JPH04135856A - Thermosetting resin decorative board and manufacture thereof - Google Patents

Abstract

PURPOSE:To reduce the production cost of the title decorative board by using a shaping sheet, which consists of a thermoplastic resin layer having protrusion configurations on its surface and colorant layers formed on the protrusion configurations, as a template. CONSTITUTION:A thermoplastic resin film 11 of a matrix sheet 1 is provided with vessel recess configuration 12 with P depth of 10-100mum to form vessel protrusion configuration 23 on a shaping sheet 3. The shaping sheet 3 consists of a thermoplastic resin layer 22 and colorant layers 31 formed on the protrusions of the resin layer 22, and it is preferable that the thermoplastic resin layer 22 is so arranged as to be supported on a resin sheet 21. Owing to this arrangement, the synthetic resin layer 22 can be protected from damage or from unnecessary expansion and contraction, which may be caused by heat and pressure generated at the time of forming or by heat and pressure generated in the case where the shaping sheet 3 is used as a template when a thermosetting resin decorative board is produced. Accordingly, a laminated sheet 2 is also constituted of the matrix sheet 1, the support sheet 21 and the synthetic resin layer 22 sandwiched therebetween.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] This invention relates to a thermosetting resin decorative board and a method for manufacturing the same. More specifically, the present invention relates to a thermosetting resin decorative board that has an embossed pattern with colored recesses and can be manufactured at low cost, and a method for manufacturing the same.

[Conventional technology]

Traditionally, thermosetting resin decorative boards have been used for architectural interior materials such as walls and ceilings, furniture such as storage furniture and cabinets, and kitchen tables. Resin decorative boards are manufactured with a so-called synchronized embossed design effect in order to bring the design feeling closer to that of the natural product. For example, as a thermosetting resin decorative board expressing natural wood, a printed layer with a wood grain pattern is provided inside, and a fine conduit pattern is printed on the surface to a depth of 10 to 10 mm.
A decorative board is manufactured in which a concave portion of about 0 μm is formed and a coloring agent is embedded in the concave portion.

Conventional manufacturing methods for such decorative laminates include metal textured plates that are subjected to treatments such as etching and sandblasting when the resin of thermosetting resin decorative laminates is cured by heating and pressure treatment, and electroforming. Emboss is formed on the surface by using the obtained metal uneven plate or a resin uneven plate reproduced from these metal plates as a template, and then a coloring agent is applied to the surface, and then a wiping treatment is performed. A manufacturing method is known in which the embossed recesses are colored.

[Problem to be solved by the invention]

However, in the conventional manufacturing method of thermosetting resin decorative laminates as described above, during production, plate-shaped templates called metal embossed plates or resin embossed plates copied from the metal embossed plates are used in a number corresponding to the number of press stages. As a result, the equipment configuration for continuously manufacturing decorative laminates becomes complicated, and as a result,
There has been a problem in that the metal uneven board is frequently damaged during hot-press molding of the thermosetting resin decorative board. Furthermore, since the metal textured plate itself is very expensive, it significantly increases the manufacturing cost of the thermosetting resin decorative board. Moreover, it is necessary to prepare a spare metal uneven board in case the metal uneven board is damaged, which further increases the manufacturing cost of the thermosetting resin decorative board.

Furthermore, a separate process is required to form embossed recesses on the surface of the decorative thermosetting resin board, and to embed the colorant in the recesses, apply the colorant to the surface of the decorative board and wipe it. Therefore, the total number of steps is large, which also increases the manufacturing cost of the thermosetting resin decorative board. In addition, there is a problem in that a large amount of colorant is wasted during coating and wiping of the colorant.

This invention aims to solve the problems of the prior art as described above, and makes it possible to manufacture a thermosetting resin decorative board having an embossed pattern with colored recesses at a low cost.
The purpose is to provide a decorative board that imitates natural wood etc. at a low cost.

