JP3972731B2 - Decorative plate manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a decorative plate for use in interior and exterior of buildings, furniture, furniture, exteriors of home appliances, interior and exterior of vehicles, and particularly for interior wall surfaces of toilets, washrooms, bathrooms, etc. The present invention relates to a method for producing a highly sharp decorative board having a high degree of surface smoothness.
[0002]
[Prior art]
Conventionally, a decorative sheet formed by printing a pattern such as grain on paper or a thermoplastic resin sheet on the surface of a base material for a decorative board such as a wooden board such as plywood, a steel plate, or an inorganic board, and an adhesive made of a synthetic resin A technique for manufacturing a decorative board laminated through a sheet is already widely used.
[0003]
However, since the surface of the base material for the decorative board is generally not a mirror-like smooth surface and has some unevenness, when a decorative sheet is laminated on this surface with an adhesive, the surface of the decorative sheet In addition, surface irregularities of the base material are likely to appear, and it is also satisfactory for applications requiring a design with a smooth surface and excellent sharpness, such as that required for interior walls such as toilets, toilets, and bathrooms. It is extremely difficult to obtain a decorative decorative board.
[0004]
Therefore, in order to obtain a decorative board with more excellent surface smoothness and sharpness, for example, the following methods have already been proposed.
[0005]
(A) A method in which a transparent resin is applied on the surface of a decorative sheet laminated on a substrate, smoothed by polishing, and further coated with a coating as necessary (Japanese Patent Laid-Open No. 50-25717, Japanese Patent Publication No. 54- No. 7842, JP-A-4-201497, etc.).
[0006]
(B) The surface of the decorative sheet laminated on the base material was thickly coated with an electron beam or an ultraviolet curable resin, and the coated surface was coated with a releasable shaping film with a mirror-like smooth surface. In this state, the resin is cured by irradiating with an electron beam or ultraviolet rays, and then the shaped film is peeled off (Japanese Patent Laid-Open Nos. 57-2754, 59-156749, 5-31871, etc.) ).
[0007]
(C) Thickly apply a high solid content adhesive on the substrate, preheat until the adhesive softens, place a decorative sheet, and bond with a hot press using a metal mirror plate To form the surface smoothly (Japanese Patent Laid-Open No. 51-101086, etc.).
[0008]
(D) Using a decorative sheet including at least a thermoplastic resin film layer that is thick and rich in thermoformability, and hot-pressing using a metal mirror surface roll when this is laminated on a substrate or after lamination. Thus, a method for forcibly forming a smooth surface (JP-A-2-55126, JP-A-4-140137, JP-A-6-179250, etc.).
[0009]
However, the method (A) requires a complicated process such as painting and polishing after the lamination of the decorative sheet, and the productivity is low, and fine irregularities on the surface of the base material appearing on the surface of the coating film are polished by polishing. There is a problem that it is not always easy to completely smooth.
[0010]
In addition to the complicated process, the method (B) requires a special material such as a shaping film, is troublesome in material management, and is expensive as an electron beam or ultraviolet irradiation device. There are problems such as requiring complicated manufacturing equipment and labor for maintenance of the equipment.
[0011]
In addition, the methods (C) and (D) require special manufacturing equipment such as a large hot press device or hot-press roll press device, an expensive metal mirror plate or mirror roll, Problems such as it is difficult to obtain satisfactory results due to the biting of dust between the decorative sheet and the mirror plate or mirror roll, and the surface of the mirror plate or mirror roll being damaged. There is.
[0012]
Instead of applying a surface smoothing treatment after laminating the decorative sheet on the base material as in the above methods, (E) the adhesive sheet is laminated on the base material via an adhesive. A method for obtaining a smooth surface without being affected by irregularities on the surface of the substrate by using an electron beam or an ultraviolet curable resin containing no volatile matter as and curing the adhesive after lamination of the decorative sheet ( There is also a proposal of JP-A-4-104866.
[0013]
However, if the electron beam or ultraviolet curable resin is solvent-free and liquid, there is no drying shrinkage due to volatilization of the solvent, but due to its high crosslink density, the crosslink curing reaction The shrinkage (curing shrinkage) that accompanies the substrate is never negligible, and the cross-linking curing reaction is virtually instantaneously completed by irradiation with an electron beam or ultraviolet rays. In reality, the influence on the sheet surface cannot be completely eliminated.
[0014]
In addition, as in the method (B) described above, there is a problem that a complicated manufacturing facility such as an electron beam or an ultraviolet ray irradiation device is required and maintenance of the facility is required.
