JPS5857917A - Preparation of decorative plate with concavity - Google Patents

Abstract

PURPOSE:To obtain a decorative plate which is prevented from sticking to a mirror surface when an expandable printing layer is heated and compressed and provided with acute and distinct concave parts by controlling heating conditions of impregnated paper. CONSTITUTION:A normal printing layer 2 with a desired pattern is provided with normal printing ink on decorative original paper 1, an expandable printing layer 3 with a desired pattern is provided with heat expandable printing ink and the decorative paper 4 provided like this is impregnated with thermosensitive resin. Then, the decorative paper is heated and dried and the expandable printing layer is expanded preparatively to prepare impregnated paper 5 under reduced expandability. Mark 6 shows impregnated and dried resin. The impregnated paper 5 obtained and the base 7 are combined, heated and pressed with a pair of heated surface plates 8, 8' and a pair of mirror plates 9, 9' into a body. The whole surface of the decorative plate with an expandable layer is coated with solvent, the expanded layer is dissolved - lubricated, then, the whole surface is polished and the expanded part is removed to produce concave parts 10 on the expandable printing layer or equivalent parts of the decoration paper.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an improved method of manufacturing decorative laminates having recesses.

Several methods are known for forming recesses, particularly recesses that match a printed pattern, in the thermosetting resin decorative board 1, such as a melamine decorative board or a diallyl phthalate decorative board. In particular, the method using the printing method is extremely easy because the same adjustment between the area where the recesses are to be provided and the other pattern is carried out in each marking process, and it is also easy to use with other methods, especially when using the printing pattern. Compared to a method using a metal plate having a matching surface shape, this method is industrially more convenient because the steps after printing can use almost all the usual steps as they are. As a method using such a printing method, the present applicant has previously manufactured a top-impregnated paper using a decorative base paper on which a foamed printing layer and other printed patterns are provided using heat-foamable ink, and further impregnated the base paper. Discloses a method for manufacturing a decorative panel for a room body by heating and press-molding paper (Japanese Patent Application Laid-Open No. 11155-1983)
Publication No. 4).

This method applies conventional printing plates and printing methods to form printed patterns and scattered recesses, and uses a special heat-foaming ink, but it is used under normal printing press operating conditions. This is a method that uses wet ink, and the thermosetting resin around the foamed part has a hardening problem, and only this part is caught by a mirror plate, etc., and is partially pine).
Chemical formation I/) forms a concave portion. However, in such methods, uncured resin is attached to the mirror plate, so
If heat and pressure molding is performed using the same mirror plate without removing it, unevenness will occur on the surface of the product.

In order to avoid unevenness, it is complicated to wash the mirror plate every time or to insert a heat-resistant, smooth-surfaced disposable sheet between the mirror plate and the decorative plate during the heating and pressure molding process. It is preferable to further extend the time of the heating and pressure molding process, which has a long cycle time (usually IO or about 20 minutes), or by adjusting the coating thickness of the foaming pattern, the foaming agent content, etc. The foaming of
If you prevent the uncured resin from being taken up on the mirror plate by keeping it from reaching kJK, the feeling of depressions will be reduced, which is undesirable.Also, the method of controlling the coating thickness depends on the printing conditions during printing, such as speed, speed, etc. Difficult due to changes in printing pressure, ink viscosity, etc.

The present inventor has conducted repeated research in order to eliminate the above-mentioned drawbacks of the invention described in the above-mentioned publication.

It has been found that the following differences occur depending on the heating and drying conditions when creating impregnated paper.

(a) When the heating temperature is lower than the foaming temperature of the foaming agent in the foamable print layer, a large amount of uncured resin adheres to the mirror plate in the Sakai heat and pressure treatment Jl.

Main) When the heating temperature is higher than the foaming temperature of the foaming agent in the foamable printing layer, there is virtually no uncured resin on the mirror surface plate during the heating and pressure treatment, but the recesses formed are The depth is shallow or it is simply matte.

In the case of -) above, the foamable printing layer was already foamed when the impregnated paper was created, and it was observed that convex portions were formed on the resin surface of the impregnated paper.

