JP2913717B2 - Shaped sheet and method of manufacturing decorative board using the shaped sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial application field> The present invention relates to a shaped sheet used for manufacturing decorative boards widely used for furniture, desks, tables, building interiors, and the like, and uses the shaped sheet. The present invention relates to a method for producing a decorative panel.

<Prior art> Conventionally, when manufacturing this type of decorative board, first, in order to obtain a decorative board having an embossed pattern or a patterned pattern with a change in gloss formed on the surface, it is necessary to determine the embossed shape of the surface. It is manufactured using a shaped plate such as an embossed metal plate or an embossed resin plate.

Specifically, as shown in FIG. 3, in a high-pressure melamine resin decorative plate which is an example of a thermosetting resin decorative plate by a lamination method, it is a normal manufacturing method of a decorative plate having an embossed pattern on its surface, This is a lamination method using an embossed resin plate.

In FIG. 3, (2a) is a shaping plate such as an embossed metal plate or an embossed resin plate engraved with an embossed pattern.
(2b) is a release film for the purpose of releasing the melamine resin and the imprinting plate (2a), and a polypropylene film or the like is used. (2c) is overlay paper impregnated with melamine resin, (2d) is print impregnated paper obtained by impregnating melamine resin on titanium paper with a printed pattern, (2e) is core paper impregnated with phenolic resin, and (2f) is melamine. Backer paper impregnated with resin. These laminated products are used as one unit, and in each stage of a multi-stage press machine, they are sequentially laminated and inserted in an amount of 1 to 20 units according to the press stroke, etc., heated and pressed, cooled, and shaped. By releasing the plate (2a) and the release film (2b), the resin of (2c) to (2f) is cured to obtain a melamine resin decorative plate having an embossed pattern on its integrated surface.

<Problems to be solved by the invention> However, when laminating the decorative plate, since it is performed manually, the shaping plate is usually about 2 to 10 mm in thickness, 2 mm thick stainless steel As a shaping plate, a normal size of 4 × 8 measures about 50 kg and requires a great deal of labor in terms of weight.

Further, since it is necessary to insert the shaping plate within a limited stroke of the press machine, the number of sheets manufactured in one shot is limited by the thickness of the shaping plate.

<Means for Solving the Problems> The present invention has been conceived to solve the above problems, and has a heat resistance, a release layer and a heat resistant resin layer on both front and back surfaces of a base sheet having dimensional stability. It is a shaping sheet formed by providing an uneven pattern on the surface of the resin layer, and a method of manufacturing a decorative board using the shaping sheet, wherein overlay paper is provided on both front and back surfaces of the shaping sheet, Print impregnated paper, core paper, backer paper, release film as one unit, laminating at least one unit at a symmetric position, heating and pressing, then cooling while maintaining the pressurized state, This is a method for producing a decorative board, which comprises removing pressure and removing the article.

 The details will be described below with reference to the drawings.

Forming Sheet (1) FIG. 1 is a sectional view of the forming sheet (1). The shaping sheet (1) is formed by forming an embossed pattern or a patterned pattern (1c) having a change in gloss on the resin layer (1b) on both the front and back surfaces of the base sheet (1a). The base sheet (1a) needs to have heat resistance and dimensional stability against the heating temperature during melamine molding, and paper, metal foil, and the like can be selected. Resin layer (1
b) is required to have releasability, heat resistance, and the like for the thermosetting resin, and extrusion-coated resin such as polyethylene terephthalate, polybutylene terephthalate, polypropylene, polyethylene, metamethyl acrylate, and polymethylpentene; or A laminated film can be used.

In the case of embossed patterns and pattern patterns with a change in gloss (1c), in the case of embossed patterns, there are a method of directly embossing on the resin layer, a method of transferring the embossed pattern on the matrix film to the resin layer, etc. A method of printing a pattern of an ink in which the particle size and blending amount of fine particles such as extender pigments such as silica, metal powders such as aluminum powder and the like are adjusted on a resin layer, and forming a matrix film printed with an ink containing those fine particles on a resin. There is a method of transferring to a layer.

Method of Manufacturing Thermosetting Resin Decorative Board FIG. 2 shows a laminating method for manufacturing a high-pressure melamine decorative board having an embossed pattern or a pattern with a change in gloss formed on the surface according to the present invention.

(1) is a shaping sheet in which an embossed pattern or a pattern with a change in gloss is formed on both front and back surfaces. As in FIG.
(3c) is overlay paper, (3b) is print impregnated paper, (3e)
Is a core paper, (3f) is a backer paper, and (3g) is a relace film for releasing two back-to-back melamine resin decorative boards.

In the present invention, a sheet obtained by symmetrically laminating a multi-layered product on both sides of the shaping sheet (1) as one unit is sequentially laminated and inserted in about 1 to 20 units, heated and pressed, cooled, and then cooled. A melamine resin decorative board with a 3C-3f resin cured and integrated to form an embossed pattern or a pattern with a change in gloss by releasing the molding sheet (1) and release film (3g) Is obtained.

<Function> The present invention has the above configuration, and at the time of decorative board production,
Because there is no need to insert a thick molding sheet such as a conventional thick embossed metal plate or embossed resin plate,
The efficiency can be improved by increasing the number of production sheets that can be inserted in one stroke, the labor is reduced, and simplification is achieved.