[0015]
[Problems to be solved by the invention]
The present invention has been made to solve the above-described problems in the prior art, and the object of the present invention is to manufacture a decorative board in which a decorative sheet is laminated on a base material via an adhesive. In this method, a cosmetic that can easily and stably produce a high-definition decorative board excellent in surface smoothness without the influence of irregularities on the surface of the base material appearing on the surface of the decorative sheet. It is in providing the manufacturing method of a board.
[0016]
[Means for Solving the Problems]
The method for producing a decorative board according to the present invention is a method for producing a decorative board in which a decorative sheet is laminated on a base material via an adhesive, using a solvent-free and room-temperature-curable liquid resin as the adhesive, After the adhesive is applied to the surface of the base material or the back surface of the decorative sheet or both, the base material and the decorative sheet are superposed in a state where the adhesive is maintained in a liquid state, and the fluidity of the adhesive Is used to smooth the surface of the decorative sheet, and then the adhesive is cured at room temperature.
[0017]
In particular, the adhesive has a viscosity of 0.3 to 2 Pa · s when the decorative sheets are overlaid.
[0018]
In particular, the adhesive is applied in an amount of 300 to 1000 g / m ² .
[0019]
In particular, the adhesive has an epoxy resin as a main component.
[0020]
In particular, the decorative sheet is mainly composed of a thermoplastic resin and has a thickness of 0.1 to 0.3 mm.
[0021]
In particular, the thermoplastic resin is an acrylic resin, a polyolefin resin, or a polyester resin.
[0022]
In particular, the decorative sheet is characterized in that a pattern printing layer is formed on the back surface of a transparent thermoplastic resin sheet.
[0023]
In particular, the base material is a breathable base material, and when the adhesive is cured, a vacuum suction device is disposed under the base material, and bubbles in the adhesive are sucked and defoamed. It is what.
[0024]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a method for producing a decorative board according to the present invention will be described below in detail with reference to the drawings. FIG. 1 is a side sectional view showing an embodiment of a method for manufacturing a decorative board according to the present invention in the order of steps.
[0025]
As shown in FIG. 1, the method for producing a decorative board of the present invention applies an adhesive 2 made of a solvent-free and room-temperature-curable liquid resin on a substrate 1, and maintains the liquid state before curing. In the state, the decorative sheet 3 is superposed on the application surface of the adhesive 2, the surface of the decorative sheet 3 is smoothed by using the fluidity of the liquid adhesive 2, and then the adhesive 2 is cured at room temperature. Consists of. Note that the adhesive 2 may be applied to the back surface of the decorative sheet 3 instead of being applied to the substrate 1, and may be applied to both of them.
[0026]
In order to smooth the surface of the decorative sheet 3 using the fluidity of the liquid adhesive 2, the adhesive 2 has flow characteristics that are easy to smooth (leveling) or the rigidity of the decorative sheet 3. If (waist) is strong and easily smoothed naturally, the decorative sheet 3 is left on the substrate 1 with the liquid adhesive 2 interposed therebetween, and is smoothed by the natural flow of the adhesive 2. May be.
[0027]
Further, when it is difficult to smooth the surface sufficiently by the above method or when it is desired to smooth the surface more quickly, the adhesive 2 is flowed by squeezing with a roller or the like from the surface of the laminated decorative sheet 3. Smoothing, pressing a smooth plate from the surface of the laminated decorative sheet 3 to make the adhesive 2 flow, or smoothing the decorative sheet 3 side down Alternatively, the adhesive 2 may be flowed and smoothed by using the weight of the substrate 1.
[0028]
After sufficiently smoothing the surface of the decorative sheet 3 by the flow of the adhesive 2, the adhesive 2 is cured at room temperature. However, the normal temperature here is not limited to the room temperature at the time of work, for example, when curing is slow at normal room temperature, or when curing is slow due to low room temperature in winter or cold districts, etc. In order to accelerate hardening, it may be heated within a range of approximately 50 ° C. or less.
[0029]
Further, it is not always necessary to cure at normal temperature until the completion of curing, and after curing has progressed to such an extent that the adhesive 2 loses fluidity, it is heated to a temperature exceeding normal temperature (for example, about 50 to 150 ° C.). The curing can be completed quickly.
