JP3096115B2 - Manufacturing method of mirror-finished decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative decorative board, and more particularly to a method for producing a decorative decorative board having an epoxy resin layer.

[0002]

2. Description of the Related Art A conventional mirror-finished veneer is made of a substrate such as a veneer,
Unsaturated polyester resin or urethane resin is applied to the surface of metal plate, synthetic resin plate, etc. by spraying or flow coater at around 100 g / m ² (dry film) each time. If the resin of the first coating is cured, # The surface of the coating film is polished with a polishing sheet of 400, and when the resin of the second coating is cured, the surface of the coating film is polished with a polishing sheet of # 600.
If the resin of the second coating is cured, the coating film surface is polished with a # 800 polishing sheet and finally finished by buffing to give a gloss, or three consecutive coatings are performed with insufficient curing to # 400 → Polish multiple times in the order of # 600 → # 800,
Eventually, it was manufactured by buff polishing and mirror finishing. In addition, an unsaturated polyester resin was dropped on a base material, a polyester film was applied, the resin was stretched with a roll from above, and after curing, the film was peeled off to produce a mirror-finished decorative board (film coating method).

[0003]

In the conventional coating method using a spray or a flow coater, since the resin has a low-viscosity solid content, a single coating amount is at most 100 μm.
m, a large number of coatings are required to obtain a dry film thickness of 200 to 1000 μm required for mirror finishing, and the number of polishings is required accordingly. Absent. In particular, when an unsaturated polyester resin is used, since the volume shrinkage during polymerization and curing is 7 to 10%, the surface has sink marks (small irregularities following the irregularities of the substrate due to shrinkage) or warpage ( Warpage) is likely to occur, and to prevent this, it was necessary to increase the number of times of polishing to increase the surface smoothness. Also, when an unsaturated polyester resin is applied by a film coating method, the volume shrinkage during polymerization and curing is as large as 7 to 10%, so that the surface of the mirror resin layer becomes thin and the surface smoothness deteriorates. was there. In order to prevent this drawback, it was necessary to reduce the amount of application for one application and repeatedly perform coating and polishing by the film application method many times, resulting in inconsistent quality and poor productivity. In particular, when the surface of the base material is uneven (wood grain, cloth grain, stone grain, Japanese paper, leather, etc.), the above-mentioned inconveniences have occurred more. An object of the present invention is to provide a method for producing a mirror-finished decorative board which is more stable, more productive and durable than these conventional production methods.

[0004]

According to the present invention, an uneven layer made of an unsaturated polyester resin containing a brilliant pigment is formed as a backing material by using a forming resin sheet, and a film coating method is applied on the uneven layer. That is, an epoxy resin layer is laminated.
Further, in the present invention, using an imprinted resin sheet as a backing material, an uneven layer made of an unsaturated polyester resin is formed, a paint containing a brilliant pigment is applied on this uneven layer, and further an epoxy resin is applied by a film coating method. It is also characterized in that a mirror surface resin layer is laminated.

[0005]

[Function] An uneven layer made of an unsaturated polyester resin containing a brilliant pigment is formed on a base material, and a mirror-surface resin layer made of an epoxy resin is laminated on the uneven layer by a film coating method. Method to produce relatively thick ones,
In addition, since the surface of the mirror-finished film fixed to the metal frame with low shrinkage and strong tension is transferred to the epoxy resin (film coating method), extremely good mirror finish and smoothness can be obtained. The upper surface of the resin was coated with a coating containing glitter pigments using a molding resin sheet to form an uneven layer, and a mirror resin layer of epoxy resin was further laminated by a film coating method, so it was elegant when viewed through the mirror resin layer. A high-quality mirror-finished veneer with a high-quality mirror-like decorative plate that reflects the uneven layer with a deep and deep pearl luster and has a high texture and a three-dimensional impression, and gives the viewer a deep and deep impression. can get.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the present invention, a mirror-finished veneer is obtained by forming a mirror-surface resin layer on a base material. The surface of the substrate of the present invention may be smooth or uneven, but an uneven shape is more effective. As a base material, a material in which a surface uneven layer is provided by adding a glittering pigment and a coloring pigment to a synthetic resin such as an unsaturated polyester resin on the surface of a backing material, for example, as a wooden base material for forming an uneven layer, wood, Veneer, plywood, fiberboard,
Hardboard, particle board, and as an inorganic base material, gypsum board, slate board, cement board and leather, and as a paper base material, titanium resin, thin paper, reinforced paper, Japanese paper, etc. Is used. Further, a base material may be formed by forming an uneven layer of a transparent synthetic resin in which a pattern of a real material is formed on a decorative paper, and wiping (filling and coloring) an opaque colored paint in the concave portions. In particular,
As the synthetic resin layer base material, it is effective to use a mixture of a brilliant pigment and an opaque color pigment on a synthetic resin plate. Further, as the backing material, the above-mentioned wood substrate, inorganic substrate, metal substrate, and synthetic resin substrate are appropriately used, and a substrate having an unsaturated polyester resin layer formed thereon may be used as the substrate.

