JP2935001B2 - Decorative plate and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[Industrial application field] High hardness, impregnated with synthetic resin,
The present invention relates to a decorative plate having wear resistance and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as a decorative plate having abrasion resistance used as a floor material or the like, as shown in FIG. 1, a decorative veneer 12 adhered to the surface of a substrate 1 such as a plywood or a wood fiber board is treated with a sealer. After performing step 9, a coating material containing an abrasive 15 is applied to the surface thereof to form a coating layer 16 having abrasion resistance. It is also known that the wear resistance is improved by increasing the mixing amount of the abrasive 15 or by selectively mixing the abrasive 15 with a particle size and a type (material).

[0003]

However, in the conventional method of applying a paint mixed with an abrasive to the surface of a wooden veneer, the surface of the decorative veneer 11 sanded is subjected to a sealer treatment S as shown in FIG. After this, the sealer S was impregnated in the decorative veneer 12, and the concave portion 12a caused by a large groove such as a conduit groove or a crack of the decorative veneer 12 remained.

[0004] Even if a coating material in which the abrasive 15 is mixed is applied to the surface of the decorative plate having such concave portions 12a, the abrasive 15
Most of them are settled in the concave portion 12a and have no function in abrasion resistance, and the abrasive 15 adhered to the remaining flat portion improves the abrasion resistance of the decorative plate surface. The amount of the abrasive 15 mixed in the above was not sufficiently functioning.

[0005] Although the wear resistance can be improved by increasing the mixing ratio of the abrasive 15, the strength of the coating film 16 of the paint decreases and the polishing Since the fixing strength for fixing the material 15 to the surface of the decorative board is remarkably reduced, the abrasive 15 is lost due to slight friction, and satisfactory wear resistance cannot be obtained. In FIG. 1, reference numeral 14 denotes an adhesive.

[0006]

Means for Solving the Problems The present inventor has made intensive studies to solve such problems, and as a result, has arrived at the present invention. That is, the present invention relates to a decorative plate in which a decorative veneer 2 is adhered to the surface of a substrate 1 via an adhesive 4, and a thermosetting synthetic resin is partially applied to the decorative veneer 2 on the surface of the decorative veneer 2. The present invention relates to a decorative board in which a thermosetting resin layer 3 is formed while being impregnated, and a coating layer 6 containing an abrasive 5 is formed on the surface of the synthetic resin layer 3 and a method of manufacturing the same.

[0007]

[Description of the structure] The following is an explanation based on the drawings. FIG.
1 shows a cross-sectional view of the decorative board of the present invention. The decorative veneer 2 is adhered to the surface of the substrate 1 via an adhesive 4. A thermosetting resin impregnated portion 3a is provided on the front side. Further, a thermosetting resin layer 3 having a flat surface is formed on the surface of the decorative veneer 3, and a coating layer 6 in which an abrasive 5 is mixed is formed on the surface.

The substrate 1 is made of wood fiber board such as plywood, hard fiber board and medium fiber board, particle board, flake board, strand board, wood chip board such as OSB, calcium silicate board, cement board, An inorganic plate such as a slag cement plate is used. The surface of the substrate is subjected to a base treatment such as a sealing treatment, a sealer treatment, and a polishing treatment as necessary, and then the adhesive 4 is applied by a coating device.

The adhesive 4 is made of vinyl acetate resin, urea resin,
It is a synthetic resin such as a melamine resin, a phenol resin, an acrylic resin, or a polyester resin, or a rubber-based adhesive, and an adhesive obtained by modifying these alone or arbitrarily is used. The amount of the adhesive applied is preferably 50 to 150 g / m ² , and the viscosity is preferably 100 to 300 poise.

After applying such an adhesive, decorative veneer 2
Place and paste. At this time, using a pressing device such as a roll press, a flat plate press or the like, the adhesive 4
Can be partially press-fitted and impregnated on the back surface of the veneer veneer 2 and can also be adhered to the surface of the substrate. 4a is an adhesive impregnated part,
2a is a concave portion of the decorative veneer 2.

The coating amount is 150 g / m ² or more,
If the viscosity is less than 100 poise,
Press-fit impregnation is easy, and oozes out on the surface of decorative veneer 2 to be described later, so that press-fit impregnation of thermosetting resin 3 to be applied later on veneer veneer 2 cannot be performed, and adhesive strength cannot be expected.

However, by using the same type of resin as the thermosetting resin 3 as the adhesive 4, mutual attraction occurs between the thermosetting resins 3 and a sufficient adhesive force can be obtained. Conversely, if the coating amount is 50 g / m ² or less or the viscosity is 300 poise or more, it is difficult to perform press-fit impregnation into a decorative veneer and adhesive strength cannot be expected.

