JPS59120450A - Continuous manufacture of embossed decorative board - 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 novel method for continuously manufacturing embossed decorative laminates, and its purpose is to provide a method for continuously manufacturing embossed decorative laminates with improved design and at low cost. .

Conventionally, methods for continuously manufacturing embossed decorative boards include (a) a method using embossing paper and (b) a method described in Japanese Patent Application Laid-Open No. 57-45060.

(a) Embossed paper is a heat-resistant base paper that is swollen with water vapor and then heated and pressed with a heated embossing roll to form an uneven pattern.

This embossed paper has the following drawbacks because it is manufactured by applying a silicone-based, Wanx-based, etc. mold release agent to the surface side and drying it.

1.It is expensive.

2. Humility has no permanence.

3. Thermosetting resin decorative laminates are continuously molded using a heated and pressurized press, so if there is a lot of water in the embossed paper, punctures will occur between the sheets.

4. It has cushioning properties because it is made of paper. (b) There is a limit to the depth of embossing.

(b) The emboss is not transferred sharply.

(c) The smooth portion of the unembossed portion becomes gently uneven, resulting in a lack of design.

((b) On the other hand, the method described in JP-A No. 57-45060 is a method in which a forming plate is manufactured from a transfer material such as a metal embossed product, and then this forming plate is used to obtain an embossed decorative board. However, since thermosetting resin prepreg is used as the base material for the forming plate, heat conduction from the steel belt is poor, and uniform heating cannot be achieved from the top and bottom of the prepreg.Also, thermosetting resin softens when heated. The embossing depth of the forming plate is greatly reduced by repeated use.

Furthermore, since the mold releasability from the decorative board is poor, there are problems such as applying a mold release agent to the forming board or interposing a single template film or metal plate.

The method of the present invention solves the above-mentioned drawbacks. First, a concave-convex pattern is formed on a continuous core paper impregnated with a thermosetting resin, dried, and stacked with the required number of continuous core paper, pattern paper, and, if necessary, overlay paper. Place a continuous metal foil, molding pressure 1-50 kfl/l:a, molding temperature 120-18
Embossed decorative laminates can be continuously obtained by continuous heating and pressure molding at 0° C. for a molding time of 5 to 300 seconds. Furthermore, the metal foil used in the present invention has a thickness of about 5 to
A value of 150 microns is good; if it is less than 5 microns, only shallow embossing can be achieved because waves are removed during embossing. However, if the diameter exceeds 150 microns, there is a problem that an extremely large pressure is required during embossing, which requires a large embossing roll or processing machine.

Furthermore, the type and thickness of the metal are not particularly limited since they are closely related to the embossing process.

1-U, this is different from the metal forming plate used in conventional batch-type processes; for example, the metal forming plate is made of aluminum or stainless steel) and is embossed by etching only one side of the V-plate. On the other hand, the continuous metal foil with the uneven pattern used in the present invention is similar to an embossing roll (-) in that it is continuously embossed with an embossing roll. However, since Gold 1 uses foil compared to paper, it has the following advantages.

1. There is very little decrease in the emboss depth of the embossed part.

2. It has very good mold release properties and is semi-permanent if an internal mold release agent is added to the surface resin of the decorative board in advance.

3. As a forming board, it has no cushioning properties and is homogeneous, so if it is pressed with a steel belt, the unembossed parts will become smooth, creating an embossed decorative board with a sharper appearance.

For these reasons, normal embossing paper could only be used 3 to 5 times at most. In contrast, according to the method of the present invention, for example, aluminum foil can be used more than 0 times, and stainless steel foil can be used more than 20 times, and the embossing depth of the decorative board is almost the same for each cycle. In terms of manufacturing cost, this method is far superior to the conventional method using embossed paper VC in terms of design glitter.

Next, the method of the present invention will be explained in detail based on the drawings. In the drawing, (1) is a continuous heating and press forming machine consisting of a double steel belt, a drum, a hot platen, etc.

+2) and (3) are fabric prepregs impregnated with continuous overlay paper and patterned paper K and dried with thermosetting resin such as melamine resin, polyester resin, shea IJ/rephthalate resin, etc.; phenolic resin,
It is a prepreg made by impregnating continuous kraft paper with a thermosetting resin such as melamine resin lIkai polyester 46J month and diallyl reflex resin and drying it.

Using these prepregs (2) to (4), the metal foil of (5) is placed on a rolled product as shown in the drawing, and after molding with a continuous heating and pressure forming machine (1), Embossed decorative board (6)%: Obtained continuously by peeling off the metal foil.

Depending on the thickness of the decorative board, the first few core prepregs or the mano-valley prepreg may be omitted.

Furthermore, in order to change the gloss of the decorative board surface, a heat-resistant film such as a polyester-based, fluorine-based, or polyamide-based film may be interposed.

In this way, according to the method of the present invention, embossed decorative laminates can be manufactured continuously, and embossed decorative laminates with high design quality and low cost can be provided.

The method of the present invention will be specifically explained below based on Examples.

Example First, prepregs as shown in Table 1 were obtained using a melamine resin varnish having a resin solid content of 50% and various continuous shaped base papers.

Table 1 Next, 4 pieces of prepreg for the core, and 4 pieces of prepreg for the pattern.

Repreg and prepreg for overlay are sequentially stacked and unrolled, and on top of that, an aluminum foil with an embossed depth of 100 microns with an 80 micron thick pattern of unevenness I is superimposed, and a continuous heating and pressure molding machine is used to press the U kg, /
d, temperature] ρ (pressurized) under the conditions of 60° C. for 1 hour and 1 minute to obtain a continuous-shaped embossed decorative board.

(Comparative example) Using the same silicone preg for decorative board as in the above example, t2oy/m instead of aluminum foil, en 7 + miss depth 60
After placing a continuous micron embossed decorative board, it was treated in the same manner as in the example to obtain a continuous embossed decorative board.

Table 2 summarizes the embossing depth and mold releasability when the methods of Examples and Comparative Examples were repeated several times using the same aluminum foil and embossing vapor.

Table 2 Note that the unembossed portion of the decorative board obtained in the example was very smooth, whereas the same portion of the decorative board obtained in the comparative example had an uneven textured finish. became.

As described above, the embossed decorative board obtained using the method of the present invention has an excellent design, has excellent durability and releasability of the metal foil, and can be manufactured continuously. Therefore, it is possible to provide an embossed IF board at a very low cost.

[Brief explanation of the drawing]

The drawings are explanatory diagrams showing an example of the method for continuously manufacturing embossed decorative boards of the present invention. 1... Continuous heating and pressure molding machine 2...
......Prepreg for overlay 8...Prepreg for pattern 4P...Prepreg for core 5...Metal foil 6 with uneven pattern 5I7 ...... Embossed decorative board / <A

Claims (1)

[Claims] 1. A continuous metal foil with an uneven pattern is placed on a continuous core paper impregnated with a thermosetting resin and dried, which is loaded with the required number of continuous core paper, pattern paper, and overlay paper if necessary. A continuous manufacturing method for embossed decorative laminates, which is characterized by heat-pressure molding.