[Means to solve the problem]

The above objects have been achieved by this invention as described below. That is, the present invention provides a method for manufacturing a thermosetting resin decorative board having a concave shape on the surface and a coloring agent embedded in the concave portion, comprising: (a) a thermoplastic resin layer having a convex shape on the surface; a step of placing a molding sheet consisting of a coloring agent layer formed on the part and a thermosetting resin-impregnated sheet a so as to sandwich the coloring agent layer; (b) the molding sheet and the thermosetting resin; curing the thermosetting resin by heating and pressing the impregnated sheet together, forming recesses corresponding to the projections of the thermoplastic resin layer, and transferring the colorant layer to the recesses; and (c) The present invention provides a method for producing a thermosetting resin decorative board, which comprises the step of peeling off the shaped sheet from the cured product in step (b), and a thermosetting resin decorative board produced by this method.

Further, a thermosetting resin decorative board comprising a thermoplastic resin layer having a convex shape on the surface and a coloring agent layer formed on the convexity, which is used for manufacturing the thermosetting resin decorative board of the present invention. We also provide molding sheets for molding and coloring.

In the manufacturing method of the present invention, when a thermosetting resin decorative board is manufactured, when the thermosetting resin is heated and pressurized to cure it, the thermosetting resin is heated and pressurized together with a molded sheet having a colorant layer provided on the convex portions of the surface. Then, by peeling off the shaped sheet, the surface embossing of the thermosetting resin decorative board and the coloring of the embossed recesses are performed simultaneously.

Hereinafter, the present invention will be described in detail based on the drawings, taking as an example a thermosetting resin decorative board having a natural wood design. Note that in each drawing, the same number indicates the same configuration.

FIGS. 1(a) to 1(c) show the manufacturing process of the shaped sheet of the present invention. This will be explained in more detail below.

FIG. 1(a) is a cross-sectional view of a master sheet 1 that serves as a mold for producing a molded sheet. This matrix sheet 1 includes a conduit having a depth of about 10 to 100 μm for forming the conduit convex shape 23 of the molding sheet 3 of the present invention shown in FIG. 1(c) in the thermoplastic resin film II. A recess shape 12 is provided.

As such a thermoplastic resin film 11, a polyvinyl chloride film, an acrylic film, or the like having a thickness of about 50 to 200 μm can be used. Note that the conduit recess shape 12 can be formed by hot-pressure embossing the thermoplastic resin film 11 with a metal roll embossing plate having a conduit convex shape.

FIG. 1(b) is a cross-sectional view of a laminated sheet 2 in which a thermoplastic resin layer 22 and a support sheet 21 are laminated on a matrix sheet 1 in order to manufacture a molded sheet 3 of the present invention. .

That is, the shaped sheet 3 of the present invention is composed of a thermoplastic resin layer 22 and a coloring agent layer 31 formed on the convex portions of the resin layer. Preferably, as shown in FIG. The layer 22 is supported by the resin sheet 21.

As a result, the synthetic resin layer 22, heat and pressure during its molding, or heat and pressure when the molding sheet 3 is used as a template when manufacturing a thermosetting resin decorative board,
For this reason, the laminated sheet 2 shown in FIG. 1(b) can be prevented from being damaged or from unnecessary expansion and contraction.
Support sheet 21 and synthetic resin layer 22 sandwiched therebetween
It consists of

Any material can be used for the support sheet 21 as long as it functions as a support for the shaped sheet 3. For example, paper, a resin film such as a polyester film, metal foil, or a composite material thereof can be used.

Further, the thermoplastic resin layer 22 is a layer that inverts and reproduces the conduit concave shape 12 on the surface of the matrix sheet 1 and functions as a template for manufacturing the thermosetting resin decorative board of the present invention,
The material enters into the conduit concave shape 12 on the surface of the matrix sheet 1 in a softened state, and after cooling, can accurately reproduce the conduit concave shape 12 on the surface of the matrix sheet 1, and is thermosetting. It is preferable to use a material that can maintain its shape even under the heating and pressure conditions during production of the resin decorative board, and in addition has good releasability from the thermosetting resin decorative board after curing. As such resin, for example, polymethylpentene resin, polypropylene resin, etc. can be used.

