JPH11245337A - Decorative plate and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a decorative plate endure outdoor use such as an outdoor sheathing, an entrance door or the like by improving a weather resistance such as a moisture resistance, light resistance and the like. SOLUTION: The method for manufacturing a decorative plate comprises the steps of impregnating a woodgrain print sheet 3 with an acrylic resin, adhering the sheet 3 onto a base material 1 made of a woody fiber plate containing a melamine resin as a binder with an adhesive 2 made of an aqueous polymer- isocyanate, coating the sheet 3 with a light stabilizer-containing unsaturated polyester resin paint, embossing the painted surface, and then coating the embossed layer 4 with a light stabilizer-containing acrylic polyurethane resin paint.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative plate which is excellent in weather resistance and is used for an exterior exterior of a house or the like, an entrance door or the like.

[0002]

2. Description of the Related Art A decorative panel as shown in FIG. 6 is an example of a conventional decorative panel used for a wall material of a house, a floor material and a surface material of furniture. This decorative board is made of a base material 11 made of a wooden board.
Wood grain printing paper 13 that adheres to the base material 11 via an adhesive 12, an embossed layer 14 formed on the wood grain printed paper 13, and a wiping layer 15 that seals recesses of the embossed layer 14. And an overcoat layer 16 formed on the emboss layer 14 and the wiping layer 15.

As the wood material used for the base material 11, orthogonal plywood (hereinafter, referred to as R / C), medium-density fiberboard (hereinafter, referred to as MDF), particle board, etc. are used alone.
Or, they are used in combination. As the adhesive 12, usually, a urea resin, a vinyl acetate resin emulsion, or the like is used alone or in combination.

The grain printing paper 13 is obtained by taking a picture of the grain of wood for a photo original and printing the grain on titanium paper by photoengraving printing from the photograph. Here, titanium paper is made by embedding titanium oxide in pulp in order to impart concealment properties. The embossed layer 14 is for giving a tactile feel to wood on the surface of the decorative board, and a transparent paint made of an unsaturated polyester resin is applied on the printing paper 13, and while the transparent paint is uncured, The surface of the coated unsaturated polyester resin is embossed by using a silicon embossing die in which the irregularities on the surface of the wood for photo originals are molded with silicon, and this is cured.

[0005] The wiping layer 15 is formed by applying a polyurethane resin paint containing a dye, a pigment and a substance content on the embossed layer 14 in order to adjust the color tone of the grain, and then removing the excess paint (wiping). It is formed so as to fill in the concave portions of the embossed layer 14. The overcoat layer 16 protects the surface of the decorative board and gives the decorative board a good appearance, a feeling of depth of grain, a deep taste, and the like. The overcoat layer 16 includes polyester polyol, 4,4′-diphenylmethane-diisocyanate (hereinafter referred to as MDI). ), A transparent paint composed of a polyisocyanate-based compound such as tolylene diisocyanate (hereinafter referred to as TDI) is applied to the embossed layer 14 and the wiping layer 15, cured, and polished. The steps of coating and curing are repeated several times as necessary.

However, when such a decorative board is used outdoors, the wood-grain printing paper 13 is inferior in moisture resistance, so that the wood-grain printing paper 13 is easily peeled off from the base material 11 due to moisture absorption. In addition, there is a disadvantage that fading and discoloration easily occur in the embossed layer 14 or the overcoat layer 16 due to ultraviolet rays. Furthermore, since the R / C and MDF used for the base material 11 are not waterproofed at all, problems such as swelling of the base material 11 due to moisture absorption and peeling of the grain print paper 13 were likely to occur. As described above, conventional decorative boards are mainly designed for indoor wall materials, flooring materials, and furniture surface materials, and thus have insufficient weather resistance such as moisture resistance and light resistance. It was not suitable for outdoor use such as doors and entrance doors.

[0007]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a decorative board having improved weather resistance such as moisture resistance and light resistance so as to withstand outdoor use, and a method for producing the same.

[0008]

Means for Solving the Problems In order to solve the above problems, according to a first aspect of the present invention, there is provided a base made of a wooden board,
Wood grain printing paper adhered to the substrate via an adhesive, an embossed layer formed on the wood grain printing paper, and a decorative board having an overcoat layer formed on the embossed layer,
The embossed layer is formed of a light stabilizer-containing unsaturated polyester resin, the overcoat layer is formed of a light stabilizer-containing acrylic polyurethane resin, and the adhesive is an aqueous polymer.
An isocyanate resin was used, and the wood grain printing paper was impregnated with an acrylic resin. In a second aspect, in the first aspect, a wood fiber board using a melamine resin as a binder is used as the base material.

