JPS6021064B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board, and more particularly, to a method for manufacturing a decorative board having a synchronized embossed pattern having an uneven pattern that is synchronized with a pattern.

Conventionally, there are roughly two methods for imparting unevenness that matches the pattern on the surface of a thermosetting resin name plate.

The first method is called the direct embossing method.
Typical methods include using an embossed plate that matches the pattern to directly create irregularities on the decorative board using a flat plate press, and directly creating irregularities on the surface of the decorative board using an embossing roll.

However, with this method, it is expensive to manufacture the embossed plate and the embossed roll, and it is difficult to register the pattern of the IQ drop with the uneven pattern of the embossed plate and the embossed roll, which takes time to manufacture, and there are cost problems. there were.
The second method is generally called the chemical embossing method, in which a pattern is formed on the base paper for side resin impregnation using ink containing a resin polymerization inhibitor, and this creates a difference in the curing speed of the resin on the surface of the decorative board. , a method of forming an embossed pattern on the surface by utilizing the difference, or a method of forming a pattern on the base paper for resin impregnation with ink containing a substance that has a repellent effect on resin, and then forming a pattern on the ink area during application or impregnation. There is a method of repelling the resin to form an embossed pattern. These methods are extremely advantageous in terms of matching the design and the embossed pattern, but in the case of the former, it takes time for the resin to harden and only the volumetric shrinkage of the resin is used, so it is difficult to form depressions. This naturally limits the width, making it impossible to form deep recesses of arbitrary width, and thermosetting resins molded under heat and pressure, such as urea resin, melamine resin, and DAP resin, are not very effective. .

On the other hand, various experiments were conducted on the latter, but the repelling effect alone was not sufficient.
There has been a problem in that a sufficient embossing effect cannot be achieved with heat and pressure molding type resins. The present invention overcomes the above-mentioned drawbacks and in a relatively simple and therefore low cost manner.
Furthermore, the object is to manufacture an embossed decorative board that can be applied to heat-pressing molding type thermosetting resin.

That is, in the present invention, a pattern is provided on decorative paper using an ink containing a resin that is releasable to the thermosetting resin to be impregnated, and then the releasable resin is cured, and then the thermosetting resin to be impregnated is After forming a curing-inhibiting pattern by overlapping it in synchronization with the pattern using ink containing a curing inhibitor, the entire surface of the decorative paper including the pattern is impregnated with a thermosetting resin and dried to produce ape-containing paper. Then, after layering the impregnated paper on the base material and further placing a molded plate or film on top of it,
After curing the thermosetting resin in the non-patterned area by applying heat and pressure, the uncured resin on the pattern and the curing-inhibiting pattern are attached onto a molded plate or film, and the molded plate or film is peeled off. The present invention is directed to a method for manufacturing a decorative board, which is characterized by forming recesses. below,
The above-mentioned present invention will be explained in detail.

First, the explanation using a principle diagram is as follows.
As shown in Fig. 1, a cloth grain pattern, a wood grain pattern, etc. are printed on the decorative paper 1 as a base pattern using a normal ink or paint composition, or a wood grain pattern, an abstract pattern, etc. is printed directly on the decorative paper 1. Apply a pattern 2 using ink containing a resin that is releasable to the thermosetting resin to be impregnated only in the areas where the coating surface is desired to be depressed, and after curing the releasable resin, impregnate. A pattern 3 for suppressing curing is provided in synchronization with the pattern using ink containing a curing inhibitor for the thermosetting resin.

Next, as shown in the second figure, the printed paper is coated with or impregnated with a thermosetting resin 4, and after drying, an impregnated decorative paper is obtained. Next, as shown in Figure 3, impregnated paper is layered on the base material 5 with the pattern 2 and the hardening-inhibiting pattern 3 on the surface, and a molded plate or film 6 such as a metal plate or plastic film is further placed on top of the impregnated paper. and heat and pressurize by normal means. By this heating and pressure molding, as shown in FIG. A portion 7 and an uncured portion 4 are formed.

