JPH08224852A - Manufacture of decorative sheet - Google Patents

Abstract

PURPOSE: To manufacture a decorative sheet, which has a strong texture due to the small quantity of mica particles and in which no bubble develops at the forming of a resin so as not to damage external appearance, without complicating the manufacturing process. CONSTITUTION: Masking paper 2 is pasted through an adhesive 3 to a base material 1. Then, fluid resin P blended with mica particles, the specific gravity of which is larger than that of the resin, is cast on the hiding paper 2. After that, under the state that a force 10, which is formed by spanning a film 12 on a frame 11, is put on the fluid resin P, the fluid resin P is spread with a rubber roller 15 from above the film 12. In succession, before the hardening of the fluid resin is turned upsidedown so as to locate the force 10 underside in order to condense the mica particles on the film 12 covering surface. After the fluid resin P hardens so as to form a resin layer 4, the force 10 is separated from the resin layer 4. Finally, a top coat layer is formed on the resin layer 4.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a decorative board in which particles to be added are aggregated on the surface of a resin layer to give the texture of a natural product, and in particular, the texture of granite may be strong by using colored mica as the particles. The present invention relates to a method for producing a decorative veneer that is excellent as a method for producing a stone-tone veneer.

[0002]

2. Description of the Related Art Conventionally, in order to express patterns and aesthetics that cannot be expressed by a single resin layer, there has been known a decorative plate in which resin chips, quartz grains, metal slags, and luster pigments are mixed. For example, by mixing black, white, gray, etc. particles in the resin layer in an appropriate ratio, a granite-tone decorative board can be obtained. And as a method of manufacturing this type of stone-tone decorative board, JP-A-6-40199 and JP-A-2
-199049 or JP-A-2-199050
Those described in Japanese Patent Publications and the like are known.

For example, in Japanese Unexamined Patent Publication No. 6-40199, after a decorative paper is attached to a substrate and a white paint is applied, an unsaturated polyester resin containing colored polyester particles is applied to the applied surface, and after curing, The items to be finished are described. Further, in JP-A-2-199049, an unsaturated polyester resin is kneaded with quartz particles, aluminum hydroxide powder, colored glass particles and the like to adjust BMC, and the BMC is heated and pressed to produce an artificial stone. After that, a method is described in which the surface is polished to expose quartz grains and the like on the surface.

[0004]

However, in the production method described in JP-A-6-40199, when the specific gravity of the colored polyester particles is higher than the specific gravity of the unsaturated polyester resin, the unsaturated polyester resin Since the colored polyester particles settle in the lower part of the unsaturated polyester resin before curing, a transparent unsaturated polyester resin layer is formed on the colored polyester particles, and the granite texture cannot be sufficiently expressed. There is a problem. Further, in the manufacturing method described in Japanese Patent Application Laid-Open No. 2-199049, it is necessary to polish the unsaturated polyester resin after the curing to expose the quartz particles and the like on the surface, which increases the number of steps and also the manufacturing cost. There is a problem of increasing. This invention has been made in view of the above problems,
A manufacturing method capable of inexpensively manufacturing a decorative plate capable of sufficiently expressing the texture of particles mixed in a resin without increasing the number of steps, and in particular, by using colored mica for the particles, a stone-tone decorative plate It is an object of the present invention to provide a manufacturing method effective as a manufacturing method of.

[0005]

In order to achieve the above object, a method for producing a stone-grained decorative board according to the present invention is characterized in that a fluid resin to which particles such as mica are added is placed on a base material, A film is placed on the flexible resin and rolled and defoamed from the film by a roller, and then the film is inverted so that the film is positioned on the lower side before the fluid resin is cured, and the film is formed after the fluid resin is cured. Was peeled off.

[0006]

According to the method of manufacturing a decorative board according to the present invention,
In order to reverse before the film is coated on the fluid resin containing particles on the substrate before curing, the particles settle inside the fluid resin and agglomerate on the film coated surface, exposing the particles on the resin surface. High quality can be obtained with a small amount of particles. And, since this manufacturing method only needs to be reversed in a state in which the film is covered with the particle-containing resin on the substrate in the so-called film method, the manufacturing process is not complicated, and the number of steps is also increased. Therefore, the decorative board can be manufactured at low cost.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. 1 and 2 show a method for manufacturing a decorative board according to an embodiment of the present invention, wherein FIGS. 1a, b, c, d are schematic diagrams showing the manufacturing process in time series, and FIG. 2 is a completed decorative board. FIG.

First, the finished decorative board will be described with reference to FIG. 2. In the figure, 1 is a base material and 2 is an adhesive (layer) on the base material 1.
Concealment paper (layer) laminated by 3; 4 is a resin layer containing particles 5 and having an uneven pattern 4a formed on its surface; 6 is a top coat layer that covers the surface of the uneven pattern 4a of the resin layer 4. . Substrate 1 is made of MDF, plywood, particle board, etc.
As the concealment paper 2, titanium paper or the like is used. As will be described later, the resin layer 4 is mainly composed of unsaturated polyester resin, the particles 5 are composed of particles of colored polyester resin, colored mica, etc., and the top coat layer 6 is composed of acrylic urethane resin.