In the third invention, as a method of manufacturing a decorative board, a grain of wood for a photo original is printed on paper by photoengraving printing, and the grain printed paper is impregnated with an acrylic resin.
The above wood grain printing paper is coated with a water-based polymer on a substrate made of a wooden board.
Adhering with an isocyanate-based adhesive, applying a light stabilizer-containing unsaturated polyester resin paint on the wood grain printing paper, applying an embossing process to the coating film surface using an embossing mold, and applying a light-stable A method of applying an agent-containing acrylic polyurethane resin paint was used.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.
FIG. 1 is a cross-sectional view showing one example of the decorative board of the present invention. This decorative board includes a base material 1 made of a wood board, a wood grain printing paper 3 adhered to the base material 1 via an adhesive 2, an emboss layer 4 formed on the wood grain printing paper 3, and an emboss layer. Layer 4
And a top coat layer 6 formed on the embossed layer 4 and the wiping layer 5.

The wood material used for the substrate 1 is as follows.
It is selected according to the use of the decorative board, and is not particularly limited. For example, solid wood, wood fiber board such as MDF, R / C, LVL, LSL, particle board, etc. may be used alone or in combination. No. Among them, a wood fiber board using a melamine resin as a binder is preferably used in terms of water resistance, moisture resistance and the like. The thickness is determined by the use of the decorative material and the like, and is not particularly limited, for example, 2 to 60 mm
Range.

As the adhesive 2, an aqueous polymer-isocyanate adhesive having good adhesion to the substrate 1 and the wood grain printing paper 3 and excellent in moisture resistance is used. The thickness of the adhesive applied on the substrate is not particularly limited, but is, for example, in a range of 20 to 50 μm.

The above-mentioned aqueous polymer-isocyanate adhesive comprises a main agent mainly composed of a water-soluble polymer and / or an aqueous dispersion, and a crosslinking agent mainly composed of a polyisocyanate compound.

Examples of the polyisocyanate compound include MDI, TDI, hexamethylene diisocyanate (hereinafter referred to as HMDI) and xylylene diisocyanate (hereinafter referred to as XDI).
DI is preferably used. The amount of the polyisocyanate compound to be used is 1 to 100 parts by weight based on 100 parts by weight of the main agent. The amount of the polyisocyanate compound used is
If the amount is less than 1 part by weight, the curing of the adhesive 2 becomes insufficient, and
If it exceeds 00 parts by weight, unreacted isocyanate increases, which is not preferable.

The grain printing paper 3 is obtained by printing the grain of wood for an original on titanium paper. Here, titanium paper is
Made from pulp with titanium oxide for hiding. Further, the wood grain printing paper 3 is impregnated with an acrylic resin in order to improve the moisture resistance of the wood grain printing paper 3 and further improve the adhesiveness with the adhesive 2 and the embossed layer 4.

Examples of the acrylic resin include unsaturated carboxylic acids such as (meth) acrylic acid, fumaric acid and maleic anhydride, methyl (meth) acrylate, ethyl (meth) acrylate, and n- (meth) acrylate. -Butyl, (meth) acrylates such as 2-hydroxyethyl (meth) acrylate, (meth) acrylonitrile, (meth)
Acrylamide, styrene, vinyl chloride, etc. alone,
Alternatively, a polymer obtained by polymerizing a plurality of combinations is used. The weight average molecular weight of the acrylic resin is not particularly limited, but is, for example, in the range of 500 to 20,000.

The embossed layer 4 is for giving a tactile feel to wood on the surface of the decorative board, and is formed by embossing the surface of the unsaturated polyester resin applied on the printing paper 3. The thickness is determined by the use of the decorative material and the like, and is not particularly limited, but is, for example, in the range of 200 to 400 μm. Examples of the unsaturated polyester resin include, for example, a dibasic acid such as maleic anhydride and phthalic anhydride, and a base resin made from a dihydric alcohol such as ethylene glycol and propylene glycol, and a reactive monomer such as styrene. What was made is mentioned.

