JPH0477667B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a decorative board and a method for manufacturing the same.
In particular, it relates to decorative laminates of improved quality and improved methods of manufacturing the same.

Conventionally, decorative boards are known in which sheet-like materials such as paper cloth or synthetic resin are adhered to the surface of plywood, fiberboard, or other substrates. It was manufactured by wearing If these substrates have defects such as conduit grooves, dowel holes, insect holes, cracks, etc. on the surface of the plywood, the defects will also appear on the surface of the sheet to which they are attached, spoiling the appearance and damaging the parts. becomes easily damaged by external force.

Therefore, if there are defective recesses on the surface of the substrate, the sheet is pasted after the surface is marked. Water-based and oil-based fillers have been used, but oil-based fillers are generally expensive, dry slowly, and therefore have the disadvantage of lowering productivity. Water-based sealants are relatively expensive and dry quickly, but have the disadvantage of increasing the moisture content of the substrate.

Furthermore, regardless of whether it is water-based or oil-based, fillers contain pigments because their purpose is to fill in imperfections. The higher the pigment content, the higher the viscosity of the filler.
As the fluidity decreases, it becomes difficult to fill the filler into narrow or deep defect recesses, and it is not possible to seal completely with one application. It also dissipates, so apply multiple times.
It was necessary to fill it. Furthermore, if the amount of pigment is reduced, it becomes easier to apply and fill into defective areas, but the eyes become noticeably thinner, which also requires multiple applications.

In order to reduce the number of times the filler is applied and prevent eye loss, a foaming agent that foams when heated is mixed into the filler, and this is applied to the defective recesses of the board and then filled. , a method was proposed in which the substrate is foamed by heating and then the protruding parts from the substrate surface are removed by sanding, etc. However, this method requires many steps and the sealing part is porous, so it is difficult to attach a decorative sheet. This has the disadvantage that a large amount of adhesive permeates through the area, resulting in insufficient adhesion in that area.

In the present invention, a hard and flat film-like portion is formed in the upper layer in the defect recess on the surface of the substrate,
Provided is a decorative board whose lower layer is filled with a thermoplastic resin in which a foamed part is formed, and a decorative sheet is affixed to the entire surface of the substrate, including the surface of the filled part, via an adhesive. It is intended to. The filling portion in the defect recess of the decorative board according to the present invention is filled to every corner of the defect recess due to foaming, and the upper layer has a hard and flat film-like portion. This ensures uniform adhesion of the decorative sheet to the substrate surface, giving it a perfect appearance, and making it difficult for the decorative sheet on the filled part to be damaged, greatly improving its quality.

In addition, the present invention applies and fills a thermoplastic resin containing a solvent into defective recesses on the surface of a substrate, and then immediately heats it to form a film on the surface of the filled thermoplastic resin. By foaming the resin, the resin is filled into every corner of the defective recesses and raised on the surface of the substrate,
Next, adhesive is applied to the entire surface of the substrate, including the surface of the raised filling part, and then a decorative sheet is pasted and heat-pressed to make the upper layer of the foamed resin into a flat and fine-grained surface. The present invention also provides a method for manufacturing a decorative board in which a hard film-like part is formed, a foamed part is formed in the lower layer thereof, and an adhesive applied later is also solidified to adhere a decorative sheet.

According to the present invention, the eye blocker only needs to be applied once without worrying about eyesightening, and each process can be performed continuously, resulting in good work efficiency and, moreover, a decorative board with improved quality as described above. can get.

The present invention will be described in detail below based on an example in which the method of the present invention is applied to plywood as a substrate.

The accompanying drawings show the stages of product production in the process of the method of the present invention divided into a to e.

As shown in the attached drawing a, the plywood substrate 1 has defective recesses 2 such as conduit grooves, dowel holes, moth-eaten holes, and cracks.

A thermoplastic resin 3 containing a solvent is applied and filled into these defective recesses using a coating device such as a roll coater or a reverse coater. This state is shown in figure b.

Thermoplastic resins include vinyl acetate, acrylic, polyvinyl acetal, vinyl chloride,
Vinylidene chloride resin, vinyl ether resin, polyethylene resin, polyester resin, polyvinyl alcohol resin, acrylic resin, urea or urea melamine resin, etc. can be used. The thermoplastic resin contains a solvent as a volatile or evaporable component. This solvent can be the same as the solvent that is generally mixed as a non-film forming element in the composition of the paint, such as acetone, ethyl acetate, isopropyl alcohol, methyl ethyl ketone, toluol, xylol, butyl alcohol, butyl cellosolve, butyl cello. Norbu, acetate, water, etc.