As the decorative veneer 3, a slice veneer, a rotary veneer, a half-land veneer, an artificial veneer or the like is used, and the thickness thereof is 0.1 to 2.0 mm. The thermosetting resin constituting the thermosetting synthetic resin layer 3 is:
Phenol resins, urea resins, melamine resins, epoxy resins, unsaturated polyester resins, etc., and thermosetting synthetic resins obtained by modifying them alone or arbitrarily modified are used.

The coating amount of the thermosetting synthetic resin is 30 to 150.
g / m ^{2 and} the viscosity thereof are preferably 0.2 to 3.0 poise. These thermosetting resins are applied to the surface of the decorative veneer using a coating device.

A decorative veneer 2 coated with a thermosetting resin is
The decorative veneer 2 and the substrate 1 are placed on the substrate 1, and the decorative veneer 2 and the substrate 1 are heated and pressurized between upper and lower presses to impregnate and impregnate the thermosetting synthetic resin 4 into the veneer veneer. The resin is cured, and a thermosetting synthetic resin layer 3 is formed on the surface of the decorative veneer 2.
Further, a thermosetting synthetic resin impregnated portion 3a is formed on the surface side in the decorative veneer 2.

At this time, if the coating amount is 30 g / m ² or less and the viscosity is 0.2 poise or less, the decorative veneer 2 is impregnated, but the thermosetting resin is not uniformly applied to the surface layer and the surface is not uniformly coated. Hardness cannot be improved. Further, even if the application amount of the thermosetting resin is 150 g / m ² or more and the viscosity is 3.0 poise or more, the thermosetting resin layer 3 is uniformly applied and the surface hardness is improved. Although the same performance as in the case of 30 to 150 g / m ² can be obtained, it causes an increase in cost. On the other hand, if the viscosity is high, the press-fit impregnation into the decorative veneer 2 cannot be performed uniformly.

In the decorative plate having the decorative veneer 2 adhered to the surface of the substrate 1 via an adhesive in this manner, the adhesive is partially impregnated on the back surface of the decorative veneer 2 and the decorative veneer 2 The decorative board having the thermosetting resin layer 3 formed on the surface and the thermosetting impregnated layer 3a formed on the surface side is obtained.

Further, in the present invention, the coating layer 6 having abrasive resistance can be formed by applying a coating material in which the abrasive 5 is mixed to a layer above the thermosetting resin layer 3. As the abrasive 5, mineral particles mainly composed of aluminum oxide, silicon carbide or the like can be used.

The abrasive 5 has a particle size of 10 to 150 μm,
Preferably, those having a size of 20 to 80 μm are used. Further, the paint mixed with the abrasive 5 preferably has a strong ability to hold the abrasive and also has excellent abrasion resistance of the paint itself. For example, a polyurethane resin, an epoxy resin, a polyester resin, or a composite resin thereof, A coating material such as an ultraviolet curable resin or an electron beam curable resin can be used. The mixing amount of the abrasive to these paints is in the range of 5 to 80% by weight.

The decorative veneer of the present invention forms a coating film containing the abrasive 5 on the thermosetting resin layer 3 formed on the surface of the veneer veneer 2. The abrasive 5 does not settle in the large groove, and the abrasive 5 is uniformly fixed on the thermosetting resin layer 3. All the mixed abrasives 5 function to improve the wear resistance. It will be. For this reason, compared with the conventional decorative plate in which a coating film in which the same amount of abrasive is mixed is formed, the decorative plate has excellent wear resistance.

The upper layer of the thermosetting resin layer 3 can be coated with a paint such as a coloring paint or a surface finish paint in addition to a paint film containing an abrasive. The formation of the coating film on the surface of the thermosetting resin layer 3 can be performed by a coating device such as a roll coater, a flow coater, a curtain coater, a spreader, or a spray.

Further, before coating on the surface of the thermosetting resin layer 3, the surface of the thermosetting resin layer 3 is sanded to form very fine irregularities.
And the adhesion strength between the film and the coating film formed on the surface thereof can also be improved.

