JPS5953867B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a decorative board using decorative paper subjected to paper embossing.

Specifically, the present invention relates to a method for finishing a decorative board using paper-embossed decorative paper without causing the embossment to return and giving it a hard texture. Traditionally, decorative boards have mainly had flat surfaces, but in recent years, textured surfaces have become popular, regardless of abstract woodgrain patterns, for reasons such as making the appearance more similar to real wood and giving a sense of luxury. It is becoming more common for them to form.

Among these, some laminate decorative boards are printed on PVC film or synthetic paper and then heat embossed, but these have poor surface properties and require the use of expensive adhesives. There were drawbacks such as the high price of the finished decorative board. An alternative method is to apply a thermosetting resin to the surface of decorative paper, perform paper embossing, then fill the resin into the uneven pattern from the back side and laminate it to the base material. Thermosetting resin coating→
There are many steps, such as paper embossing → filling the uneven pattern with resin → applying adhesive → laminating the base material, and the resulting decorative board becomes expensive. In addition, in the above decorative board, the resin filled in the uneven pattern is replaced with adhesive, and the process of paper embossing → application of adhesive to the back of the decorative paper → lamination to the base material while pushing the adhesive into the uneven pattern is performed. There are methods to do this, but as the adhesive dries, the moisture contained within it causes the embossment to return to its original form, causing the unevenness to disappear. The present invention has been made in order to eliminate the above-mentioned drawbacks.

That is, the object of the present invention is to reduce the weight from 30 to 100 g/m2.
The process of coating and impregnating a base paper with resin or not and then applying a pattern, the process of applying a thermosetting synthetic resin to the entire surface including the pattern to create decorative paper, the process of embossing the decorative paper Emulsion A step of applying an adhesive prepared by mixing 60 to 100 parts by weight of a urea adhesive to a base material at 80 to 200 g/m (wet) to 100 parts by weight of the adhesive; Layer the embossed decorative paper and use a laminator to heat it to a temperature of 30 to 60℃.
The present invention aims to provide a method for manufacturing a decorative board, which comprises sequentially carrying out the steps of pressing the adhesive with a roll and forcing the adhesive into the embossed convex portions, and curing the adhesive over time. 7 Next, the present invention will be explained in detail with reference to the drawings.

First, resin 2 is applied and impregnated onto base paper 1 having a weight of 30 to 100 g/m2. The base paper 1 used is 30 g/m· or more in order to maintain some degree of physical strength after embossing.
Also, it is possible to use a mixed material such as a synthetic valve, or a material impregnated with a resin. The purpose of the resin 2 is to strengthen the interlayers of the base paper, and resins such as aminoalkyd, urethane, polyester, vinyl chloride, melamine, and acrylic resins can be used. However, if the base paper 1 is impregnated with a resin, or if the strength between paper layers is high, such as resin paper, the coating and impregnation of the resin 2 can be omitted. Next, a pattern 3 is applied, and a thermosetting synthetic resin 4 is applied to the entire surface including the pattern 3, thereby producing decorative paper as shown in FIG.

The pattern 3 can be applied by any method such as letterpress printing, intaglio printing, offset printing, gravure offset printing, screen printing, and flexographic printing. The inks used include oils and fats such as linseed oil and soybean oil, natural resins such as rosin, maleic acid resins, alkyd resins, amino alkyd resins, urethane resins, acrylic resins, phenolic resins, melamine resins, vinyl resins, etc. Vehicles such as synthetic resins, cellulose derivatives such as nitrocellulose and ethylcellulose, and synthetic rubbers such as chlorinated rubber can be used. The coating amount and type of the thermosetting resin 4 can be changed depending on the required physical properties, and aminoalkyd, urethane, polyester, acrylic, melamine, and other resins can be used. The coating method may be any method such as a roll coater, gravure coater, knife coater, air knife coater or reverse roll coater. Next, as shown in FIG. 2, the decorative paper is embossed.

The embossing method is a paper embossing method, and for synthetic pulp mixed paper, etc., the embossing is performed at a temperature close to the melting point of the synthetic pulp. Next, as shown in FIG. 3, adhesive 5, which is a mixture of 60 to 100 parts by weight of urea adhesive to 100 parts by weight of emulsion adhesive, is applied to the base material 6 in a wet amount of 80 to 200 g/m. Then, as shown in FIG.
The adhesive is pressed into the embossed convex portions by pressing with a roll at ~60°C.

Next, the adhesive 5 is cured over time to complete the decorative board. The base material 6 may be a wooden board such as plywood or particle board, an inorganic board such as gypsum board or asbestos slate board, or any other suitable material. Next, the adhesive 5 will be described. Possible causes of the undoing of the embossing, which is a drawback of the prior art, include moisture in the adhesive (1), temperature of the laminating roll (2), and pressure during lamination (3). For example, use a regular laminator to apply emulsion adhesive at a rate of about 60 g/m, let it semi-dry, and set the temperature of the laminating roll to 100°C.
When laminated with the front and back sides, most of the embossed uneven pattern disappears, and the surface becomes soft and easily damaged. To improve this, the temperature of the laminating roll should be set to 60° C. or lower. In other words, by keeping the temperature of the laminating roll below 60°C, it is possible to prevent the emboss from returning due to heat, and it is also possible to minimize the evaporation of water in the adhesive. There is no blistering on the laminate surface that occurs with laminate surfaces, and therefore adhesives with high moisture content can be used, and urea-based adhesives can be used where the embossed convex parts need to be hardened. desirable.

