JPH02233245A - Preparation of laminated sheet having uneven surface and uneven laminated sheet using thin base layer - Google Patents

Abstract

PURPOSE:To relax the effect of unevenness on a base layer by a method wherein a stress dispersing layer is bonded to the surface of the thin-thick base layer and a sheet like decorative layer is subsequently bonded to the surface of the stress dispersing layer and a synthetic resin material is further applied to the surface of the decorative layer to form a surface coating layer which is, in turn, subjected to embossing pressure. CONSTITUTION:As the material of a base layer 4, a board material composed of gypsum or wood, plywood, a fiberboard, a metal plate or a synthetic resin plate is used and a material from a thin one of below 10mm to a thick one can be adapted. A stress dispersing layer 5 is composed of a material such as a fabric, a nonwoven fabric or kraft paper and has a slight compression flange in the thickness direction thereof. A decorative layer 6 is composed of a stretched sheet of a synthetic resin material, paper or cloth and a pattern or color is applied to the surface thereof. After the stress dispersing layer 5 and the decorative layer 6 are bonded to the base layer 4, a synthetic resin material 7 for forming a surface coating layer is spread to the surface of said decorative layer 6 in a uniform thickness after or before a used adhesive is dried and cured to form the surface coating layer. Next, a mold equipped with an embossing press surface is pressed to said surface coating layer and heated simultaneously.

Description

Detailed Description of the Invention Object of the Invention (Industrial Field of Application) The present invention provides a method for manufacturing a laminate with an uneven surface, and a method for manufacturing a laminate with a thin base layer among those obtained by this manufacturing method. The present invention relates to a concavo-convex laminate used in the present invention.

(Prior art) Fig. 5 is an enlarged schematic cross-sectional view of a conventional laminate plate with an uneven surface (hereinafter referred to as conventional laminate plate) published in Japanese Patent Publication No. 52-27686. It is. The conventional laminate is used to decorate the front panel or deck of furniture with a three-dimensional pattern to make it appear as if it has been carved, and the height of the unevenness on the outermost surface of the laminate is The difference was actually as large as 4 to 5 liters.

The cross-sectional structure of this conventional laminate consists of a sturdy substrate 1 having a thickness of 12 mm or more, a thin decorative laminate 2 made of a veneer or the like adhered to the surface 1a of the substrate 1, and a It consisted of a resin layer 3 provided on the entire surface and thickness of the substrate 1 as well as on the surface portion of the substrate 1 so as to be in a surface coating state or an impregnated state. Note that the decorative board 2 was unnecessary if the surface quality of the substrate 1 was satisfactory from the viewpoint of appearance.

By the way, the resin N3 was provided in such a way that a thermosetting resin and a thermoplastic resin were stacked in two layers. In other words, one thermosetting resin is conventionally located on the outermost side of a laminate, and has the function of maintaining an uneven shape and exhibiting moisture resistance after curing, while the other thermoplastic resin is , the surface portions of the decorative board 2 and the substrate 1 are protected from cracking, while making it easy to deform them into an uneven shape. As described above, since the resin layer 3 was formed of a thermosetting resin and a thermoplastic resin, when forming unevenness on the resin layer 3, it is necessary to It was heated at the same time as the embossing, and this embossing state was maintained for 2 to 3 minutes until the thermosetting resin hardened.

(Problems to be Solved by the Invention) In the conventional laminate, firstly, in forming the resin layer, the entire thickness of the decorative board 2 and the surface of the substrate 1 were impregnated with thermoplastic resin; Secondly, the substrate 1 was made thicker (121
1 or higher). Therefore, conventional laminates have generally been used for high-end furniture and furnishings, and have had poor versatility for other uses. This is because if conventional laminates are used for items other than luxury-oriented furniture, there is a risk that the proportion of conventional laminates in the manufacturing cost of the entire product will be too high. In this case, too, it was because the precision of the workmanship could not be balanced with the other parts. Furthermore, in conventional laminates, the thermoplastic resin had to be impregnated not only to the entire thickness of the decorative board 2 but also to a predetermined depth on the surface of the substrate 1. The heating that accompanied the pressing had to be maintained for as long as 2-3 minutes.

