JPS58112726A - Uneven decorative composite board and its manufacture - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a textured decorative composite board used for furniture, architectural interior materials, etc., and a method for manufacturing the same.

Furniture, cabinets/fts of electrical appliances, doors, interior walls of buildings, etc. often have deep uneven patterns, but most of them are veneered on a base material such as verticle board or plywood processed into deep uneven patterns. Alternatively, a vinyl chloride sheet or the like printed with a wood grain pattern or the like may be attached. NC for forming deep uneven patterns on substrates such as verticle board or plywood
Using woodworking materials such as f1/-K allows for the formation of complex uneven patterns more easily than K, but the more complex the shape, the more expensive machinery is required, and compared to wood, it is difficult to use cutlery. It has the drawback that it requires a large amount of processing cost, such as the fact that it consumes much more. In addition, when using veneer as a surface decorative material, the veneer and thin paper are glued together and pasted on the base material with the uneven pattern described above, but after temporary adhesion while following the uneven pattern of the core material. Pressure bonding requires many steps to prevent the veneer from tearing, which not only lowers productivity, but also requires finishing such as painting on the product after main bonding, which is extremely expensive. becomes. On the contrary,
When using vinyl chloride sheet as a decorative surface material,
Although it can be bonded more easily than vacuum-formed P1/:XK, it has drawbacks such as the surface of the base material being more likely to appear on the product, and the surface performance of the product such as hardness, heat resistance, and abrasion resistance being inferior.

On the other hand, thermosetting resin decorative boards used as surface decorative materials generally have an uneven pattern formed during the manufacturing process, and an uneven pattern that matches the design or a delicate uneven pattern that covers the entire surface can be expressed. However, the depth of the uneven pattern is at most about 800 μm, making it difficult to create a deep uneven pattern. In addition, when a thermosetting resin decorative board for post form is used as a decorative surface material, it is known that, for example, when attaching a sink to a sink, a drawing process is applied to the part. This is essentially no different from the method of attaching a veneer or a vinyl chloride sheet to the surface.

The present invention uses a thermosetting resin decorative board as a surface decorative material, interposes a synthetic resin foam between it and the base material, and when laminating and integrating with an adhesive layer, the surface of the thermosetting resin decorative board is By applying the unevenness imparting material of any shape and applying heat and pressure,
By effectively utilizing the elasticity, heat deformability, and other properties of the intermediate layer of synthetic resin foam, a deep-drawn pattern of any shape can be added to the thermosetting resin decorative panel of the front door without creating an uneven pattern on the base material. It is something to do.

Hereinafter, the present invention will be explained in detail based on the drawings.

Thermosetting resin decorative board (1) refers to a decorative board made of melamine resin, diallyl phthalate resin, I-lyester resin, pheno-μ resin, modified resins of these resins, etc., and can be used as a flat board depending on the purpose. They are broadly classified into general products and square foam products that are used for one side, and although the latter are more suitable for the purpose of the present invention, they are not particularly limited.

There is no particular restriction on the thickness of this thermosetting resin decorative board (1); if you want a deep uneven pattern, you need a thin one, and if you want to improve the surface performance of the product, you need a thick one. The properties are determined depending on the intended use of the uneven decorative composite board of the present invention.

Therefore, the thermosetting resin decorative board (1) that can be used in the present invention (i) ranges from the so-called flexible type with a thickness of about 0.11 to 0.8 cm to the high-pressure melamine decorative board with a thickness of about 1.2 cm. Wide I! This includes the following. In addition, the synthetic resin foam (2) is made of polystyrene resin, polyethylene resin, polypropylene resin, polyvinyl chloride/
They are broadly classified into those made of thermoplastic resins such as l/resin, and those made of thermosetting resins such as phenol resins, polyurethane resins, and urea resins, and include both of these. The hardness and density of this synthetic resin foam (2) are appropriately selected depending on the desired values such as cushioning properties of the product obtained by integrally molding by hot pressing, and are not particularly limited. Also, it goes without saying that the thickness needs to be thicker than the depth of the unevenness of the desired product, but other than that, there are no particular limitations.

