JPS6035280B2 - Method for manufacturing molded plate with carved pattern - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a molded board having a carved pattern, which is made of a mirror layer of a decorative veneer, an adhesive resin-impregnated sheet, and a fibrous plywood.

So-called molding panels are used to decorate high-end furniture, doors, cabinets, ceiling panels, pillars, etc.
Wood was made using a manual cutting technique that was complicated and required skill, but due to the depletion of precious natural wood and the shortage of labor, an alternative method that is technically easy and economically advantageous has been developed. As a method, a decorative veneer (hereinafter referred to as ``Ki-board'') is layered on a plywood formed from a fibrous material such as particle board, plywood, or hard fiberboard, and a template with a carved pattern is applied to the surface of the plywood. Pressure forming methods are being put into practical use.

However, depending on the original method of applying adhesive to fibrous plywood, pasting the plating board, and forming the pattern with a pattern, the plating board was prone to cracking and damage due to the compression of the template, and the adhesive plating board was damaged. Only penetration into the surface and blow-out occurred, making it impractical. As an improved method, an impregnated adhesive sheet is used as a reinforcing material, and a plywood board and a fibrous plywood are laminated and bonded through this sheet, and then the pattern is heat-pressed (Tokukan Sho 50-1142).
No. 705). That is, in this method, an impregnating agent of ethylene, vinyl acetate, copolymer, nitrated cellulose, or polyethylene glycol is applied to the plywood, an impregnated adhesive sheet is temporarily adhered to the plywood, and a plating board is layered on this to form a pattern. A process of heat compression is used. However, in this method, the impregnating agent softens and flows out during hot pressing, penetrates into the plating board, and blows out, staining the plating board surface, and cracks in the plating board due to the patterned compresses still remain. Furthermore, the dimensional stability of the pattern template is poor, making it difficult to obtain detailed and beautiful engraved patterns.
It is not possible to obtain a product that passes the two types of immersion peeling tests for "special plywood" stipulated in . As a result of intensive research to solve these problems, the inventors have discovered the method of the present invention.

That is, in the present invention, a mixed resin is prepared by blending 50 to 50 parts by weight (in terms of resin content) of a thermoplastic resin with 10 parts by weight (in terms of resin content) of a thermosetting resin, and a synthetic fiber is used as the material. Layer the decorative veneer on the adhesive resin-impregnated sheet that has been soaked to the standard and dried thoroughly, apply heat and pressure to bond and integrate the decorative veneer and the adhesive resin-impregnated sheet, and then apply heat to the surface of this integrated product. Lay them on the fibrous plywood coated with a hardening adhesive so that the side of the fibrous plywood coated with the thermosetting adhesive is in contact with the surface of the resin-impregnated sheet that will be worn afterwards, and then place it on top of the decorative veneer. This is a method for manufacturing a molded plate having an engraved pattern, which is characterized by placing a template having an engraved pattern on the mold and heating and pressurizing it. According to the present invention, the adhesive does not permeate or blow out into the plate during hot pressing and stain the plate surface, and the plate does not crack due to pattern-shaped pressing. A product that has excellent dimensional stability when used as a template and can produce finely detailed and beautiful engraved patterns as well as passes the JAS "Special Plywood J Class 2 Immersion Peeling Test" can be obtained.

In the conventional method, as the plate is deformed and expanded by pressure during compression molding using a template, the sheet is torn, and the plate cannot withstand the stress and cracks occur. The impregnating agent applied to the plywood penetrates into the plywood through the sheet layer and tears and is blown out onto the surface of the plywood. In contrast, the adhesive resin-impregnated sheet according to the present invention is made of a synthetic fiber base fabric and a specific mixture. Since it is made of resin, it has a sufficient elongation rate, and since it is bonded and integrated with the plate in advance, it receives the deformation stress caused by pressing the template together, and the plate and sheet become one piece. Since the plywood can be stretched as it is and maintain its elongation, cracks do not occur in the plywood, and since a thermosetting adhesive is used for the adhesive applied to the plywood, it is easy to heat press with a template. Since the adhesive does not penetrate or blow out and is cured by heating, it is thought that the dimensional stability when the template is released is improved. In the present invention, the mixed resin to be impregnated into the synthetic fiber base fabric is a mixture of 50 to 500 parts by weight of a thermoplastic resin to 10 parts by weight of a thermosetting resin (hereinafter, all parts by weight are expressed in terms of resin content). The resin mixture is usually used in the form of a solution or emulsion in water, various solvents, or a mixed system containing two or more of these as a medium.