FIG. 1 is an explanatory view showing one embodiment of a method for manufacturing a mirror-surface decorative board according to the present invention. . Epoxy resin D is used as the resin for forming the mirror surface resin layer.
100 parts of ER331J (Dow Chemical Japan), reactive diluent Heroxy MK-116 (ACI Japan) 15
Part, curing agent Ancamine 2196 (ACI Japan) 45
Parts were used. Other examples include epoxy resin AY
-103 (Nippon Ciba-Geigi) 100 parts, curing agent HY95
6 (Nippon Ciba Geigy), 100 parts of epoxy resin Epicoat 815 (Ciel), 45 parts of curing agent Ancamine 2196 (ACI Japan) and the like were used.

In this case, when the mirror-surface resin layer is formed of the epoxy resin 3, the smoothness of the surface of the base material layer, that is, the unevenness of the veneer, Japanese paper, cloth, or the synthetic resin layer obtained by shaping the unevenness is 100 μm. In the following cases, a mirror-surface resin layer having a thickness of 300 μm or more is formed to give a sense of depth and depth. In addition, the base material layer is formed of real material such as ostrich leather, canvas-like deep cloth, deep stone-like, floating wood grain, or the like, or 100 to 8 in which the unevenness is formed.
In the case of unevenness having a thickness of 00 μm, a mirror-surface resin layer having a thickness of 300 to 1200 μm is formed.

To form the mirror surface resin layer, a film coating method using the mirror surface film 4 is used. Since the epoxy resin 3 tends to adhere well to other materials, the mirror-finished film 4 used in the film coating method is made of silicone resin,
It is necessary to use a resin that has been treated with a resin having releasability such as a fluororesin, and one surface of a transparent PET film or the like has been treated with a release agent such as a silicone resin or a fluororesin, and a fluorine resin film, a polyimide resin film, A silicone rubber sheet can also be used. The epoxy resin 3 is selected to have a slight discoloration, and when bubbles are generated in the epoxy resin layer, about 0.5 part of an antifoaming agent (Kusumoto Kasei Co., Ltd., DISPARON 1930N silicon type) is added.
When the viscosity of the resin exceeds 1000 cps, a reactive diluent (Heroxy MK-116) is added. If necessary, use an ultraviolet absorber (Sand, Inc.
The light resistance can be improved by adding 1 to 8 parts, preferably 2 to 4 parts of 212 with respect to 100 parts of the epoxy resin. It is necessary to select an epoxy resin and its curing agent having as good colorless transparency and light resistance as possible when cured. As the epoxy resin, a resin synthesized from epichlorohydrin and bisphenol A (Dow Chemical Co., Ltd., DER331J, DER383J) is preferable, and as a curing agent, a cyclic aliphatic polyamine (AC) is used.
I Japan, Ankamin 2196, Ankamin 207
4) is the best, followed by aliphatic polyamines (ACI Japan, Ancamine 1768). When it is necessary to further increase the adhesive strength between the substrate 1 and the epoxy resin 3 of the mirror surface resin layer, a primer (Washin Chemical, acrylic urethane, polyurex # 548A solution + B solution 4: 1 to 2 to 30 g as a dry film
/ M ² coating), and then a mirror-surface resin layer of the epoxy resin 3 is formed. The method for forming the mirror-surface resin layer is not limited to the film coating method, but may be a coating method using a spray or a flow coater.