After applying and filling the resin, immediately put it in a hot air dryer,
Heating with a heating drying means such as an infrared dryer,
By vaporizing or evaporating the solvent contained in the resin, a film 3' is first formed on the upper layer of the filled resin, and then the vaporization of the solvent in the resin progresses in the lower layer. The resin is then foamed. This state is shown in Figure c of the attached drawing, where the gas is trapped inside by the upper layer coating 3', and the foamed resin 3'' spreads to every corner of the defect recess, and also causes bumps on the substrate surface. arise.

It is best to heat at a high temperature, generally 100℃.
The temperature above is preferably 120°C or higher.

Further, when the solvent as a volatile or evaporative component contained in the resin has low volatility or a high evaporation temperature, it is preferable to rapidly heat the resin to boil it and foam it.

Thereafter, adhesive 4 is applied to the entire surface of the substrate, including the raised surface of the filling portion. This situation is shown in Figure d.

Adhesives used include amino resin, urea resin, melamine resin, phenolic resin, resorcinol resin, epoxy resin, polyurethane resin, acrylic resin, vinyl acetate resin, polyvinyl acetal resin, vinyl chloride resin, vinylidene chloride resin,
Thermoplastic and thermosetting resin adhesives conventionally used for pasting decorative sheets, such as vinyl ether resin, polyethylene resin, polyester resin, and polyvinyl alcohol resin, can be used.

After applying the adhesive, a decorative sheet is placed on top of it and heat-pressed using a hot roll, hot plate, etc. The ironing effect causes foaming, flattening the raised upper layer of the resin in the filled areas and improving the texture. A fine hard film-like part 3 is formed, and the adhesive applied later is also solidified to adhere the decorative sheet. The resin forming the coating 3' is once melted by the heat during hot pressing, but it is maintained in a smooth state by the press pressure from above and the foaming pressure from the foaming part 3'' from below.
A dense and hard film-like portion 3 is formed by subsequent resin curing. At this time, the foamed resin 3'' is also cured to form a solidified foamed portion 3''', thus completing the decorative board 1'. This state is shown in e of the attached drawing.

As described above, according to the present invention, the sealant only needs to be applied once, and all subsequent steps can be performed continuously without the sanding process, so productivity is significantly improved. A flat, dense, hard film-like part 3 is formed on the surface, and a hard foamed part 3'''' is formed in the lower layer that spreads over every corner of the defective recess, so that the adhesiveness of the decorative sheet is good. Furthermore, the surface properties of the decorative surface are greatly improved.

[Brief explanation of the drawing]

FIG. 1 is a process diagram showing the steps of product production in the process of the method of the present invention divided into a to e. Explanation of symbols, 1: Substrate, 2: Defect recess, 3: Resin, 3': Film, 3'': Foamed resin, 3: Film-like part, 3'''': Foamed part, 4: Adhesive, 5: Decorative sheet, 6: Heat pressure means.

Claims (1)

[Scope of Claims] 1. Thermoplastic material in which a flat film-like part is formed in the upper layer in the defect recess on the surface of the substrate, and the lower layer is a foamed part formed by expansion of a solvent. 1. A decorative board characterized by being filled with resin and having a decorative sheet adhered to the entire surface of the substrate including the surface of the filled portion via an adhesive. 2 After coating and filling the thermoplastic resin containing a solvent into the defective recesses on the surface of the substrate, the resin is immediately heated to a high temperature to vaporize the solvent in the filled thermoplastic resin and form a film on the surface. By allowing the solvent to vaporize inside and foaming the resin, the resin is completely filled into the defect recess and raised on the substrate surface, and then the substrate including the surface of the raised filling part is filled with the resin. Adhesive is applied to the entire surface, a decorative sheet is placed on top of the applied adhesive, and the resin is plasticized by hot pressing to smooth out the raised filling areas, and then the plasticized resin is A method for manufacturing a decorative board, characterized by curing the adhesive and curing the applied adhesive to adhere the decorative sheet.