The thermosetting resin may be any adhesive resin that can be cured by heat, and these include urea formaldehyde resin, melamine formaldehyde resin, and co-condensed resins thereof, phenol formaldehyde resin, resorcinol formaldehyde resin, and co-condensed resins thereof. Typical examples include polyurethane resin, epoxy resin, unsaturated polyester resin, etc., and one or more of these may be used. The thermoplastic resin may be any resin for adhesives that has the property of softening when heated, but these include vinyl acetate resin, acrylic resin, ethylene/vinyl acetate copolymer resin, vinyl chloride/vinyl acetate copolymer resin, Typical examples include polyvinyl acetal resin, chloroprene rubber, ptadiene/acrylonitrile rubber, butadiene/styrene rubber, urethane rubber, etc., and one or more of these may be used. When using a synthetic fiber base fabric impregnated with a mixed resin in which less than 5 parts by weight of thermoplastic resin is mixed with 10 parts by weight of thermosetting resin, it is difficult to bond when laminating it with the plate and bonding it under heat and pressure. Although the resin permeates and blows out to the surface of the plate, there is no cracking of the surface of the plate when the template is applied to the plate and molded by heating and pressing. On the other hand, when using a synthetic fiber base fabric impregnated with a mixed resin in which more than 500 parts by weight of a thermoplastic resin is mixed with 10 parts by weight of a thermosetting resin,
When bonding the plate with heat and pressure, the resin does not penetrate or blow out onto the surface of the plate and the beauty of the plate is not damaged. During molding, the resin softens and flows out due to heat and pressure, so the plate cannot withstand the tensile stress caused by the clamping of the template, and has the disadvantage of causing cracks. Only when using a mixed resin in which 10 parts by weight of the thermosetting resin of the present invention is mixed with 50 to 50 parts by weight of a thermoplastic resin, penetration and blow-out of the resin into the plate surface and cracking of the plate can be prevented. Both can be prevented.

The mixed resin is preferably impregnated in an amount of 100 to 300% by weight (in terms of resin content) with respect to the weight of the synthetic fiber base fabric.
If it is less than 00%, the adhesive strength between the plywood board and the synthetic fiber base fabric is insufficient, and the effect of preventing the thermosetting adhesive used for adhesion to the plywood from penetrating and blowing out is reduced.
In addition, if it exceeds 300%, when the coating board and the synthetic fiber base fabric are overlapped and bonded under heat and pressure, the resin may penetrate and blow out onto the surface of the coating board, which may impair the aesthetic appearance of the coating board. It is also economically disadvantageous because the amount of agent increases. As mentioned above, the resin is used in the form of a solution or emulsion in water and/or a solvent, but the synthetic fiber base fabric impregnated with this resin can be bonded to a wood veneer by heat and pressure. In order to prevent the mixed resin from penetrating and blowing out into the keyboard, the resin-soaked base fabric is dried in advance by an appropriate method before bonding to reduce the water and/or solvent content relative to the weight of the synthetic fiber base fabric. It is necessary to keep it below 10%, preferably below 6%.

Impregnation methods include generally applying a solution or emulsion of the mixed resin in water and/or a solvent to the synthetic fiber base fabric, such as brush coating, spray coating, roll coating, spreader coating, and dipping. It can be done using the method described.

The synthetic fiber base fabrics used in the present invention mainly include synthetic fibers such as polypropylene fibers, polyethylene fibers, polyester fibers, polyamide fibers, polyvinyl acetal fibers, acrylic fibers, acrylic fibers, vinylidene chloride fibers, and polyurethane fibers. The material used is nonwoven fabric, woven fabric, or knitted fabric. The above synthetic fiber base fabrics show high elongation even after being impregnated with a mixed resin and heat-cured, whereas fiber base fabrics made of rayon, cotton, or pulp exhibit high elongation after being impregnated with a mixed resin and heat-cured. rate is significantly low.
It is thought that such a difference in elongation rate is based on the difference in affinity between the fiber and the synthetic resin. Table 1 shows examples of elongation rates after curing of resin-impregnated sheets impregnated with mixed resins for various fiber base fabrics. Table 1 (Test method) - Elongation rate = Sample length when tension is cut off - Sample length before tension x, oo% Sample length before tension 2 Elongation rate measurement method:
Measured at 2000 according to the method of JIS-L 1068 "Tensile test method for textiles" 3 Preparation of sample Impregnate the above fiber base fabric with a mixed resin of polyvinyl petyral resin/phenol formaldehyde resin of the following composition (wt% of impregnation rate 10) 6000C for 15 minutes.

