JP3632989B2 - Manufacturing method of decorative sheet for decorative board - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a method for producing a decorative sheet for a decorative board for performing surface decoration of the decorative board inexpensively and easily.
[0002]
[Prior art]
Typical examples of the decorative board include a polyester decorative board, a DAP decorative board, and a melamine decorative board.
The polyester decorative board is obtained by applying printing paper or monochromatic paper to a base material (plywood, particle board, etc.) with an adhesive such as urea vinyl acetate resin or polyester resin, and drying and then applying an unsaturated polyester resin thereon. .
[0003]
The DAP decorative board is called by this name because diallyl phthalate resin (DAP resin) is used. A DAP resin is impregnated into a decorative paper, which is hot-pressed over a plywood or particle board or other substrate.
[0004]
Melamine decorative boards are broadly classified into high-pressure melamine decorative boards and low-pressure melamine decorative boards according to the difference in molding pressure.
The high-pressure melamine decorative board is laminated and molded with a melamine resin-impregnated paper using a phenol resin-impregnated paper as a substrate, and is used by being secondarily bonded to a plywood or the like.
[0005]
The low-pressure melamine decorative board is obtained by press-molding a plywood board, a hard board, a particle board, or the like on a substrate and overlaying a melamine resin-impregnated paper thereon.
[0006]
When applying an embossed pattern to the surface of each decorative board, use a thermosetting resin mold plate obtained by transferring from the master mold, or a backing plate made by etching stainless steel or duralumin, and impregnating paper or resin. Use a polypropylene film or silicon sheet with excellent releasability in between.
In addition, the embossed decorative plate is subsequently wiped with a coloring material in the embossed recess and further top-coated.
[0007]
[Problems to be solved by the invention]
In any of the conventional decorative plate manufacturing, there are disadvantages in cost, such as using an expensive silicon sheet, using an expensive metal embossed plate, and requiring a wiping process.
The present invention can impart an excellent design property by using an inexpensive material, and can make a decorative board that is inexpensive and has an excellent design property by omitting the wiping process and improving workability. It aims at providing the manufacturing method of the shaping sheet for boards.
[0008]
[Means for Solving the Problems]
In order to achieve the above object in the present invention, in the first aspect of the invention, the molten thermoplastic resin extruded from the T-die is cooled and solidified between a cooling roll having a concave pattern on the surface and a nip roll, thereby forming a decorative plate for a decorative board. In the method for producing a sheet, the colorant is filled in the concave portion of the cooling roll and then dried with warm air to adhere the colorant to the concave wall surface, and then the colorant is adhered to the convex portion of the shaping sheet. This is a method for producing a decorative sheet for a decorative board.
[0009]
In the second aspect of the invention, in the method for producing a decorative sheet for a decorative board, the molten thermoplastic resin extruded from the T-die is cooled and solidified between a cooling roll having a concave pattern on the surface and a nip roll. A decorative board characterized in that a colorant is continuously filled in a concave part of a roll, followed by drying with warm air to adhere the colorant to the wall surface of the concave part, and then a colorant is continuously adhered to the convex part of the shaping sheet. This is a method for producing a molded sheet for use.
[0010]
According to a third aspect of the present invention, in the method for producing a decorative sheet for decorative board according to claim 1 or 2, the thermoplastic resin is polyethylene, polypropylene, polybutylene, polymethylpentene, ethylene / vinyl acetate copolymer resin, ethylene -Cosmetics characterized by using polyolefin resins such as acrylate copolymer resins, ethylene / methacrylate copolymer resins, ethylene / methyl acrylate copolymer resins, ethylene / ethyl acrylate copolymer resins, polyethylene terephthalate, or polybutylene terephthalate This is a method for producing a plate-shaped shaping sheet.