The unsaturated polyester resin includes:
For the purpose of preventing fading and discoloration of the decorative board surface due to ultraviolet rays, a light stabilizer such as a benzotriazole-based, benzophenone-based, salicylate-based, or cyanoacrylate-based light-absorbing agent is used in an amount of 1 to 1% based on the unsaturated polyester resin solids. 5% by weight is added. When the amount of the light stabilizer is less than 1% by weight, the curing of ultraviolet absorption is insufficient, and when the amount exceeds 5% by weight, the adhesiveness of the unsaturated polyester resin to the grain printing paper 3 is undesirably reduced. As the benzotriazole-based light stabilizer, benzotriazole, 2
-(2'-hydroxy-5'-methylphenyl) benzotriazole, 2- (2'-hydroxy-3'-t-butyl-5'-methylphenyl) -5-chlorobenzotriazole and the like, and the above-mentioned benzophenone Benzophenone, 4-methylbenzophenone, 2-hydroxy-4-methoxybenzophenone, o
-Methyl benzoylbenzoate and the like. Examples of the salicylate-based stabilizer include 4-t-butylphenyl salicylate, and examples of the cyanoacrylate-based stabilizer include ethyl-2-cyano-3,3-diphenylacrylate.

The wiping layer 5 is formed by using an acrylic polyurethane-based resin paint containing a pigment so as to fill the concave portions of the embossed layer 4 in order to adjust the color tone of the grain. The acrylic polyurethane resin has excellent light resistance and adhesiveness as compared with the polyurethane resin used for the conventional decorative board, and prevents the wiping layer 5 from being faded, discolored, and peeled off. As the acrylic polyurethane resin paint, for example, a transparent agent comprising a main agent mainly composed of an acrylic polyol resin, a pigment, a solvent and the like, and a curing agent made from a mixture of polyisocyanate compounds such as HMDI alone or as a mixture is used as a raw material. , A translucent paint is used.

The acrylic polyol resin is an acrylic resin having two or more hydroxyl groups in the molecule.
Acrylic monomer having a hydroxyl group such as 2-hydroxyethyl (meth) acrylate and, if necessary, (meth) acrylic acid, alkyl (meth) acrylate, (meth) acrylate
It is obtained by polymerizing other acrylic monomers such as acrylonitrile and styrene alone or in combination.

Examples of the polyisocyanate compound include MDI, HMDI, XDI and the like. Above all, acrylic polyurethane-based resins using HMDI are preferably used because of their excellent weather resistance. The amount of the polyisocyanate compound used is such that the equivalent of the isocyanate group of the polyisocyanate compound to the hydroxyl group of the acrylic polyol as the main component is 0.9 to 1.2.
If the amount of the polyisocyanate compound is less than 0.9 equivalent, the curing of the acrylic polyurethane resin becomes insufficient, and if it exceeds 1.2 equivalent, unreacted isocyanate increases, which is not preferable. Further, as the pigment,
For example, titanium oxide, talc, calcium carbonate and the like can be mentioned.

The overcoat layer 6 protects the surface of the decorative board and gives the decorative board a good appearance, a sense of depth of wood grain, a deep taste, and the like. The transparent coat made of an acrylic polyurethane resin is used. Is formed on the emboss layer 4 and the wiping layer 5. The thickness is determined by the use of the decorative material and the like, and is not particularly limited, but is, for example, about 100 μm.

The acrylic polyurethane resin is superior in light resistance and adhesiveness to the resin composed of a polyester polyol resin / polyisocyanate compound (mainly TDI) used in a conventional decorative board, and has a superior overcoat layer 6. To prevent fading, discoloration, peeling, etc. As the acrylic polyurethane-based resin paint, a paint composed of an acrylic polyol and a polyisocyanate-based compound (mainly HMDI) is used, similarly to the paint used for the wiping layer 5.

In order to prevent fading or discoloration of the decorative board surface due to ultraviolet rays, the acrylic polyurethane resin contains a benzotriazole- or benzophenone-based light stabilizer that absorbs ultraviolet rays in the acrylic polyurethane resin solids. It is added in an amount of 1 to 5% by weight. 1 light stabilizer
If the amount is less than 5% by weight, curing of ultraviolet absorption is insufficient, and
If the content is more than 10% by weight, the adhesiveness of the acrylic polyurethane resin is undesirably reduced.