[0030]
As described above, the decorative plate manufacturing method of the present invention uses a solvent-free and room-temperature-curable liquid resin as the adhesive 2 for bonding the base material 1 and the decorative sheet 3, and further adheres to it. Since the base material 1 and the decorative sheet 3 are superposed in the state where the agent 2 maintains the liquid state before curing, the fluidity (leveling property) of the adhesive 2 is used to smooth the surface of the decorative sheet 3. In addition, since the adhesive 2 is cured at room temperature after the smoothing, even if the adhesive 2 may shrink due to curing, the adhesive 2 has fluidity. In this case, the unevenness generated by picking up the unevenness on the surface of the base material 1 due to the shrinkage of the adhesive 2 is filled with the flow (leveling) of the adhesive 2 and cured while being re-smoothed. Compared to wire or UV curable adhesives The curable resin generally has less curing shrinkage than the electron beam or ultraviolet curable resin, and thus the influence of the unevenness of the surface of the substrate 1 on the surface of the decorative sheet 3 is greatly reduced, and the surface smoothness is excellent. A highly clear decorative board can be easily obtained.
[0031]
In addition, when the surface of the decorative sheet 3 is smoothed by using the fluidity of the adhesive 2, the hot-pressing method can be used even when the plate is pressed with a roller or the like as described above. Unlike the case, the decorative sheet 3 does not need to be heated so as to be thermally deformed, and can be performed at room temperature, so that dust is caught between the decorative sheet 3 and the roller or the plate, or the surface of the roller or the plate is damaged. (Especially with protrusions), even if the decorative sheet 3 is locally recessed, when the pressure is released after the smoothing, the adhesive 2 under the decorative sheet 3 flows. Since the dents are corrected, it is possible to easily obtain a high-definition decorative board excellent in surface smoothness without being affected by dust and scratches.
[0032]
In order to fully bring out the effects of the present invention, the viscosity of the adhesive 2 is 0.3 to 2 Pa · s, more preferably 0.5 to 1 Pa at least when the base material 1 and the decorative sheet 3 are overlapped. -It is preferable to be within the range of s. If the viscosity of the adhesive 2 is too low, it is difficult to thickly coat the surface of the base material 1 to fill the unevenness of the substrate 1, and the leveling failure due to dripping or overflow of the adhesive is difficult. It may be a cause. On the other hand, even if the viscosity of the adhesive 2 is too high, it may cause uneven coating, or smoothing may be difficult due to poor fluidity.
[0033]
Moreover, it is preferable to set it as the application amount of the adhesive agent 2 in the range of 300-1000 g / m < ² >. If the coating amount of the adhesive 2 is too small, the unevenness on the surface of the base material 1 cannot be filled sufficiently, or it is sandwiched between the base material 1 and the decorative sheet 3 and flows sufficiently for the capillary effect. The smoothing effect tends to be insufficient. On the other hand, if the amount of the adhesive 2 applied is too large, it may be difficult to apply the adhesive 2 or may cause leveling failure due to dripping or overflow, and it is also uneconomical.
[0034]
The type of the adhesive 2 used in the method for producing a decorative board of the present invention is not particularly limited as long as it is made of a solventless and room temperature curable liquid resin. Such adhesives are known to be composed of various resin systems such as epoxy resins, isocyanate curable urethane resins, cyanoacrylate resins, and anaerobic curable acrylate resins. In view of leveling characteristics, curing characteristics, etc., it is most desirable to use an epoxy resin.
[0035]
The room temperature curable liquid epoxy resin is, for example, a liquid epoxy resin that is a polymer compound having a glycidyl group (epoxy group) introduced at the terminal and / or side chain, such as a bisphenol type epoxy resin or a novolac type epoxy resin. For example, polyamines, polyamides, acid anhydrides, polyphenols and the like are blended as curing agents, and among them, those blended with polyamines or polyamides as curing agents are excellent in room temperature curability. Is preferred.
[0036]
Since various kinds of room temperature curing type liquid epoxy resins are commercially available for bonding or casting, the adhesiveness and fluidity (leveling property) to the substrate 1 and the decorative sheet 3 are among them. These may be selected and used as appropriate. However, the high filling type has strong pseudoplasticity and thixotropy and tends to be inferior in leveling. Therefore, it is desirable to use the non-filling or low filling type, especially in the low shear region. A casting type having an excellent resistance is suitable.
[0037]
The adhesive 2 may be colorless and transparent, or may be colored translucent or opaque by adding a colorant such as a dye or a pigment as necessary. Further, for example, various additives such as a filler, an ultraviolet absorber, a light stabilizer, an antistatic agent, a flame retardant, and a tackifier may be appropriately added as necessary.
