decorative board, comprising: a cosmetic processing step of performing cosmetic processing on the surface of the decorative base material.   The method for producing a decorative board according to any one of claims 1 to 3, wherein the wooden substrate is plywood. In the manufacturing method of the decorative board of Claim 1 or 2,
After the hot-pressing process and before the decorative processing process, the surface of the wood thin veneer is floated on the surface of the wood thin veneer to the depth from the back of the wood thin veneer to the portion that has penetrated by the shot blast method. A method for producing a decorative board, further comprising a float processing step of performing a manufacturing process. In the manufacturing method of the decorative board of Claim 3,
After the second hot-pressing step and before the cosmetic processing step, by shot blasting, the surface of the wood thin veneer is deepened up to the depth from the back of the wood thin veneer on the veneer side of the wood veneer. A method for producing a decorative board, further comprising a float process step for performing a float process. In the manufacturing method of the decorative board of Claim 5 or 6,
In the decorative process, with the heated wooden thin veneer, a transparent impregnated resin is applied, impregnated and cured so as not to fill the recessed concave portion of the wooden thin veneer. A method for producing a decorative board characterized by the above.

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