JPH09104097A - Embossed decorative board and door using this board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an embossed decorative board with a conduit groove embossment of resemblance to real natural wood like the conventional design of the embossment and a doorcase layout on the peripheral part, manufactured with saved labor and at a low cost, for a door and a door facing as well as the door using this embossed decorative board. SOLUTION: This embossed decorative board consists of a transparent or translucent synthetic resin layer of at least, one layer with a total thickness of 50-700μm formed on a base and a conduit groove-like embossed pattern provided on the surface of the synthetic resin layer. A door using this board is obtained by sticking these embossed decorative boards together, each of which is made of a doorcase with the embossed pattern formed by the conduit groove, arranged on the four or two sides of the doorcase and a mirror plate member arranged in the center of the doorcase.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a door of a house or a door and a door surface imitating a wood grain conduit groove shape used for a door as a substitute for a natural material which is becoming difficult to obtain due to depletion of natural wood in recent years. The present invention relates to an embossed decorative plate for wood and a door or door using the same.

[0002]

2. Description of the Related Art There has been known an embossed decorative board which imitates or faithfully reproduces the shape of a conduit groove on the surface of wood. In particular, in the field of polyester decorative boards using unsaturated polyester resins, many products and trials have been made up to now depending on the difference in the embossing method. An embossing mold (film-like) that faithfully molds the uneven shape of the conduit groove etc. on the surface using a curable resin with good mold. b) Those using an embossing roll by an electroforming method or the like obtained by using them. c) Using an embossing die (film form) formed by hot pressing or high frequency pressing on a natural wood original or a master die obtained by reversing casting a thermoplastic film or the like. d) An embossed (film-shaped) stencil printing method using gravure printing or screen printing using an arbitrary plate obtained by making a plate based on a positive (or negative) manuscript of a natural wood conduit portion. Are widely known. Among the above four methods, especially regarding a), b) and c), it is possible to easily obtain a realistic reproduction of the conduit groove shape of the natural tree due to its technical characteristics.

Further, when a door or door having a frame shape is manufactured by using these wood grain embossed decorative plates, it is customary to arrange a grain pattern such as a grain, a trailing grain, and a disordered grain on the surface of the frame member. However, the surface of the end plate member is laid out with a grain pattern such as grain, grain, and the like. Prepare a wood grain embossed decorative plate consisting of both of these and perform secondary processing and materialization. Was there.

[0004]

However, in order to obtain a realistic reproduction of the conduit groove shape, the thickness of the resin layer, which is the emboss forming layer in the decorative plate, tends to be large, and any synthetic resin widely used at present is used. Even if the resin is used, the secondary workability such as cracking or chipping of the resin layer during cutting as a decorative board is likely to decrease, and
It is necessary to prepare an embossing mold for double-sided materials for frames and mirror plates. Furthermore, there is an undeniable effect such as a cost increase due to a decrease in the yield of decorative boards caused by the wood removal (allocation) of frames and mirror surface materials. there were. The present invention has been made in view of these facts, and an object thereof is to have a more labor-saving, inexpensive, and realistic natural wood conduit groove-shaped embossing, and a peripheral portion. (EN) Provided are a door having a frame layout, an embossed decorative plate for a door surface material, and a door or a door using the same.

[0005]

In order to achieve the above object, the first invention is to provide a transparent or semitransparent synthetic resin layer having a total thickness of 50 to 700 μm on a substrate and having at least one layer. An embossed decorative plate provided with a conduit groove-shaped embossed pattern on the surface of the synthetic resin layer, wherein the conduit groove-shaped embossed pattern is arranged on four sides or two sides, and a frame member is provided at the center thereof. An embossed decorative plate for a door and a door surface material, characterized in that it constitutes an end plate member arranged.

Further, in the second invention, a decorative sheet having a plain or printed pattern layer is adhered between the base material and the transparent or translucent synthetic resin layer via an adhesive layer. ,
Alternatively, a print pattern layer is provided on the base material by a transfer method via an adhesive layer.

Further, in the third invention, after a coloring agent is wiped on the concave portion of the conduit groove-shaped embossed pattern on the surface of the synthetic resin layer, the convex portion of the embossed pattern or the convex portion and the concave portion are top-coated with a synthetic resin. It is characterized in that a layer is provided.

Further, in the fourth invention, one of the wiping treatment and the top coat layer is applied to the surface of the embossed decorative plate.

