JPH10138438A - Manufacture of decorative plate made of woody plate as base material by laminator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative plate having excellent surface with a small coating quantity of adhesive. SOLUTION: In a method for manufacturing a decorative plate by a laminator, after a surface of a woody plate 10 as a base material is coated with an adhesive by a spreader 1, decorative sheets are continuously stuck on the adhesive-coated face. As a pre-processing of the adhesive coating process by the spreader 1, the surface of the woody plate is heated being pressed by a heated roll 20 whose surface is smooth. As the surface of the woody plate is smoothed and a seal layer of lignin is formed, and absorption of the adhesive is prevented, the decorative plate having excellent surface can be obtained with a small coating quantity of the adhesive.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative board using a laminator, and more particularly to a method of manufacturing a decorative board based on a wooden board using a laminator.

[0002]

2. Description of the Related Art Laminators have been conventionally used to manufacture decorative boards using plywood or wood board as a base material. FIG. 2 is a view for explaining main components of a conventionally used laminator. The plywood or the wood substrate 10 is attached to the surface by a dust remover (not shown) as necessary. Is removed, and is fed into a spreader 1, a curing agent such as an ammonium chloride aqueous solution is applied by a first application roll 2 in the spreader 1, and moisture in the curing agent is blown by an infrared heater 3. The second coating roll 4 applies an adhesive agent such as a urea resin. After the applied adhesive is put into a semi-dry state by the similar infrared heater 5, the substrate on which the adhesive is applied is sent between one or more pairs of hot roll presses 6, where the sheet winding roll 7 Are laminated.

When a double-sided decorative board is manufactured, an adhesive is applied to both sides of a base material, and decorative sheets are attached to both sides. By providing an emboss on any one of the plurality of pairs of hot roll presses 6, a decorative board having an embossed surface can be obtained.

[0004]

The present inventors have long been involved in the production of decorative boards using the above-described laminator. In the process, the present invention uses wood substrates such as particle boards and medium fiber boards as base materials. When manufacturing a decorative board using a board, we experienced that the amount of adhesive applied to the surface of the base material had a great effect on the quality of the decorative board. For example, a particle board is used as a base material, and 4.5
When an adhesive (eg, curing agent: ammonium chloride aqueous solution, main agent: urea resin) is applied at ± 0.5 g / scale ² , part of the applied adhesive is sucked into the particle board, and the surface has irregularities. An adhesive layer was formed. When the absolute amount of water in the adhesive was large, chipping was likely to occur on the substrate surface. When a precoated decorative tissue paper of 30 g / m ² was stuck thereon, poor adhesion did not occur, but a part of the decorative plate was wrinkled and the surface property was deteriorated.

[0005] Under the same conditions, the amount of adhesive applied is about 1.
When the amount was set to 0 to 3.0 g / scale ² , most of the adhesive was sucked from the surface of the base material, and similarly, 30 g /
was pasted precoat makeup tissue paper m ^2, the surface resistance is much generated bonding defective portion of those improved, peeling of the thin paper was observed.

[0006] A decorative board was manufactured in the same manner using a vinyl acetate emulsion as an adhesive. However, if the amount of the adhesive applied was too large, the surface property was also deteriorated due to the occurrence of irregularities such as wrinkles. If the amount is too small, many adhesion failure portions occur. Therefore, usually, in order to avoid the occurrence of a product defect due to peeling of the decorative sheet, 4.5 is used.
g / scale ² or more adhesive is applied to manufacture decorative panels. In some cases, irregularities are generated on the surface and surface properties are reduced, and more adhesive is used. This also contributes to high costs.

An object of the present invention is to provide a method of manufacturing a decorative board which eliminates the above-mentioned inconvenience which has occurred in a conventional method of manufacturing a decorative board based on a wooden board using a laminator. Specifically, it is an object of the present invention to provide a method for producing a decorative board using a wooden board as a base material by using a laminator, which has a high surface smoothness with a small amount of an applied adhesive and does not cause defective bonding.