Furthermore, as for the base material (4), various materials can be used depending on the purpose of the uneven decorative composite board of the present invention. Plates, metal plates, etc. can also be used.

The thermosetting resin decorative board (1), synthetic resin foam (2)
The adhesive layer (3) for bonding these layers of the uneven decorative composite board of the present invention having the base material (4) as its main surface component may be any type of adhesive such as thermosetting resin, thermoplastic resin 11 or rubber adhesive. However, there are restrictions due to factors such as the exchangeability of the resulting product and hot-press molding conditions.

The uneven decorative composite board of the present invention has a surface layer of a thermosetting resin decorative board (υ) which is deep-drawn in an arbitrary pattern, and which is completely in sync with the 9 deep-drawn patterns of this thermosetting resin decorative board (1). Uneven KW
1. The shaped synthetic resin foam part) is adhered via the adhesive layer (2), and these are further adhered to the base material (4) K via the adhesive layer (2), and the thermosetting resin decorative board (1 ), synthetic resin foam (2) and base material 0) are integrated. This uneven decorative composite board is made of synthetic resin foam that is elastic and easily follows complex and large deformations, and has a density that is smaller than that of base materials such as particle board or plywood, and can be easily deformed with a fairly small force. Since the body (1) is used as an intermediate layer, it is formed into an uneven shape that perfectly matches the deep drawing pattern of the surface layer thermosetting resin decorative board (1), and the adhesive layer 1) K of both layers For synthetic resin foam (
The repulsion elastic force (2) always acts to strengthen the bond.

In addition, if the thickness of the synthetic resin foam (2) is selected to be thicker than the depth of the desired unevenness as a product, then the surface layer of the thermosetting resin decorative board (1) can be The uneven patterns corresponding to the deep drawing patterns are all created using synthetic resin foam as an intermediate layer (
2), and the base material (4) is not affected in any way. Adhesion between the synthetic resin foam (2) and the base material (4) is achieved through an adhesive layer (3), which is different in type from the thermosetting resin decorative board (1) and the synthetic resin foam (1). Resin foam (
It does not necessarily have to be the same as the adhesive layer (3) between the base material (2) and can be freely selected depending on the type of the base material (4).

As described above, the textured composite board of the present invention uses a thermosetting resin decorative board (1) that has excellent performance as a surface decorative material and does not require finishing processes such as painting, and has a textured pattern on the base material. By applying the process to the synthetic resin foam (2) K, which can easily and freely conform to complex shapes with extremely low pressure, instead of applying it to (4), the base material (4) is processed to have irregularities. Synthetic resin foam (
By changing the type of 2), it is possible to give a product a kufushi carbonaceous property, and as described later, when using a net-like body or a perforated plate-like body as an embossing material during hot press molding, It has many excellent features, such as the ability to freely express soft curved surfaces from concave parts to convex parts.

Next, a method for manufacturing the uneven decorative composite board of the present invention will be explained.

First, a synthetic resin foam (V) and a thermosetting resin decorative board (υ) are sequentially laminated on a base material (4) via an adhesive layer (3). Furthermore, various methods are possible for forming this adhesive layer.The first option is to use a sheet-like material made of thermosetting resin or thermoplastic resin as it is. In this method, it is inserted between the layers of the thermosetting resin decorative board (1) and the synthetic resin foam (2) and between the synthetic resin foam (z) and the base material 0) to form the adhesive layer (3). This method is easy to handle and guarantees stable adhesive strength as long as the hot-press molding conditions are constant.

The second method is to apply a thermosetting resin, thermoplastic resin 11, or rubber adhesive to the surface to which the thermosetting resin decorative board (1), synthetic resin foam (illustration) and base material (4) will be bonded. This is a method of using this as the adhesive layer (3).Depending on the type of adhesive, this method is somewhat cumbersome in terms of operation, as it may be necessary to apply adhesive to both sides of the adhesive surface, but it can be used with many types of adhesive. Since there are several types of adhesives, it is possible to select one that has good adhesion to any type of base material (4).

