【発明の詳細な説明】
本発明は、意匠性が優れているのみならず、耐熱性、耐
衝撃性にも優れていて、カウンターやテーブルの表面等
水平面用途にも使用可能なＵｖ塗装複合化粧板に関する
ものである．
〔従来の技術〕
最近では、木質系基材に転写印刷により模様を印刷し、
表面にＵｖ塗装した化粧材が多く使用されるようになっ
てきた．これは、加工が容易で、しかも意匠性に優れて
いるためである．しかしながら、たとえば、光沢のある
仕上げにするためには、木質基材表面の平滑性が必要で
あり、通常は加工しやすく、表面の平滑性が優れた中、
高密度パーチクルボード（以下ＭＤＦと記す）等が使用
される．アクリル樹脂系やポリエステル樹脂系のＵｖ塗
膜は表面硬度の優れたものであるが、ＭＤＦを使用した
ものでは衝撃に弱く、ものがあたったりすると凹み等が
生じやすく、ワレが生じることもある．
衝撃に強くするためには塗膜を厚くすればよいが、２Ｍ
を厚くするとコストが高くなるばかりでなく、使用中経
時変化し、ヒビワレ等が生じやすくなる欠点がある．
〔発明が解決しようとする課題〕
本発明者は、従来化粧層の耐熱性、耐シガレット性が劣
り、水平面用途には実用化しにくい表面性能を改善する
ために研究した結果、表面に金属箔を貼合せたプラスチ
ック積層板を木質系基材に貼合わせ、その表面に印刷し
、ＵＶ塗装することにより、基材として平滑性が劣るパ
ーチクルボードや合板が使用可能になるばかりでなく、
衝撃性や耐熱性が優れ、カウンター等の水平面用途にも
使用可能な化粧材を見いだし、本発明を完成するに至っ
たものである．
〔課題を解決するための手段〕
本発明は、木質基材の表面に金属箔付プラスチック積層
板を貼りその上に模様を印刷し、その上にＵＶ塗装する
ことを特徴とする金属箔入りＵＶ塗装複合化粧板に関す
るものである．
本発明に使用される．木質系基材としては、ＭＤＦ１合
板、パーチクルボード等あるいはその複合材質が使用で
きる．金属箔を複合化粧板の中間層に入れ、耐熱性、難
燃性を向上させる方法は一般によく使われる方法である
．しかし、木質基材と金属箔を貼り合せるには、非常に
工数がかかり、熟練のいる作業である．
たとえば、木質基材表面にゴム系接着剤を用いて金属箔
を貼り合せる場合、接着剤を平滑に塗布することがむず
かしい．またエポキシ系接着剤やアクリル系エマルジッ
ンタイプの接着剤を使用し、貼り合せることも可能であ
るが、木質基材表面に直接金属箔を貼り合せただけでは
、耐衝撃性が弱く、カウンターなどの水平面用には使い
づらい．もちろん金ＷＡ箔を厚くすれば耐衝撃性は向上
するが、一般には木質系基材に比べて金属箔は非常に価
格が高い．また耐熱性向上させるためだけであれば１０
〜５０μの厚さがあれば十分である．本発明は金属箔付
プラスチック積層板を作威し、これを木質基材表面に貼
り合せるという二段法をとることにより、作業性が優れ
ているばかりでなく、平滑性が優れ、しかも耐熱性、耐
衝撃性にすぐれた複合化粧板を容易に生産することにあ
る．金属箔としては比較的安価なアルξ箔を使用するが
、たとえば印刷回路基板用のｗ４Ｍ等も使用できる．ア
ル逅箔としては、取扱い作業性、コスト等を考えて、通
常２０〜１００μの厚さのものを使用するが、もちろん
これ以上厚いものでも使用できる．
金属箔付プラスチック積層板は一般の熱硬化性樹脂化粧
板に準じた条件で生産できる．たとえば、金属箔裏面に
、印刷回路基板用銅箔裏面に塗布されているのと同じよ
うに接着剤を塗布したものと、紙にフェノール樹脂を含
浸塗布したものを数枚積層威形する方法がとれる．また
、紙にエボキシ樹脂系接着剤壱含浸塗布したものを接着
用フィルムとして使用し、金属箔、接着用フィルム、フ