Although it looks like a watermelon with mirror surface #RK after being heated and pressurized, the truth is that it is different. The reason for this is that the surface of the convex portions of the impregnated paper in case - is coated with a resin made by drying the impregnated thermosetting resin liquid, so the foamed printing layer of the convex portions is This is because the printed layer does not touch the mirror plate directly, and the printed layer is bulky and lacks strength, so it is easily compressed by heating and pressure treatment. In addition, the reason why there is a large amount of uncured resin attached to the mirror plate in (a) above is that the impregnated and foamable printing layer on the paper in the case of (a) has not lost its foaming ability and is rapidly heated and pressurized. This is because when the resin of the impregnated paper becomes fluid during expansion, the resin is easily pushed away and closely observed on the mirror plate.

Based on the above findings, the present inventors have conducted further studies and found that by controlling the heating and drying conditions of the impregnated paper, it is possible to prevent the foamable printing layer from being attached to the mirror plate during the heating and pressure treatment. We discovered this and arrived at the present invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail with reference to the drawings.

FIG. 1 is a sectional view showing the structure of the decorative paper 4 according to the present invention. First, the decorative base paper 1 is a paper commonly called titanium paper that is used for ordinary melamine decorative boards and diallyl phthalate decorative boards, such as paper that uses purified pulp and contains a large amount of titanium oxide etc. You can use any of them if you have them.

Next, a normal printing layer 2 with a desired pattern is formed using a normal printing ink on the decorative base paper IK, and then a foamable printing layer 3 with a desired pattern is flattened using heat-foaming printing ink. Create paper.

As a general printing ink, one prepared using an appropriate vehicle can be used, but it is preferable to use one that has good impregnability with the thermosetting resin liquid described below. Preferred examples include butterfly and ethyl cellulose.

Ethylhydroxyethylcellulose 211. Examples include cellulose derivatives such as cellulose acetate propionate, nitrocellulose, and cellulose acetate, and butyral resin. To form the normal printing layer 2 with a desired pattern using normal printing ink, gravure printing, gravure offset printing, planographic offset printing, dilithography, dilithography, etc.
Intaglio printing, je, doublint, silk screen printing,
This can be carried out by a known printing method such as electrostatic printing, and in particular, to form a regular printing layer with a wood grain pattern, a gravure printing plate that is capable of continuously (endlessly) making a wood grain pattern is used. Gravure printing, gravure offset printing, rotary screen printing, etc. are preferred, but are not limited thereto.

As the heat-foamable printing ink, one obtained by adding a known foaming agent to a printing ink using an appropriate vehicle can be used, and the appropriate vehicle and L2 are examples of the above-mentioned usual printing ink vehicles. In addition to the resins listed above, acrylic or methacrylic resins such as styrene resins and styrene copolymer resins such as polystyrene and polyα-methylstyrene, polymethyl methacrylate, polyethyl methacrylate, polyethyl acrylate, and polybutyl acrylate. Single or copolymer resin, rosin, rosin-modified maleic acid resin, rosin-modified phenolic resin.

Rosin ester resins such as polymerized rosin, polyvinyl acetate resins, coumaron resins, and vinyltoluene resins.

Using one or more of vinyl chloride resin, polyester resin, polyurethane resin, butyral resin, polyamide resin, vinyl chloride-vinyl acetate copolymer resin, etc.,
As blowing agents, inorganic blowing agents such as sodium bicarbonate, ammonium carbonate, sodium boron hydride, and silicone oxine hydride, which are known blowing agents, azodicarbonamide, azobisisobutyronitrile, dinitrosopentamethylenetetramine, para Organic blowing agents such as toluenesulfonyl hydrazide, 4,4'-oxybisbenzenesulfonyl hydrazide, etc., as well as gases and low-boiling point organic solvents, are added to the synthetic resin capsules at the softening temperature of the vehicle. In addition to one or more vehicles and foaming agents, dyes and
Pigment colorants, plasticizers, stabilizers, surfactants, waxes, greases, desiccants, auxiliary desiccants, hardeners, emulsifiers, thickening networks, fillers, dispersants, solvents and diluents as appropriate. Add,
Knead and use. As a method for forming the foamable print layer 3 with a desired pattern using the heat foamable ink as described above, there may be mentioned a known printing method similar to the method for forming the normal print layer 2 described above. A method using a printing method in which a relatively large amount of ink is transferred during printing is preferable because the pattern is raised due to foaming, and in that sense, gravure printing, gravure offset printing, intaglio printing, or silk screen printing are preferable. In addition, when forming a wood grain pattern as a normal printing layer, printing a wood grain conduit groove pattern as a foamable printing layer, and producing partial depressions in the conduit groove pattern in a post-process, the woodgrain pattern that is the normal printing pattern and the foaming printing are used. It is preferable that the wood grain conduit groove pattern which is the layer is formed by the same printing method because it can be formed using the same printing machine and it is easy to adjust both patterns. In addition to the wood grain conduit groove pattern described above,
The pattern of the part where you want to create a concave part within the pattern of the normal printing layer,
- Examples include the joints of tiles, the beading grooves of wood, the cracks of stones, and other materials with three-dimensional surface textures such as leather and cloth. It is a good idea to set it up.