Naturally, during this heating period, various subsequent operations are delayed, so conventional laminates have been inferior in manufacturing efficiency.

The present invention has been made in view of the above-mentioned circumstances, and by not being limited to the use of thick substrates, and by not being limited to increasing the height difference of the unevenness, A new manufacturing method for laminates with uneven surfaces that expands its versatility and improves manufacturing efficiency (hereinafter referred to as
Among the laminates obtained by the method of the present invention, a new uneven laminate (hereinafter referred to as the method of the present invention) using a thin base layer (substantially corresponding to the substrate of conventional laminates) The purpose is to provide laminates (called laminates).

"Structure of the Invention" (Means for Solving the Problems) The gist of the method of the present invention is given by Aisaka. Fiberboard. Various board materials. A stress dispersion layer made of woven fabric, nonwoven fabric, kraft paper, etc. is attached to the surface of a thin to thick base layer such as solid wood, and an appropriate coating is applied to the surface of the stress dispersion layer prior to attachment of the stress dispersion layer. A sheet-like decorative layer is adhered, and a suitable synthetic resin material is further spread and coated on the surface of the decorative layer to form a surface coating layer, and then an uneven pressure surface is provided to the surface coating layer. The object of the present invention is to press a mold to reduce the effect of the unevenness formed on the surface coating layer by the uneven pressing surface of the mold from reaching the base layer beyond the stress dispersion layer.

The gist of the laminate of the present invention is that it includes a thin wooden base layer having a wall thickness of 101 m or less, and a woven or nonwoven fabric formed on the surface of the thin base layer. The surface coating consists of a stress dispersion layer made of kraft paper or the like, an appropriate decorative layer formed on the surface of the stress dispersion layer, and a surface coating layer made of a synthetic resin material formed on the surface of the cosmetic layer. layer. The decorative layer and the stress dispersion layer have irregularities extending up and down to the thin base layer.

(Function) The base layer used in the method of the present invention is intended to form the basis of a laminate, almost the same as the substrate of a conventional laminate.
The wall thickness ranges widely from thin to thick. The main reason why even a thin base layer can be used in the method of the present invention is the stress dispersion layer adhered to the surface of the base layer. In other words, the stress dispersion layer spreads the pressing force of the mold for giving the uneven shape over the entire surface of the base layer, and prevents the formation of cracks due to stress concentration in the decorative layer and the base layer. It is. Furthermore, due to this, in the method of the present invention, whether or not the surface coating layer made of a synthetic resin material formed on the surface of the decorative layer is impregnated into the decorative layer or the base layer is not given much importance. Become.

Therefore, in the method of the present invention, the embossing and simultaneous heating for imparting the uneven shape can be maintained for only an extremely short period of time. If the method of the present invention is carried out, even if the base layer has a thickness of 101 or less, it can be used without any problems. In other words, in the case of the laminate of the present invention in which the wall thickness of the base layer is limited to 1 (hm or less), the overall wall thickness can also be made thinner, so that the use is limited to luxury-oriented furniture and furnishings. There will be no more problems.

(Examples) Hereinafter, the present invention will be described based on drawings showing examples thereof.

FIG. 1 is a schematic diagram showing an exploded view of the main steps in the method of the present invention. The method of the present invention includes a base layer 4, a stress dispersion N5
．． The decorative layer 6 and the surface coating layer (depicted as a synthetic resin material 7 before being spread into a layer) are laminated in this order so as to overlap each other, and then embossed to give an uneven shape ( (not shown).

The base layer 4 serves to form the basis of the laminate, and roughly corresponds to the substrate 1 in a conventional laminate (see FIG. 5). However, the material of the base layer 4 used in the method of the present invention includes board materials such as gypsum board, particle board, and wooden board, as well as plywood,
11 Fiberboard, solid wood, metal plate, synthetic resin plate. Any material may be used as long as it has a smooth surface (it does not need to be flat), such as a synthetic board made of paper or cloth. Further, although not shown in the drawings, a so-called flash material, such as a frame formed by the outline of a plate-like material and plywood or the like adhered to the front and back surfaces thereof, may be used as the base N4. Therefore, the base layer 4 can be as thin as less than 10n+ to as thick as (no limitations).
It is applicable over a wide range of areas.

