JPS5939310B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a thermosetting resin decorative board such as a melamine resin decorative board or a diallyl phthalate resin decorative board. The present invention relates to a method for manufacturing a highly decorative decorative board that is strongly colored.

Conventionally, the method for manufacturing this type of decorative board is to form a decorative board using a metal plate such as a stainless steel plate with irregularities etched on its surface as a backing plate, and then to form a decorative board into the recessed parts of the finished decorative board. A so-called wiping method of coloring with ink or the like is known. However, with this method, it is actually very difficult to select an ink that firmly adheres to the surface of the decorative board and has considerable physical properties. Even if the surface is protected, it is extremely difficult to obtain surface properties comparable to the performance of the original thermosetting resin decorative board. Furthermore, it is difficult to obtain a surface with smooth concave portions and rough convex portions with mirror-finished plates produced by etching.
Normally, the situation is the opposite, so the decorative laminate product can only have rough convex portions and smooth concave portions. If you try to obtain a mirror-finish plate in the opposite state, you will have to go through many complicated processes, and the cost of one mirror-finish plate will therefore be extremely high. It is not economically possible to perform presses. Another method is to make a resin copy mold from an expensive mirrored plate and use this resin mold as a backing plate, but in this case, the resin mold does not have mold releasability, so a separate mold release film is used as the mold. As a result, the surface condition of the product must be as uniform as that of the release film. In addition, in the method of using this release film,
A decorative board with a colored pattern matching the uneven pattern as obtained by the method of the present invention cannot be obtained in any way.
The present invention solves these problems by using an enameled plate, a material that has not been conventionally used as a backing plate, for the backing plate.

The principles of the method of the present invention are as follows: (1) Since the enamel plate itself has a very hard and dense surface, it has sufficient mold releasability even for thermosetting resins such as melamine resin. . (2) It is relatively easy to provide rough concave portions on the surface of the enamel board by known means such as screen printing using frit ink containing a matting agent. (
3) The surface of the enamel base surface corresponding to the recesses is very smooth, so colorants such as ink are difficult to adhere to, and even if they do adhere, they can be easily removed. Therefore, it is easy to apply the colorant only to the bare surface of the recess. (4) When a decorative laminate is molded using the enamel board colored on the rough surface of the convex portion as a backing plate, the colorant adhering to the rough surface is completely transferred to the concave portion of the decorative laminate, which is the object to be molded, due to the molding. In order to
To obtain a decorative board having a colored pattern that completely matches the uneven pattern. (5) The colorant that has migrated to the decorative board must adhere firmly to the decorative board, as it becomes integrated with the decorative board by melting the thermosetting resin of the decorative board. Based on the principles described above, a highly designed thermosetting resin decorative board with a strong colored pattern that perfectly matches the uneven pattern can be obtained. Next, the method of the present invention will be explained in detail based on the drawings.

First, as shown in FIG. 1, the front and back surfaces of a steel plate 1 for enameling are subjected to necessary treatments such as degreasing, pickling, and water washing, and then a lower glaze layer 2 is provided.

The lower glaze layer is necessary to improve the adhesion between the next upper glaze layer and the steel plate, and it is common to use a so-called black lower glaze containing cobalt. Next, an upper glaze layer 3 is provided on the surface of the lower glaze layer.

The upper glaze layer corresponds to the smooth surface of the plate, and the surface condition is a mirror surface or a mirror reflectance of at least 50 (
It is necessary to consider the composition of the slip and the firing conditions to obtain a smooth surface of fl) or above. However, the surface of the upper glaze layer does not need to be flat, and may have smooth waves or ridges. Furthermore, if an upper glaze layer is provided on the surface of the lower glaze layer on the back side of the steel plate, it is effective in preventing the enamel plate from warping, and can also be used as a release surface on the back side when molding decorative boards. Next, a rough surface portion 4 is provided on the surface of the upper glaze layer.

The most common method for this is to print enamel frit ink using a screen plate.
The ink layer may be transferred using a transfer paper that has been previously printed on a substrate such as paper or film with a similar frit ink.
For screen ink, finely pulverized printing frit is used.
You can use one mixed with screen oil. The firing conditions for the ink are such that the surface does not melt and become glossy.
Need to keep it low. Further, in order to make the surface of the ink layer rough, a matting agent can be added as an additive.
Furthermore, by mixing particles of high melting point substances such as zirconium oxide and alumina, various surface roughnesses can be obtained. By appropriately adjusting the gauze thickness or film thickness of the screen plate, the height of the ink layer relative to the upper glaze layer can be freely selected from almost the same height to several 100 μm.