As described above, there are two types of printing layers of decorative base paper IK, namely.

A decorative paper 4 is formed by forming a normal printing layer 2 and a foamable printing layer 3, and first, the decorative paper 4 is impregnated with a thermosetting resin liquid.

Examples of the thermosetting resin liquid include thermosetting resins used in the production of known decorative boards, such as melamine resin, phenol resin, diallyl phthalate resin, benzoguanamine resin,
Epoxy resins, thermosetting modified vinyl chloride resins, etc. can be used, and if necessary, these resins can be dissolved in suitable solvents or monomers and added with catalysts, etc. to form a resin liquid, and then used as the decorative paper. It is coated and impregnated using a known coating method. The coating method can be gravure coating, roll coating, dip coating, or the like.

The resin shown is obtained by impregnating decorative paper with a thermosetting resin liquid as described above, then heating it to dry it, and foaming and drying it. The thermal foaming conditions depend on the thickness of the decorative base paper, the vegetation or wrinkles of the vehicle and foaming agent of the heat-foamable printing ink constituting the foamable printing layer, the composition of the thermosetting resin liquid, and the amount of coating. However, depending on the foaming temperature of the foaming agent used, the kill time until the foamable pattern of the impregnated paper is completely foamed at that temperature is 20 to 809 g.
It is preferably 30 to 50 hours or 10 to 80 hours, preferably 10 to 80 hours, based on the fully foamed thickness of the foamable printing layer.
By adjusting the foaming conditions such as temperature and time, a thickness of 1 to 70 inches can be obtained.

-For example, basis weight 80 fAx? Foaming temperature 1 on titanium paper
When forming a foamable printing layer with a thickness of 15 to 201 tHL using an ink containing 2011 parts of a capsule blowing agent at 20°C and 25 parts of a butyl methacrylate resin vehicle, the heating time is 90 seconds at a temperature of 120°C. Completely foamed and the thickness reaches 80~100111nVC,
In this case, heating at the same temperature for 25 to 45 seconds will result in a
A foaming ratio of 0 to 60 μm is obtained, and when a decorative board is produced in a subsequent process using the nine-impregnated paper obtained in this time range, the resin is not attached to the mirror board, but the foamable printing layer foams and the surface It can be easily removed by solvent coating and polishing, but if it is used for less than 25 seconds, the resin will adhere to the mirror plate, and if it exceeds 45 seconds, the foaming properties will decrease and foaming will not be sufficient in the subsequent process, and solvent coating will be difficult. , sufficient recesses are not formed even after polishing. Alternatively, instead of heating at 120°C for 2+ to 45 seconds, heating at a temperature lower than 120°C increases the heating time and is less susceptible to heating time setting errors, so it is preferable, for example, in the above example. In this case, heating at 100°C for 7 to 15 minutes produces the same effect as heating at 120°C for 27 to 45 seconds.

The impregnated paper 5 is formed as described above, and the obtained impregnated paper 5 is further heated and pressurized together with the base material 7 as shown in FIG. For example, the base material 7 has a basis weight of 140 to 1
80 f/rr? 40 to 50 - of phenolic resin on paper
Core paper made of several sheets of impregnated paper, wood, plywood, wood substrates such as particle board, gypsum fiber substrates such as gypsum board and gypsum slag board, pulp cement board, asbestos cement board, wood chip cement Fiber cement boards such as boards, GRC and concrete, iron, aluminum, metal foils or sheets such as edges, and composites of the above base materials can be used.

