JPH04353446A - Manufacture of decorative panel - Google Patents

Abstract

PURPOSE:To manufacture a decorative panel having decorative paper and a surface protecting layer both of which are made hard to release and excellent in surface aptitude with excellent manufacturing efficiency. CONSTITUTION:A decorative panel is manufacture by a method wherein a surface protecting resin layer 8 consisting of electron beam curable resins 5, 6 is formed on the surface of raw paper 1 subjected to smoothing treatment on its surface side and improved in resin permeability on its rear side through a pattern layer 3 to prepare decorative paper 4 to allow the electron beam curable resins 5, 6 to penetrate in the decorative paper 4 from the rear thereof and this decorative paper 4 is integrated with a base material whose surface is coated with high viscosity electron beam curable resins 5, 6 and a resin film is superposed on the surface of the surface protecting resin layer 8 to irradiate the whole with electron beam.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a method for manufacturing decorative laminates for use in furniture, housing equipment, etc., and particularly to a method for efficiently manufacturing high-grade decorative laminates with high surface hardness and excellent durability at low cost. be.

0002

[Prior Art] Conventionally, decorative laminates used for horizontal surfaces such as furniture and housing equipment are first printed on a highly permeable base paper such as titanium paper, and then heated with melamine resin, diallyl phthalate resin, etc. Resin-impregnated paper is made by impregnating it with a curable resin, and then the resin-impregnated paper is placed on a base material such as phenol core paper or particle board, and then heated and pressed through a mirror plate.

0003

[Problems to be Solved by the Invention] However, according to the above-mentioned conventional method, a decorative board with surface hardness and abrasion resistance required for use on horizontal surfaces can be produced, but on the other hand, the production efficiency is low and it becomes expensive. I had no choice. In addition, titanium paper has a rough surface because it places importance on resin impregnation, and its printability is not very good.

[0004] In order to improve costs, various methods have been studied to strengthen the paper layer by applying an electron beam curing resin from the surface without impregnating it with a thermosetting resin. For some reason, I have not been able to get anything satisfactory. That is,
Resin applied from the surface permeates into the paper layer, but if the viscosity of the resin is lowered with emphasis on permeability, the amount of resin remaining on the surface will decrease, resulting in a poor surface finish of the decorative paper. On the other hand, if the viscosity of the resin is increased in order to limit the penetration of the resin with emphasis on the surface finish, the penetration into the paper layer will be reduced, and the original purpose of strengthening the paper layer will not be achieved. Also,
When applying two types of resin from the surface, one with a low viscosity and one with a high viscosity, if a high viscosity resin is applied while the low viscosity resin applied first is still wet, the high viscosity resin will Problems arise when the resin is applied, such as the pattern becoming blurred or the finish not being uniform. Furthermore, if the first layer of resin is cured and then the second layer is applied, the finish will be good, but since the first layer of resin is cured and forms an interface, the second layer will The problem of interfacial peeling of the eye resin was unavoidable.

On the other hand, according to the so-called quick-step method, which is a conventional manufacturing method for decorative laminates mainly used for furniture facing materials, a water-based adhesive is applied to the surface of the base material, and at the same time, a water-based adhesive is applied to the back side of the decorative paper. Decorative boards are manufactured by applying a water-based adhesive, bonding, and pressing with a press, but a certain amount of pressing time is required to remove the moisture in the adhesive. It wasn't necessarily efficient. Furthermore, since the adhesive did not have a solid content of 100%, the reinforcement of the paper layer was not sufficient. Furthermore, even in the above conventional techniques, the surface finish of the manufactured decorative material was not uniform, and it was not possible to obtain a decorative board with excellent surface suitability.

[0006] The present invention maintains good printability while
The purpose of the present invention is to disclose a method for manufacturing highly efficiently and inexpensively a high-grade decorative board that has hardness and abrasion resistance that can be used on horizontal surfaces, has a uniform surface finish, and has excellent surface suitability.

[0007]

[Means for Solving the Problems] In order to solve the above-mentioned problems, the method for manufacturing a decorative board of the present invention uses a base paper whose surface is smoothed and whose back surface has good resin permeability. After forming a pattern layer and further forming a surface protection resin layer on top of the pattern layer to create decorative paper, a low-viscosity electron beam curing resin is applied to the back of the decorative paper to allow it to pass through the paper layer, and at the same time, a base layer is applied. After applying a high viscosity electron beam curable resin to the surface of the material and pasting them together, a resin film is laminated on the surface of the decorative paper, and the gas between the decorative paper and the resin film is removed by rolling. Finally, it is irradiated with an electron beam to harden it as a whole.
It is characterized by peeling off the resin film.