This is thought to be because the curing inhibitor contained in the curing-suppressing pattern 3 moves to the upper part of the curing-suppressing pattern layer, so that the thermosetting resin impregnated above the curing-suppressing pattern layer becomes hardened. Next, as shown in Figure 5, when the molded plate or film 6 is peeled off, the resin in the uncured portion 4 and the pattern 3 for suppressing hardening adhere and are peeled off. Since the hardened part 4 has poor affinity with the peelable resin in the pattern 2, it does not remain on the pattern 2 at all and peels off together with the hardening suppressing pattern 3, and since it is in an unhardened state, it is molded by hot pressure. It is in a state where it is extremely easy to adhere to boards or films. In this way, pattern 2
A decorative board 8 having a concavo-convex pattern that is in tune with this can be obtained. In this decorative board 8, the pattern 2 is exposed because there is no hardened layer of thermosetting resin in the recessed portion, but since the peelable resin in the pattern 2 is hardened, it is highly robust. In the present invention, the decorative paper may be paper such as titanium paper, thin paper, or kraft paper, cloth such as cotton cloth or glass cloth, or nonwoven fabric. Furthermore, as a method for applying base patterns such as cloth grain patterns and wood grain patterns, and patterns for areas to be recessed, to these decorative papers, there are conventional methods such as letterpress printing, offset printing, gravure printing, or screen printing. It can be formed by printing, drawing, or painting using a printing method, a hand-drawing method, or a normal painting method. Next, in the present invention, the ink or paint composition for applying the base pattern is a known one, for example, a coloring agent such as a dye or pigment is added to an ink or paint vehicle, and further, for example, a plasticizer, a stabilizer, etc. Ink made by adding optionally known additives such as drying agent, wax/grease, drying agent, auxiliary drying agent, curing agent, thickener, dispersing agent, filler, etc., and thoroughly kneading with solvent, diluent, etc. or paint compositions can be used.

In the above ink or coating composition, the vehicle may be a known one, such as various oils and fats such as linseed oil, soybean oil, or synthetic drying oil, natural resins such as rosin, copal dammar, hardened rosin, rosin ester, or polymerized rosin; Processed resins, rosin-modified phenolic resins, 100% phenolic resins, maleic acid resins, alkyd resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, amino alkyd resins and other synthetic resins, nitro resins Cellulose, cellulose derivatives such as ethyl cellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, and other materials such as keratin, casein, dextrin, and zein can be used.

Next, the ink composition used to form the pattern formed in the recesses in the above has a release resin as the main component of the vehicle, to which coloring agents such as dyes and pigments are added, and any necessary additives are optionally added. The resin is added and sufficiently kneaded with a solvent, diluent, etc., and among these constituent components, resins that have releasability to the thermosetting resin to be immersed include thermoplastic resins such as fluorine resins, melamine resins, Thermosetting resins such as urea resins and silicone resins are used.

In particular, when using a reactive type resin as the thermosetting resin to be impregnated, it is preferable to use a resin that has a type of releasability different from the curing reaction of the thermosetting resin to be impregnated. For example, condensation type silicone resins or melamine resins are suitable as release resins for diallyl phthalate resins. In addition, the ink composition used to form the curing-inhibiting pattern in the above is composed of a curing inhibitor, a vehicle, a solvent or a diluent, and the above-mentioned additives may be optionally added as necessary. . First, in the above ink composition, the curing inhibitor may be any agent as long as it can inhibit the curing of the thermosetting resin to be impregnated. For example, the thermosetting resin to be impregnated is unsaturated polyester resin. , hydroquinone, methoquinone, etc. in the case of radical polymerization type such as diallyl phthalate resin. Further, in the above ink composition, the amount of the curing inhibitor is 3 to 60 Wt with respect to 100 Wt of the ink composition.
% Preferably, it is desirable to use 15 to 40 Wt%.