[0010] FIGS. 2, 3, 4 show an example in the case of forming the uneven layer 1 ₂ unsaturated polyester resin on a substrate 1 of backing material 1 _1, the backing 1 ₁ thickness 5.5
consists density fiberboard in the mm, unsaturated polyester resins Unsaturated polyester resin layer 1 _2, Rigorakku 2
265 BFU (Showa Kogaku) 100 parts, and 1 part of Permec N (Nippon Shokubai) as a curing catalyst, and a textured resin sheet 2 is used to form a concavo-convex layer on the unsaturated polyester resin. The textured resin sheet 2 is a composite sheet of a 25 μm-thick vinylon film and a 150 μm-thick low-density polyethylene film, and is formed by forming textured irregularities on the surface of the vinylon sheet. 2 an uneven surface is placed in contact with the unsaturated polyester resin surface on the backing material 1 _1, shaping the resin sheet 2
By extending without Manhen while removing bubbles unsaturated polyester resin on the substrate by a roll over of forming the uneven layer 1 ₂ unsaturated polyester resin substrate surface of the substrate. Next, as shown in FIG. 3, the epoxy resin 3 is laminated as a specular resin layer. The specular resin film 3 and the metal frame 5 and the roll 6 are applied by a well-known film coating method in one application. ₁ is formed smoothly.
(FIG. 4)

[0011] Figure 5 shows another embodiment, uneven layer of unsaturated polyester resin on the backing material 1 ₁ as the substrate 1 1
_When forming No. 3, the unsaturated polyester resin was the same as the embodiment shown in FIGS. 2, 3 and 4, 3 parts of opaque colored pigment PCN toner 6706G, and 10 parts of brilliant pigment Iriodin 217 (Merck) Is further added. Lamination of specular resin 3 ₁ by forming method and the epoxy resin of the uneven layer 1 ₃ of the unsaturated polyester resin, 2, 3, is similar to the embodiment shown in FIG.

FIG. 6 shows another embodiment, in which a backing material ₁₁ is formed by forming a specular resin layer (not shown) on a medium density fiberboard having a thickness of 18 mm as a base material. free unsaturated polyester resin layer 1 ₂ unsaturated polyester resin Goserakku 500B (Nippon synthetic chemical) 1
00 parts, curing accelerator 6% cobalt naphthenate 0.5 part,
A curing resin sheet composed of 1 part of Permec N and a red part of opaque coloring pigment 4313 is used. As the molding resin sheet 2, a molding resin sheet in which irregularities of Japanese paper are formed on one surface of silicon rubber (Shin-Etsu Chemical KE-1300TRTV) is used. This is shown. The formation of the mirror-surface resin layer (not shown) is the same as the method shown in FIGS.

[0013] Figure 7, in the embodiment of FIG. 6, as the urethane paint coating 1 ₄ on the unsaturated polyester resin irregular layer 1 ₂ containing no bright pigment, and urethane coating Poriurekkusu # 548A liquid 4, the curing agent # 548B liquid 1
100 parts of a mixture of the (Washin Chemical Industry), made bright pigment Marlin super white 9020C (Mahr) 2 parts, the dry film 1 to 10 g / ^{m 2} was applied as a coating amount of the urethane paint coating _{1 4} A mirror surface resin (not shown) of an epoxy resin is laminated and formed thereon.

As the glittering pigment to be contained in the unsaturated polyester resin, 100 parts of the resin are coated with glittering pigments (pearl powder, metal powder such as aluminum powder or a small piece of a colored vapor-deposited film, a small piece of a rainbow film). ) And 0.5 to 20 parts of an opaque coloring pigment, the dispersion unevenness of the glitter pigment can be remarkably reduced. Also, when a urethane resin paint containing a glitter pigment is applied to the surface of the uneven layer of unsaturated polyester resin by a general-purpose coating method, when viewed through the mirror surface resin layer, it has an elegant deep pearl luster. The uneven layer is reflected and a high-quality mirror-finished veneer can be obtained. Further, as the molding resin sheet, a silicon rubber mold having irregularities obtained by transferring irregularities of wood, paper or other real base material may be used. If necessary, a hard coating agent (Mitsubishi Rayon Co., Acryking N-101, a polyfunctional acrylate ultraviolet curing resin, a pencil hardness of 5H) may be applied to the surface of the mirror resin layer to prevent damage. It may be coated.

