JPH08197697A - Decorative sheet and production thereof - Google Patents

Abstract

PURPOSE: To keep high adhesive strength by holding a sufficient amt. of an adhesive and to fill the surface unevenness of a base material to smooth the surface thereof. CONSTITUTION: A decorative sheet is obtained by successively laminating decorative paper 10 having an abrasion-resistant resin layer formed on the surface thereof, resin impregnated paper 11 impregnated with a thermosetting resin, an adhesive layer 12 and a base material 13.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board having smoothness and abrasion resistance, and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a conventional method for manufacturing a decorative board, as described in, for example, Japanese Patent Laid-Open No. 6-99561, a thermosetting resin material is interposed between a base material and a surface material,
A method is known in which the base material and the surface material are bonded to each other via the thermosetting resin material by heat-pressing them.

[0003]

However, the decorative board obtained by the above method has the following problems.
In other words, the thermosetting resin material and the base material are bonded together by using the resin in the thermosetting resin material as an adhesive agent during hot pressing, so the adhesive amount is inevitably insufficient. When the base material with poor quality that has unevenness on the surface is used because it cannot exert its force, it may peel off after curing, and naturally the amount of adhesive is insufficient. The surface of the decorative plate is uneven. The present invention has been made in view of such circumstances, and a decorative plate capable of holding a sufficient amount of an adhesive to maintain high adhesive strength and filling irregularities on a surface of a base material to smooth the surface. And its manufacturing method.

[0004]

A method according to the above-mentioned object.
The decorative board described, a decorative paper on which a wear-resistant resin layer is formed on the surface, resin-impregnated paper impregnated with a thermosetting resin, an adhesive,
The base material is laminated in order and configured. The method for manufacturing a decorative board according to claim 2, wherein after applying an adhesive on a base material, a resin-impregnated paper impregnated with a thermosetting resin and a decorative paper having an abrasion-resistant resin layer formed on the surface are sequentially formed. It is configured to be placed and heat-pressed and attached. According to a third aspect of the present invention and a method for manufacturing the same, in the second aspect, a filler such as an inorganic filler is mixed in the adhesive.

Here, the base material refers to flooring materials, plywood used for various furniture such as counter tops and table tops, wood chip cement plywood, fiber boards, hard boards and particle boards. The decorative paper is formed by applying a wear resistant resin on a paper on which a wood grain pattern or the like is printed and then curing the resin. The abrasion-resistant resin is a mixture of amino alkyd resin, polyurethane resin, polyester resin and the like with ceramic powder such as aluminum oxide and zirconium oxide. Resin impregnated paper means phenol resin, melamine resin, diallyl phthalate (DA
P) Plural sheets of paper (cloth, non-woven fabric, etc.) that become the core material are dipped in a thermosetting synthetic resin such as resin or guanamine resin, and laminated and pressure-bonded under high pressure to obtain adhesiveness to the base material and uneven surface. Is a material that can be adhesively cured by hot pressing. A urea resin, a melamine-urea co-condensation resin, or the like can be used as the adhesive applied to the base material. Clay, alumina,
By premixing an inorganic filler such as silica powder, it is possible to exert a filling effect of filling defects such as irregularities and scratches on the surface of the base material.

[0006]

In the decorative board according to claim 1, since the decorative paper, the resin-impregnated paper, the adhesive, and the base material are laminated in this order, the amount of adhesive which is insufficient by the resin of the thermosetting resin-impregnated paper is sufficient. The amount is replenished, sufficient adhesive force is exhibited, and mutual resins are melt-integrated to be extremely strong and peel resistance is remarkably improved. Further, in the method for manufacturing a decorative board according to claims 2 to 3, after applying an adhesive on a substrate, a resin-impregnated paper impregnated with a thermosetting resin and an abrasion-resistant resin layer are formed on the surface. Place the decorative paper in order,
Since the hot pressing is applied, the adhesive fills the irregularities of the base material of poor quality, and the irregularities of the base material hardly appear on the surface. Particularly, in the method for manufacturing a decorative sheet according to claim 3, since a filler such as an inorganic filler is mixed in the adhesive, the effect of filling the irregularities on the surface of the base material is enhanced, and the decorative sheet is smoothed. The property is further improved.

[0007]

Embodiments of the present invention will now be described with reference to the accompanying drawings to provide an understanding of the present invention. Here, FIG. 1 is an explanatory view of a method for manufacturing a decorative board according to an embodiment of the present invention.

As shown in FIG. 1 (a), a polyurethane resin mixed with 5 parts by weight of aluminum oxide in advance is coated on a beautiful paper on which a wood pattern is printed by means of a roll coater or the like, and is cured. A decorative paper 10 having an abrasion-resistant resin layer formed on the surface thereof and a resin-impregnated paper 11 obtained by impregnating paper with diallyl phthalate resin, which is an example of a thermosetting resin, are prepared. An adhesive 12 made of a melamine-urea co-condensation resin containing an inorganic filler is applied to the surface and attached. The amount of the inorganic filler mixed is preferably 5 to 20 parts by weight with respect to 100 parts by weight of the adhesive to be mixed, from the viewpoint of maintaining the adhesive strength. First, on the base material 13 in which the adhesive 12 is applied with a spreader and the defective portion is filled,
The resin-impregnated paper 11 and the decorative paper 10 were sequentially laminated. (FIG. 1 (a)) Then, by pressing the above-mentioned laminated body with a hot press 14 at a temperature of 135 ° C. and a pressure of 10 kgf / cm ² for 20 minutes (FIG. 1 (b)), a smooth and wear-resistant surface is obtained. A decorative board having (Fig. 1 (c))

Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and changes in conditions and the like without departing from the scope of the invention are all within the scope of application of the present invention. For example, in this embodiment, an example in which only one sheet of resin-impregnated paper is used has been described, but it is also possible to use a combination of various types of resin-impregnated paper.

[0010]

In the decorative board according to the first aspect of the present invention, the amount of the adhesive which is insufficient by the resin of the thermosetting resin-impregnated paper alone is replenished so that sufficient adhesive force is exhibited and the mutual resin is used. Since they are melt-integrated, they become extremely strong and the peel strength is significantly improved. In addition, claims 2 and 3
In the method for manufacturing a decorative board described above, after the adhesive is applied onto the base material, the resin-impregnated paper and the decorative paper are placed in order, and heat-pressing and sticking are performed. The irregularities of the base material hardly appear on the surface by filling the irregularities of No. Particularly, in the method for manufacturing a decorative board according to claim 3, since a filler such as an inorganic filler is mixed in the adhesive, the effect of filling irregularities on the surface of the base material is enhanced, and Smoothness is further improved.

[Brief description of drawings]

FIG. 1 is an explanatory view of a method for manufacturing a decorative board according to an embodiment of the present invention.

[Explanation of symbols]

 10 Decorative Paper 11 Resin-impregnated Paper 12 Adhesive 13 Base Material 14 Hot Press

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B32B 27/20 Z 33/00

Claims (3)

[Claims] 1. A decorative board having a surface on which a wear-resistant resin layer is formed, a resin-impregnated paper impregnated with a thermosetting resin, an adhesive and a base material, which are laminated in this order. 2. After applying an adhesive on a base material, a resin-impregnated paper impregnated with a thermosetting resin and a decorative paper having an abrasion-resistant resin layer formed on the surface thereof are placed in this order, and heat-pressed. A method for manufacturing a decorative board to be fastened. 3. The method for manufacturing a decorative board according to claim 2, wherein a filler such as an inorganic filler is mixed in the adhesive.