[0008]

In order to solve the above-mentioned problems, the present invention is to apply an adhesive to one or both surfaces of a wooden board as a base material with a spreader, and then to apply a decorative sheet to the adhesive-applied surface. A method for manufacturing a decorative board using a wooden board as a base material, which is to be stuck on the surface, as a pre-process of applying an adhesive by the spreader, one or both surfaces of the wood board as a base material Is heated while pressurizing with a heated surface smooth roll.

The laminator used to carry out the method of the present invention is conventionally used except that a heated flat roll 20 is located upstream of the spreader 1, as shown in FIG. May be the same as the laminator. The room temperature wooden board 10 as a base material is subjected to pressure and heat by passing between the heating rolls 20, and the surface is smoothed. Thereafter, the spreader 1 applies an adhesive to the surface of the wooden board of the substrate in this state, and then performs drying, and a decorative sheet is attached by a hot roll press.

According to this method, since the adhesive is not sucked into the wood board and the surface is smoothed, even if the applied amount of the adhesive is as small as about 1 to 3 g / scale ^2. , The decorative sheet is fully bonded without any defective bonding
A decorative plate having a smooth surface and good surface properties without surface chipping is obtained. As the wood board as the base material, a wood processing material such as a particle board, an oriented particle board, a medium fiber board, and a hard fiber board is used.

As the adhesive applied by the spreader, the adhesive used for manufacturing a decorative board by attaching a decorative sheet to the surface of a wooden board by a conventional method can be used as it is. For example, urea resin alone or urea resin 2-5
A mixture of 8 to 5 parts by weight of vinyl acetate with respect to parts by weight, or an aqueous adhesive such as a thermosetting vinyl acetate emulsion may be used. A suitable adhesive may be used. As shown in the figure, it is not essential to separately apply the curing agent and the main adhesive, and a mixture of the curing agent and the main adhesive in advance may be applied by a single spreader.

There is no particular limitation on the decorative sheet.
m ² about tissue paper, 80g / m ² about titanium paper, 60
It may be a kraft paper of about g / m ² , a resin-impregnated sheet (FF sheet) having no self-adhesiveness, a vinyl chloride sheet, a polyolefin sheet, or the like.

In the present invention, the wooden board as the base material is subjected to pressure and heat by a heated flat roll, preferably a metal roll, before entering the spreader. The lignin on the surface of the wooden board undergoes heat softening by pressurization and heating,
A seal layer of lignin is formed on the surface. In addition to the smoothing of the surface of the wooden board by the compression with the smooth surface rolls, the formation of the lignin-based sealing layer prevents the applied adhesive from being sucked into the inside of the substrate, thereby reducing the amount of application. A sufficient adhesive strength can be obtained with the amount, the surface can be smoothed, and the surface chipping can be prevented.

When the material is a wood board (eg, a particle board), the heat softening temperature of the ligulin component is about 134 ° C. to 235 ° C. in an air-dried state, and the heating temperature by the heating roll is the heat softening of the ligulin component. It is desirable that the temperature is higher than the temperature, preferably about 50 ° C. to 150 ° C. According to the experiments of the present inventors, the higher the heating temperature by the heating roll, the smaller the amount of the adhesive to be applied, and using a particle board as a base material, at a line speed of 30 to 40 m / min. In the case of manufacturing, in the case of the conventional method (that is, in the case where the adhesive is directly applied to the wood board at normal temperature), about 4.5 g / scale ² was required to obtain good adhesiveness. At a temperature of 180 ° C., about 3 g / scale ² is sufficient.
When heated to 350 ° C., about 1 g / scale ² was sufficient. In addition, it is sufficient to press the wooden board with a heated surface smooth roll at a linear pressure of about 10 to 100 kg / cm. Pressing more than this is inconvenient for the reason of reducing the board, and the following pressures are inconvenient. The purpose cannot be sufficiently achieved by pressurization.