In particular, when applying the method of the present invention to melamine decorative boards,
The composition for producing a normal melamine decorative board is as follows: - For example, several sheets of core paper (140 to 180 PAυ with a basis weight impregnated with 40 to 50 layers of phenolic resin, depending on the required thickness), and balance paper (140 to 180 PAυ, depending on the thickness It is carried out using the above-mentioned order of impregnating melamine resin in an amount of 80 fil>.It is preferable not to use overlay paper, which is used in general melamine decorative boards, in the present invention because it prevents the formation of recesses. Alternatively, decorative paper can be impregnated with a melamine resin solution containing known abrasion-resistant particulates for the purpose of combining the effect of recessed portions with abrasion resistance, and the decorative paper obtained by such a process can be used. This improves abrasion resistance even without using a resin-impregnated overlay paper.

As described above, the impregnated paper is used as a base material! After combining with other materials according to the requirements, heat and pressure treatment is performed to integrate the impregnated paper, base material, and others. Heat and pressure treatment is jIa
As shown in the figure, this is carried out using an ordinary press machine, and a pair of heated surface plates 8 and 8I and a pair of mirror plates 9 and 9I. °The heating and pressurizing conditions are based on the type of decorative board,
Although it varies depending on the type of base material and the thickness and pressure of the material, the usual conditions can be used as they are6. For example, for melamine decorative boards, especially high-pressure melamine decorative boards, the heating temperature is 130 to 150 °C and the pressure is 80 to 121 °C. , hours 10-2
0 minutes, and for low-pressure melamine decorative boards, the heating temperature is 1
40 to 190 tons, pressure 10 to 20% l1 hour 1 to 20 minutes, heating temperature 125 for diallylphthalate decorative board
-140°C, pressure 10-201C, time 5-15 minutes.

As a result of the heating and pressure treatment described above, the foamable printing layer of the impregnated paper foams and exerts pressure on its surroundings, so that despite being pressurized by a press etc., its volume remains unchanged without being compressed. maintained.

From the surface of the decorative base paper of the impregnated paper to the surface of the decorative board.

A foamed layer is formed by foaming the foamable printing layer, and since the foamability is reduced by pre-foaming, the resin near the Ti side of the impregnated paper is pushed away as the foaming progresses, and the paper is attached directly to the mirror plate. The solvent, which will be described later, is likely to penetrate into areas where foaming occurs.

Next, a solvent is applied to the entire surface of the decorative board having the foam layer. The solvent to be used is one that dissolves, dissolves, or swells the foam layer, and more specifically, a solvent that dissolves or swells the heat-foamable ink vehicle or the microballoons constituting the foamable printing layer is appropriately selected. For example, aromatic hydrocarbons such as toluene and xylene, ketones such as acetone and methyl ethyl ketone,
It can be selected from esters such as ethyl acetate and normandyptyl acetate, and alcohols such as methanol, ethanol and isopropanol.

These solvents may be applied to the decorative board by any application method such as roll coating, spray coating, pour coating, flow coating, or spraying.

After applying a solvent to the entire surface of the decorative board to dissolve or swell the foam layer as described above, the entire surface of the decorative board is polished using a puff roller or a brush to remove the foam layer. As shown in the figure, a recess 10 is formed in a portion of the decorative paper corresponding to the foamable printing layer.

The present invention has the above-described configuration, and therefore, compared to the conventional method, it is easier to wash and remove uncured resin attached to the mirror plate during heating and pressure treatment, or to remove uncured resin from the mirror plate. The trouble of inserting and removing sheets for attachment 111!7j is eliminated, and moreover, those Kl! This reduces the time required for one cycle of heat and pressure treatment to the minimum necessary, and it is also more efficient than the conventional method of attaching numbers to mirror plates and removing them. The method of the present invention, which involves active dissolution or swelling with a solvent and subsequent removal operation, can completely remove the foam layer, so it is possible to form recesses more reliably, resulting in sharp and clear results. It is suitable for thermosetting resin decorative boards with a nine-grain pattern in which the conduit grooves in the wood grain pattern are formed as recesses, and it is suitable for use in recesses such as tile joints, beading grooves, and cracks in stones. It is also suitable for expressing the texture of leather, textiles, etc.

The following is a series of examples for explaining the present invention in more detail.

Example 1 A wood grain pattern was printed by gravure printing on the surface of a base paper for a decorative laminate in which 80 g of tsubo titanium oxide had been made.

Cellulose cellulose acetate 5-6 weight - Colored pigment
15~35 weight it dibutyl phthalate 2~3 weight oboro-solvent (1)
56-78% by weight However, in the above composition, solvent (
1) has the following composition.