This is determined in consideration of the intended unevenness pattern and effect. By forming the ink layer on the surface of the upper glaze layer in this way, the surface of the enamel board has a smooth part corresponding to the upper glaze layer surface and a rough part corresponding to the ink layer surface. Become. The ink layer after printing or transfer must be fired at a low temperature that does not completely melt the frits in the ink and create a glossy surface, but depending on the firing conditions, as shown in Figure 2, It is also possible to finish b such that only the portion 5 corresponding to the shoulder of the ink layer is melted and becomes a glossy surface, while the portion 6 corresponding to the top of the ink layer remains as a rough surface.
When a decorative board is molded using such an enamel board as a backing board, the shoulder 7 of the convex part is rounded and the bottom part 8 of the concave part is formed as shown in Fig. 3.
A decorative board 9 with a rough surface is obtained. Furthermore, depending on the firing conditions, the ink layer 10 may sink into the upper glaze layer 11, as shown in FIG. 4, so that the surface heights are almost the same. In this case, the resulting decorative board 12 (FIG. 5) has a flat surface but partially has rough surface portions 13 and smooth portions 14. As mentioned above, the rough surface area is formed in a pattern on the upper glaze layer, that is, on the smooth surface, by direct printing or transfer printing, and the surface of the obtained plate has a tile-like appearance. In the case of the decorative board, the part forming the joint of the tile is a convex part with a rough surface D, and the part forming the part other than the joint is a smooth part. In addition, when the decorative board to be manufactured is a decorative board with a wood grain pattern, the portion forming the conduit groove of the wood grain is a convex portion having a rough surface portion, and the other portion is a smooth portion. Next, obtained as above,
The coloring agent is applied only to the rough surface of the enamel plate, which has a rough surface and a smooth surface.

The coloring agent may be anything as long as it has good compatibility with the thermosetting resin melted during the next molding process, or it may be a single pigment, but we have conducted various studies in consideration of the durability of the finished decorative board. In addition to pigments, the coloring agent is either a thermosetting resin that is the same as the thermosetting resin used for decorative laminates, or a thermosetting resin that is compatible with this and is also a thermosetting resin used for decorative laminates. It has been found that if a binder is made of a resin that hardens at a lower temperature than a synthetic resin, the colored portion of the finished decorative board will be extremely strong.
Further, the coloring agent may be in liquid or powder form, but when it is in powder form, the workability is very good because excess smoothing agent adhering to the smooth portion of the enamel plate can be easily removed.
Next, Table 1 shows the results of studies on melamine resin decorative boards using various colorants. The durability of the decorative board was determined by the degree of discoloration when the surface was wiped 100 times with a cloth impregnated with Lutzker thinner. As mentioned above, in the case of melamine decorative board, melamine resin is used as a coloring agent and a binder.
It has been found that by using a material containing thermosetting resin such as epoxy resin, the thinner resistance of the colored part can be improved.

Further, in powder coating B in Table 1, the binder itself is thermosetting, but it is thought that sufficient curing did not occur because the curing conditions were higher than the molding temperature of the melamine decorative board.
In conclusion, in order to obtain a colored part with sufficient resistance, it is necessary to use a thermosetting resin of the same type as that used for decorative laminates as a coloring agent, or a thermosetting resin that hardens at a lower temperature. It has been found that this purpose can be achieved by using a resin as a binder. It has been found that this relationship holds similarly for thermosetting resin decorative boards other than melamine decorative boards, such as dia-9 luphthalate resin decorative boards and poly-9 ester resin decorative boards. Next, we will discuss how to apply a coloring agent to the rough surface of the enamel board.

