JPS6227990B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an embossed decorative board, particularly an embossed decorative board having a brick joint pattern, tile joint pattern, or other appropriate concave pattern, and whose surface has the wood texture of natural precious wood. It is.

Traditionally, the method for manufacturing this type of decorative board is to attach a veneer of natural wood to the surface of a substrate such as plywood, then use a router to carve grooves in the shape of tile or brick joints, and then finish with a coat of paint. After placing a resin-impregnated paper with an appropriate pattern such as a wood grain pattern on the surface of the substrate, an embossed planar plate is placed on the surface of the resin-impregnated paper and heated and pressed, and the embossed planar plate is used to form conduit grooves and tile joints. There is a method of reprinting a concave pattern to create an artificial wood texture and the appearance of tile joints.

However, the former method of using veneer has the disadvantage that it becomes expensive due to the depletion of natural wood.Furthermore, since the veneer of natural wood is used, there are many differences in color and grain pattern, and decorative board has uniform decorative properties. is not suitable for mass production.

In addition, in the latter method of using resin-impregnated paper, the concave patterns on the surface, such as conduit grooves and tile joints, are engraved by the heat pressure of an embossing plate, so the concave portions are slow and less natural. At the same time, when matching the embossed pattern of the embossed flat plate to the printed pattern such as the wood grain pattern of resin-impregnated paper arranged on the surface of the substrate, it is difficult to see the embossed pattern of the embossed plate directly from the outside, so heat is applied to accurately match the two patterns. It is very difficult to press and requires great care in aligning the embossing plate. In addition, in the case of mass production, a large number of embossing flat plates are required, and each embossing flat plate must be placed in an accurate position on the pattern surface of the resin-impregnated paper, which is a time-consuming process. The disadvantage is that the product is expensive due to poor efficiency.

The present invention was made in view of these drawbacks, and uses Kapol, which is abundant and inexpensively available.
Using breathable material made of wood thin boards such as lauan and apitone or appropriate decorative paper, it has a decorative surface that closely resembles natural precious woods such as teak, rose, oak, and mahogany, and has a three-dimensional effect such as brick joints or tile joints. To provide a method for manufacturing an embossed decorative board that can inexpensively and efficiently manufacture an embossed decorative board having a rich concave pattern.

An embodiment of the method of the present invention will be explained with reference to the drawings. Fig. 1 shows the method of the present invention in the order of steps. 1 is a substrate made of synthetic material, particle board, fiberboard, or other suitable plate-like material, and its surface is A rotary wood veneer made of miscellaneous trees such as lauan, capor, and apitong is adhered to the surface to form a surface decorative layer 2.

The wood veneer used as the surface decorative layer 2 may be bleached or colored in advance to have a uniform color tone.

Next, concave grooves 4 in the form of a brick joint pattern are imprinted on the surface of the decorative layer 2 using an embossing roll 3 or the like.

The grooves 4 are not limited to a brick joint pattern, but may be a tile joint pattern, a frame pattern, or a parallel groove pattern depending on the intended use of the decorative board, and the pattern is not particularly limited.

Furthermore, an embossing plate may be employed as a method for reprinting the grooves 4.

After the patterned grooves 4 are formed on the surface of the decorative layer 2 of the substrate 1, a transparent PVC film or the like is printed with a grain pattern 6a of teak, mahogany, oak, or other suitable natural wood on the surface of the decorative layer. The plastic synthetic resin film 6 is placed on its back surface with an adhesive such as a urethane adhesive that becomes transparent after hardening.

At this time, the thermoplastic synthetic resin film 6 is printed with a block-like wood grain pattern, and the printed pattern 6a and the patterned grooves 4 in the shape of brick joints provided in the decorative layer 2 on the surface of the substrate are aligned. They may be overlapped like this. In this case, since the thermoplastic synthetic resin film 6 is transparent, it is easy to align the patterns of both.