ェノール樹脂含浸紙数枚の順に重ねて積層戒形する方法
がとれる．
加圧或形条件は、一般のメラミン樹脂化粧板の条件（温
度１００〜１７０℃、圧力６０〜１２０ｋｇ／ｃｊ）に
準ずる．
金属箔付プラスチック積層板の厚さは耐衝撃性を良くす
るためには厚い方が好ましいが、コストが高くなる．ま
たあまり薄くすると取扱い作業性が悪く、また基材の凹
凸が積層板表面にまで影響するようになる．一般には０
．３閣から１． ２ ｍ程度の厚さのものが、作業性、
耐衝撃性、コスト面から考えて適当である．
このようにして生産した金属箔付プラスチック積層板の
周辺を裁断し、裏面をサンディゾグしておけば、一般の
メラ竃ン樹脂化粧板を木質系基材に貼合せるのと同じよ
うな方法で、容易に木質系基材表面に金属箔付プラスチ
ック積層板を貼合せることが可能となる．
この複合基材のアルミ箔表面には、塗装したり捺染印刷
をほどこしたりすることにより模様をほどこすことも可
能であるが、転写印刷は作業性が良い上にさらに意匠性
を増すことができるので、好ましい方法である．転写印
刷の方法は、一般にトピラやカウンター等家具関係の加
工時に使用されている方法が使用できる．転写印刷によ
り模様をほどこした後ｕｖｌ装をして仕上げを行う．Ｕ
Ｖ塗料としては、アクリル樹脂系やポリエステル樹脂系
のものが使用できる．塗装装置、紫外線照射装置等も一
般に市販されているものが使用できる．
〔実施例〕
図面に基づいて、本発明の実施例を説明する．■ 固形
のエポキシ樹脂をアセトンに溶解させ、樹脂分５０％の
樹脂液をつくり、高温硬化型の硬化剤を添加し、これを
化粧板用オーバーレイ原紙（米坪４０ｇ／ポ）に含浸塗
布し、１２０゜Ｃの乾燥胴で乾燥させ、接着用フィルム
（６ａ）を作威した．
■ メラミン樹脂化粧板のコアー用フェノール樹脂含浸
祇（４ａ） ３枚の上に■で作威した接着用フィルムを
重ねさらにその上に３０μの硬質アルミＮ（３）を重ね
、メラミン樹脂化粧板と同じ戒形条件で積層威形し、周
辺を裁断し、裏面をサンディングして１． ２ ｗａ厚
のアルξ箔付フェノール樹脂積層板（Ａ）を作戒した．
■ ２０ｍ厚さの木質基材（ハ・−ドボード）（５）の
上に木工用酢酸ビニル系エマルジッンタイプの接着剤（
７ａ）を塗布し、アルミ箔付フェノール樹脂積層板（Ａ
）をアルミ箔面が表面側になるように重ねて圧締し、ア
ルξ箔付複合基板（Ｂ）を作威した．
■ アルξ箔付複合基板（Ｂ）を７５０ ｘ １５００
−の大きさに裁断し、周辺をＮＧルーターで曲面加工し
、テーブル用の合板を作戒した．この合板に転写印刷に
より曲面部分までつながった木目模様（２）を印刷し、
さらにその上にポリエステル系Ｕｖ塗料（１ａ）を用い
、ＵＶ塗装装置を用い、塗！（１）が約０．３−になる
ように塗装し、仕上げた。Detailed Description of the Invention The present invention is a UV coating composite makeup that not only has an excellent design but also has excellent heat resistance and impact resistance, and can be used for horizontal surfaces such as counters and table surfaces. It is related to the board. [Conventional technology] Recently, patterns have been printed on wooden base materials by transfer printing.