(Composition of mixed resin) Phenol formaldehyde resin (manufactured by Dainippon Ink and Chemicals Co., Ltd. - Plyophen 5010, Juzuki Umami 58%) 7 parts polyvinyl butyral resin (manufactured by Denki Kagaku Kogyo Co., Ltd. - Denka Butyral 3000-1) 14 Parts Ethyl alcohol 55 parts Toluene 24 parts Here, parts are parts by weight.

In addition, thermosetting resin (phenol formaldehyde resin)
The ratio of the resin content of the thermoplastic resin and the thermoplastic resin (polyvinyl butyral resin) is 100:345. 4 Curing conditions: 13 and ○, 5 kg/20% Synthetic fiber base fabric has a basis weight (weight per 1 piece of base fabric expressed in g) of 20 to 60 g/It is preferable to use a similar material, 20 g If the strength is less than 60g/force, the strength in the mixed resin impregnation process will be insufficient, and if it is more than 60g/force, the amount of resin to be impregnated will increase, which is economically disadvantageous.

Furthermore, the resin-impregnated synthetic fiber base fabric used in the present invention has a content of 5% or more, preferably 1.
It is desirable to have an elongation rate of 0% or more. The decorative veneer chikki board used in the present invention is made from logs of natural precious trees such as domestic materials such as naph, elm, cherry, and shioji, and imported materials such as teak, walnut, rosewood, and mahogany. The wood was cut into a medium-thick flitch and then cut to a thickness of about 0.15 to 0.7 mm.
After drying, the synthetic fiber base fabric impregnated with the mixed resin described above is stacked on the plate and heated and pressurized to bond and integrate it. The heating and pressurizing conditions vary depending on the type of resin used, but generally 10
It is appropriately selected in the range of 0 to 140 qo, 5 to 10 k9/enemies 1 to 2 qo. For example, for a vinyl acetate resin/urea formaldehyde resin mixed system, the temperature is 100-110℃, 5-10k.
9/ground, 1 to 2 minutes: 1 for acrylic acid ester/acrylic acid copolymer resin/melamine formaldehyde resin mixed system
30qo, 5-10k9/lump, 5-10 minutes: 130qo, 5-1 for putagene acrylonitrile rubber/phenol formaldehyde resin mixed system and polyvinyl butyral resin/phenol formaldehyde resin mixed system
It can be carried out under conditions such as 0 kg/c〆 and 10 to 20 minutes. If the heating temperature exceeds 14,000 degrees Celsius, the surface of the plate may become discolored and the appearance may be impaired, so it is preferable that the heating can be carried out under the above conditions. As the plywood used in the present invention, fibrous plywood mainly made of fibrous materials such as particle board, hardboard, plywood, wood, and various other hard fiberboards is used.

In the present invention, the adhesive to be applied and impregnated onto the fibrous plywood mainly made of fibrous material is an adhesive containing a thermosetting resin that can be easily cured at room temperature or by heating.

These include, for example, phenol formaldehyde resin,
Examples include adhesives made of epoxy resin, polyurethane resin, unsaturated polyester resin, and the like. These thermosetting adhesives are used as a solution or emulsion in water, various solvents, or a mixture containing two or more of these, or in a solvent-free system. After immersion in the coating chamber, those containing water need to be substantially dried, those containing organic solvents dry faster, and those without solvents require no drying and can be used more preferably. Such a solvent-free thermosetting adhesive can be selected from polyurethane resin adhesives, epoxy resin adhesives, and the like. For example, vinyl acetate resin/urea formaldehyde resin mixed system, or acrylic acid ester/acrylic acid copolymer resin/melamine formaldehyde can be used as the namigo resin for adhesion and integration of the above-mentioned plate and synthetic fiber base cloth. When a resin mixture system is used, any of the adhesives containing a thermosetting resin that is coated and impregnated onto the plywood has excellent adhesive properties and can be used to form a surface layer with a carved pattern on the molded board. can improve the dimensional stability of