[0038]
The decorative sheet 3 is used for the purpose of protecting the surface of the base material 1 and imparting an appearance design to the decorative board, and the material thereof is not particularly limited in the present invention. For example, paper, woven fabric, and non-woven fabric are used. What is conventionally used as a constituent material of a decorative sheet for a decorative board, such as a veneer, a thermoplastic resin sheet, a metal foil, or a laminate of two or more thereof, can be arbitrarily used.
[0039]
However, in order to fully exhibit the smoothing effect utilizing the fluidity of the adhesive 2 in the present invention, the decorative sheet 3 is a material excellent in rigidity (waist, flexure restoring property) that tries to maintain smoothness by itself. From this point of view, it is preferable that the main component is a thermoplastic resin. Further, if the thickness of the decorative sheet 3 made of the thermoplastic resin is too thin, it is difficult to be smoothed due to insufficient rigidity, and conversely, if it is too thick, it is difficult to overlap the base material 1 without entraining air. In addition to being inferior in workability and being uneconomical, it is preferable to be within a range of about 0.1 to 0.3 mm.
[0040]
The type of the thermoplastic resin used for the decorative sheet 3 is not particularly limited, but the surface properties such as abrasion resistance, scratch resistance, water resistance, solvent resistance, and stain resistance required as a surface material of the decorative board, and weather resistance In addition, it is preferable that the material is excellent in rigidity as described above. From such a viewpoint, it is preferable to use acrylic resins such as polymethyl methacrylate, polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate and polycarbonate, and the like.
[0041]
The detailed configuration of the decorative sheet 3 is not particularly limited in the present invention. For example, the decorative sheet 3 may be a single colored or non-colored transparent or opaque thermoplastic resin sheet, or may be a colored thermoplastic resin sheet. It may be one having a pattern printing layer on the surface. However, in order to emphasize the sharpness of the decorative board produced by the production method of the present invention, it is desirable to have a configuration having a transparent thermoplastic resin sheet on at least the surface side.
[0042]
Specifically, a configuration in which a decorative sheet 3 made of a single transparent thermoplastic resin sheet is provided on the colored adhesive 2, or a transparent thermoplastic resin on the colored or non-colored adhesive 2. Structure (FIG. 1) or coloring provided with a decorative sheet 3 provided with a pattern printing layer 32 (including a solid printing layer or a combination of a solid printing layer and a pattern printing layer) on the back surface of the resin sheet 31 Or it is preferable to set it as the structure which uses the decorative sheet 3 formed by laminating | stacking a transparent thermoplastic resin sheet on a non-colored transparent or opaque thermoplastic resin sheet through a pattern printing layer.
[0043]
Among these, as shown in FIG. 1, the configuration using a decorative sheet 3 in which a pattern printing layer 32 is provided on the back surface of a transparent thermoplastic resin sheet 31 is most preferable. According to this configuration, since the transparent thermoplastic resin sheet 31 having a sufficient thickness can be used, the rigidity (waist, deflection recovery property) is strong and advantageous for smoothing using the fluidity of the adhesive 2. In addition, high definition is emphasized by the thickness of the transparent layer, and a high-level design expression can be imparted by the pattern printing layer 32.
[0044]
Thus, in order to obtain a decorative board in which high definition is more emphasized by the production method of the present invention, the transparent thermoplastic resin sheet 31 has high transparency, low haze, hard and rigid ( It is most desirable to use an acrylic resin sheet such as polymethylmethacrylate, which has a strong elasticity and flexibility, and is easily available as a mirror-like glossy surface.
[0045]
The transparent thermoplastic resin sheet 31 may be colored by adding a colorant such as a dye or a pigment as long as the transparency is not impaired. Further, for example, additives such as an ultraviolet absorber, a light stabilizer, a heat stabilizer, a filler, a flame retardant, a lubricant, an antistatic agent, an antibacterial agent, and an antifungal agent may be appropriately added as necessary. . Further, if necessary, a surface protective layer made of a transparent resin composition such as a two-component curable urethane resin or an acrylate ionizing radiation curable resin may be provided on the surface. Of course, various additives may be added to the layer.
[0046]
There is no restriction | limiting in particular in the kind of base material 1 used in this invention, If it is a base material for decorative boards generally used widely conventionally, it can be used arbitrarily. Specifically, for example, metal base materials such as steel plates, brass plates, aluminum plates, and stainless steel plates, inorganic base materials such as glass plates, ceramic plates, gypsum boards, calcium silicate plates, cement-based incombustible plates, Wood based substrates such as board, plywood, laminated wood, medium density fiber board and particle board can be used.