Further, the thickness of the thermoplastic resin layer 22 is determined by the conduit concave shape 23.
Although it depends on the depth of the thermoplastic resin layer 22 itself and the strength of the thermoplastic resin layer 22 itself, it is preferably about 15 to 120 μm.

Any method can be used to mold the laminated sheet 2 as long as the thermoplastic resin layer 22 can be molded to have a conduit convex shape 23 corresponding to the conduit concave shape 12 of the matrix sheet 1. For example, a molten thermoplastic resin is extruded from an extrusion die onto the support sheet 21 to form a thermoplastic resin layer 2.
2, and then the matrix sheet 1 is coated with a synthetic resin layer 22.
It can be preferably manufactured by a method of stacking one on top of the other, applying pressure, and cooling.

According to this method, forming the conduit convex shape 23 on the thermoplastic resin layer 22, peeling the matrix sheet 1 from the thermoplastic resin layer 22, and forming the conduit convex shape 23 on the thermoplastic resin layer 22. Applying the colorant can be done in a series of steps.

Note that these molding conditions can be appropriately set depending on the thermoplastic resin used. For example, when using an extrusion die, the thermoplastic resin is extruded from the die onto the support sheet 21 at a temperature of about 150 to 330°C, and then, when the temperature of the thermoplastic resin layer 22 reaches 50 to 150°C, the matrix sheet is 1 on the thermoplastic resin layer 22 and about 2 to 20
It is pressurized at a pressure of Kg/cm2 and cooled with water or allowed to cool.

Note that if the thermoplastic resin layer 22 itself can be used as a template without a support sheet, the support sheet can be omitted.

FIG. 1(c) is a sectional view of the forming sheet 3 of the present invention. In the shaped sheet 3 shown in the same figure, a thermoplastic resin layer 22 having a conduit convex shape 23 on its surface is disposed on a support sheet 21.
are laminated, and a coloring agent layer 31 is further formed on the conduit convex shape 23.

This shaping sheet 3 is obtained by peeling and removing the matrix sheet 1 from the laminated sheet 2 shown in FIG. It can be manufactured by applying a coloring agent layer 31 onto the shape 23.

In this way, it is preferable to form the colorant layer 31 only on the conduit convex shape 23 of the thermoplastic resin layer 22 because the subsequent wiping step as in the conventional method is not required.

The colorant layer 31 is to be embedded in the conduit concave shape of the thermosetting resin decorative board, so a coloring agent layer 31 that has good adhesion to the thermosetting resin layer is appropriately selected and used.

For example, in the case of a melamine resin decorative board, cellulose acetate ink, polyamide ink, etc. can be used.

Although the shaped sheet 3 of FIG. 1(c) shows an embodiment in which the thermoplastic resin layer 22 is formed only on one side of the support sheet, the shaped sheet of this invention has a thermoplastic resin layer 22 formed only on one side of the support sheet. may be formed on both sides of the support sheet. In that case, it can be used as a template for two thermosetting resin decorative laminates at once.

FIG. 2 illustrates a method for manufacturing a thermosetting resin decorative board using the shaped sheet 3 of the present invention.

As illustrated in the figure, in the method for manufacturing a decorative board of the present invention, thermosetting resin is impregnated into paper or cloth or the like using a thermosetting resin in accordance with a conventional method except that the molding sheet 3 is used as a template. A decorative board is manufactured by using a resin-impregnated sheet and subjecting it to heating and pressure molding. That is, upper and lower heating plates 47, heat-resistant cushion sheets 46. Between metal plates 45 such as mirror panels, there is a backer paper 44 as a thermosetting impregnated sheet that plays the role of preventing warping of the decorative laminate, and a core paper 43 that serves as the base material of the decorative laminate and mainly determines the thickness of the decorative laminate. Titanium paper 42 and overlay paper 4I with wood grain pattern printed on them
are sequentially laminated, and further a molding sheet 3 having a conduit convex shape 23 that matches the wood grain pattern printed on the titanium paper is placed on the overlay paper 41 from the colorant layer 31 side. Here, the backer paper 44 has a basis weight of 55 to 160 g.
A melamine resin-impregnated paper obtained by impregnating a titanium paper of 40% to 100% by weight with melamine resin and drying it can be preferably used.