A fifth aspect of the invention is characterized in that the embossed decorative plates for the door and door surface material are adhered from the front and back surfaces of the door or door core material, or the back surfaces of the embossed decorative plates are adhered to each other. A door or a door using an embossed decorative plate.

In a sixth aspect of the present invention, the embossed decorative plate for the door and the door surface material is cut and grooved on the boundary line between the peripheral frame portion and the end plate portion arranged at the center, and then the groove portion is framed. A door or door using an embossed decorative plate, which is characterized in that a material is embedded or a groove is cut and molded into a frame shape, and then a coating process is performed to form a drop shape.

[0011]

1 is a sectional view showing the structure of an embossed decorative plate for a door and a door surface material of the present invention. As described above, the embossed decorative plate for doors and door surface materials according to the present invention has a transparent or translucent synthetic resin layer surface provided on a base material, and the opening shape of the conduit portion on the surface of the natural wood is reversed. The embossing pattern formed, or a decorative plate having a conduit groove-shaped embossing pattern formed by an embossing type having a conduit shape similar to this, the embossing pattern by the conduit groove shape of this decorative plate,
It is characterized in that a frame member arranged on four sides or two sides, which is a door / door member, and an end plate member arranged at the center thereof are configured. That is, FIG. 1 shows a cross section of this embossed decorative plate, in which 1 is a base material layer, 2 is an adhesive layer, and 5 is a decorative sheet layer in which a printed pattern layer 4 is provided on a sheet 3. , 6 is a synthetic resin layer, 7 is a conduit groove, 8 is a wiping colored layer, and 9 is a top coat resin layer.

2 (a) and 2 (b) show a method for imparting a conduit groove-shaped embossed pattern to these decorative plates. FIG. 2 (a) shows a conduit portion on the surface of natural wood. This figure shows the state in which the synthetic resin layer surface is rolled and embossed with an embossing die with an inverted opening shape or an embossing die 12 having a similar conduit shape. Reproduced embossed resin layer 1
0 and the base film layer 11. Furthermore, FIG.
(B) is an embossing roll formed by reversing the opening shape of the conduit on the surface of the natural wood such as the above-mentioned embossing mold, or an embossing roll prepared based on a master mold obtained from an embossing mold having a conduit shape similar to this. 13 shows a step of embossing the surface of the synthetic resin layer.

FIG. 3 shows a basic layout of doors or doors with embossed decorative plates for doors and door face materials.
4 is a vertical frame, 15 is a horizontal frame, 16 is an end plate, and 17 is a drop-in portion.

FIG. 4 shows an example of a door or a door manufacturing method using an embossed decorative plate, wherein 18 is a frame-shaped embossed decorative plate, and 19 is a core material of a door member.

FIG. 5 shows that the embossed decorative plate is used by cutting and processing the door or the peripheral part of the inside of the frame of the door part and the center end plate part along the boundary line to cut and process the necessary width and depth from the surface side. The part 17 is formed, and as shown in the AA cross-sectional view, 19 is a core material, and 20 is a frame material embedded in the dropping part.

As the base material 1 used in the present invention, wood base materials such as plywood, MDF (medium density fiber reinforced board), hard board, particle board, etc., which have been widely used for decorative boards, metal plates, resin plates. Materials such as an inorganic plate can be used. Also, a combination of a plurality of base materials made of these materials can be used. Further, the size of the base material can be selected to have any size and thickness according to the size of the door or door required. The decorative sheet layer 5 having a print pattern layer is provided on the base material 1 via the adhesive layer 2, or the print pattern layer is provided by a transfer method. In both cases of transfer of the decorative sheet layer or the printed pattern layer and any lamination, the adhesive used as the present adhesive layer 2 can be arbitrarily selected in consideration of its adhesiveness. As an example, in the case of a combination of a plywood base material and a decorative sheet with a decorative paper having a basis weight of 80 g / m ² , an adhesive such as a vinyl acetate emulsion type or a urea-vinyl acetate emulsion type is common and suitable. As an application method of the adhesive layer, an application method such as a roll coater, a reverse coater, a knife coater, a flow coater, a spray, or a combination of a plurality of them can be arbitrarily selected.

A print pattern layer is provided via the adhesive layer 2. At this time, a decorative sheet layer 5 provided with a printed pattern layer 4 such as wood grain pattern printing or monochrome printing in advance is laminated on the sheet 3, or a transfer pattern formed by printing on any base film is used to print a printed pattern. A method of laminating only layers can be selected. As a printing method used at this time, an arbitrary method such as gravure printing, silk screen printing, offset printing, or the like can be selected.