The stress dispersion layer 5 is made of woven fabric. It is made of non-woven fabric, kraft paper, etc., and has a slight compression allowance in the thickness direction.

The decorative layer 6 is a sheet made of a synthetic resin material such as vinyl chloride resin. It is a sheet-like material made of paper, cloth, etc., and a desired pattern or color is printed on the surface of the sheet. Further, as the decorative layer 6, a veneer or the like may be used as in the case of conventional laminates.

The stress dispersion layer 5 is attached to the surface of the base layer 4, and the decorative layer 6 is attached to the surface of the stress dispersion layer 5. As the adhesive used for these attachments, it is preferable to use diallyl phthalate resin (generally called dasop resin), polyester resin, phenol resin, and the like. The adhesive may penetrate into each layer by adhering the base layer 4 and the stress dispersion layer 5 and the stress dispersion layer 5 and the decorative layer 6, but the degree of penetration is twofold. This is kept to the minimum necessary for adhesion of parts, and in terms of penetration depth and amount, it is by no means comparable to "impregnation" as explained in the conventional laminate. Of course,
The method of the present invention is not intended to provide the same effect as that obtained by such "impregnation."

The surface coating layer is made of a suitable synthetic resin material 7 and the decorative layer 6.
It is made by spreading and coating on the surface of.

The synthetic resin material 7 to be used may be thermosetting or thermoplastic; for example, polyester. Melamine type. Acrylic and urethane adhesives, diallyl phthalate resins used as the adhesive, and the like may be used alone or in combination.

In this example, the base layer 4 is made of veneer plywood with a thickness of about 2.5 * A thermosetting diallyl phthalate resin was used as the synthetic resin material 7 for forming the surface coating viiN. And stress distribution 1' for the base layer 4! 5 and the decorative layer 6, a synthetic resin material 7 for forming a surface coating layer is applied on the surface of the decorative layer 6, with or without waiting for the adhesive used to dry and harden. Apply in nodules. Next, as shown by the white arrow in FIG. 2, a resin spreader 8 is pressed down from above the synthetic resin material 7 applied on the surface of the decorative layer 6.

The resin spreader 8 has a thin film 9 made of polyvinyl alcohol fiber (trade name: Vinylon) stretched over an iron frame 10 without wrinkles. Then, the roller 11 is placed on the film 9 of the resin spreader 8.
By handling the synthetic resin material 7 using, for example,
is spread over the decorative layer 6 to a uniform thickness to form a surface coating layer. Note that when the resin spreader 8 as described above is not used, the synthetic resin material 7 for forming the surface coating layer is applied to the decorative layer 6.
curtain or spray using a flow coater
It is sufficient to apply the coating to a uniform thickness from the beginning by rolling it.

Next, although not shown, a mold having an uneven pressure surface is pressed against the surface coating layer and heated at the same time.

The pressing and heating conditions with the mold are as follows: When the difference in height of the unevenness formed on the uneven pressure surface is 0.4 mm, the press pressure is 50k.
g/cJ, the heating was maintained for about 1 minute at the same time as the pressing, and the heating temperature was about 60°C. Note that in the synthetic resin +47 for forming the surface ri layer, if an exothermic reaction occurs due to the synthesis and use of a plurality of resin materials, there is no need to take the trouble to heat the mold. FIG. 3 is a diagram schematically showing the thus obtained laminate on the same scale as FIG. 5. In this embodiment, the surface coating layer 12
Among the unevenness provided on the surface of
- It is made to look like a square tile, and the recesses are made to form joints between each of the tiles. Therefore, if the laminate according to this embodiment is used to finish the interior wall of a bathroom or the wall around xotin, it becomes possible to express the surface to which tiles are attached very easily. Therefore, the operational and cost benefits obtained are immeasurable.

