JPS621819B2 - - Google Patents

Description

[Detailed Description of the Invention] This invention relates to a method for manufacturing decorative laminates that can faithfully reproduce the texture of materials such as natural wood. By pressing the colored resin film against the curable resin liquid on the decorative laminate material and grinding the surface of the colored resin film after curing, the colored resin film that is an integrated colored resin film made of the cured resin and the decorative laminate material, it can be applied to the concave portions of the uneven pattern. This eliminates the need to seal the colorant.

Conventionally, decorative plywood in which the color pattern and uneven pattern of natural wood match has been widely known as a material with high reproducibility of the texture and texture of natural wood.
As an example of a manufacturing method for such decorative plywood, a curable resin liquid is poured onto a mold that faithfully imprints the uneven pattern of natural wood, and wood grain printing is applied while the curable resin liquid is in an uncured state. The decorative sheet is aligned and laminated on the curable resin, and after the resin has hardened, the integrated product of the cured resin and decorative sheet is peeled off from the mold, and colored paint is applied to the entire uneven surface formed on the cured resin. There is a method of removing the paint on the convex parts before it hardens.

However, in this method, the colored paint must be applied to the entire uneven surface of the cured resin, and the colored paint on the convex parts must be removed before it solidifies, which increases the number of manufacturing steps and makes the work complicated. There were disadvantages such as low productivity of decorative plywood and complicated equipment.

This invention was made in view of the above circumstances,
The purpose of this decorative laminate manufacturing method is to shorten the manufacturing process, simplify work, and obtain a decorative laminate that fully retains the texture of natural wood.The mold is coated with a colored resin film and then cured. The colored resin film, the cured resin, and the decorative board material are peeled off from the mold, and the surface (convex parts) of the colored resin film is removed from the mold. It is characterized by being removed by grinding.

Hereinafter, the present invention will be explained in detail with reference to the drawings.

FIGS. 1 to 7 show an example of the method for manufacturing a decorative board of the present invention in the order of steps. First, as shown in Fig. 1, a natural wood 1 to be replicated is prepared, and a mold 2 is made to faithfully copy the uneven pattern on the surface of the natural wood 1 by pouring a synthetic resin solution for molding onto the surface of the wood 1. Create. As the mold-making synthetic resin liquid, transparent or translucent room temperature curing liquid silicone resin is preferable. Next, as shown in FIG. 2, a colored resin liquid 3 is applied to the surface of the mold 2 on which the uneven pattern is formed. As this colored resin liquid 3,
Black or brown opaque synthetic resin paints such as polyurethane resin paints, vinyl resin paints, epoxy resin paints, and alkite resin paints are used.
As the colored resin liquid 3 solidifies, the resin liquid 3 becomes a solid colored resin film 4, and an uneven pattern following the uneven pattern of the mold 2 is formed. Since the thickness of the colored resin film 4 is very thin at 10 to 20 μm, the uneven pattern of the mold 2 is almost accurately reproduced.

On the other hand, as shown in FIG. 3, a decorative board material 7 is prepared in which a wood grain printing paper 6 on which a color pattern of natural wood 1 is printed using a normal plate-making technique is adhered to the surface of a substrate 5 such as round plywood.

Then, as shown in FIG. 4, a curable resin liquid 8 is applied onto the wood grain printing paper 6 of the decorative board material 7. As the curable resin liquid 8, an uncured liquid of a crosslinkable synthetic resin such as a liquid unsaturated polyester resin, a liquid diallyl phthalate resin, a liquid urethane resin, etc. is used, and a transparent or translucent one is particularly preferable. Also, the coating thickness of this curable resin liquid 8 is
The thickness is preferably 100 to 150 μm.

Then, before the curable resin liquid 8 is cured,
As shown in FIG. 5, the mold 2 on which the colored resin film 4 is formed is placed over the curable resin liquid 8. As shown in FIG. At this time, the color pattern of the wood grain printing paper 6 of the decorative board material 7 and the uneven pattern of the mold 2 are aligned. Then, the back surface of the mold 2 is lightly pressed with a roller or the like to sufficiently remove air bubbles that have been caught in the interface between the mold 2 and the curable resin liquid 8.