If the colorant is liquid, a normal wiping method can be applied. That is, as shown in FIG. 6, the colorant 16 is applied to the entire surface of the enamel board 15 and then wiped off with cloth or paper IT. In this case, wiping can be easily performed by impregnating cloth or paper with a solvent for the coloring agent. The colorant is easily wiped off on the smooth part 18 of the enamel plate, while the rough part 19
In this case, the coloring agent gets into the minute recesses on the surface and remains without being completely wiped off. In actual production, the backing plate will be large and it will be difficult to wipe the entire surface uniformly by hand, so it is desirable to use a wiping machine as shown in Figure 7. The principle of this machine is to wipe off the coloring agent 20 applied to the entire surface using rubber wiping rolls 21 and 22 that rotate in the opposite direction. Can be applied and wiped off. Further, when using powder as the coloring agent, it can be carried out in the same manner as in 1 by making the material of the wiping roll a soft material such as a cotton roll. That is, by applying a powder coloring agent to the entire surface of the enamel board by any method, and then wiping it off with a cotton roll or the like, the coloring agent can be left only on the rough surface. Another method is to use screen printing. That is, as shown in Fig. 8, the screen plate 23 used to provide a rough surface portion on the enamel plate surface is held on the enamel plate 24, and the dashed line portion of the screen plate and the rough surface ink portion of the enamel plate are completely separated. After fixing them so that they match, by screen printing the coloring agent 25, it is possible to attach the coloring agent only to one rough surface portion 26. In this case, the screen plate used to provide the rough surface portion is not used. , another plate made using the same positive may be used.
In particular, if the screen plate used to form the rough surface is a thick one with a low mesh, printing colorant using the same plate will result in too much adhesion, which is undesirable. Good results can be obtained by separately preparing and using a thin plate, usually about 200 meshes. In addition, if you make a screen plate using a positive that has been modified so that the image area is slightly narrower than the positive used to create the rough surface area, the colorant will be applied to the outside of the rough surface area of the enamel plate. Since it is difficult to protrude, work efficiency is improved. Furthermore, by dividing the rough surface into two or more screen plates, each screen plate can be colored with a coloring agent of a different tone.

The decorative board obtained in this manner has a rough surface colored in two or more different tones, resulting in a highly varied product. Among the above-mentioned methods of applying colorants to rough surfaces, the method of applying colorant to the entire surface and then removing the excess colorant is suitable for creating delicate patterns such as conduits with wood grain patterns, and is suitable for creating delicate patterns such as conduits with wood grain patterns. This method is more suitable for rough patterns such as tile joints. As above,
A method of molding a thermosetting resin decorative board using an enamel board whose rough surface has been coated with a coloring agent will be described.

When a liquid coloring agent is used, the volatile components such as water and solvent in the coloring agent adhering to the rough surface of the enamel plate are removed by thorough drying.

If a large amount of this remains, it may evaporate during molding and cause surface roughness and blistering. If the colorant is a powder, such consideration is not necessary. Taking the case of a melamine resin decorative board as an example, as shown in FIG.
, the same impregnated pattern paper 28, barrier paper 29 if necessary,
A required number of sheets of phenol resin-impregnated core paper 30 and anti-binder stopper 31 are stacked in sequence, and a plurality of sets of this combination are stacked and set between heating plates 32, and pressed and heated via a cushion.
The molding conditions are the same as those for ordinary melamine resin decorative boards, such as a hot cold method with a pressing pressure of 80 to 100 Kf/Cdl, a heating temperature of 145°C, a heating time of 20 minutes, and a cooling time of 20 minutes. In this case, since the surface of the enamel plate has mold releasability, there is no need to use a mold release film or apply a mold release agent. In addition, if a lower glaze layer or an upper glaze layer is provided on the back side of the enamel board, this side also has mold releasability, so it can also be used between the back side of the adjacent impregnated paper set.
No special mold release treatment is required, which is extremely advantageous in terms of production.
By the way, the melamine resin that is partially melted during the hot-press molding process fuses with the coloring agent adhering to the rough surface of the enamel board and hardens in one piece, so the coloring agent corresponds to the concave parts of the melamine resin decorative board that is the product. It firmly adheres to the rough surface of the paper, and when the paper is removed from the mold, it completely transfers to the decorative board and does not remain on the surface of the enamel board. Therefore, the enamel board can be immediately moved to the coloring process for the next molding. Melamine resin decorative board 33 as shown in FIG. 10 obtained in this way
In this case, the convex portion 34 has a very smooth surface unique to enamel, and the concave portion 35 has a rough surface and is colored, resulting in an extremely high design as a whole of the square D1. In particular, if the pattern on the patterned paper is a tile or stone grain design, and the rough surface design (embossed design) of the enamel board is a matching design such as a sand grain or tile grout, the following results can be obtained. The decorative board has a finish that closely resembles the actual tiles or ceramics, and has an especially excellent design. Next, the method of the present invention will be specifically explained based on Examples.

[Example 1] After cutting a 1.67 m thick ultra-low carbon steel plate for enameling into predetermined dimensions, it was degreased, pickled, and washed with water.