If it is less than 3 Wt%, the effect of inhibiting hardening of the thermosetting resin to be impregnated is not sufficient, so the cohesive force between the parts of the thermosetting resin affected by the inhibitor and the parts not affected by the inhibitor is large, resulting in poor peelability. It is impossible to obtain an uneven shape due to insufficient affinity with the resin and the force of adhesion to the molded plate or film, and if the amount exceeds 60 Wt%, it will lose its suitability as a normal ink, and the strength of the ink film will decrease. When the thermosetting resin is impregnated, the ink film is physically or chemically destroyed, and the inhibitor remains in the thermosetting resin layer, suppressing the curing of the resin liquid. be fucked

In addition, as mentioned above, the ink vehicle containing the curing inhibitor or its additives maintains the physical (mechanical) and chemical (solvent) strength when impregnating the thermosetting resin, and also maintains the thermal strength. Any material may be used as long as the curing inhibitor migrates at the stage of impregnating the curable resin and drying it, giving the thermosetting resin a property of imparting an inhibitory effect.

Furthermore, if the resin has an affinity with the thermosetting resin to be impregnated, it will easily be peeled off while being integrated with the uncured resin when peeled off after molding.

The vehicle for the curing-inhibiting ink or coating composition may be a known vehicle, such as various oils and fats such as linseed oil, soybean oil, synthetic bag oil, rosin, copal dammar, hardened rosin, rosin ester, or polymerized rosin. Natural resins and processed resins, rosin modified phenolic resin, 100%
Synthetic resins such as phenolic resin, maleic acid resin, unsaturated polyester resin, melamine/alkyd resin, alkyd resin, petroleum resin, vinyl resin, acrylic resin, polyamide resin, epoxy resin, amino alkyd resin, nitrocellulose , cellulose derivatives such as ethylcellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, and other materials such as pig, casein, dextrin, and zein can be used.

Also effective as additives are substances that assist in internal migration of the curing inhibitor. Next, in the above-mentioned present invention, the method of applying resin treatment to the above-mentioned printing paper includes, for example, a method of soaking the negative printing paper in a solution-type or emulsion-type resin liquid and drying it;
Alternatively, it can be carried out by coating or applying the above-mentioned resin liquid onto printing paper and drying it.

As the resin liquid in the above, for example, one or two thermosetting resins such as urea resin, melamine resin, acetoguanamine resin, benzoguanamine resin, unsaturated polyester resin, diallyl phthalate resin, or initial condensates thereof. A resin liquid containing the above as main components can be used.

In this case, the amount of resin attached to the impregnated paper is 5
Although the object of the present invention can be achieved with a resin adhesion amount of 0 to 150%, it is preferable to use a resin adhesion amount of 60 to 80%.

Further, the base materials applicable to the above-mentioned present invention include plywood, /gootail board, flexible board, calcium silicate board, pulp cement, etc., and include resin-containing twill laminated core paper.

In the present invention, during heating and pressure forming, metal plates such as duralumin plates and stainless steel plates, polypropylene,
A plastic film such as vinylon can be used as the molded plate or film.

As is clear from the above explanation, in the method of the present invention, there is a curing-inhibiting pattern made of ink containing a curing inhibitor above the pattern formed in the recessed part, which is made of a cured film of a removable resin. Sometimes the thermosetting resin is extremely easy to peel off, so the recesses are formed sharply, and the thermosetting resin is
The top of the pattern is completely repelled due to the releasable resin,
No thermosetting resin remains.

However, since the releasable resin in the concave portions where the pattern is exposed has been cured, it is as solid as the cured resin in the convex portions. Furthermore, if the molded plate or film is peeled off and the next molding is performed without removing the resin attached to the plate or film, it will be integrated with the thermosetting resin and will not cause any damage to the resulting decorative board. Since it does not have any adverse effect, it is not necessary to remove it in each decorative laminate manufacturing process, so decorative laminates can be manufactured extremely efficiently. The recessed board obtained by the method of the present invention can be used for various purposes, such as decorative boards for building materials such as doors, wall materials, furniture, kitchens, etc.

Next, the present invention will be explained in more detail with reference to Examples.