<Example> Hereinafter, an example of the present invention will be described with reference to the drawings.

Forming sheet A 50μ thick polyvinyl chloride surface is controlled by a heat-pressurized embossed board with a crystalline geometric pattern that controls the reflection and aroma of light and forms a visual pattern. Pre-create a matrix film with uneven patterns,
Basis weight 127 g / m ² fine paper as the substrate sheet of the shaping sheet (1
a) Extrude a polypropylene resin to a thickness of 25μ on the surface of a)
At the same time as laminating, the matrix film was pressed and pressed with a nip roll and a cooling roll. Furthermore, high quality paper (1a)
At the same time as extruding and laminating a polypropylene resin (1b) to a thickness of 25 μm on the back surface of the substrate, a matrix film was pressed and pressed with a nip roll and a cooling roll. After cooling sufficiently,
By exfoliating and removing the front and back master films, the fine uneven pattern formed on the master film is transferred to the resin layer (1b), and the fine uneven pattern (1c) is formed on both the front and back surfaces. (1) was obtained. The imprint sheet was about 172 g / m ² , and was about 560 g in a size of 4 × 8.

Manufacturing method of thermosetting resin decorative board As shown in FIG. 2, 100 g / m ²
(300% weight resin) overlay paper (3c), to print a geometric pattern on a titanium paper of 80 g / m ^2, was impregnated with a melamine resin 12
8 g / m ² (resin layer 37.5%) printing impregnated paper (3b), 240 g / m ² (resin amount 50%) phenol core paper (3e) 8 sheets, 167 g / m
16 units were laminated with a laminate of ² (40% resin) backer paper and a 30 μm thick polypropylene resin release film (3f) as a unit, and heated and pressed. Regarding the lamination, it was a lamination of 1 kg or less in 4 × 8 dimensions, and the work labor was easy. The maximum heating temperature is 145 ° C and the pressure is 80kg /
The operation was performed for 30 minutes in a cm ² , and then cooled with cold water for 40 minutes while maintaining the pressure, and the decorative melamine resin plate was taken out. Then
The release film (3f) and the shaping sheet (1) were sequentially released from the laminated upper part to control the light reflection direction on the surface and form a visual pattern. A high-pressure melamine decorative board having fine irregularities of a crystalline geometric pattern and further having a printed pattern in the lower layer was obtained.

In the case of using a 5-stage press having a stroke of 450 mm in one stage, 16 units could be easily inserted in one stage, and 32 high-pressure melamine decorative boards were obtained. On the other hand, 7m thick by the conventional method
In order to obtain a high-pressure melamine decorative board having the same thickness as in the above embodiment as shown in FIG. 3 using an embossed resin board of m, the lamination thickness of one unit is about 14 mm, and within one stroke of the same step , Only 17 high-pressure melamine decorative boards were obtained.

<Effects of the Invention> Since the present invention has the above-described configuration, the present invention has the following excellent practical effects.

By laminating and manufacturing a shaped sheet with an embossed pattern or a pattern with a change in gloss on both sides, a thermosetting resin decorative board with an embossed pattern or a pattern with a change in gloss formed on the surface can get.

Since there is no need to use a thick embossed metal plate or embossed resin plate when manufacturing a thermosetting resin decorative board, efficiency can be improved by increasing the number of sheets that can be inserted in one stroke.

Since it is not necessary to use a heavy embossed metal plate or embossed resin plate when manufacturing a thermosetting resin decorative plate, labor is reduced and simplification is achieved. In addition, if a material having cushioning properties is selected as a base material, when foreign matter (such as dust) is mixed between the press plate and the molding sheet during the production of a decorative sheet, only a dent is formed on one side of the molding sheet. However, there is no influence (projection) of the dent on the other side.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a shaping sheet according to the present invention, FIG. 2 is an explanatory view showing a manufacturing process of a decorative board using the same shaping sheet, and FIG. 3 is an explanatory view showing a conventional technique. (1) ... shaping sheet, (1a) ... shaping sheet (1b) ... resin layer (1c) ... embossed pattern or pattern with gloss change (2a) ... embossed shaping plate, (2b) ... release film (2c) ... Overlay paper, (2d) ... Print impregnated paper (2e) ... Core paper, (2f) ... Backer paper (3c) ... Overlay paper, (3d) ... Print impregnated paper (3e) ... Core paper, (3f) )… Backer paper (3g)… Release film

Continuation of the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) B29C 33/00-33/76 B32B 31/00-33/00 B29C 43/18-43/36 B29C 59/00-59 / 02

Claims (2)

(57) [Claims] 1. A molded sheet comprising a substrate sheet having heat resistance and dimensional stability, having a resin layer having releasability and heat resistance on both front and back surfaces thereof, and providing an uneven pattern on the surface of the resin layer. 2. A method for manufacturing a decorative board using the imprint sheet according to claim 1, wherein an overlay paper, a print impregnated paper, a core paper, a backer paper, and a release film are provided on the front and back surfaces of the imprint sheet. The makeup is characterized in that at least one unit is laminated at a symmetrical position, heating and pressurization is performed, and then, while maintaining the pressurized state, cooling is performed, then pressurization is released, and the laminate is taken out. Plate manufacturing method.