In addition, epoxy resin or polyurethane resin adhesives have excellent adhesive properties for butadiene/acrylonitrile rubber/phenol formaldehyde resin mixed systems, and polyurethane resin adhesives have excellent adhesive properties for polyvinyl butyral resin/phenol formaldehyde resin mixed systems. It has excellent adhesive properties. In this way, by appropriately selecting the thermosetting adhesive to be applied and impregnated on the plywood in accordance with the selection of the mixed resin for impregnation used in the resin-impregnated sheet for adhesion to the plywood, it is possible to achieve good results. You can get good results. In particular, polyurethane resin adhesives have excellent performance in all cases and are therefore the most preferred thermosetting adhesives. The amount applied to plywood depends on the type of thermosetting adhesive used, but in general, the amount applied to the plywood is 1
00~200g/〆 is preferable.If it is less than 100g/me, the shape retention may be weakened, and if it exceeds 20g/me, the adhesive may penetrate into the plate and blow out. . The adhesive resin soaked sheet that is integrated with the adhesive board and the plywood that has been soaked in a thermosetting adhesive are placed so that the adhesive resin soaked sheet and the adhesive-coated side of the plywood are in contact with each other. When heating and pressing a template with a carved pattern on top of the plate, the following conditions may apply: 20 to 1000 C, 200 to 300 k9/ground,
Conditions of 5 to 10 minutes are usually employed.

The present invention will be further explained below with reference to Examples.

Note that, without any particular explanation, "capital" or "%" simply means parts by weight or weight %. The amount of the mixed resin adhesive to be impregnated into the base fabric is determined by the following formula: weight of the resin-impregnated sheet after drying - weight of the base fabric x.

〇=Impregnation rate % It is shown as the impregnation rate % defined by the weight of the base fabric.

Example 1 A polyamide fiber tricot fabric with a basis weight of 20 g/gap was coated with Namiai resin having the following composition at an impregnation rate of 150% with respect to the tricot fabric.
The coating chamber was immersed so that the coating temperature would be 100%, and then dried at room temperature for 2 hours.

(Mixed resin composition) Urea formaldehyde resin
10 parts of foundation (Euroid #22, manufactured by Mitsui Tosho Co., Ltd., resin content 70%) 10 parts of pinyl acetate resin emulsion (manufactured by Konishi Co., Ltd., Bond CH7 resin content 46%) 1 part of ammonium chloride 10% aqueous solution 1 part of thermosetting resin (urea The resin content ratio of formaldehyde resin) and thermoplastic resin (vinyl acetate resin emulsion) is 10.
The ratio is 0:66.

The resin soaked sheet obtained above and a teak plywood board having a thickness of 0.2 ribs were placed on top of each other, and heated and pressed in a hot press at a temperature of 110 qo and a pressure of 5 k9/m for 2 minutes to bond and integrate them. A predetermined amount of curing agent was added to alcohol-soluble phenol-formaldehyde resin adhesive (manufactured by Konishi Co., Ltd. - Bond PR2, resin content 75%) on the surface of 15-thick lauan plywood using a rubber roller. At 15
An amount corresponding to each coat was applied and left to dry at room temperature for 3 coats.

The above-mentioned integrated product of the adhesive resin-impregnated sheet and the plated board is superimposed so that the adhesive-coated surface of the lauan plywood and the adhesive resin-impregnated sheet are in contact with each other, and the mold having the engraved pattern is inserted. Place it on the surface of the board, insert it into the hot press machine, and heat it to a temperature of 8.
A molded plate resembling a natural precious wood having a beautiful engraved pattern was obtained by heat-pressing molding at a pressure of 200 k9/base for 1 minute. This molded board showed no surface cracks at all and passed the JAS ``Special Plywood'' Class 2 bond peeling test. For comparison, we used a thermoplastic ethylene/vinyl acetate copolymer methyl alcohol solution adhesive instead of the thermosetting phenol formaldehyde resin bush adhesive to apply to the surface of the lauan plywood. When adhesion and molding were performed in the same manner as in Example 1 using an agent (manufactured by Nippon Gosei Kagaku Co., Ltd., Solex S4303, resin content: 45%), the thickness of the compressed part did not return when the pressure was removed from the hot press machine. 10 to 20% (0 in Example 1)
%), JAS ``Special Plywood'' Class 2 bond peeling test was conducted, but cracking occurred between the adhesive composite and the plywood, and the product did not pass.