Next, a method for producing the decorative board of the present invention will be described. First, the grain of the surface of the wood for photo manuscript is photographed, and a printing plate is created from the photograph by photoengraving.
For photolithography, a usual method widely known in this technical field is used. The printing plate is prepared in 1 to 5 plates according to the purpose such as the number of colors to be printed. Further, a silicon embossing die 9 in which irregularities on the surface of the wood for photo originals are molded with silicon is simultaneously prepared.

Then, as shown in FIG. 2, using a printing plate obtained by the above-described photoengraving on a piece of titanium paper 7, a wood grain for a photo manuscript is printed to an original size to form a printing layer 8. By doing so, the wood grain printing paper 3 is created. For the printing, a normal printing method such as gravure printing, offset printing, or flexographic printing is used. Further, it is preferable to use a printing ink having good weather resistance. Further, the wood grain printing paper 3 is impregnated with an acrylic resin. Examples of the impregnation method include a method of dipping the woodgrain printing paper 3 in an acrylic resin liquid and applying a treatment such as pressure as necessary, and a method of applying an acrylic resin to the woodgrain printing paper 3.

Next, as shown in FIG. 3, an adhesive 2 is applied on the base material 1 and the wood grain printing paper 3 is laminated thereon,
By performing thermocompression bonding, the base material 1 and the wood grain printing paper 3 are bonded. Examples of the thermocompression bonding method include a method using a hot press, a hot roll, or the like.

Next, as shown in FIG. 4, a transparent paint composed of an unsaturated polyester resin containing a light stabilizer is applied on the wood grain printing paper 3 and the unsaturated polyester resin is cured while it is not cured. Then, the silicon embossing die 9 is superimposed on the unsaturated polyester resin so that the grain of the wood grain printing paper 3 and the unevenness of the silicon embossing die 9 coincide with each other. Then, using a defoaming roll from above the silicon embossing die 9, the air remaining between the unsaturated polyester resin and the silicon embossing die 9 is completely defoamed, and the surface of the unsaturated polyester resin is embossed. Heat to cure the unsaturated polyester resin. Thus, the embossed layer 4 is formed.

Then, as shown in FIG. 5, an acrylic polyurethane resin paint containing a pigment is applied on the embossed layer 4, and immediately after the application, excess paint is removed (wiping). Then, the acrylic polyurethane resin remaining in the concave portions of the embossed layer 4 is cured, and the surface thereof is polished as necessary, whereby the wiping layer 5 is formed so as to fill the concave portions of the embossed layer 4.

The plate on which the wiping layer 5 is formed is processed into a product shape as required. Then, a transparent paint made of an acrylic polyurethane-based resin containing a light stabilizer is applied on the embossed layer 4 and the wiping layer 5 and cured, and then the surface is polished to form the overcoat layer 6. The above-mentioned steps of application and curing are repeated several times as necessary in order to give the decorative plate a good appearance, a feeling of depth of wood grain, a feeling of deep taste, and the like.

In the decorative plate thus obtained, the embossed layer 4 contains a light stabilizer that absorbs ultraviolet light, and the overcoat layer 6 uses an acrylic polyurethane resin containing the light stabilizer. Therefore, it is excellent in light resistance and can prevent fading and discoloration of the surface of the decorative board. Also,
Since the aqueous polymer-isocyanate adhesive is used as the adhesive 2 and the wood grain printing paper 3 is impregnated with an acrylic resin, the wood grain printing paper 3 and the adhesion between the substrate 1 and the wood grain printing paper 3 are bonded. The portion is excellent in moisture resistance, and can prevent peeling of the wood grain printing paper 3 from the base material 1.

Further, by using a wood fiber board using a melamine resin having excellent water resistance and moisture resistance as a binder as the substrate 1, swelling of the substrate 1 due to moisture absorption and peeling of the grain printing paper 3 are prevented. can do.

Hereinafter, examples will be described. (Example) First, the grain of the surface of the wood for photo manuscripts was color-separated using a filter and photographed for three colors, and three gravure plates were prepared from these photographs by photoengraving.
Further, a silicon embossed mold in which irregularities on the surface of the wood were molded with silicon was simultaneously produced.