As the sheet 3 used for the decorative sheet layer 5, vinyl chloride, acryl, olefin,
It is possible to select a single or a combination of a plurality of synthetic resin films having an arbitrary thickness such as ABS, or paper having a basis weight of about 15 to 200 g / m ² , titanium paper, mixed paper, impregnated paper, synthetic paper and the like. It is also possible to use the sheet alone without the printed pattern layer 4. Further, a primer coat layer may be appropriately provided on the decorative sheet layer 5 for the purpose of protecting the printed pattern layer 4 and improving the adhesion between the sheet layer and the synthetic resin layer 6 to be embossed.

Then, a synthetic resin layer 6 for forming a wood grain conduit groove by an embossing type is provided on the decorative sheet layer 5. As the resin used for the resin layer, there are many choices as long as the resin is a transparent or translucent curable resin such as a polyester resin, an epoxy resin, a urethane resin, a melamine resin, and a tap resin, and any selection is possible. It is. Further, it is possible to laminate a plurality of these resin layers, but the total thickness is about 50 to 700 μm in consideration of the conduit groove shape of the natural wood surface imparted to and formed on the resin layer surface. It is enough.

Further, as shown in FIG. 2 (a), an embossing mold 12 in which the opening shape of the conduit on the surface of the natural wood is formed on the surface of the resin layer 6 or an embossing mold 12 having a conduit groove shape similar to this. After being laminated and rolled in the curing process of the resin layer, the embossing die 12 is awaited until the synthetic resin layer 6 is cured.
Are removed and demolded to form the conduit groove 7. Further, as shown in FIG. 2B, an embossing mold in which the opening shape of the conduit on the surface of the natural wood is reversely formed on the surface of the resin layer 6 or a master mold obtained from an embossing mold having a conduit groove shape similar to this. It is also possible to form the conduit groove 7 by embossing the resin layer with an embossing roll 13 manufactured based on the above, or after the resin layer is cured.

As the embossing mold 12 used here, the base film layer 11 is made of a synthetic resin film such as a vinylon film, a polyester film, an olefin film, a fluorine film or a polyvinyl chloride film, or a composite thereof. Can be used. At this time, by laying out the natural wood prepared for obtaining the embossing die 12 or the embossing roll 13 as shown in FIG. 3, an embossed pattern having a frame shape suitable for the door and the door surface material is obtained. To be Of these, the type of the embossed die 12 is
The reverse casting process from natural wood, which has a frame layout as an embossed manuscript, is relatively simple and is not subject to size restrictions, making it suitable for both door and door layouts. Further, in the case of the embossing roll 13, considering the complexity of the embossing roll manufacturing process and the restriction of the embossable area caused by the outer diameter of the embossing roll, the embossing roll 13 is suitable for manufacturing a door surface material having a relatively small area.

After the step of providing the conduit groove 7 on the surface of the synthetic resin layer 6, the wiping colored layer 8 is then provided in the main conduit groove 7, and further on the wiping colored layer 8 in the conduit groove 7 and the conduit groove. The top coat layer 9 made of a resin is provided only on the peripheral surface including 7 or on the convex surface around the conduit groove 7.

A door or door obtained by using a wood grain embossed decorative plate faithfully reproducing the surface of natural wood having the frame and the end plate layout obtained as described above will be described. Although not shown, first, the two embossed decorative plates obtained are adhered / laminated to each other with an adhesive layer between the back surfaces, or as shown in FIG. Core material 19 formed by combining a plurality of
Then, the face materials 18 and 18 obtained through the adhesive layer are adhered and laminated on the front and back sides to form a door or a rectangular parallelepiped-shaped member that serves as the base of the door, and the precise cut in the long axis direction and the width direction. After doing
Makeup treatment of the cut surface of this cut is performed by a method such as painting or attaching edge tape. At this point, if metal fittings such as a door knob and a handle are processed, the door or door is completed, but the following steps can be performed for the purpose of further imparting designability.

As shown in FIG. 5, first, on the surface of the embossed decorative plate for the door and the door surface material, along the boundary line between the peripheral frame portion and the central end plate portion, which are laid out, the width and depth required from the surface side are provided. After cutting and grooving, the frame material 20 prepared in advance is embedded in the groove portion 17, or the main groove portion is molded into a shape similar to a frame material, and then it is easily dropped by applying a coating treatment. The door or door has a shape. In addition, at this time, it is needless to say that a sufficient cutting allowance can be secured so that the door or the base material of the door or the core material can be provided with the drop shape. Further, it is possible to embed the glass plate and the louver slit after appropriately cutting and removing the end plate portion and the horizontal frame portion.