Next, the manufacturing method thereof will be described. First, the concealment paper 3 is attached to the substrate 1 with the adhesive 3, and the concealment paper 3 is attached.
A fluid resin P containing colored mica (particles) 5 is poured on the top, and as shown in FIG. 1A, the fluid resin P is covered with a pressing die 10 for shaping unevenness. The colored mica 5 has a larger specific gravity than the resin P. Subsequently, the rubber roll 15 is rolled from above the pressing die 10 to defoam, and as shown in FIG.
The fluid resin P is spread over the entire surface of the base material 1. Here, as the pressing die 10, a well-known one in which a film 12 having irregularities is stretched on a frame 11 or a pressing die of silicone rubber is used, and as the fluid resin P containing the colored mica 5, a concrete example is used. For example, the following are used.

Flowable resin P ・ Unsaturated polyester resin Gosserakk 500B (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) Goserac 510A (manufactured by Nippon Synthetic Chemistry Co., Ltd.) Goserac 770 (manufactured by Nippon Synthetic Chemicals Co., Ltd.) Ester R280 (Mitsui East) Pressure chemical Co., Ltd.) and Ester R1710 (Mitsui Toatsu Chemical Co., Ltd.) mixed at a ratio of 1: 1 100 parts of any of the above-Curing accelerator cobalt naphthenate (6%) Ester EP400 ( Mitsui Toatsu Chemical Co., Ltd.) Ester EP430 (Mitsui Toatsu Chemical Co., Ltd.) 0.5 to 1.5 parts of the above, or 0.3 to 1.5 parts of any of the above. Agent Methyl acetoacetate Ester EP440 (manufactured by Mitsui Toatsu Chemicals, Inc.) 0.1 to 2.0 parts of any of the above-Curing agent Permec N (manufactured by NOF Corporation) Permek H (Japan Oil and fat Co., Ltd. 0.1 to 5.0 parts of any of the above-Particles (colored mica) Diamond tip DM (manufactured by Diamond Industry Co., Ltd.) (DM-5 No. 1) Color mica (Wakida Minoru ( Co., Ltd.) 5 to 30 parts of a mixture of any of various colors-Coloring pigment Polyester toner (manufactured by Tokyo Ink Co., Ltd.) (PCN toner) 0.05 to 1.0 part if necessary

The above-mentioned fluid resin P is colored mica 5
By increasing the viscosity when the content of
When rolling with the rubber roll 15, thixotropy (thix
Since it may fall off due to the influence of otropy), it is desirable to provide an enclosure around the base material 1 or fix the periphery with an adhesive tape.

Subsequently, before the fluid resin P is hardened, as shown in FIG.
The pressing die 10 is inverted so as to be positioned vertically below while being covered with. Here, the fluid resin P is in an uncured state, and the specific gravity of the unsaturated polyester resin is around 1.1,
The specific gravity of the diamond tip is 2.8 and the specific gravity of the color mica is 2.7. Since the specific gravity of the colored mica 5 of these diamond tips and the color mica is larger than that of the unsaturated polyester resin, the colored mica 5 sediments. And agglomerate on the contact surface of the pressing die 10. At the same time, the air bubbles that have not been completely defoamed and the air bubbles newly generated from the inside of the concealing paper float and aggregate on the surface of the concealing paper. Then, after the fluid resin P is cured, that is, after the resin layer 4 is molded, the pressing die 10 is peeled off. As is clear from FIG. 2, the resin layer 4 has an uneven pattern 4a on the surface, and the colored mica 5 inside is aggregated and exposed on the uneven surface.

Next, coating with a natural roll coater using a fluid resin having the following composition as a material, or
The top coat layer 6 is formed on the uneven surface 4a of the resin layer 4 by a method such as spray coating. Fluid resin for forming top coat layer 6-Main ingredient Polyurex 548-Clear P liquid (Washin Chemical Co., Ltd.)
100 parts of polyurex 548-7P liquid (manufactured by Woshin Chemical Co., Ltd.) polyurex 548-5P liquid (manufactured by Woshin Chemical Co., Ltd.), or curing agent polyurex 548 D liquid (washin chemical ( Co., Ltd.)
25 parts-UV absorber Tinuvin 320 (manufactured by Ciba Geigy Co., Ltd.) Tinuvin 1170 (manufactured by Ciba Geigy Co., Ltd.) 0.1 to 5.0 parts

The stone-grained decorative board manufactured as described above has a transparent and reflective scale-like scale on the uneven surface of the resin layer 4, that is, the boundary surface between the resin layer 4 and the top coat layer 6. The colored mica 5 of a certain color aggregates and is exposed, so that the texture of the granite may be strong, resulting in excellent aesthetics and high commercial value. Also, the amount of the colored mica 5 is small and the manufacturing cost is reduced. Further, by adding an appropriate amount of a coloring agent to the resin layer 4, the hiding property is improved and the amount of colored mica can be further reduced. In addition, even if there are air bubbles that have not been completely defoamed in the step of forming the resin layer 4, they are aggregated and hardened at the boundary surface between the resin layer 4 and the base material 1, so that the appearance is not impaired. .