Next, on the surface of the thermoplastic synthetic resin film 6 superimposed on the decorative layer 2, a backing plate 7 made of a metal plate or the like whose lower surface is formed with a finely uneven rough surface 7a is placed and hot pressed 8, 9. The thermoplastic synthetic resin film 6 is softened and adhered to the surface of the decorative layer 2 by heating and pressing between hot plates.

At this time, when heated and pressed between the hot presses 8 and 9, the thermoplastic synthetic resin film softens and expands due to heating, and conforms to the surface shape of the decorative layer 2.
Sagging will occur at the conduit grooves 2a and the patterned grooves 4 on the surface of the decorative layer 2, and furthermore, sagging will occur between the finely uneven rough surface 7a on the lower surface of the backing plate 7 and the synthetic resin film 6. At the same time, the air is heated and expanded, and the air pressure between them rises, causing the softened synthetic resin to fill the concave portions of the decorative layer 2 formed by the conduit grooves and the concave grooves 4 in the shape of brick joints engraved by the embossing roll. The film 6 is pushed in by the pressure of the heated air, and as shown in FIGS. 2 and 3, the synthetic resin film 6 connects to the conduit of the decorative layer 2 through the adhesive applied to its back surface. Groove 2
a and the inner bottom surface of the brick joint-like groove 4 in close contact with each other.

Note that in order to push the synthetic resin film 6 from the surface side of the synthetic resin film 6 into the inner bottom surface of the recess of the decorative layer 2 by the expansion pressure of air, the decorative layer 2 must have air permeability and the synthetic resin must have air permeability. It is also necessary that the synthetic resin film 6 is thermoplastic, and that the lower surface of the plate 7 that heat-presses the surface of the synthetic resin film has a finely uneven rough surface 7a.

This is because when the decorative layer 2 on the surface of the substrate is formed of a non-breathable material such as a synthetic resin layer or a metal sheet, the air existing between the grooves of the synthetic resin film cannot escape to the outside and This is because, despite being pushed by air pressure from the surface side of the resin film, the film cannot be brought into close contact along the inner bottom surface of the groove, resulting in poor adhesion. It is necessary to use an air-permeable material such as the aforementioned wood veneer or paper.

In addition, when the bottom surface of the backing plate 7 used for hot-pressing the surface of the thermoplastic synthetic resin film 6 is smooth, the surface of the synthetic resin film and the bottom surface of the backing plate are completely in close contact with each other, and there is no space between them. Although it is difficult to generate the desired air pressure, since the method of the present invention uses the contact plate 7 whose lower surface is formed with the uneven rough surface 7a as described above, the gap between the uneven rough surface 7a and the surface of the synthetic resin film is This air is heated and expanded, and the synthetic resin film 6 softened by the air pressure is pressed and adhered to the bottom surface of the concave groove of the decorative layer 2 on the lower surface side. It's something you get.

Next, specific examples of the present invention will be shown.

Example: 200mm outer circumference on the surface of Capole's 3-ply plywood
After engraving a concave brick joint pattern using a metal embossing roll heated to ℃, a 50μ thick transparent PVC film with a teak wood grain pattern printed on the back side was attached to the printed side with urethane adhesive. 30
g/m ² and placed on the surface of the Capol plywood. Next, a duralumin board whose lower surface had a rough textured surface was placed on the surface of the PVC film, and these were placed in a hot press. It was inserted between hot plates and heated and pressed under the conditions of 120°C, 10Kg/cm ² , and 5 minutes.

As a result, the PVC film, which had softened and expanded due to heating, entered the inside of the conduit groove and the brick joint-like concave pattern on the surface of the Kapor plywood, and the PVC The film was adhered to the surface of the front veneer of plywood by completely adhering to the conduit grooves and the inner bottom surface of the concave pattern, thereby obtaining a decorative board having a brick-like appearance and a natural conduit pattern with a teak pattern.