The eighth method is to use a synthetic resin foam (2) for the intermediate layer that is pre-impregnated with a thermosetting resin or a thermoplastic resin.In this case, the synthetic resin foam ( 2) A portion of the resin impregnated in the synthetic resin foam (2) oozes out onto the surface of the synthetic resin foam (2), and this resin becomes an adhesive layer (3). This method requires bonding the synthetic resin foam (2), thermosetting resin decorative board (1), and base material (4) with one type of resin, and the method used depends on the type of base material (4). Although the type of adhesive obtained is limited,
By impregnating the synthetic resin foam (2) with a resin, the properties of the synthetic resin foam (2) can be significantly improved.

Next, thermosetting resin decorative board (1), synthetic resin foam (
2) and the base material (4) are laminated with the adhesive layer (3) interposed therebetween, and an irregularity-imparting material of an arbitrary shape is applied to the surface of the footwear and then hot-press molded. The irregularity-imparting material of any shape used here is selected according to the desired unevenness pattern on the surface thermosetting resin decorative board (1), and is made of a material that can withstand the heat and pressure during thermoforming. Anything is fine, including phenol resin, aluminum plate, which is used in the production of conventional uneven decorative boards, etc.
Stainless steel plate, wire mesh, extracted band metal,
A net-like body such as a cloth, a perforated plate-like body such as a punched metal, etc. can be used. When using a forming plate with relatively shallow irregularities, which is used in the production of conventional uneven decorative boards, etc., the surface layer thermosetting resin decorative board (1) is Since it is in contact with the entire surface, it is only possible to express an uneven pattern that is exactly the same as the uneven pattern of the forming plate. On the other hand, when using a net-like body, a perforated plate-like body, etc., when hot-pressing molding, there are parts where pressure is applied to the surface layer thermosetting resin decorative board (1) and parts where no pressure is applied at all. In the areas where pressure is applied, the intermediate layer synthetic resin foam (2) is compressed to form a concave part, whereas in the areas where no pressure is applied, a convex part is formed, but there is a transition from a concave to a convex part. Since it is in an unrestricted state, which is different from the case where it is restrained by a forming plate or the like, it has the excellent feature of expressing a soft curved surface that cannot be created artificially. Also,
When using a reticular material with asymmetric cut surfaces such as Exband Meta μ, the resulting decorative composite board with an uneven pattern will naturally have four asymmetrical uneven patterns, which will be rich in variation when viewed from a different perspective. You can get something extremely unique that allows you to enjoy the appearance. Furthermore, even when using a forming plate, the depth of the unevenness of the forming plate is sufficiently deep, and during hot press forming, only the convex portions of the forming plate are the surface layer of the thermosetting resin decorative board (
1), and under conditions where the four parts of the molded plate do not come into contact with the surface layer thermosetting resin decorative board (1), it is completely different from when using the above-mentioned net-like body, perforated plate-like body, etc. Needless to say, a similar phenomenon occurs. In this way, various materials can be used as the irregularity-imparting material for arbitrary shapes, but the unique taste of the irregularities is provided by effectively utilizing the repulsion elasticity of the synthetic resin foam (2) of the intermediate layer. In addition, it is optimal for the textured decorative composite board of the present invention to use a net-like body or a perforated plate-like body, which are available in many types as ready-made products. In addition, the thickness of the unevenness-imparting material having an arbitrary shape is automatically determined according to the desired depth of unevenness in the present invention, and it is naturally impossible to obtain an unevenness depth greater than the thickness of the unevenness-imparting material having an arbitrary shape. It is necessary to select an irregularity imparting material having an arbitrary shape and a thickness equal to or greater than the desired depth of the irregularities.