Using a gravure plate obtained by the above-described photoengraving on 80 g titanium paper, a grain of wood for a photographic original is printed using a gravure printing machine of full-size and multicolor printing. Created. Further, the wood grain printing paper was immersed in an acrylic resin liquid having a weight average molecular weight of 2000, and 100 parts by weight of the wood grain printing paper was impregnated with 10 parts by weight of an acrylic resin.

Next, a 3.0 mm thick substrate made of MDF using a melamine resin as a binder was prepared. On this substrate, an aqueous polymer-isocyanate adhesive is applied for 30 minutes.
１００100 g / m ^{2 was} applied, and the woodgrain printing paper was laminated thereon, followed by thermocompression bonding using a hot press.

Next, a transparent paint composed of an unsaturated polyester resin containing 2% by weight of benzotriazole is applied on the wood-grain printing paper. The surface of the printed paper is superimposed on the saturated polyester resin so that the grain of the printed paper and the silicon embossed pattern match, the surface is embossed, and the unsaturated polyester resin is cured by heating. A layer was formed.

Then, an acrylic polyurethane resin paint containing 5% by weight of a pigment is applied on the emboss layer, immediately after the application, excess paint is removed, and the acrylic polyurethane resin remaining in the recesses of the emboss layer is cured. As a result, a wiping layer was formed so as to seal the recesses of the embossed layer 4. Here, as the acrylic polyurethane resin, the hydroxyl group of the acrylic polyol resin and HMDI
The isocyanate group having an equivalent ratio of 1: 1 was used.

Next, a transparent paint composed of an acrylic polyurethane resin containing 2% by weight of benzotriazole is applied on the emboss layer and the wiping layer, and cured.
Next, the surface was polished. By repeating the steps of coating, curing and polishing three times, an overcoat layer having a thickness of about 30 μm was formed, thereby obtaining a desired decorative board. Further, the decorative panel was cut into a desired size of the entrance door, and panel processing was performed to manufacture the entrance door.

Using the thus-obtained decorative sheet sample, an exposure test was carried out outdoors for 5 years. As a result, no problems such as fading, discoloration, and peeling occurred. Similarly, the above-mentioned entrance door was subjected to a three-year exposure test, but no problems such as fading, discoloration, and peeling occurred.

[0040]

As described above, in the decorative board of the present invention and the method for producing the same, the weather resistance such as moisture resistance and light resistance is improved as compared with the prior art, so that the exterior exterior and the entrance door can be used. The present invention can provide a decorative plate that can be used for, for example, the present invention.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing an example of a decorative board of the present invention.

FIG. 2 is a schematic cross-sectional view showing an example of a grain printing paper obtained in a printing step in the production method of the present invention.

FIG. 3 is a schematic cross-sectional view showing an example of a plate obtained in a bonding step in the production method of the present invention.

FIG. 4 is a schematic sectional view showing an example of an embossing step in the manufacturing method of the present invention.

FIG. 5 is a schematic sectional view showing an example of a plate obtained in a filling step in the production method of the present invention.

FIG. 6 is a schematic sectional view showing an example of a conventional decorative board.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Base material, 2 ... Adhesive, 3 ... Wood grain printing paper, 4 ... Embossed layer, 6 ... Overcoat layer

Claims (3)

[Claims] 1. A base material made of a wood board, a wood grain printing paper adhered to the base material via an adhesive, an embossed layer formed on the wood grain printed paper, and a wood grain formed on the embossed layer A decorative plate having an overcoat layer, wherein the emboss layer is made of an unsaturated polyester resin containing a light stabilizer, the overcoat layer is made of an acrylic polyurethane-based resin containing a light stabilizer, and the adhesive is aqueous. A decorative plate comprising a polymer-isocyanate system, wherein the woodgrain printing paper is impregnated with an acrylic resin. 2. The decorative board according to claim 1, wherein the base material is a wood fiber board using a melamine resin as a binder. 3. A wood grain for a photo original is printed on paper by photoengraving printing, and the wood grain printed paper is impregnated with an acrylic resin. -Adhered with an isocyanate-based adhesive, applying an unsaturated polyester resin paint containing a light stabilizer on the wood grain printing paper, applying an embossing process to the coating film surface using an embossing mold, and curing the coating film. After that, an acrylic polyurethane-based resin paint containing a light stabilizer is applied on the embossed layer.