[0015]

According to the present invention, a backing material is formed by using a shaped resin sheet obtained by shaping cloth, stone, Japanese paper or wood grain.
An uneven layer made of an unsaturated polyester resin is formed, and a glossy pigment is contained in the uneven layer, or a mirror resin layer of an epoxy resin is formed by a film coating method on the uneven layer obtained by applying a paint containing a bright pigment on the uneven layer. Due to the lamination, the epoxy resin of the mirror resin layer has a very small volume shrinkage of 0.2 to 0.4% during polymerization and curing. Unevenness due to unevenness of the material does not occur, and good mirror finish and smoothness can be obtained not only with a smooth base material but also with a deep uneven layer, and elegant deep pearl luster when viewed through the mirror resin layer As a result, a high-quality mirror-finished veneer can be obtained, and a mirror-surface resin layer having a thickness of 300 to 1200 μm, which is necessary to obtain depth by one coating of the mirror-surface resin, can be obtained. Tsu surface polishing process can also be omitted. In addition, epoxy resin adheres well to many materials and has high mechanical strength, so it is possible to manufacture a durable mirror-finished veneer, and it is possible to perform post-processing such as cutting and molding of the mirror-surface veneer. Even after being used as a material,
There is no peeling or scratching of the base material and the mirror-surface resin layer, and the man-hours and processes required in the past can be greatly reduced, work can be performed easily, and production can be performed efficiently at low cost. In addition, the texture of the surface of the decorative decorative panel is deep, and it is possible to easily produce a durable mirror decorative panel that is stable in quality as well as maintaining excellent appearance quality.

[Brief description of the drawings]

FIG. 1 is an explanatory view of one embodiment of the method of the present invention.

FIG. 2 is a cross-sectional explanatory view of a manufacturing method of the base material of the embodiment of FIG.

FIG. 3 is an explanatory sectional view showing a method of manufacturing the decorative board of the embodiment shown in FIG. 2;

FIG. 4 is a cross-sectional view of the decorative board according to the manufacturing method of FIG.

FIG. 5 is a cross-sectional view of a decorative board using an unsaturated polyester resin layer containing a glitter pigment according to another embodiment of the present invention.

FIG. 6 is an explanatory sectional view showing another embodiment of the base material and the shaping resin sheet.

FIG. 7 is an explanatory sectional view showing still another embodiment of the base material.

[Explanation of symbols]

1 substrate 1 ₁ lining material 1 ₂ unsaturated polyester resin layer 1 ₃ unsaturated polyester resin layer (including the bright pigment) ₁ (including bright pigment) ₄ urethane coating 2 shaping the resin sheet 3 Epoxy resin 3 ₁ Mirror surface resin layer 4 Mirror surface film 5 Metal frame 6 Rubber roll

────────────────────────────────────────────────── ─── Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI B32B 27/36 101 B32B 27/36 101 // B32B 31/00 31/00 (72) Inventor Shoichi Amano Koishikawa Bunkyo-ku, Tokyo 4-14-12 Kyodo Printing Co., Ltd. (72) Inventor Kisumi Akashi 4-14-12 Kyodo Printing Co., Ltd. Bunkyo-ku, Tokyo 4-72 Inventor Shunsuke Nishikawa 4 Koishikawa 4 Bunkyo-ku, Tokyo Chome 14-12, Kyodo Printing Co., Ltd. (72) Inventor Yuji Watanabe 4-chome, Koishikawa, Bunkyo-ku, Tokyo (72) Inventor Yukiko Chika 4-14, Koishikawa, Bunkyo-ku, Tokyo No. 12 in Kyodo Printing Co., Ltd. (72) Inventor Katsuaki Terada 4-14-12 Koishikawa, Bunkyo-ku, Tokyo Kyodo Printing Co., Ltd. (56) References JP-A-59-136257 (JP, A) Showa 6 1-106247 (JP, A) JP-A-1-1633065 (JP, A) JP-B 1-42748 (JP, B2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00 -35/00

Claims (2)

(57) [Claims] 1. An uneven layer made of an unsaturated polyester resin containing a brilliant pigment is formed using a shaped resin sheet as a backing material, and a mirror surface resin layer made of an epoxy resin is laminated on the uneven layer by a film coating method. A method for producing a mirror-finished veneer. 2. An uneven layer made of an unsaturated polyester resin is formed using a shaped resin sheet as a backing material, a paint containing a brilliant pigment is applied on the uneven layer, and an epoxy resin is formed by a film coating method. A method for manufacturing a mirror-finished veneer, wherein a mirror-surface resin layer is laminated.