Next, a method of applying the unevenness imparting material of an arbitrary shape to the surface of the laminate and hot-pressing it will be described. This thermoforming is generally carried out using a flat plate press, and cushioning material and a backing plate are used as necessary between the irregularity imparting material and base material (4) of arbitrary shapes and the pressing plate facing each other. However, the thermoforming of the present invention is not limited to only flat press.

The first point in the dust pressure molding method is the heating temperature.
For example, the temperature range is 80~180℃ for melamine resin decorative laminates, q6G-160℃ for diallyl phthalate resin decorative laminates, and 60~140''C for polyester resin decorative laminates. Suitable for thermosetting of the surface layer that is pressurized by the convex portions of the unevenness imparting material of arbitrary shape when applying an unevenness imparting material of an arbitrary shape onto the surface layer thermosetting resin decorative board (1) and performing hot pressure molding. The thermosetting resin decorative board (1) is largely wedged into the synthetic resin foam (2) of the intermediate layer, and the thermosetting resin decorative board of the surface layer in the part where no pressure is applied due to the unevenness imparting material of an arbitrary shape. The board (1) has an intermediate layer of synthetic resin foam (3
) if the hardness of the synthetic resin foam (2) is high, the amount of compression of the synthetic resin foam (2) is small, but if the hardness of the synthetic resin foam (2) is small, the thermosetting resin makeup on the convex parts of the irregularity imparting material of any shape The plate (1) almost bites into the synthetic resin foam (2). In this state, when the surface layer thermosetting resin decorative board (1) is heated to the above-mentioned temperature, the flexibility of the thermosetting resin decorative board (1) increases, and the intermediate layer synthetic resin foam is heated. The thermosetting resin decorative board (1) elongates due to the rebound elastic force of (2), and the surface layer of the thermosetting resin decorative board (1) where no pressure is applied due to the unevenness imparting material of an arbitrary shape.
) will be in a raised state, resulting in a deep drawing process. The unevenness imparting material according to the manufacturing method of the present invention is achieved by the above-mentioned principle by combining the surface layer of the thermosetting resin decorative board (1) and the intermediate layer of the synthetic resin foam (
2) Compressive force is always applied to the adhesive layer (3), ensuring strong adhesive force, and the transition from the convex part to the concave part is very smooth, providing a soft curved surface. There is a relationship. In addition, the relationship between the hot press molding conditions and the type of synthetic resin foam (2) of the intermediate layer will be described here. When the synthetic resin foam 2) used for the intermediate layer is made of thermoplastic resin, not only the thermosetting resin decorative laminate (1) on the surface is often heated during thermoforming, but also the intermediate layer 2) is made of thermoplastic resin. The synthetic resin foam (2) of the layer is also heated. As a result, the synthetic resin foam (2) made of thermoplastic resin is softened by heating and has a certain degree of fluidity.
The synthetic resin foam (2) in the area that is pressurized by the convex portions of the unevenness-imparting material in an arbitrary shape flows to the area where no pressure is applied at all by the unevenness-imparting material in the arbitrary shape. Coupled with the above-mentioned repulsion elastic force possessed by ), a deep drawing process is applied to the surface layer of the IP curable resin decorative board (1). Next, if the synthetic resin foam (2) used for the intermediate layer is made of thermosetting resin, even if it is hot-press molded, the synthetic resin foam (2) will rebound when released from the hot-pressure state. Due to its large elasticity, it is difficult to create deeper patterns than in the case of synthetic resin foam made of thermoplastic resin, but as an adhesive layer (3), melamine resin, phenol resin etc.
%/ Resin-resistant urea resin, epoxy resin, or other thermosetting resin is used, and the synthetic resin is deep drawn into the surface layer thermosetting resin decorative board (1) by hot pressure molding. Since the foam (2) is fixed, deep drawing becomes possible. Regarding the magnitude of the pressure applied in the second part molding method, the magnitude of this pressure is the same as the thermosetting resin decorative board (1) and the synthetic resin foam (1) used in the uneven decorative composite board of the present invention. The properties are automatically determined by factors such as the type of 2), the desired depth of deep drawing, and the temperature during hot press forming. In other words, if the thermosetting resin decorative board (1), synthetic resin foam (2), and the temperature during hot-pressing molding are held constant, the pressure during hot-pressing molding can be changed. It is possible to adjust the depth of deep drawing obtained as a product. Furthermore, the temperature of the surface layer of the decorative thermosetting resin board (1) when applying pressure is not particularly limited and may be at room temperature, but it cannot be generalized depending on the type of the decorative thermosetting resin board, but it is 60 to 60°C. It is important to carry out the process after it has been heated to about 100°C, especially when performing deep drawing.