[0025]

The embossed decorative board for doors and door surface materials of the present invention is made of natural wood on the surface of a synthetic resin layer having a total thickness of 50 to 700 μm, which is provided on a base material and has a total thickness of 50 to 700 μm. An embossed type in which a door formed by a frame member arranged on one side or two sides and an end plate member arranged in the center thereof and an opening shape of a conduit portion on the door surface is inverted, or a conduit shape similar to this. By providing the embossed pattern of the conduit groove, it becomes possible to construct a door or a frame layout of doors.

Also, the door or door can be easily and inexpensively obtained by attaching the embossed decorative plate from the front and back surfaces of the core material of the door and the door, or by attaching the back surfaces of the embossed decorative plate to each other. be able to.

Further, on the surface of the embossed decorative plate for the door and the door surface material, along the boundary line between the peripheral frame portion and the central end plate portion laid out, cutting and grooving are made to the required width and depth from the surface side. After that, by embedding a frame material prepared in advance in the groove portion concerned, or by molding the main groove portion into a shape imitating a frame material and then applying a coating treatment, it easily has a drop shape, which has a high designability. Doors or doors are obtained.

[0028]

EXAMPLES Specific examples will be described below.

Example 1 First, as a wood grain embossing base material, the size is 920 mm × 1830 mm and the thickness is 2.5 mm.
80g / m of vinyl acetate emulsion adhesive on one side of this base material using a natural roll coater.
^An adhesive layer was formed by applying ² wet. Furthermore, gravure printing is applied to the base paper with a basis weight of 60 g / m ² , and an oak grain pattern with a vertical frame and horizontal frame layout on four sides and a wood grain pattern for door surface material with an oak grain pattern as a mirror plate in its center Pre-printed decorative paper is overlaid on the adhesive layer, and the base material and the decorative paper are attached by bonding and curing with a hot press at 100 ° C. for 60 seconds. Is.

Then, an unsaturated polyester resin (epolac,
1.5 parts of Permec (manufactured by Nippon Oil & Fats Co., Ltd.) as a catalyst was added to and stirred by Nippon Shokubai Co., Ltd., and immediately applied with an appropriate coating amount, and an embossed type separately prepared on this. Were piled up and rolled with a rubber roll. As the embossing type used at this time, a vinylon film having a thickness of 25 μm was used for the base film, a polyvinyl alcohol resin was used for the embossing resin layer, and the embossed manuscript was made of North American white oak wood grain and a perimeter grained frame. The surface shape of the door, which is made of a mirror member using a sheet material placed in the center of the door, is inverted and cast, and prepared and prepared.
After curing and drying the unsaturated polyester resin in this way, the embossing mold is released, and further, a wiping colored layer is provided in the surface conduit groove of the obtained embossed decorative plate, and urethane is provided in the peripheral part including the surface conduit groove. A top coat layer was provided with a resin to obtain a wood embossed decorative board for a door surface material having a vertical frame / horizontal frame on four sides and a mirror plate part in the center thereof.

<Embodiment 2> Two embossed decorative boards for doors and door surface materials obtained in Embodiment 1 are adhered / laminated on their back surfaces via an adhesive layer, or a door and a door core. Attach the door and door surface material to the front and back with an adhesive layer on the core material that is a combination of multiple boards and square materials that can be used as materials.
After stacking, precisely cutting in the long axis direction and width direction on the door or the rectangular parallelepiped member that is the base of the door, make a decorative treatment on the cut surface by painting or attaching edge tape. Further, at this point, doors or doors can be easily obtained by performing metal fitting processing such as door knobs and handles.

<Embodiment 3> On the surface of the embossed decorative plate for the door and door surface material obtained in Embodiment 1, it is necessary from the surface side along the boundary line between the peripheral frame portion and the central end plate portion laid out. It is easy by cutting and grooving with various widths and depths, then embedding a frame material prepared in advance in the groove portion, or by molding after forming this groove portion into a shape imitating a frame material and then painting. A door or door having a drop shape was obtained. Further, at this time, it is necessary to secure a sufficient cutting allowance for installing the drop shape on the door or the base material of the door or the core material. In addition, cut the end plate and horizontal frame appropriately.
After the removal, it is possible to embed a glass plate or a louver slit.