[0011]
Furthermore, in the fourth invention, in the method for producing a decorative sheet for decorative plate according to claim 1 or 2, the coloring material is polyethylene, polypropylene, polybutylene, polymethylpentene, ethylene / vinyl acetate copolymer resin, ethylene・ Attach to polyolefin resin such as acrylate copolymer resin, ethylene / methacrylate copolymer resin, ethylene / methyl acrylate copolymer resin, ethylene / ethyl acrylate copolymer resin, polyethylene terephthalate, or polybutylene terephthalate and make up Polyvinyl chloride / vinyl acetate copolymer resin, polyurethane resin, vinyl acetate / urethane copolymer resin, or acrylic / urethane copolymer resin with excellent transfer adhesion to polyester, melamine, or diallyl phthalate resin forming the plate It is obtained by the production method of shaping sheet for decorative plate, characterized by use.
[0012]
That is, the present invention is characterized by using a polyolefin-based resin, a polyethylene terephthalate resin, or a polybutylene terephthalate resin, which are inexpensive materials and excellent in releasability from many resins, as an extrusion resin.
[0013]
More specifically, in the production method of the present invention, as shown in FIGS. 1, 2, and 3, a metal roll having a conduit embossed portion made of an intaglio is used as a cooling roll (2) of a melt extruder.
The intaglio part is filled with the colored ink for conduit (8) so that the cooling roll (2) is immersed in the ink of the ink pan (6), and the excess ink is scraped off by the doctor (5) provided immediately after.
[0014]
Next, hot air is blown to the cooling roll (2) by the hot air blower (7), and the colored ink (8) is dried with hot air. As a result, the solvent is diffused from the colored ink (8), causing volume shrinkage. Adheres to the embossed wall.
The molten thermoplastic resin (4) is extruded from the T-die (1) of the melt extruder to the cooling roll (2) thus formed, but the colored ink (8) is softened by the heat of the thermoplastic resin (4). And it transfers to a thermoplastic resin (4) from the metal surface of a cooling roll (2).
[0015]
Finally, it is cooled and solidified between the cooling roll (2) and the nip roll (3), further dried by a dryer (9), and taken up by a take-up roll (10), thereby attaching the colored ink (8) to the convex part. The shaped sheet (15) made is continuously produced.
[0016]
In addition, although the above showed the example produced continuously by a rotary system, you may produce intermittently by a circular pressure system etc.
[0017]
[Action]
The present invention is excellent in design by producing an extrusion-molded sheet with convex embossing by using an intaglio roll as a cooling roll, using a low-polyolefin resin, polyethylene terephthalate, polybutylene terephthalate as a thermoplastic resin, and using an intaglio roll as a cooling roll. Manufacture decorative sheet for decorative board that is cheaper than before.
[0018]
【Example】
Polypropylene resin (Union Polymer Co., Ltd .: “XF1932”) is used as the polyolefin resin for extrusion of the thermoplastic resin (4), and two-component curable urethane resin ink (Toyo Ink Manufacturing Co., Ltd.) is used as the wiping ink for the colored ink (8). Ltd.): “Lamister R92 ink”).
[0019]
Polypropylene resin was extruded at 230 ° C. from a T-die extruder.
The discharge amount of the resin and the winding speed were finely adjusted so that the thickness of the sheet was 50 μm at the flat part.
The intaglio part of the cooling roll (2) had a plate depth of 100μ, the height of the convex part of the finished shaped sheet (15) was 100μ from the sheet surface, and the reproducibility was almost 100%.
[0020]
The cooling roll was immersed in an ink pan filled with the colored ink (8), and the ink other than the recesses was scraped with a doctor.
Thereafter, the volume of ink in the recesses was reduced by evaporating the solvent by hot air drying. For this reason, the ink was attached to the wall surface of the recess.
[0021]
The polypropylene resin was dropped between the chill roll and the silicone rubber nip roll (3) and solidified by cooling to continuously produce a polypropylene resin shaped sheet (15) having ink on the convex portions (FIG. 2). ).
[0022]
As shown in FIG. 3, using the embossed shaping sheet (15) of the above example, the unsaturated polyester resin was cured by ultraviolet rays to prepare a decorative board. The curing rate was almost the same for heating and ultraviolet rays, and the emboss reproducibility was almost 100%.