The fur paper 43 has a basis weight of 14 (1 to 181) g.
/m2 paper impregnated with 30 to 100% by weight of phenolic resin and dried can be used, and it is preferable to use about 4 to 8 sheets of this paper in a stacked manner. As the titanium paper 42 on which the wood grain pattern is printed, melamine resin-impregnated titanium paper that is impregnated with 40 to 100% by weight of melamine resin and dried is preferably used.

The overlay paper 41 is preferably a transparent resin-impregnated paper made by impregnating rayon pulp or nonwoven fabric with a basis weight of 25 to 45 g/m2 with 40 to 300% by weight of melamine resin and drying it.
Can be used.

The thermosetting resin used in the decorative board of the present invention includes, in addition to such melamine resins and phenol resins, those known to those skilled in the art, including diallyl phthalate resins that require heating and pressurization for molding. Resins can be widely used.

Next, the thermosetting resin-impregnated papers 41 to 4 laminated in this way
4 and the forming sheet 3 are heated and pressed together. The heating and pressurizing conditions depend on the thermosetting resin used, etc., but in the case of melamine resin, the maximum temperature is about 140-150°C, the pressure is about 60-IN kg/cm2, and it is about 15-30 minutes. Heat and pressure mold. After that, soak in cold water while pressurized for about 1 hour.
By cooling for 5 to 60 minutes, the thermosetting resin-impregnated papers 41 to 44 are cured as one piece. By this curing, a conduit concave shape is formed on the surface of the cured product in accordance with the conduit convex shape 23 of the molding sheet 3, and the coloring agent layer of the molding sheet 3 is embedded in the conduit concave shape.

Subsequently, by peeling and removing the imprinting sheet 3 from the cured product, a design very similar to natural wood can be obtained, which is in tune with the printed wood grain pattern and has a tuned conduit concave shape in which the colorant is embedded. A thermosetting resin decorative board having the following properties is obtained.

The thermosetting resin decorative board of the present invention having a colored concave shape on its surface can not only express natural wood, but also natural materials such as stone or leather, or artificial geometric patterns. You can also do it.

[Effect]

The shaping sheet of this invention consists of a thermoplastic resin layer having a convex shape on the surface and a coloring agent layer formed on the convex shape. Manufacturing a resin decorative board eliminates the need to use expensive metal templates, simplifies the configuration of equipment for manufacturing the decorative board, and eliminates the need for colorant coating and wiping. As a result, it has become possible to manufacture thermosetting resin decorative boards with colored recesses on the surface at low cost, including thermosetting resin decorative boards imitating natural wood etc., which have the design effect of so-called tonal embossing. Become.

〔Example〕

This invention will be further explained by giving examples. However, it goes without saying that the invention is not limited to this embodiment.

Example 1 As shown in Fig. 1(a), a 120 μm thick vinyl chloride resin film was hot-pressure embossed using an electroforming roll embossing plate having a conduit convex shape molded from natural oak wood as a manuscript. A master sheet was manufactured by forming a conduit concave shape with a depth of about 70 μm.

Next, as shown in FIG. 1(b), a polymethylpentene resin was extruded from an extrusion die to a thickness of about 90 μm at an extrusion temperature of 330° C. onto a high-quality paper having a basis weight of 52 Jg/m2.

At the same time, a matrix sheet is crimped onto the extruded resin, and the pressure is 5 kg/cm between the nip roll and the cooling roll.
After pressurizing under the conditions of 2, at room temperature (or about 25℃)
Cooled to .

Next, as shown in Figure 1 (c), the matrix sheet is peeled off, and then cellulose acetate-based brown ink (manufactured by Toyo Ink ■) is applied to polymethylpentene resin using an inking roll (made of butyl rubber). A molded sheet was manufactured by applying the ink to a thickness of 3 μm on the conduit convex shape to form a brown ink layer.