[0023]

According to the decorative panel of the present invention and the decorative panel obtained by the method of the present invention, the surface of the decorative veneer is partially impregnated with the thermosetting synthetic resin layer and the thermosetting resin layer. Is formed, and a coating layer containing an abrasive is formed above the synthetic resin layer. Therefore, when forming a coating film containing an abrasive, a conduit groove of a veneer veneer, a large concave groove such as a crack. Because the thermosetting resin layer is formed on the surface of the concave portion due to the above, the abrasive is uniformly dispersed and fixed without sedimentation in these concave portions, so that the mixed abrasive sufficiently improves the wear resistance performance Thus, the conventional decorative plate has better wear resistance than the decorative plate in which the abrasive is mixed in the same ratio.

Furthermore, since the thermosetting resin layer is formed on the surface of the decorative veneer and the thermosetting resin is partially impregnated in the decorative veneer, the surface hardness of the decorative veneer is improved and the caster test performance is improved. Alternatively, it has an excellent surface strength such that it is hardly dented even when a load is locally applied.

[0025]

EXAMPLE 1 A medium specific gravity fiber board was used as a substrate, and an adhesive was applied to the surface thereof using a roll coater at 100 g / m ² .
As the adhesive, a denatured melamine resin-based adhesive was used, and flour was mixed as an additive, with the viscosity being emphasized to 200 to 250 poise.

An oak veneer 0.23 mm thick was placed on this surface. Next, the substrate and the veneer veneer were put into a hot press, and a pressure of 7 g / m ² and a temperature of 100 ° C.
By hot-pressing for 50 seconds, a part of the adhesive was pressed and impregnated into the back surface of the veneer veneer, cured, and adhered.

Next, a thermosetting resin is applied to the surface of the oak veneer using a roll coater at 65 g / m ² . A modified melamine resin having a viscosity of 0.38 poise was used as the thermosetting resin. Immediately after applying the thermosetting resin, the substrate and the veneer veneer were put into a hot press, and the pressure was 7 kg / m ² and the temperature was 13
Hot-pressing at 0 ° C for 60 seconds, press-fitting and impregnating a part of the thermosetting resin into the surface of the oak veneer and curing the thermosetting resin, impregnating the surface of the oak veneer with a part of the thermosetting resin At the same time, a thermosetting resin layer was formed on the surface.

Further, after applying a colored paint to the surface of the thermosetting resin layer by using a sponge roll, an abrasive containing aluminum oxide as a main component and having an average particle diameter of 35 to 43 μm is contained at 50% by weight with respect to the resin. A UV curable coating of an unsaturated polyester resin was applied using a roller coater at 27 g / m ² , cured by irradiation with UV light, and further applied with a roller coater to obtain a decorative plate.

[0029]

COMPARATIVE EXAMPLE The same procedure as in Example 1 was carried out except that the steps of applying the thermosetting resin, impregnating the thermosetting synthetic resin by hot pressing and forming the thermosetting resin layer were omitted. A decorative plate was obtained by directly applying a paint mixed with an abrasive.

Example 2 An abrasion test (wear A test of flooring) was performed using the decorative plate obtained in Example 1 and the decorative plate obtained in Comparative Example. Although the surface material remained in the decorative board of Example 1 even after 3000 rotations, the decorative board of Comparative Example had a defect in the surface material.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a conventional decorative board,

FIG. 2 is a cross-sectional view of the decorative board of the present invention,

[Explanation of symbols]

(FIG. 2) 1: substrate, 2: decorative veneer, 3: thermosetting resin layer, 3a: thermosetting resin impregnated part, 4: adhesive, 4a:
Adhesive impregnated part, 5: abrasive, 6: coating layer, (FIG. 1) 11: substrate, 12: decorative veneer, 12a: recess,
14: adhesive, 15: abrasive, 16: coating film.

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields investigated (Int. Cl. ⁶ , DB name) B32B 21/00-21/14 B27D 5/00 B27M 3/00 B05D 7/06-7/10 E04C 2 / 00-2/54

Claims (3)

(57) [Claims] 1. A decorative veneer having a decorative veneer attached to the surface of a substrate via an adhesive, wherein the surface of the veneer veneer is partially impregnated with a thermosetting synthetic resin and thermally cured. A decorative plate comprising a conductive resin layer formed thereon and a coating layer containing an abrasive formed above the synthetic resin layer. 2. A decorative veneer is adhered to the surface of a substrate via an adhesive, a thermosetting synthetic resin is applied to the surface of the veneer, and pressure is applied between upper and lower pressing plates. The decorative veneer is characterized in that the veneer veneer is partially impregnated with a thermosetting resin on the surface of the veneer and a thermosetting resin layer is formed, and then a paint containing an abrasive is applied to a layer above the synthetic resin layer. Production method. 3. The method according to claim 2, wherein after sanding the surface of the thermosetting resin layer, the surface is coated.