A black underglaze slip was applied to the front and back surfaces by spraying, and after drying, firing was carried out at a maximum temperature of 870°C for 3 minutes. Next, a white top glaze slip was applied to the front and back surfaces in the same manner, and after drying, firing was carried out at a maximum temperature of 850° C. for 2 minutes. The surface of the obtained upper glaze layer had the high gloss and smooth surface condition unique to enamel. Next, parts corresponding to the joints of the hexagonal tile pattern were printed on the surface of this upper glaze layer using a 70-mesh screen plate. The ink used was a commercially available b-frit containing a printing glossing agent (pulverized) kneaded with screen oil. When baking was carried out at a maximum temperature of 750° C. for 2 minutes, the edges of the ink portion were partially melted and became rounded and glossy, while the top of the b1 ink portion became rough. In addition, the ink film is fused and integrated with the upper glaze layer. Next, a coloring agent having the composition shown in Table 2 was applied to the entire surface of the enamel board, and then wiped off with a damp cloth so that the coloring agent remained only on the rough surface.

After drying the water in the colorant, a melamine decorative board was molded using an enamel board with the colorant adhered only to the rough surface as a backing plate.

Titanium paper with a pattern on the surface of the tile previously printed was used as pattern paper, and hot-pressure molding was performed according to a conventional method. The molding conditions were a hot cold method with a maximum temperature of 145° C., a heating time of 20 minutes, and a pressure of 80 Kf/Cdl and a cooling time of 20 minutes. No release film was used. The resulting decorative board has a smooth surface with a gloss unique to enamel in the convex parts, which harmonizes well with the printed pattern, and concave parts corresponding to tile joints become matte, and at the same time completely match the coloring, making the entire surface look smooth. This resulted in a finish b with an extremely high design quality. The melamine resin decorative board thus obtained had an appearance that closely resembled the surface of actual continuous tiling. In addition, the colored part of the concave part is made by using a cloth impregnated with B1 thinner so that the coloring agent fuses with the melamine resin and firmly adheres to it.
No abnormality was observed even after wiping 00 times. In addition, all the coloring agent was transferred to the decorative board during the molding stage, and no coloring agent remained on the surface of the enamel board after the molding of Figure b1 was removed.

[Example 2] In addition to Example 1, a screen plate was used as a means for applying the coloring agent to the enamel board.

The screen plate used was a plate made with a 200 mesh nylon screen using the hexagonal tile pattern positive used to provide the rough surface. According to this method,
Coloring of the rough surface is extremely easy, and it is possible to color the rough surface with high density. [Example 3] A melamine resin decorative board was obtained in the same manner as in Example 1, using as a colorant a powder of a colorant having the composition shown in Table 2, which had been dried and ground in advance.

The coloring agent could be applied much more easily and uniformly than when it was in liquid form. Moreover, the resistance of the colored parts of the obtained decorative boards was the same. [Example 4] Screen printing of the following combination was performed on the surface of the upper glaze layer obtained by the same method as in Example 1.

f). After printing No. 1 was completed, the ink film was heated to 100° C. to dry, and then Black No. 2 was printed, followed by firing to fuse and integrate the ink film with the upper glaze layer. The firing conditions were the same as in Example 1. The surface of the patch plate obtained in this way has a rough surface with a slightly convex portion corresponding to the stone grain texture. As the coating progresses, the part corresponding to the shoulder of the ink film becomes round and has a glossy finish (b). Next, based on the positives used for printing black 1 and wash 2, 20
Screen plates of 0 mesh were prepared, and each plate was used to color the rough surface as follows. The composition of the colorant is as follows.

After drying the enamel board, a melamine resin decorative board was molded using it as a backing board.

The resulting decorative board has a rough surface with the tile joints colored black, and a smooth surface with fine rough concavities colored gray on the b1 tile surface, giving it an extremely high design quality as a whole. The result is a surface that closely resembles that of real tiles. [Example 5] Using the patch plate obtained in Example 1, the rough surface was colored with a coloring agent having the composition shown in Table 6, and then diallyl phthalate resin impregnated paper was placed on a 4rm plywood. 130℃, 10K
Hot pressure molding was performed for q/Cdll for 5 minutes.

Complete mold releasability was observed without a release film, and the obtained tap decorative board had the same appearance as the melamine resin decorative board obtained in Example 1.