Example 2 A polypropylene fiber nonwoven fabric having a basis weight of 40 g was coated with a mixed resin having the following composition so that the impregnation rate was 100%, and dried at a temperature of 8000 for 5 minutes.

A walnut board with a thickness of 0.18 ribs was superimposed on this, and a hot press was applied at a temperature of 130°C and a pressure of lk9/kg.
They were heated and pressed for 15 minutes to bond and integrate. (Mixed resin composition) Phenol formaldehyde resin 10 units (manufactured by Schenectaday Co., Ltd., SP, 2, resin content 100%) Butadiene/acrylonitrile rubber 10 units (manufactured by Nippon Zeon Co., Ltd., Hiker 1001) Methyl ethyl ketone
80 foundation groups, thermosetting resin (phenol formaldehyde resin) and thermoplastic resin (butadiene,
The resin content ratio of acrylonitrile rubber is 100:100.
This is the percentage of

Next, apply a solvent-free epoxy resin adhesive (manufactured by Konishi Corporation - Bond E Set L) to the surface of the particle board with a thickness of 2 m.
) is applied in an amount equivalent to 120 g/filter, and immediately stack the above-mentioned adhesive resin soaked sheet and plate board together so that the adhesive-coated surface of the particle board and the adhesive resin soaked sheet are in contact with each other. Place the mold with the engraved pattern on the surface of the plate, insert it into a hot press, and heat it to a temperature of 90q.
A natural precious wood molded board having a carved pattern called "Biroku" was obtained by heating and pressing under the conditions of 150 k9 pressure/5 minutes.

This molded board has no surface cracks at all and is JA
Passed the Type 2 bond peeling test for S "special plywood". For comparison, the adhesive resin-impregnated sheet obtained in Example 2 was not integrated with the plate by hot pressing in advance, but was simply combined with the plate, the adhesive side resin-impregnated sheet, and Example 2.
Plywood coated with adhesive in the same manner as above was stacked, a mold with a carved pattern was placed on the surface of the plywood, and the mold was inserted into a hot press machine and heated and pressed at a temperature of 13,000 and a pressure of 150 k9/base for 5 minutes. Cracks occurred due to the stress of the mold before the plate was bonded to the adhesive resin-impregnated sheet, and the molded product had numerous cracks on the surface of the plate, significantly lowering its commercial value.
Example 3 A mixed resin having the following composition was coated on a polyester plain woven fabric having a basis weight of 60 g per gram to give an impregnation rate of 200%, and then dried at a temperature of 600° for 15 minutes.

This was laminated with a 0.3 skin thick oak board, and heated and pressed in a hot press at a temperature of 120q0 and a pressure of 7k9/cm for 2 minutes to bond and integrate. (Mixed resin composition) Phenol formaldehyde resin 7 parts (manufactured by Dainippon Ink & Chemicals Co., Ltd., Pryophen 5010, resin content 58%) Polyvinyl butyral resin 14 parts (manufactured by Denki Kagaku Kogyo Co., Ltd., Denka Bitiful 3000-1 ) Ethyl alcohol 55 parts Toluene
24 parts The resin content ratio of thermosetting resin (phenol formaldehyde resin) and thermoplastic resin (polyvinyl butyral resin) is 100:
The ratio is 345.