[0023]
Once used, the polyolefin shaped sheet can be continuously applied to the crusher to extrude the shaped sheet.
[0024]
【The invention's effect】
As described above, the decorative sheet for decorative board according to the present invention uses an inexpensive polyolefin resin or the like as a raw material, and provides reliable embossing reproduction from a mother mold by melt extrusion and reliable embossing ability for a product. Have.
It also has the advantage of shortening the process.
[0025]
In addition, since the sheet can be produced continuously, it has a feature that can be applied to any lengthy decorative board.
[0026]
By using the decorative sheet for decorative board of the present invention, the cost for embossing in the conventional decorative board manufacture can be suppressed, and the molded sheet can be recycled.
Further, since it can be applied to products of special sizes, the utility value of the decorative sheet for decorative plates such as polyester is extremely high.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory view, represented by a cross section, showing a method for producing a decorative sheet for decorative plate, showing an embodiment of the present invention.
FIG. 2 is an explanatory view showing a cross section of a shaped sheet showing an example of the present invention.
FIG. 3 is an explanatory view showing a cross section of a decorative board using the shaping sheet of the present invention.
[Explanation of symbols]
1 ... T-die 2 ... Cooling roll 3 ... Nip roll 4 ... Thermoplastic resin 5 ... Doctor 6 ... Ink pan 7 ... Hot air blower 8 ... Colored ink 9 ... Dryer 10 ... Winding roll 11 Unsaturated polyester resin 12 Printed decorative paper 13 Base material (plywood, particle board, etc.)
15 ... Molding sheet

Claims (4)

In a method for producing a decorative sheet for a decorative plate by cooling and solidifying a molten thermoplastic resin extruded from a T-die between a cooling roll having a concave pattern on the surface and a nip roll, the concave portion of the cooling roll is filled with a coloring material. A method for producing a decorative sheet for a decorative board, comprising: drying with warm air and attaching a colorant to the wall surface of the concave part , and then attaching a colorant to the convex part of the moldable sheet. In a method for producing a decorative sheet for a decorative board by cooling and solidifying a molten thermoplastic resin extruded from a T die between a cooling roll having a concave pattern on the surface and a nip roll, the concave portions of the cooling roll are continuously colored. A method for producing a decorative sheet for a decorative board, comprising: filling a material, drying with warm air to attach a coloring material to a wall surface of a concave portion, and then continuously attaching the coloring material to a convex portion of the shaping sheet. 3. The method for producing a decorative sheet for decorative board according to claim 1, wherein the thermoplastic resin is polyethylene, polypropylene, polybutylene, polymethylpentene, ethylene / vinyl acetate copolymer resin, ethylene / acrylate copolymer resin, ethylene / acrylate copolymer, A method for producing a decorative sheet for a decorative board, characterized by using a polyolefin resin such as methacrylate copolymer resin, ethylene / methyl acrylate copolymer resin, ethylene / ethyl acrylate copolymer resin, polyethylene terephthalate, or polybutylene terephthalate . 3. The method for producing a decorative sheet for decorative board according to claim 1 or 2, wherein the coloring material is polyethylene, polypropylene, polybutylene, polymethylpentene, ethylene / vinyl acetate copolymer resin, ethylene / acrylate copolymer resin, ethylene / methacrylate. Polyester, melamine, which adheres to a resin such as a copolymer resin, an ethylene / methyl acrylate copolymer resin, a polyolefin resin such as an ethylene / ethyl acrylate copolymer resin, polyethylene terephthalate, or polybutylene terephthalate, and a decorative board Uses vinyl chloride / vinyl acetate copolymer resin, polyurethane resin, vinyl acetate / urethane copolymer resin, acrylic / urethane copolymer resin, etc. that have excellent transfer adhesion to diallyl phthalate resin粧板 for shaping sheet manufacturing method of.

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