"Parts" in the following text indicate "parts by weight." [Example 1]
80 evenings/A wood grain pattern was gravure printed on the titanium paper using a regular gravure ink, and a conduit portion was printed using a gravure printing machine using the following releasable ink.

(Ink formulation A) Silicone tree 15 parts (K
S-70 Inshinetsu Chemical Industry Co., Ltd.) Pigment
10〃Toluene 36〃Xylene 39〃The printing paper was dried at 120 pm for 1 minute to harden the silicone ink in the conduit section, and then, using the same printing plate for the conduit section, the next hardening inhibitor ink was applied. Overprinting was performed to create a pattern to suppress hardening.

(Ink formulation B) Cellulose acetate resin
13 parts alkyd resin 5
Ethyl acetate 32〃ethanol 25〃toluene
1. Hydroquinone
15. Next, the printing paper obtained as described above was impregnated with the following resin mixture for 80 minutes per solid content.

(Resin blend) diallyl phthalate polymer
1 Isobe diallyl phthalate monomer 12 Penzoyl peroxide 12 Lauric acid 0.6 Methyl ethyl ketone 150 Toluene
50 Dry the impregnated liquid at 80°C for 10 minutes to obtain impregnated paper.

Next, the impregnated paper was layered on a 3 m/m plywood board with the ink side facing up, and a polished duralumin board was placed on top of it with the mirror surface facing downward, and pressed at 140°C and 10k9/ground for 8 minutes. . After pressing, when the duralumin board is used as a template, the resin only in the conduit part has poor affinity with the ink layer that forms the conduit part, and the resin in this part is uncured due to the hardening inhibitory effect, so a pattern for hardening inhibition is used. At the same time, it was transferred to a duralumin board, resulting in a sharp and deep tone-embossed decorative board.

Similar results were also obtained when an aluminum plate or a polypropylene film was used instead of the duralumin plate.

[Example 2] 80 pm/A wood grain pattern was gravure printed on the titanium paper using ordinary gravure ink, and a conduit portion was printed using a gravure printing machine using the following releasable ink.

(Ink formulation A) Fluororesin 15 parts Acrylic modified varnish 8 The printing paper was dried at 200° C. for 1 minute to harden the ink in the conduit portion.

Next, the following ink composition was used to overprint the previous conduit portion to provide a pattern for suppressing hardening. (Ink formulation B) Nitrocellulose RSI'4 6 parts Ethyl cellosolve 38〃Hydroquinone 20'' Polylite J-908 20〃Toluene
16. The printing paper obtained as described above was impregnated with the following resin compounded liquid at a solid content of 8M/〆.

(Resin blend) Diallyl phthalate polymer 1 Oribe diallyl phthalate monomer 12 Penzoyl peroxide 12 Lauric acid
0.6〃Methyl ethyl ketone
150〃Toluene
50 The impregnated liquid is dried for 1 minute at 8000 to obtain impregnated paper.

Next, the impregnated paper was layered on 3 pieces of plywood with the ink side facing up, and a polished duralumin board was softened and pressed on top of it with the mirror surface facing downward for 8 minutes at 140:00, 10k9/. . After pressing, when the duralumin board is placed next to the mold, the resin only in the conduit part has poor affinity with the conduit part, and due to the hardening suppressing effect, the resin in this part is uncured, so it transfers to the duralumin board together with the hardening suppressing pattern. , a sharp and deep matching embossed decorative board was obtained.

[Example 3] After gravure printing a wood grain pattern on that titanium paper using ordinary gravure ink, and then printing a conduit part with a gravure printing machine using the same ink composition A as in Example 1,
The ink on the conduit part was cured by drying at 120 qo for 1 minute, and then overprinting was performed using the same plate with the same ink composition B as in Example 1, and the solid content was 55% with the same impregnating resin liquid as in Example 1. 80% of the impregnating solution that was impregnated with
It was dried for 10 minutes with a hot iron to obtain impregnated paper.