As described above, the present invention provides a suitable decorative layer having air permeability on the surface of a substrate, and then imprints a tile joint shape or other suitable concave pattern on the surface of the decorative layer using an embossing roll or an embossing plate, and then A transparent thermoplastic synthetic resin film with an appropriate printed pattern on the surface of the decorative layer is placed on the back side of the film by applying an adhesive that becomes transparent after curing, and then the thermoplastic synthetic resin film is coated with an adhesive that becomes transparent after curing. By placing a backing plate made of a metal plate or the like with a finely uneven rough surface and applying heat pressure, the film is softened, and the air pressure of the heated air between the film and the lower surface of the backing plate causes the film to be bonded to the surface of the decorative layer. The method for producing an embossed decorative board is characterized in that the thermoplastic synthetic resin film placed on the decorative layer on the surface of the substrate and the recesses in the decorative layer are bonded to the surface of the decorative layer. The air existing between the patterns is smoothly removed from the breathable decorative layer by the air pressure on the surface side of the film when the film is heated and cured, thereby ensuring that the lower surface of the film also covers the inner bottom surface of the concave pattern of the decorative layer. Furthermore, if a wood veneer or the like is used as the surface decorative layer, the natural concave patterns such as conduit grooves and the artificial concave patterns created with embossing rolls, etc. can be reproduced on the film surface. At the same time, it is possible to obtain a beautiful decorative surface in which these concave patterns and the printed pattern of the thermoplastic synthetic resin film harmonize, and since the synthetic resin film is transparent, the printed pattern and the surface of the decorative layer can be The embossed decorative board can be easily and accurately matched with the concave pattern of the embossed board, and an embossed decorative board can be manufactured at low cost and efficiently.

Also, during hot pressing, using a backing plate whose lower surface has a rough surface with minute irregularities, the film is pressed into the concave pattern of the decorative layer using the air pressure of the heated air between the lower surface of the plate and the surface of the film. Since the film is pressed into the inner bottom surface of the concave pattern, it can completely adhere to the inner bottom surface of the concave pattern, creating a decorative surface with a rich three-dimensional effect.Moreover, the uneven rough surface of the above-mentioned backing plate also serves as a matte surface of the film. It is possible to form a decorative surface with a heavy feeling and less shine.

[Brief explanation of the drawing]

The drawings show an embodiment of the method of the present invention.
The figure is a diagram of the manufacturing process, Figure 2 is a sectional view of the decorative laminate heated by the plate, Figure 3 is a partially enlarged sectional view of the decorative laminate, and Figure 4 is a perspective view of the obtained decorative laminate. be. DESCRIPTION OF SYMBOLS 1... Substrate, 2... Decorative layer, 3... Emboss roll, 4... Concave groove, 6... Thermoplastic synthetic resin film, 6a... Print pattern, 7... Backing plate, 7a...
Uneven rough surface.

Claims (1)

[Scope of Claims] 1. After providing a suitable decorative layer with air permeability on the surface of the substrate, a tile joint shape or other suitable concave pattern is imprinted on the surface of the decorative layer using an embossing roll or an embossing plate, and then the decorative layer is A transparent thermoplastic synthetic resin film with an appropriate printed pattern on the surface of the layer is coated with an adhesive that becomes transparent after curing on the back side, and then placed on the surface of the thermoplastic synthetic resin film. The film is softened by heat-pressing a backing plate having an uneven rough surface, and the film is brought into close contact with the inner surface of the concave pattern on the surface of the decorative layer by the air pressure of the heated air between the film and the lower surface of the backing plate. A method for manufacturing an embossed decorative board, which is characterized in that the embossed decorative board is pasted by being pressed until it is . 2. The method for manufacturing an embossed decorative board according to claim 1, wherein the decorative layer is a wood veneer. 3. The method for producing an embossed decorative board according to claim 1, wherein the decorative layer is a decorative paper.