(Study of Alternative Embodiments) The specific material names and numerical values listed in the above examples are examples for manufacturing the laminate of the present invention (thickness of the base layer 4). Therefore, it goes without saying that it can be changed as appropriate when making the base layer 4 thicker.

Furthermore, in the method of the present invention, by increasing the thickness of the base layer 4 and the stress dispersion layer 5, it is possible to form irregularities with large height differences, similar to the conventional laminate (see FIG. 5). For example, if the method of the present invention is carried out using a mold 13 having a wavy uneven pressure surface 13a as shown in FIG. A deep groove is formed. Therefore, when used on luxury-oriented furniture, the front panel and deck can be made to look as if they are carved. As described above, the detailed structure of the method of the present invention and the shape and structure of the laminate of the present invention can be changed as appropriate depending on the embodiment.

"Effects of the Invention" As is clear from the above explanation, the method for manufacturing a laminate with an uneven surface according to the present invention can be applied to a wide range of base layer thicknesses, from thin to thick. Furthermore, it has become possible to form irregularities on the outermost surface side as desired, from large to small differences in height. Therefore,
The versatility of the resulting laminate is infinitely expanded. In addition, the synthetic resin material used to form the surface coating layer does not need to be impregnated into the decorative layer or base layer, so the conventional mold maintenance time required for this is no longer required, and the amount of synthetic resin material used is reduced. can also be reduced. Therefore, manufacturing efficiency can be increased and manufacturing costs can be reduced. On the other hand, according to the uneven laminate using a thin base layer according to the present invention,
Not only can the overall wall thickness be made thinner, but the unevenness provided on the outermost surface side can also be made to have small undulations, so it can be used for furniture and other items other than those with a high-end orientation. Even when used, there is no risk of causing discomfort due to the delicate proportions of the workmanship. Therefore, it has many excellent advantages, such as being able to be effectively used as unit furniture that is relatively popular among the common people and as a wall panel with a large area.

[Brief explanation of the drawing]

FIG. 1 is an exploded schematic diagram showing the main steps of the method of the present invention, FIG. 2 is an exploded perspective view showing the formation of a surface coating layer in the method of the present invention, and FIG. 3 is an example of the laminate of the present invention. FIG. 4 is a side view showing a mold having a wavy uneven pressure surface, and FIG. 5 is an enlarged sectional view schematically showing a conventional laminate. 4... Base layer 5... Stress dispersion layer 6...
Decorative layer l2...Surface coating rM layer 7...Synthetic resin material 13 for surface coating layer formation...Mold 1
3a... Wavy uneven pressure surface patent applicant Hayashi
Judo Hide Masatariyo Fujikawa Patent Attorney Toshihiko Uchida

Claims (1)

[Claims] 1. A stress dispersion layer made of woven fabric, nonwoven fabric, kraft paper, etc. is adhered to the surface of a thin to thick base layer such as plywood, fiberboard, various board materials, solid wood, etc., and the stress dispersion layer is applied. Prior to adhering the layers, an appropriate sheet-like decorative layer is adhered to the surface of the stress dispersion layer, and an appropriate synthetic resin material is further spread and coated on the surface of the decorative layer to form a surface coating layer. Thereafter, a mold having an uneven pressure surface is pressed against the surface coating layer, and the influence of the unevenness formed on the surface coating layer by the uneven pressure surface of the mold is applied to the base layer over the stress dispersion layer. A method for producing a laminate with an uneven surface, characterized by reducing the amount of damage to the surface of the laminate. 2. A thin wooden base layer with a wall thickness of 10 mm or less, a stress dispersion layer made of woven fabric, nonwoven fabric, kraft paper, etc. formed on the surface of the thin base layer, and a stress dispersion layer formed on the surface of the stress dispersion layer. Consisting of an appropriate decorative layer and a surface coating layer made of a synthetic resin material formed on the surface of the decorative layer, the surface coating layer,
1. A textured laminate using a thin base layer, characterized in that the decorative layer and the stress dispersion layer are formed with unevenness extending up and down to the thin base layer.