Below, using vinylon film under the same conditions as in Example 1, 4 m/
When the impregnated paper was placed on the plywood again and heated and pressurized to release the vinylon film, the resin on the conduit was transferred to the vinylon film together with the hardening inhibiting pattern, resulting in an embossed decorative board in which the concave portions and the pattern were perfectly aligned. Ta.

[Example 4] A wood grain pattern was gravure printed on a pillow titanium paper using a regular gravure ink, and a conduit portion was printed using a gravure printing machine using the following ink composition.

(Ink formulation A) Fluororesin
18 parts acrylic modified varnish 1
.

After drying and curing the printing paper at 200° C. for 1 minute, ink formulation B of Example 2 was used to perform synchronous printing with the above printing. The solid content of the printed paper was reduced to 96% by using the following resin compounding liquid.
It was impregnated with water. (Resin blend) Diaryl phthalate polymer 12$ Partly unsaturated polyester 40〃Penzoyl peroxide 12''Lauric acid
0.6 parts methyl ethyl ketone
150″ toluene
50〃 80oo of the mixed impregnating liquid
The impregnated paper was dried in 1 powder, and the impregnated paper was layered on a 3 kite/m plywood board with the ink side facing up, and further softened so that the 20% matte side was on the bottom, the same as in Example 1. It was heated and pressurized under the following conditions.

After pressing was completed, the duralumin board was released from the mold, and a sharp and deep tone-embossed decorative board was obtained. 〔Example
5] 80th evening: A wood grain pattern was gravure-printed on the titanium paper using ordinary gravure ink, and the conduit portion was printed using a gravure printing machine using the following releasable ink.

(Ink formulation A) Pigment 22″ Ethyl acetate/Toluene/Isopropyl alcohol
150 copies of 64 copies of the printed paper
After drying at 00 for 1 minute to harden the ink on the conduit,
Overprinting was carried out using the ink of ink composition B of Example 2 in exactly the same manner as the above printing, and after drying, the following resin composition was impregnated with the solid content for 50 days/pillow.

(Resin formulation) Diaryl phthalate polymer 1 Spotted diallyl phthalate monomer 12 Penzoyl peroxide 12 Lauric acid
0.6〃Methyl ethyl ketone
15〃Toluene
50. Dry the impregnated liquid at 80 qo for 10 minutes to obtain impregnated paper.

Next, the impregnated paper was layered with the ink side facing up on a 3/m plywood board, and a polypropylene film was placed on top of it.
○, pressed for 8 minutes at 10k9/ground. After pressing, when the polypropylene film is used as a template, the resin in only the conduit part has poor affinity with the conduit part, and the resin in this part is uncured due to the hardening inhibiting effect, so it is not cured with the pattern to inhibit hardening. Transferred to polypropylene film, a sharp and deep tone-embossed decorative board was obtained.

[Brief explanation of the drawing]

FIGS. 1 to 5 are cross-sectional views schematically showing steps for manufacturing a decorative board by the method of the present invention. Explanation of the symbols representing the main parts of the figure, 1... Ihi shipboard, 2... Pattern, 3... Curing suppression pattern, 4... Heat curing 5...base material,
6... Molded plate or film, 7...
Hardened portion, 8... Decorative board. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5

Claims (1)

[Claims] 1 After providing a pattern on decorative paper with an ink containing a resin that has release properties for the thermosetting resin to be impregnated, the release resin is cured, and then a curing inhibitor for the thermosetting resin to be impregnated is applied. After forming a pattern for suppressing hardening by layering the same pattern with the ink containing the pattern, the entire surface of the decorative paper including the pattern is impregnated with a thermosetting resin and dried to produce impregnated paper, and then the impregnated paper is After stacking the paper on the base material and further placing a molded plate or film on top of it, heat and pressurize to harden the thermosetting resin in the non-patterned area, then uncured resin on the pattern and A method for manufacturing a decorative laminate, comprising the steps of: adhering a hardening-inhibiting pattern onto a molded plate or film, and forming recesses by peeling off the molded plate or film.