Although the resin layer 4 is directly formed on the concealing paper 3 in the above-described embodiment, a colored primer layer is provided as an undercoat layer on the concealing paper 3 and the resin layer 4 is formed on the colored primer layer. It is also possible to provide. And
When this colored primer layer is provided, it is formed by coating with a natural roll coater using the following materials. Material of colored primer layer: Main agent: UV-28 (polyol type) (manufactured by Gengen Kagaku Co., Ltd.) 50 parts; Curing agent CB-19 (isocyanate type) (manufactured by Gengen Kagaku Co., Ltd.) 50 parts: Colored pigment polyester toner ( PCN toner) (Tokyo Ink Co., Ltd.) 20-50 parts

Further, in the above-mentioned embodiment, the uneven pattern 4a is formed on the resin layer 4, but the surface of the resin layer 4 can be a smooth surface, and when the surface of the resin layer 4 is a smooth surface. It is desirable to form a finishing mirror surface layer on the resin layer 4. In this case, the finished mirror surface layer is formed by a film method using a fluid resin material having the following composition and a mold in which a vinylon film or a PET film is stretched in a frame. Fluid resin material for the finishing mirror surface layer ・ Unsaturated polyester resin Gosseralc 500B (manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) Gosserac 510A (manufactured by Nippon Synthesizing Chemicals Co., Ltd.) Gosserac 770 (manufactured by Nippon Synthesizers Chemicals Co., Ltd.) Gosseralc 7161 (Japan) Synthetic Chemical Co., Ltd. Gocelac 6151 (Nippon Synthetic Chemical Co., Ltd.) Ester R280 (Mitsui Toatsu Co., Ltd.) Ester R1710 (Mitsui Toatsu Co., Ltd.) Any one of the above and any of the above 7 : 3
100 parts at a ratio of up to 8: 2 or 100 parts at a ratio of 1: 1 with the above-Curing accelerator cobalt naphthenate (6%) Ester EP400 (manufactured by Mitsui Toatsu Co., Ltd.) Ester EP430 (Mitsui) Toatsu Co., Ltd.) 0.5 to 1.5 parts of the above, or 0.3 to 1.5 parts of any of the above: -Curing accelerator auxiliary methyl acetoacetate Ester EP440 (manufactured by Mitsui Toatsu Co., Ltd.) 0.1 to 2.0 parts of any of the following: -Curing agent Permec N (manufactured by NOF Corporation) Permec H (manufactured by NOF Corporation) 1.0-3.0 parts 0.1 to 5.0 parts of any one of the absorbent: TINUVIN 320 (manufactured by Ciba-Geigy Co., Ltd.) and TINUVIN 1170 (manufactured by Ciba-Geigy Co., Ltd.)

Further, in the above-mentioned embodiment, the colored mica 5 is exemplified as the chip, but the above-mentioned JP-A-2-199 is used.
It is also possible to obtain a decorative board having a multi-patterned pattern, not limited to a stone tone, by using quartz particles or the like described in Japanese Patent No. 050, or various particles such as resin chips or metal slag.

[0018]

As described above, according to the method for manufacturing a decorative board of the present invention, a fluid resin having particles added is placed on a substrate, and the film is coated on the fluid resin. Roll from the top with a roller, then invert so that the film is located on the lower side before the fluid resin is cured and peel the film after the resin is cured, so that the particles are aggregated on the surface of the resin layer It is possible to easily manufacture a decorative board having a strong texture with a small amount of particles,
At the same time, even if there are air bubbles that have not been completely defoamed, they can be aggregated at the bottom of the resin layer without impairing the appearance.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view showing a method of manufacturing a stone-tone decorative board according to an embodiment of the present invention in time series in the order of a, b, c, d.

FIG. 2 is a schematic cross-sectional view of a decorative board manufactured by the same manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Concealment paper 3 Adhesive (layer) 4 Resin layer 4a Uneven pattern 5 Colored mica (particles) 6 Top coat layer 10 Push mold 11 Frame 12 Film 15 Rubber roller

Claims (4)

[Claims] 1. A fluid resin to which particles such as mica are added is placed on a base material, a film is covered on the fluid resin, and the film is rolled and defoamed by a roller from the film, and then the fluid resin. A method for producing a decorative board, which comprises reversing the film so that it is positioned on the lower side before being cured, and peeling the film after the fluid resin is cured. 2. The method for producing a stone-tone decorative board according to claim 1, wherein the particles have a specific gravity larger than that of the fluid resin. 3. The method for manufacturing a decorative board according to claim 1, wherein the particles are colored mica. 4. The method for manufacturing a decorative board according to claim 3, wherein the fluid resin is mixed with a coloring agent.