In the thermo-press molding method, regarding whether cooling is performed at the end (after heating), this is a property that is determined by the type of synthetic resin foam (2) of the intermediate layer and/or the type of adhesive layer (3). This does not affect the finish such as the deep drawing pattern of the uneven decorative composite board obtained by the present invention.

By the above-mentioned hot-press molding method, the surface layer thermosetting resin decorative board (1) is deep-drawn using an irregularity imparting material of an arbitrary shape, and at the same time, the intermediate layer synthetic resin foam (2 ) is formed with a concavo-convex shape that is completely in sync with the deep-drawn pattern of the surface layer thermosetting resin decorative board (1), and this inner layer is firmly adhered via the adhesive layer (3), and is further bonded to the base material (4). )
To provide an uneven decorative composite board which is integrally adhesively bonded via an adhesive layer (3). As described above, the method for manufacturing a textured decorative composite board of the present invention rationally combines the thermosetting resin decorative board (1), the synthetic resin foam (2), and the base material (4), and furthermore, the thermal and It is extremely excellent as it makes effective use of its mechanical properties.

In addition, in this case, the synthetic resin foam (2) is placed on the base material (4).
, only the one in which the thermosetting resin decorative board (1) is laminated has been described, but the present invention has a synthetic resin foam (2) and a thermosetting resin decorative board (1) on both sides of the base material (4). Of course, this also includes those that are laminated and subjected to deep drawing 7X on both sides.

Next, embodiments of the present invention will be described.

Example 1 4 thick polyethylene foam (density 0.14 g/-) and 0.5M on 2011IJl barnacle board
A thick diallyl phthalate resin decorative board is laminated with a polyolefin thread adhesive sheet interposed between each layer.

A flat-top type wire mesh with a wire diameter of 8 mm and an opening of 85 mesh is placed on the surface of this laminate, and a stainless steel backing plate and several sheets of Kutsushiron paper are placed on top of this, and a stainless steel backing plate is also placed under the laminate. Apply several pieces of paper.

This set of laminates is inserted between the hot discs of a flat press so that the laminates and the press hot discs are in slight contact with each other.

Next, heating is started and when the surface temperature of the diallyl phthalate resin decorative board reaches 80°C, pressure is applied until the flat top wire mesh, which is the unevenness imparting material, forms a deep-drawn pattern with a depth of 8 degrees on the diallyl phthalate resin decorative board. . In this state, when the surface temperature of the diallyl phthalate resin decorative board reaches about 180°C, heating is stopped, forced cooling is performed, and when the surface temperature of the diallyl phthalate resin decorative board reaches 50°C, the pressure is released.

The uneven decorative plywood thus obtained has a surface of 85
Deep recesses are formed in the squares of ■, and the protrusions surrounded by the recesses show a smooth rise toward the center, providing not only visual softness but also tactile elasticity due to the polyethylene foam in the middle layer. It is extremely unique.

Undercurrent side 2 Melamine resin for adhesive (solid 40%) and laminated in this order.

The surface of this laminate has a wire diameter of 1.5fi and an opening of 186 x 2.
Apply 8-kame extract band metal, then place a stainless steel backing plate and several sheets of cushion paper on top of this, and place a stainless steel backing board and several sheets of cushion paper under the laminate.