The present invention will be explained in detail based on the drawings. FIG. 1 shows a cross-sectional view of a decorative paper (4) used in manufacturing a decorative material by the method of the present invention, and FIG. 2 shows a cross-sectional view of a decorative material manufactured by the method of the present invention. As shown in Figure 1, the decorative paper (4) has a hidden solid layer (2) on the surface of the base paper (1).
After printing the pattern layer (3), the surface protection resin layer (8)
This is the configuration that formed the . Here, the base paper (1) used is one whose front side is smoothed and becomes dense and has good printability, and whose back side is rough and has good resin penetration. For example, the basis weight is 20g with calendering applied only to the surface.
/m2 to 120 g/m2 of decorative board base paper such as titanium paper, tissue paper, bleached kraft paper, etc. is suitable. Here, if the thickness of the base paper for decorative laminate is less than 20g/m2 in basis weight, the hiding power of the paper will be poor, that is, the paper will become translucent due to the penetration of the resin, and the color of the base material for the decorative laminate will appear. If it is more than 120 g/m2, the amount of resin to be coated will be large, resulting in high cost, and the time required for coating will also be long, resulting in poor productivity.

A concealing solid layer (2) is formed on the surface of the base paper (1), if necessary. The ink forming the concealing solid layer (2) must be able to withstand electron beam irradiation in the subsequent process, such as acrylic resin, butyral resin,
Something like urethane resin can be used. The coating amount is 1 g/m2 to 20 g/m2, and the coating method can be a gravure printing method or a gravure coating method. Further, for the purpose of imparting design properties, a pattern layer (3) is formed directly on the base paper (1) or on the concealing solid layer (2) by a gravure printing method. The ink that forms the pattern layer (3) also
Like solid ink, it must be able to withstand irradiation with electron beams in the subsequent process.

Next, a low-viscosity electron beam curable resin (5) is applied to the back side of the thus obtained decorative paper (4) and allowed to penetrate into the paper layer. The composition of the resin used here includes (meth)acrylic acid ester oligomers such as urethane acrylate, epoxy acrylate, and polyester acrylate, 2-HEA (2-hydroxyethyl acrylate), TMPTA (trimethylolpropane triacrylate), and HDDA ( Preferable results are obtained by adding monofunctional or polyfunctional monomers such as hexanediol diacrylate to lower the viscosity to 50 to 500 cps. The appropriate coating amount is in the range of 5 g/m2 to 30 g/m2.

On the other hand, as shown in FIG. 4, on the surface of a base material (7) such as particle board, phenol core paper, plywood, etc., an electron beam curable resin (6) of the same type with a viscosity adjusted to 1000 cps or more is applied. Immediately bond them together using a roll laminator, and then use an electron beam irradiation device (
10) to be cured. Here, the electron beam curable resin is applied by a method such as roll coating or reverse coating.

The surface protective resin layer (8) may be a normal thermosetting resin, but if an electron beam curing resin is used,
Provides high surface hardness and excellent wear resistance. The resin used in this case is a known electron beam curable resin such as (meth)acrylic acid ester oligomer such as urethane acrylate or polyester acrylate, and has a viscosity of 1000 to 5.
000cps range, coating amount 5g/m2 to 50g
/m2 is applied. The coating method is roll coating or knife coating. Further, the accelerating voltage of the electron beam is preferably 150 to 250 Kv, and the irradiation amount is preferably about 2 to 6 Mrad. This treatment brings together all the layers and provides a decorative board with excellent surface performance. Usually this process is 50~
Since it is possible at a line speed of 150 m/min, production efficiency is extremely high.

When irradiating the electron beam, a resin film (9) is simultaneously attached as shown in FIG. 3 in order to form a uniform surface on the surface of the decorative material. The resin film (9
) is after applying an electron beam curable resin to the surface of the decorative paper (4), roll laminating it on the surface of the decorative paper, rolling and deaerating it, and curing it integrally by irradiating it with an electron beam. Release the resin film. The surface of the resin film (9) is transferred to form a uniform surface. As the resin film (9), known resin films such as polyester film and acrylic film can be used. Thickness is 12μm to 100μm
Preferably, the range is .

[0014]

[Action] The surface of the base paper is dense and smooth, so it has good printing suitability, while the surface protective resin layer does not penetrate into the paper layer more than necessary, so the amount of resin on the surface is secured, and the resin film can be transferred. This results in a uniform and excellent surface finish. Since resin has good permeability to the back side of decorative paper, electron beam curing resin diluted to a low viscosity penetrates and strengthens the paper gap. In addition, since the surface protective resin layer comes into contact with the base paper in the middle, interfacial peeling does not occur. In addition, the electron beam curable resin applied to the base material has a high viscosity, so it does not seep into the base material more than necessary and does not cause glue loss. In addition, these electron beam curable resins are hardened and integrated by the action of the electron beam that passes through the decorative paper on the surface irradiated by the electron beam irradiation device, so there is no weak layer in any of the decorative layers and it is extremely strong. It is possible to manufacture decorative laminates with high quality.