Next, as shown in Figure 2, on the lower heating plate are a heat-resistant cushion sheet, a mirror plate, a backer paper made of titanium paper with a basis weight of 100 g/m2 impregnated with 80% by weight of melamine resin, and a backer paper with a basis weight of 150 g.
/m2 paper impregnated with 60% by weight of phenolic resin, oak pattern printed on titanium paper with a basis weight of 80g/m2, and melamine resin-impregnated titanium paper impregnated with 80% by weight of melamine resin. Paper and an overlay paper made of rayon pulp with a basis weight of 25 g/m2 impregnated with 300% by weight of melamine resin were laminated in this order, and then the above-mentioned imprinting sheet was layered on top of this from the brown ink layer side, and then A mirror plate and a heat-resistant cushion sheet were placed on top, and then sandwiched between upper heating plates.

This laminate was heated at a maximum temperature of 145°C and a pressure of 80kg/Cm.
It was heated and pressurized for 30 minutes under the conditions of 2.

Thereafter, the thermosetting resin layer was cured by cooling with cold water for 40 minutes while being pressurized.

Next, a melamine resin decorative board was obtained by peeling and removing the molded sheet from the cured product.

The obtained melamine resin decorative board has an oak pattern,
A conduit concave shape molded from natural wood was formed on its surface, and brown ink was embedded in the concave part, so it had a design very similar to natural wood.

〔Effect of the invention〕

According to this invention, a thermosetting resin decorative board is manufactured using a molding sheet consisting of a thermoplastic resin layer having a convex shape on the surface and a coloring agent layer formed on the convex shape as a template. Therefore, the configuration of the decorative board manufacturing apparatus is simplified without using an expensive metal template, and colorant coating and wiping processes are not required. Therefore, it is possible to manufacture at low cost a decorative board imitating natural wood or the like, which has the design effect of so-called tone embossing, as well as a decorative thermosetting resin board with colored recesses on the surface.

In addition, if the matrix sheet is manufactured using an electroformed roll embossing plate molded from natural wood, a metal relief plate manufactured by conventional methods such as etching or a resin letterpress plate reproduced from it can be used as the template. A thermosetting resin decorative board having a sharper conduit shape can be obtained compared to a case where a thermosetting resin decorative board is manufactured by using the above method.

[Brief explanation of the drawing]

FIG. 1(a) is a cross-sectional view of the matrix sheet, and FIG.
b) is a sectional view of a laminated sheet for forming a shaped sheet of this invention, FIG. 1(c) is a sectional view of a shaped sheet of this invention, and FIG. FIG. 2 is an explanatory diagram of a method for manufacturing a thermosetting resin decorative board of the invention. DESCRIPTION OF SYMBOLS 1... Matrix sheet, 2... Laminated sheet, 3... Shaping sheet, 11... Thermoplastic resin film, 12...
- Conduit concave shape, 2I... Support sheet, 22... Thermoplastic resin layer, 23... Conduit convex shape, 31... Colorant layer.

Claims (1)

[Scope of Claims] 1. A method for manufacturing a thermosetting resin decorative board having a concave shape on the surface and a coloring agent embedded in the concave portion, comprising: (a) a thermoplastic resin layer having a convex shape on the surface; and a step of placing a molding sheet consisting of a colorant layer formed on the convex portion and a thermosetting resin-impregnated sheet so as to sandwich the colorant layer; (b) placing the molding sheet and the heat curing the thermosetting resin by heating and pressing the curable resin-impregnated sheet together, forming recesses corresponding to the projections of the thermoplastic resin layer, and transferring a colorant layer to the recesses; (c) A method for producing a thermosetting resin decorative board, comprising a step of peeling the molded sheet from the cured product of step (b). 2. A thermosetting resin decorative board produced by the method according to claim 1. 3. A shaping sheet for shaping and coloring a thermosetting resin decorative board, comprising a thermoplastic resin layer having a convex shape on the surface and a coloring agent layer formed on the convexity.