[0015]

The present invention will be described below with reference to examples. [Embodiment 1] As shown in Fig. 1, a pair of iron rolls having a smooth surface were arranged upstream of a spreader of a conventionally known laminator, and heating was possible by an electric heater. A particle board of 15 mm × 909 mm × 1818 mm as a base material was heated to 180 ° C. with the iron rolls facing each other at a linear pressure of 50 kg / cm, and passed at a speed of 30 m / min. Sent.

In the spreader, on one surface, first, an aqueous solution of ammonium chloride was used as a curing agent in an amount of 0.5 g / m ^2.
After applying and blowing out the moisture of the curing agent with an infrared heater,
The urea resin-based adhesive was applied at ² g / scale ² . The adhesive was put into a semi-dry state, and then 45 g / m ² as a decorative sheet
Was applied between the hot roll presses on the surface side on which the adhesive was applied.

Example 2 As in Example 1, the application of an adhesive and the attachment of a decorative sheet were performed on both sides of the particle board. [Example 3] As a substrate, 2.7 mm x 909 mm x 1
Using 818 mm high quality fiberboard, 30
using precoated paper g / m ^2, except that the adhesive application weight base resin 1.0 g / scale ^2, and the curing agent 0.2 g / scale ^2,
A decorative board was manufactured in the same manner as in Example 1.

Example 4 Example 1 was repeated except that urea resin 3: vinyl acetate emulsion 7, a urea vinyl acetate emulsion 7 was applied as an adhesive at a rate of 2 g / scale ² and dried with an infrared heater after the application. Similarly, a decorative board was manufactured.

Example 5 18 mm × 909 as a base material
mm × 1818 mm particle board was used.
g / size ² and 0.15m as decorative sheet
Example 1 except that a m-thick vinyl chloride sheet was used.
A decorative board was produced in the same manner as described above.

[Comparative Example 1] As Example 1, except that pressurization and heating with an iron roll were not performed. [Comparative Example 2] Example 1 was repeated except that the amount of adhesive applied was 4.5 g / size ² and pressure and heating with an iron roll were not performed.
A decorative board was produced in the same manner as described above.

[Comparison] For each example product and comparative example product,
The surface smoothness, the occurrence of surface chipping, the lack of adhesion, and the like were compared. In each of the examples, there was no chipping (roughness) on the surface, and no adhesion failure of the decorative sheet occurred. In the comparative example, surface smoothness was deteriorated, surface chipping occurred, and adhesion was insufficient.

[0022]

According to the method of the present invention, it is possible to obtain a decorative plate having no adhesive failure and high surface properties with a small amount of adhesive applied, which can contribute to a reduction in manufacturing cost.
In addition, when a formalin-based adhesive is used, an additional effect that the amount of formalin released can be reduced by the small amount of application is also exerted.

[Brief description of the drawings]

FIG. 1 is a diagram illustrating a laminator used for carrying out a method of the present invention.

FIG. 2 is a diagram illustrating a conventional laminator.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Base material (wood board), 20 ... Heated surface smooth roll, 1 ... Spreader, 6 ... Hot roll press, 7 ... Decorative sheet.

Claims (3)

[Claims] An adhesive is applied to one or both surfaces of a wooden board as a base material by a spreader, and a decorative board is continuously attached to the adhesive applied surface. A step of heating one side or both sides of a wooden board as a base material under pressure by a heated smooth surface roll as a pre-process of an adhesive application process using the spreader. A method for producing a decorative board using a laminator. 2. The decorative board according to claim 1, wherein a heating temperature of the roll having a smooth surface is equal to or higher than a temperature at which a sealing layer made of lignin is formed on one or both sides of a wooden board as a base material. Manufacturing method using a laminator. 3. The heating temperature of the roll having a smooth surface is about 50 ° C. to 150 ° C. higher than the thermal softening temperature of lignin of a wooden board material as a base material. A method of manufacturing a decorative board using a laminator.