[0015]

[Example] Basis weight 30g/with calendering on the surface
A concealing solid layer and a wood grain pattern layer were printed on a m2 decorative board base paper using an ink made of an acrylic resin binder. Next, on the back side of the decorative paper obtained in this way, an electron beam curing resin (LR8555 manufactured by BASF Corporation) adjusted to have a low viscosity was applied.
:2-HEA=2:1, viscosity of about 200 cps) was applied and allowed to penetrate between the sheets. On the other hand, a high viscosity electron beam curing resin (
20g of the same LR8555 stock solution (approx. 8000cps)
/m2, and the base material was immediately attached to the decorative paper using a rubber roll.

Next, an electron beam curing resin (
20g of Aronix M8030 (manufactured by Toagosei Co., Ltd.)
/m2, a polyester film with a thickness of 25 μm was roll laminated, rolled and degassed, and immediately passed through an electron beam irradiation device (area beam type manufactured by Nissin High Voltage Co., Ltd.) at an accelerating voltage of 200 Kv and 3 Mrad.
The resin on the surface and the resin in the paper layer were simultaneously cured by irradiation with an electron beam, and the polyester film was peeled off to obtain a decorative board. The obtained decorative board had high surface hardness and good wear resistance. Furthermore, even if adhesive tape was applied to the surface and peeled off, the decorative layer did not come off. Furthermore, since a polyester film was also bonded together, a uniform surface was formed.

<Comparative Example 1> A decorative board was prepared in the same manner as in the example except that the application of resin to the back side of the decorative paper was omitted. When the obtained decorative board was subjected to an adhesive tape test, peeling occurred between the decorative paper sheets.

<Comparative Example 2> A decorative board was prepared in the same manner as in the example except that the bonding of the resin film was omitted. The resulting decorative board had poor surface uniformity, with roll marks from the resin application roll remaining on the surface.

[0019]

[Effects of the Invention] The wood-grain decorative board of the present invention uses a base paper with a dense surface and good printability, so it has good pattern reproducibility and excellent design. In addition, since the surface is dense, the surface protection resin does not penetrate more than necessary and forms a layer of a constant thickness, resulting in excellent surface gloss and smoothness. Furthermore, since the resin films are overlapped at the same time during bonding, it is important to form a uniform surface. Also, since it does not penetrate too much and form an interface on the back side of the decorative paper, it does not cause poor adhesion to the base material. On the other hand, since the resin has good permeability on the back side of the base paper, the low viscosity electron beam curable resin easily penetrates into the paper layer and becomes integrated with the high viscosity electron beam curable resin coated on the base material. Since the adhesive is cured, a decorative board with excellent surface performance in which all layers from the base material to the surface are firmly adhered can be obtained. Furthermore, since the decorative paper is laminated continuously using rolls, the production of decorative laminates is extremely efficient.

[0020]

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of decorative paper produced by the method of the present invention.

FIG. 2 is a cross-sectional view of a decorative board manufactured by the method of the present invention.

FIG. 3 is a cross-sectional view showing lamination of resin films.

FIG. 4 is a schematic diagram showing the manufacturing method of the present invention.

[Explanation of symbols]

1 Base paper 2 Concealing solid layer 3 Pattern layer 4 Decorative paper 5 Low viscosity electron beam curable resin 6 High viscosity electron beam curable resin 7 Base material 8 Surface protection electron beam curable resin 9 Resin film 10 Electron beam irradiation device

Claims (3)

[Claims] Claim 1: A pattern layer is formed on the surface of a base paper whose surface has been subjected to a smoothing treatment and whose back surface has good resin penetration,
Furthermore, after forming a surface protective resin layer on top of the decorative paper to create decorative paper, a low-viscosity electron beam curing resin is applied to the back side of the decorative paper to transmit it through the paper layer, and at the same time, a high-viscosity resin is applied to the surface of the base material. After applying an electron beam curing resin of A method for producing a decorative board, which comprises irradiating a wire to cure the resin film integrally, and then peeling off the resin film. 2. The method for manufacturing a decorative board according to claim 1, wherein an electron beam curable resin is used as the surface protection resin. 3. The method for producing a decorative board according to claim 1 or 2, wherein the bonding of the decorative paper and the base material and the formation of the protective layer are carried out continuously using a roll.