An amount equivalent to 200 g of solvent-free polyurethane resin adhesive (manufactured by Konishi Co., Ltd. - Bond KU661/662) was immersed in the coating chamber on the surface of the hard fiberboard (product of Gohi Shin Plywood Co., Ltd. - Starwood) with a thickness of 15. Immediately overlay the above-mentioned integrated product of the adhesive resin impregnated sheet and the plate so that the adhesive-coated surface of the hard fiberboard and the adhesive resin-impregnated sheet are in contact with each other, and then cover the mold with the engraved pattern. Place it on the surface of the plate and insert it into a hot press machine at a temperature of 8000℃ and a pressure of 200kg/.
By heating and press molding for 8 minutes, a natural precious wood molded board having a beautiful engraved pattern as in Examples 1 and 2 was obtained. This molded plate showed no surface cracks at all, and J
Passed the second class bond peeling test for AS "special plywood". Example 4 In place of the epoxy resin adhesive applied to the particle board in Example 2, a solvent-free fast-curing epoxy resin adhesive (manufactured by Konishi Co., Ltd. - Bond Quick Set) was used,
A product with a beautiful engraved pattern and passing the JAS "special plywood" type 2 bond peeling test was produced in the same manner as in Example 2, except that the molding conditions were 2000 ℃ temperature, 150 k9/cm pressure, and 12 minutes. Obtained.

Experimental Example 1 Mixed resins of phenol formaldehyde resin/polyvinyl butyral resin were prepared on various fiber base fabrics listed in Table 2 to give various resin mixture compositions listed in Table 3. The material was impregnated to give the desired result, and dried at a temperature of 60 pm for 15 minutes.

This was treated in the same manner as in Example 3 to produce carved pattern molded plates using various fiber base fabrics. The phenol formaldehyde resin used was Pryophen 5010 (resin content 58%) manufactured by Dainippon Ink and Chemicals, and the polyvinyl butyral resin used was Denka Butyral 3 manufactured by Denki Kagaku Kogyo Co., Ltd.
Using 000-1, this polyvinyl butyral resin was dissolved in a 1:1 (by weight) mixed solvent of ethyl alcohol and toluene to make a 2% solution by weight, and this solution was mixed with the above phenol formaldehyde resin in various amounts in terms of resin content. A mixed resin used in this experimental example was prepared by mixing the resins to have a resin mixture composition of . Table 3 shows the penetration and blow-out of the resin into the plate during heating and pressurization of the resin-impregnated fiber base fabric and the plate, and the occurrence of cracks in the plate during the molding of the engraved pattern.

The evaluation results are displayed using the symbols below. Table 2 Table 3 Table 3 shows the weight ratio of phenol formaldehyde fishing rod/vinyl buteral resin (calculated by resin fraction).

The upper row shows the penetration and blowing of the sea bream fingers, and the lower row shows the cracks in the sea bream. Experimental Example 2 Using various fiber base fabrics listed in Table 4, a carved pattern molded plate was prepared in the same manner as in Example 3, except that the fiber base fabrics were impregnated with the following mixed resin of phenol formaldehyde resin/polyvinyl phthyral resin. Similar to Experimental Example 1, the penetration and blowout of the resin during the process and the occurrence of cracks in the base plate were examined, and the results are listed in Table 5.

(Composition of mixed resin) Phenol formaldehyde resin 10 parts (manufactured by Dainippon Ink & Chemicals Co., Ltd., Pryophen 5010, resin content 58%) Polyvinyl butyral resin 10 parts (manufactured by Denki Kagaku Kogyo Co., Ltd., Denka Butiful 3000 1. ) Ethyl alcohol 20 parts Toluene 20 parts The resin content ratio of thermosetting resin (phenol formaldehyde resin) and thermoplastic resin (polyvinyl butyral resin) is 100 parts.
:172 ratio.

Claims (1)

[Claims] 1 (a) 100 parts by weight of thermosetting resin (resin content equivalent)
50 to 500 parts by weight (resin content equivalent) of a thermoplastic resin is impregnated into a base fabric made of synthetic fibers and thoroughly dried to form an adhesive resin-impregnated sheet.
The decorative veneers are stacked, (b) the decorative veneers and the adhesive resin-impregnated sheet are bonded together by heating and pressurizing, and (c) this integrated product is then bonded to fibers with a thermosetting adhesive applied to the surface. Lay the fibrous baseboard on top of the veneer so that the surface of the fibrous baseboard coated with a thermosetting adhesive is in contact with the surface of the resin-impregnated sheet for adhesion of the integrated product, and (d) further create a carved pattern on the decorative veneer. A method for producing a molded plate having an engraved pattern, the method comprising: placing a template having a pattern on the molded plate, and (e) heating and pressurizing the molded plate.