Decorative materials with UV-coated surfaces are increasingly being used. This is because it is easy to process and has an excellent design. However, for example, in order to achieve a glossy finish, the surface of the wood base material needs to be smooth, and while it is usually easy to process and has an excellent surface smoothness,
High-density particle board (hereinafter referred to as MDF) is used. Acrylic resin-based and polyester resin-based UV coatings have excellent surface hardness, but those made of MDF are weak against impact and are prone to denting and cracking when hit by objects. In order to make it more resistant to impact, the coating film can be made thicker, but 2M
Making the material thicker not only increases the cost, but also has the disadvantage that it changes over time during use, making it more likely to crack and crack. [Problems to be Solved by the Invention] As a result of research to improve the surface performance of conventional decorative layers, which have poor heat resistance and cigarette resistance and are difficult to put into practical use in horizontal surface applications, the present inventor has developed a method using metal foil on the surface. By laminating the bonded plastic laminate to a wood base material, printing on the surface, and applying UV coating, it not only becomes possible to use particle board and plywood, which have poor smoothness, as the base material, but also
They discovered a decorative material that has excellent impact resistance and heat resistance, and can be used for horizontal surfaces such as counters, leading to the completion of the present invention. [Means for Solving the Problems] The present invention provides a UV-containing metal foil, which is characterized in that a plastic laminate with metal foil is pasted on the surface of a wooden base material, a pattern is printed thereon, and UV coating is applied thereon. This article concerns painted composite decorative boards. Used in the present invention. As the wood base material, MDF1 plywood, particle board, etc., or composite materials thereof can be used. A commonly used method is to add metal foil to the intermediate layer of composite decorative boards to improve heat resistance and flame retardancy. However, bonding the wooden base material and metal foil is a very time-consuming process that requires skill. For example, when attaching metal foil to the surface of a wood base material using a rubber adhesive, it is difficult to apply the adhesive smoothly. It is also possible to bond using epoxy adhesive or acrylic emulsion type adhesive, but simply bonding metal foil directly to the surface of the wood base material has poor impact resistance and cannot be used as a countertop. It is difficult to use for horizontal surfaces such as Of course, making the gold WA foil thicker will improve its impact resistance, but metal foil is generally much more expensive than wood-based base materials. Also, if it is just to improve heat resistance, 10
A thickness of ~50μ is sufficient. The present invention employs a two-step process in which a plastic laminate with metal foil is made and bonded to the surface of a wooden base material, which not only provides excellent workability but also excellent smoothness and heat resistance. The objective is to easily produce a composite decorative board with excellent impact resistance. Aluminum foil is used as the metal foil, which is relatively inexpensive, but W4M for printed circuit boards, for example, can also be used. Considering handling efficiency, cost, etc., aluminum foil is usually used with a thickness of 20 to 100 μm, but of course thicker sheets can also be used. Plastic laminates with metal foil can be produced under conditions similar to those for general thermosetting resin decorative laminates. For example, one method is to laminate several sheets of metal foil coated with an adhesive similar to that applied to the back side of copper foil for printed circuit boards, and paper coated with phenolic resin impregnated. It can be taken. Another method is to use paper impregnated with an epoxy resin adhesive as an adhesive film, and then stack metal foil, adhesive film, and several sheets of phenol resin-impregnated paper in that order. The pressurization and shaping conditions are similar to those for general melamine resin decorative boards (temperature 100-170°C, pressure 60-120 kg/cj). The thickness of the plastic laminate with metal foil is preferably thicker in order to improve impact resistance, but this increases the cost. Furthermore, if it is made too thin, it will be difficult to handle, and the unevenness of the base material will affect the surface of the laminate. Generally 0