In addition, the rough surface of the concave portion was strongly colored and had the same performance as the convex portion.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, in which Fig. 1 is a cross-sectional view of an enamel plate used in the method of the present invention, and Fig. 2 is a cross-sectional view of the enamel plate used in the method of the present invention, and Fig. 2 shows a cross-sectional view of the enamel plate used in the method of the present invention, and Fig. 2 shows a cross-sectional view of the enamel plate used in the method of the present invention. Figure 3 is a cross-sectional view of the enamel board with a glossy surface. Figure 3 is a cross-sectional view of a decorative board made by molding the enamel board in Figure 2 as a backing plate. Figure 4 is a cross-sectional view of the enamel board with a glossy surface. Figure 4 shows the height of the rough and smooth surfaces being equal. A cross-sectional view of an enameled board. Figure 5 is a cross-sectional view of a decorative board formed using the enameled board shown in Figure 4 as a backing plate. Figure 6 is a method of applying a coloring agent to the rough surface of an enameled board, wiping it with a cloth. A schematic diagram of the method, FIG. 7 is a schematic diagram showing the method of coloring a rough surface using a wiping machine,
Fig. 8 is a schematic diagram showing a method of coloring a rough surface by screen printing, Fig. 9 is a schematic diagram of a melamine resin decorative board molded by the method of the present invention, and Fig. 10 is a schematic diagram showing a method of coloring a rough surface by screen printing. The cross-sectional views of the decorative laminates are respectively shown. DESCRIPTION OF SYMBOLS 1... Steel plate for enameling, 2... Lower glaze layer, 3... Upper glaze layer, 4... Rough surface portion, 5... Portion corresponding to the shoulder of the ink layer, 6... Ink The part corresponding to the top of the layer, 7
...Shoulder of convex part, 8... Bottom part of concave part, 9... Decorative board, 10... Ink layer, 11... Top glaze layer, 12.
... Decorative board, 13... Rough surface part, 14... Smooth part, 1
5... Enamel board, 16... Coloring agent, 17... Cloth or paper, 18... Smooth part, 19... Rough surface part, 20...
- Colorant, 21... Wiping roll, 22... Wiping roll, 23... Screen plate, 24...
Enamel plate, 25...Coloring agent, 26...Rough surface part, 2
7... Overlay paper, 28... Pattern paper, 29
... Barrier paper, 30 ... Core paper, 31 ... Anti-b stopper, 32 ... Heat plate, 33 ... Melamine resin decorative board, 34 ... Convex part, 35 ... Concave part , 36...Enamel board.

Claims (1)

[Scope of Claims] 1. In a method for manufacturing a thermosetting resin decorative board using an enameled board as a patch plate during molding, a smooth part and a rough surface part are provided in advance on the surface of the enameled board, and the rough part is coated with the above-mentioned material. After attaching a coloring agent with high affinity to the thermosetting resin by any means, a thermosetting resin decorative board is molded using the enamel plate as a backing plate, so that the coloring agent is attached to the thermosetting resin. A method for manufacturing a thermosetting resin decorative board, which comprises transferring and adhering to the surface of the decorative board and at the same time curing it integrally with the thermosetting resin. 2. The method for manufacturing a thermosetting resin decorative board according to claim 1, characterized in that an enameled board is used in which the height of the rough surface portion is higher than that of the smooth surface portion. 3. As a method of applying coloring agent to the rough surface area of the enamel board, the coloring agent is applied to the rough surface area of the enamel board by a screen printing method using a screen plate that has been provided with a print area that matches the rough surface area of the enamel board in advance. A method for manufacturing a thermosetting resin decorative board according to claims 1 and 2, characterized in that: 4. As a method of applying colorant to the rough surface of the enamel board, the colorant is applied uniformly to the entire surface of the enamel board in advance, and then wiped off with felt, a brush, etc. to remove the colorant that has adhered to the smooth surface other than the rough surface. Claims 1 to 3 are characterized in that a coloring agent is applied to the rough surface portion of the enamel plate by removing it.
2. The method for producing a thermosetting resin decorative board according to item 2. 5 As a colorant, a thermosetting resin of the same type as the thermosetting resin used for the decorative board, or a thermosetting resin that has a high affinity with this and cures at a temperature below the curing temperature of the thermosetting resin. A method for producing a thermosetting resin decorative board according to claims 1 to 4, characterized in that a pigment composition having as a binder is used. 6. The method for producing a thermosetting resin decorative board according to claims 1, 2, 4, and 5, wherein the colorant is a powder.