However, when a urea adhesive is mixed with an emulsion adhesive, the amount is usually 20% of the emulsion adhesive.
Since the amount of urea-based adhesive is considered to be appropriate, there is a problem that the ratio of the urea-based adhesive to the total amount of adhesive becomes small. However, the reason why the temperature is limited to about 20% is that the moisture inside the urea adhesive evaporates when heated, causing blistering on the laminated surface. Since the temperature is set at ~60°C, there is very little concern that the above-mentioned blistering will occur. Therefore, it is possible to mix 60 to 100 parts by weight to 100 parts by weight of the emulsion adhesive, and the hardness of the decorative board surface is Sufficiently secured. Also, the amount of adhesive applied varies depending on the shape of the emboss, but since it is necessary to push the adhesive into the convex part of the emboss, even if the shape of the emboss is thin, a weight of 80 g/m or more is required. be.

As the emulsion adhesive, vinyl acetate emulsion, acrylic emulsion, and other adhesives are suitable. As described above, the embossed decorative board manufactured by the method of the present invention has good surface performance and has the ability to pass the FW type of the Japanese Agricultural Standards for Special Plywood (hereinafter referred to as JAS for Special Plywood). have.

It is inexpensive because it requires fewer steps and does not use expensive adhesives.

3 Emboss recovery due to heat, moisture in adhesive. There is no return to the embossed pattern.

It has the following effects.

[Example 1] Amino alkyd resin (undercoat NO4 Dainippon Ink Chemical Industry Co., Ltd.) was applied to 40 g/M2 building material paper (manufactured by Nagoya Pulp).
Co., Ltd.) was coated and impregnated with 4 g/M2 (dry), then an abstract pattern was printed using an intaglio printing method using nitrocellulose ink, and then urethane resin (UR-
203 (manufactured by Toyo Ink Manufacturing Co., Ltd.) at 5 g/m (dry), roll temperature 100°C, pressure 70 kg/CH
An embossed decorative paper was prepared by embossing the pattern of the cloth grain under the conditions of f.

Next, apply adhesive with the following composition to a 5.5 mm thick plywood board in an amount of 100 g/M2 (wet).
After drying at 00°C for 15 seconds, the embossed decorative paper was laminated under the conditions of a laminating roll temperature of 40°C and a roll pressure of 7 kg/cm2.

Adhesive formulation: Vinegar emulsion adhesive WH-3000L (manufactured by Chuo Rika Kogyo Co., Ltd.) 100 parts by weight 5 Urea adhesive Euroid #120 (manufactured by Mitsui Toatsu Co., Ltd.)
40 parts by weight of 10% ammonium chloride solution (curing agent) 5 parts by weight Then 24 parts by weight at room temperature
After curing for some time, a decorative board was obtained.

The resulting decorative board has a hard surface and a sharp uneven pattern.
It also had the performance to pass the JAS (7) FW type standard for special plywood.

[Example 2] 80g/M2 mixed with 40% polyethylene synthetic pulp
An abstract pattern is printed on mixed paper HIMIC 40 (manufactured by Iwano Paper Co., Ltd.) using an intaglio printing method using nitrocellulose ink, and then urethane resin (UR-2
03 Toyo Ink Manufacturing Co., Ltd.) 5g/M2 (dry)
Coating, roll temperature 150℃, pressure 70kg/(112
Embossed decorative paper was created by embossing the pattern of the cloth grain under the following conditions.

A decorative board was manufactured under the same conditions as in Example 1.

The resulting decorative board has a hard surface and a sharp uneven pattern.
It also had the performance to pass the JAS (7) FW type standard for special plywood.

[Brief explanation of the drawing]

FIG. 1 shows a decorative paper, FIG. 2 shows an embossed decorative paper, FIG. 3 shows a state in which an adhesive 5 is applied to a base material 6, and FIG. 4 shows a decorative paper manufactured according to the present invention. A cross-sectional view of each decorative board is shown. 1...Base paper,...Resin, 3...Picture, 4...
Thermosetting synthetic resin, 5... Adhesive, 6... Base material.

Claims (1)

[Claims] 1. A step of coating base paper with a weight of 30 to 100 g/m^2 with or without impregnation with resin, and then applying a pattern, a step of applying a thermosetting synthetic resin to the entire surface including the pattern to create decorative paper, In the process of embossing decorative paper, add 60 to 60 parts of urea adhesive to 100 parts by weight of emulsion adhesive.
80 to 200 g of adhesive mixed with 100 parts by weight to the base material
m^2 (wet) application process: Layer the embossed decorative paper on the base material coated with the adhesive, and use a laminator to press it with a roll at a temperature of 30 to 60°C to form the embossed convex part. A method for manufacturing a decorative board, which comprises sequentially performing the steps of pressing the adhesive and curing the adhesive over time.