This set of laminates is hot-pressed in the same manner as in Example 1. However, if the surface temperature of the modified melamine resin decorative board is 100
When pressurized at °C, maximum temperature is 140'C150°C
The pressure is released when

The uneven decorative composite board thus obtained has a surface of 18
A deep diamond-shaped recess of 11jl x 28fl is formed, and the protrusion surrounded by the recess not only draws a smooth curved surface toward the center, but also the asymmetric cut surface unique to extended metal is projected as it is, making it easy to see from the viewpoint. By changing it from side to side, it gives a different uneven feel, and can be used as a wall covering material. Furthermore, as the melamine resin used as the adhesive hardens, the rebound elasticity of the flexible polyurethane foam is suppressed to some extent, so the cushion paper of the textured decorative composite board after pressureless molding becomes quite small.

Example 8 Urea resin for adhesive (
An 8 mm thick flexible polyurethane foam (density: 07 f/d) impregnated with 50% solids and a 0.4 mm thick polyester tvmpii decorative board were laminated.

A large number of holes with an inner diameter of 50fi were drilled on the surface of this laminate.
■Place a thick stainless steel plate, then place a stainless steel backing plate and several sheets of cushion paper on top of this, and place a stainless steel backing plate and cushion paper under the laminate.

This set of laminates is hot-pressed in the same manner as in Example 1. However, the surface temperature of the polyester resin decorative board is 60″
Pressure is applied when the temperature is C, and the pressure is released when the maximum temperature is ioo°C and 150°C, and the pressure is applied until a deep drawing pattern with a depth of 2U is formed on the polyester decorative board.

The uneven decorative composite board thus obtained has a diameter of 5 mm on the surface.
Q w , a large number of circles with a height of about 1.51111 stand out, resulting in a visually soft deep-drawn pattern. However, as the urea resin impregnated into the flexible polyurethane foam hardens during hot press molding, the flexibility of the flexible polyurethane foam is completely suppressed, and the foam hardly feels like cushion paper to the touch.

[Brief explanation of drawings]

The drawing is a cross-sectional view of the uneven decorative composite board of the present invention, (1)
(2) is a synthetic resin foam, (3) is a thermosetting resin decorative board, (3) is a synthetic resin foam,
) represents the adhesive layer, and (4) represents the base material. Patent applicant name: Ibigawa Ichiki Kogyo Co., Ltd. Representative: Jun Taga

Claims (1)

[Scope of Claims] 1. A surface layer consisting of a thermosetting resin decorative board deep-drawn in an arbitrary pattern, and a nine-synthetic surface layer formed into an uneven shape according to the deep-drawing pattern of the thermosetting resin decorative board. An uneven decorative composite board formed by laminating an intermediate layer made of a resin foam (2) on a base material (0) via an adhesive layer (3). 1. On the base material (6), the synthetic resin foam (=) and the thermosetting resin makeup Iida are sequentially laminated via an adhesive layer (layer), and these are made into a set. The surface layer is made of thermosetting resin decorative board C0KRR.
At the same time as applying FI processing, the intermediate layer synthetic resin foam (2
) is formed into an uneven shape corresponding to the deep drawing pattern of the thermosetting resin decorative board (1). 8. The method for manufacturing a textured decorative composite board according to claim 2, wherein the intermediate layer (synthetic resin foam) is a highly plasticized resin foam. t. The uneven decorative composite according to claim 2, characterized in that the synthetic resin foam (2) of the intermediate layer is a thermosetting resin foam, and the adhesive layer (3) is made of a thermosetting resin. Method of manufacturing the board. 6. The intermediate layer synthetic resin foam (2) is impregnated with a thermosetting resin or thermoplastic resin, and the thermosetting resin or thermoplastic resin is used for the thermosetting resin decorative board (1) and the base material. The method for manufacturing a textured decorative composite board according to claim 2, characterized in that the method also serves as an adhesive layer (3) with (4). 6. The method for manufacturing an uneven decorative composite board according to claim 2, wherein the unevenness imparting material having an arbitrary shape is a net-like body or a perforated plate-like body.