．． 1 from 3 temples. A thickness of about 2 m is good for workability,
Appropriate in terms of impact resistance and cost. If the periphery of the plastic laminate with metal foil produced in this way is cut and the back side is sandizogged, it can be made using the same method as laminating a general melasma resin decorative board to a wood base material. It becomes possible to easily attach a plastic laminate with metal foil to the surface of a wood base material. Patterns can be applied to the aluminum foil surface of this composite base material by painting or textile printing, but transfer printing is easy to work with and can further enhance the design. Therefore, this is the preferred method. Transfer printing methods can be those that are generally used when processing furniture-related items such as topiras and counters. After the pattern is applied by transfer printing, UVL binding is applied to finish. U
As the V-paint, acrylic resin-based or polyester resin-based ones can be used. Commercially available coating equipment, ultraviolet irradiation equipment, etc. can also be used. [Example] An example of the present invention will be described based on the drawings. ■ Dissolve solid epoxy resin in acetone to create a resin liquid with a resin content of 50%, add a high-temperature hardening agent, and apply this to overlay base paper for decorative laminates (40g/Po) by impregnating it. It was dried in a drying cylinder at 120°C to form an adhesive film (6a). ■ Lay the adhesive film prepared in ■ on top of the three sheets of phenolic resin-impregnated material (4a) for the core of the melamine resin decorative board.Furthermore, layer 30μ hard aluminum N (3) on top of the adhesive film, Laminated and shaped under the same conditions, cut out the periphery, and sanded the back side.1. A phenolic resin laminate (A) with aluminum foil of 2 wa thickness was prepared. ■ Apply vinyl acetate-based emulsion type adhesive for woodworking (
7a) and coated with aluminum foil attached phenolic resin laminate (A
) were stacked and pressed so that the aluminum foil side was on the front side, and a composite substrate with aluminum foil (B) was made. ■ Composite board with Al ξ foil (B) 750 x 1500
- I cut it to size, processed the curved surface with an NG router, and carefully trimmed the plywood for the table. On this plywood, we print a wood grain pattern (2) that extends to the curved surface using transfer printing,
Furthermore, use polyester UV paint (1a) on top of it and use a UV coating device to paint! It was painted and finished so that (1) was approximately 0.3-.
■ このテーブル用台板はＪＩＳ−Ｋ−６９０２ ｒ耐
衝撃試験を行ったところ、４００ｍｍの高さから鋼球を
落しても凹みはつかなかった．
またタバコに火をつけて直接台板表面に置き、火が消え
るまで静置したが、′コゲ゜゜や変色の跡はみられなか
った．
〔発明の効果〕
本発明の方法によると、意匠性が優れているばかりでな
く、耐熱性、耐衝撃性に優れ、カウンターやテーブルの
水平面に使用できる複合化粧板を作業性良く製造するこ
とができる．特に耐シガレット性が優れ、火のついたタ
バコを直接置いてもコゲたり表面が変色したりすること
もない．■ When this table base plate was subjected to a JIS-K-6902 r impact test, no dents were formed even when a steel ball was dropped from a height of 400 mm. I also lit a cigarette, placed it directly on the surface of the base plate, and let it stand until the flame went out, but no signs of burning or discoloration were observed. [Effects of the Invention] According to the method of the present invention, it is possible to manufacture a composite decorative board with good workability, which not only has an excellent design but also has excellent heat resistance and impact resistance, and can be used for horizontal surfaces such as counters and tables. can. It has particularly excellent cigarette resistance, and the surface will not burn or discolor even if a lit cigarette is placed directly on it.
【図面の簡単な説明】[Brief explanation of the drawing]
第１図は本発明の金属箔付複合化粧板の一例の断面図で
ある．
１：ＵＶ塗装膜
２：木目模様
３：アルξ箔
４：プラスチック積層板層
５：木質基材
６：金属箔とプラスチック積層板との接着層７：金属箔
付プラスチック積層板と木質基材との接着層
第２図は本発明の実施例の製造工程概略断面図である．
（ａ）は金属済付プラスチック積層板の作威工程、（ｂ
）は木質基材に金Ｂ箔付プラスチック積層板の貼合せ工
程、（ｃ）は転写印刷及びＵＶ塗装工程を示す．Figure 1 is a cross-sectional view of an example of a composite decorative board with metal foil according to the present invention. 1: UV coating film 2: Wood grain pattern 3: Al ξ foil 4: Plastic laminate layer 5: Wood base material 6: Adhesive layer between metal foil and plastic laminate 7: Plastic laminate with metal foil and wood base material FIG. 2 is a schematic sectional view of the manufacturing process of an embodiment of the present invention.
(a) is the production process of plastic laminate with metal pre-attached; (b)
) shows the lamination process of a plastic laminate with gold B foil on a wooden base material, and (c) shows the transfer printing and UV painting process.