When the curable resin liquid 8 is sufficiently cured to become a cured resin 9, the mold 2 is peeled off and removed, and the colored resin film 4, cured resin 9, and decorative board material 7 are removed, as shown in FIG. An integrated object 10 is obtained. The surface of this integrated object 10 has an uneven pattern that faithfully imitates the uneven pattern of the natural wood 1, but the color pattern of the wood grain printing paper 6 is covered by the colored resin film 4 as the top layer. It's summery.

Finally, the convex portions of the colored resin film 4 on the uppermost layer of the integral body 10 are ground and removed to obtain the intended decorative board 11 shown in FIG. 7. The above-mentioned grinding is performed by buffing or the like in addition to the usual milling and planing methods, and as shown in FIG. 7, the colored resin film 4
This is done until the protrusions are completely scraped off and the underlying cured resin 9 is exposed on the surface. As a result, the colored resin film 4 remains only in the concave portions of the uneven pattern.

According to this method of manufacturing decorative plywood, the decorative board 11 is completed with the colored resin film 4 buried in the recesses of the uneven pattern on the surface of the decorative board 11, which eliminates the troublesome process of filling the recesses with conventional manufacturing methods. Sealing work becomes unnecessary, workability is improved, and the realism of the decorative board 11 is further emphasized. Further, since the colored resin film 4 protects the uneven pattern of the mold 2, the mold 2 is not damaged. Furthermore, the interface between the mold 2 and the curable resin liquid 8 hardly contains any air bubbles.

In addition, in the above embodiment, the substrate 5 is attached to the decorative board material 7.
Although we used a board with wood grain printing paper 6 pasted on it, it is not limited to this, but it is also possible to use a board 5 with a color pattern printed directly on it, a thin iron plate pasted on the board 5 to give it heat resistance, and a titanium paper etc. , a photosensitive layer is formed on the surface, and a color pattern is formed by photographic coloring processing. Also,
After grinding the colored resin film 4, a top coat of transparent paint may be applied to protect the colored resin film 4 in the recessed portions.

As explained above, the method for manufacturing decorative plywood of the present invention involves forming a colored resin film on a mold with an uneven pattern of an original plate made of natural wood, etc., and pressing this mold into a curable resin liquid on the decorative board material. After applying and curing the mold and peeling off the mold, the convex parts of the colored resin film are ground away, eliminating the need for the conventional troublesome work of filling in the concave parts of the concave-convex pattern, improving work efficiency and reducing manufacturing costs. It is possible to measure the reduction in In addition, the colored resin film in the recesses further improves the texture of the decorative plywood, resulting in a decorative plywood with a design that is extremely similar to natural wood. Furthermore, since the uneven pattern of the mold is protected by the colored resin film, the number of times the mold can be used is extended.

[Brief explanation of the drawing]

Figures 1 to 7 show an example of the method for manufacturing decorative plywood of the present invention in the order of steps, with Figure 3 being a schematic perspective view, and Figures 1 to 7 excluding Figure 3 being schematic sectional views. be. 2... Mold, 4... Colored resin film, 7... Decorative board material, 8... Curing resin liquid, 10... Integral object, 11
... Decorative board.

Claims (1)

[Claims] 1. (a) A step of applying a colored resin liquid to a mold on which a concave-convex pattern has been formed to form a colored resin film; (b) A step of applying a curable resin liquid onto a decorative board material on which a colored pattern has been formed. (c) After the curable resin is cured, the colored resin film, curable resin and It is characterized by comprising the steps of (a), (b), (c), and (d) above, including a step of peeling off the integral piece of decorative board material, and (d) a step of grinding the surface of the colored resin film of the integral piece. Manufacturing method of decorative board.