Solvent (1) Methanol 15% by weight Ethyl acetate 60% Ii-*vvy
15111Iscyclohexanone
Next, a wood grain conduit groove pattern was printed by gravure printing in synchronization with this wood grain pattern using a heat-foamable gravure ink having the following composition.

Composition of heat-foamable gravure ink Butyl methacrylate resin 25 Weight - Foaming agent
20 weight aS (Matsumoto Yushi Seiyaku Micropearl F-3o) color pigment
5-fold ilL diphenyloctyl thiphosphate 1-fold i
ts solvent (It) 491
1. Sagi - However, in the above composition, the solvent (button) has the following composition.

It was impregnated with a melamine resin solution using a normal impregnating machine so that the amount of impregnation upon drying was 90 P or more.

Then, it was dried for 10 minutes in a dryer at a temperature of 100°C±2°C to obtain impregnated paper.

The obtained 9-impregnated paper was layered on top of 4 sheets of normal phenolic resin-impregnated core paper, and heated to a humidity of 135°C.
When heated and pressurized using a press at a pressure of 100% for 1 hour and 10 min, cooled to room temperature and taken out,
A decorative board was obtained in which the surface of the area corresponding to the wood grain channel pattern became somewhat matte. Furthermore, ethyl acetate was applied to the surface of the decorative board at a ratio of 10 PR, and the surface was immediately polished using a puff roller. The portion corresponding to the groove was removed by polishing, and a decorative board with the large bowl exposed as a recess was obtained. In addition.

In this example, the resin in the conduit groove portion was not numbered on the press surface.

Example 2 A decorative paper was prepared in the same manner as in Example 1, except that the foaming agent in the heat-foamable gravure eyelid was changed to Micropearl RQ-507 manufactured by Matsumoto Yushi Seiyaku ■. A fast-setting melamine 11 fat solution of 108y//rr? was applied when dry using a normal impregnating machine. Impregnated paper was prepared by impregnating the paper so that the paper became impregnated and drying at a temperature of 100°C ± 2°C for 10 minutes.

Next, the above-mentioned impregnated paper was layered on the surface of a particle board with a thickness of 15 mil with K so that the pattern was on top, and then heated and pressure-treated at a pressure of 20% and a heating temperature of 150°C for 1 hour and 8 minutes to integrate it. Then, in the same manner as in Example 1, a decorative board having concave portions was obtained.

k Example 3 A decorative paper was prepared in the same manner as in Example 2, and the obtained decorative paper was impregnated with a thermosetting resin liquid of the following composition so that the dry impregnation amount was 1209/rd, and the temperature was 100°±
An impregnated decorative sheet was prepared by drying at 2° C. for 10 minutes.

This impregnated decorative sheet was layered on a particle board with a thickness of 15 g, and a mirror-finished duralumin board was used to apply a pressure of 20
~． Heat and pressure molding was carried out at 130°C for 15 minutes.
A matched embossed diallyl phthalate decorative board was obtained in which the conduit pattern portion became somewhat matte and slightly concave compared to the same day. Note that the resin of the conduit portion of the duralumin board was not numbered.

Further, when the above decorative board was coated with ethyl acetate 109A'' using a roll coater and the surface was polished with Nokuflora, the conduit pattern portion was further recessed.

A decorative board with a three-dimensional effect was obtained.

[Brief explanation of drawings]

1 to 83 are cross-sectional views showing each step of the present invention,
Figure 1 is decorative paper, ji! Figure 2 shows the impregnated paper, the three times the heating and pressure treatment process, and Figure 4 shows the decorative board obtained in the present invention. 1... Decorative base paper 2... Normal printing layer 3... Foaming printing layer 4...
- Decorative paper 5... Impregnated paper 6...
...Resin 7...Base material 8,8/...
...Press 9.9'...Mirror plate
10... Concavity Fig. 1 Fig. 3

Claims (1)

[Claims] A normal printing layer with a desired pattern is formed on decorative base paper using normal printing ink, and then a foamable stamp and a desired pattern are formed using thermal foaming ink. The decorative paper formed as described above is impregnated with a thermosetting resin liquid, then heated and dried, and the foamable printing layer is pre-foamed to create an impregnated paper, and the impregnated paper is used as a base material. After combining, heat and pressure molding is performed, and then a solvent is applied to the entire surface. 1. A method for producing a decorative board having concave portions, characterized by removing a foam layer formed by foaming the foamable printed layer.