[0047]
In the method for producing a decorative board of the present invention, if air bubbles are mixed in the adhesive 2, this may give slight unevenness to the surface of the decorative sheet 3 and impair high definition. For this reason, when superimposing the base material 1 and the decorative sheet 3, it is necessary to pay close attention so that air bubbles are not caught in the adhesive 2. In addition, when the base material 1 has air permeability, after the base material 1 and the decorative sheet 3 are overlapped via the adhesive 2, a vacuum suction device is disposed on the back side of the base material 1. The air bubbles in the adhesive 2 are sucked and defoamed, thereby eliminating the influence of the bubbles on the surface of the decorative sheet 3 and stably producing a high-definition decorative board having excellent surface smoothness. Can do.
[0048]
【Example】
Gravure a wood grain pattern consisting of four colors: base plate, blurred plate, bone plate, and conduit plate on the back of a 0.3 mm thick transparent polymethylmethacrylate resin sheet (Mitsubishi Rayon Co., Ltd., trade name “Acryprene”) A decorative sheet was prepared by printing in the reverse order of printing by a printing method to form a pattern printing layer.
[0049]
Epoxy for casting having a viscosity of 0.85 Pa · s (850 cp) (25 ° C) as an adhesive on the surface of a 6 mm thick volcanic glassy multilayer board (trade name “Dailite” manufactured by Daiken Kogyo Co., Ltd.) 500 g / m ^{2 of} resin (manufactured by Yuka Shell Epoxy Co., Ltd., trade name “Epicoat”, blended with polyamine curing agent) was applied.
[0050]
After the application, the adhesive is leveled by leaving it at room temperature for several minutes, and then the adhesive coating surface is overlaid with the surface of the decorative sheet facing the pattern printing layer side and lightly rubbed with a rubber roll. Then, it was placed on a horizontal table, the adhesive was sufficiently leveled again to smooth the surface of the decorative sheet, and cured and cured at 20 ° C. for 12 hours to produce the decorative board of the present invention.
[0051]
The resulting decorative board has a mirror-like smooth surface, and has a highly transparent and thick resin sheet layer on the surface. Met.
[0052]
【The invention's effect】
As described above in detail, according to the method for producing a decorative board of the present invention, a decorative sheet is superposed on a base material via an adhesive made of a solvent-free and room-temperature-curable liquid resin, Since the decorative sheet surface is smoothed using the fluidity of the material and cured at room temperature, expensive materials and special equipment such as mirror plates or mirror rolls, hot-pressing devices, electron beams or ultraviolet irradiation devices, etc. Without being affected by the biting of dust, scratching of the mirror plate, etc., and without being affected by the curing shrinkage of the resin. A vivid decorative decorative board can be easily and stably manufactured with simple equipment.
[Brief description of the drawings]
FIGS. 1A to 1C are side sectional views showing an embodiment of a method for manufacturing a decorative board according to the present invention in the order of steps.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Base material 2 Adhesive 3 Makeup sheet 31 Transparent thermoplastic resin sheet 32 Picture printing layer

Claims (8)

In the method for producing a decorative board in which a decorative sheet is laminated on a substrate via an adhesive, a solvent-free and room-temperature curable liquid resin is used as the adhesive, and the adhesive is used on the surface of the substrate or the In a state where the adhesive is kept in a liquid state after being applied to the back surface of the decorative sheet or both, the base material and the decorative sheet are overlaid, and the surface of the decorative sheet is applied using the fluidity of the adhesive. A method for producing a decorative board, comprising: smoothing and then curing the adhesive at room temperature. The method for producing a decorative board according to claim 1, wherein the adhesive has a viscosity of 0.3 to 2 Pa · s when the decorative sheets are overlapped. Veneer method according to claim 1 or 2 coating amount of the adhesive is characterized by a 300~1000g / m ^2. The said adhesive agent has an epoxy-type resin as a main component, The manufacturing method of the decorative board in any one of Claims 1-3 characterized by the above-mentioned. The method for manufacturing a decorative board according to any one of claims 1 to 4, wherein the decorative sheet is mainly composed of a thermoplastic resin and has a thickness of 0.1 to 0.3 mm. 6. The method for manufacturing a decorative board according to claim 5, wherein the thermoplastic resin is an acrylic resin, a polyolefin resin, or a polyester resin. The method for producing a decorative board according to claim 5 or 6, wherein the decorative sheet has a pattern printed layer formed on the back surface of a transparent thermoplastic resin sheet. The base material is a breathable base material, and when the adhesive is cured, a vacuum suction device is disposed under the base material, and bubbles in the adhesive are sucked and defoamed. Item 8. A method for producing a decorative board according to any one of Items 1 to 7.

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