[0033]

As described above in detail, the embossed decorative board for doors and door surface materials of the present invention is a substrate in which a decorative sheet layer having a plain or printing layer is laminated with an adhesive layer interposed therebetween. On the surface of the synthetic resin layer provided on the substrate on which the printing layer was transferred via the adhesive layer, an embossed type in which the opening shape of the conduit portion on the surface of natural wood was inverted or a conduit shape similar to this was formed. It is an embossed decorative plate with a conduit groove-shaped embossing pattern formed by the existing embossing type, which has a realistic expression of natural wood conduit grooves, and already has a vertical frame, horizontal frame and its adjacent center panel. The layout of the door and door surface material that consists of parts is reproduced on one decorative plate. By using the embossed decorative plate having this frame layout, it becomes possible to omit the manufacturing process of each of the frame member and the end plate member and the assembly process of the frame member and the mirror member in the door or door manufacturing process, and the front and back of the core material can be omitted. You can easily obtain a door or door by sticking this embossed decorative board to each other, or by sticking the backsides of the embossed decorative boards together, and also greatly reduce material loss due to wood removal of the surface material. It has become possible.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a configuration of an embossed decorative plate for a door and a door surface material of the present invention.

2A and 2B show a method for imparting a conduit groove-shaped embossed pattern in the embossed decorative sheet of the present invention, wherein (a) is a sheet-shaped embossing method and (b) is a roll-shaped embossing method. FIG.

FIG. 3 is an explanatory view showing an embossing type used for an embossed decorative plate for doors and door surface materials of the present invention, showing a basic layout for doors and door surface materials.

FIG. 4 is an explanatory view showing an example of a door or a method of manufacturing a door using the embossed decorative plate of the present invention.

FIG. 5 is an explanatory view showing a state in which the door or the peripheral frame portion of the door and the central end plate portion of the present invention are cut and grooved from the surface side to a necessary width and depth along the boundary line, and the groove portion. FIG. 3 is a cross-sectional view taken along line AA showing a state in which a frame material prepared in advance is embedded.

[Explanation of symbols]

 1 ... Substrate 2 ... Adhesive layer 3 ... Sheet 4 ... Printed pattern layer 5 ... Decorative sheet layer 6 ... Synthetic resin layer 7 ... Conduit groove 8 ... Wiping coloring layer 9 ... Topcoat layer 10 ... Resin groove-shaped resin layer 11 ... Base film layer 12 ... Sheet-like embossing type 13 ... Embossing roll 14 ... Vertical frame 15 ... Horizontal frame 16 ... End plate 17 ... Drop-in portion 18 ... Frame-shaped decorative plate 19 ... Door and door-forming core material 20 ... Frame material

Claims (6)

[Claims] 1. An emboss having a transparent or semi-transparent synthetic resin layer having a total thickness of 50 to 700 μm on at least one layer and having a conduit groove-shaped embossed pattern on the surface of the synthetic resin layer. A door and a door, which is a decorative plate, characterized in that the conduit groove-shaped embossed pattern constitutes a frame member arranged on four or two sides and an end plate member arranged in the center thereof. Embossed decorative board for face materials. 2. A printed pattern layer is formed by sticking a plain sheet or a decorative sheet having a printed pattern layer on the base material via an adhesive layer, or by transferring the decorative sheet on the base material via an adhesive layer. The embossed decorative plate for doors and door surface materials according to claim 1, wherein the embossed decorative plate is provided. 3. A top coat layer made of synthetic resin is provided on the convex portion or convex portion and concave portion of the embossed pattern after wiping a coloring agent to the concave portion of the conduit groove-shaped embossed pattern on the surface of the synthetic resin layer. The embossed decorative plate for doors and door surface materials according to claim 1 or 2, characterized in that. 4. The embossed decorative plate for doors and door surface materials according to claim 3, wherein any one of the wiping treatment and the top coat layer is applied to the surface of the embossed decorative plate. 5. The embossed decorative plate for door and door surface material according to any one of claims 1 to 4 is adhered from the front and back of a door or door core material, or the back surfaces of the embossed decorative plate are adhered to each other. A door or a door using an embossed decorative plate characterized by being worn. 6. After cutting and grooving on the boundary line between the peripheral frame portion and the end plate portion arranged in the center of the embossed decorative plate for doors and door surface materials according to any one of claims 1 to 4. A door or door using an embossed decorative plate, characterized in that a frame material is embedded in the groove portion, or the groove portion is cut / molded into a frame material shape, and then a coating process is performed to form a drop shape.