JPH0226858B2 - - Google Patents

Description

[Detailed description of the invention] The present invention is applied to paper pasting used for floorboards etc.
The present invention further relates to a method of manufacturing a decorative board with a raised pattern formed thereon.

Conventional methods for manufacturing this type of base plate for decorative laminates are as follows.

Method: A method that involves the steps of forming plywood → pasting paper → undercoating → printing → topcoating.

Method: Forming plywood → pasting paper → sanding sealer →
A method that involves the process of grinding and then applying paint to the entire surface.

By the way, in this method, the paper surface is porous because the adhesive is not sufficiently permeated into the paper. For this reason, paper peeling is likely to occur, and uneven paint suction occurs due to gaps between fibers or differences in density, resulting in uneven concealment. Also,
Pinholes occur in the paint film due to bubbling during paint application. Furthermore, there is a drawback that the surface fibers become fluffy due to the absorption of paint, making the printed pattern unclear and giving only a blurry appearance. Next, in the method (2), a sanding sealer is applied to strengthen the paper quality and suppress fuzz, and then the paper is ground, so that the paper surface is almost smooth. but,
Since only low heat is applied when pasting the paper, the adhesive does not fully penetrate into the paper. Therefore, fine fuzz still remains on the paper surface. As a result, even if paint is applied uniformly and printing is performed, the pattern becomes unclear. In order to prevent such fuzzing, it may be possible to treat the paper surface with a sealer, but it is difficult to uniformly impregnate the entire paper with the sealer, and peeling occurs frequently.

What is common to methods a and b is that in both methods, papering is carried out as a separate process after the plywood is manufactured, so the penetration of the adhesive into the plywood is shallow. Furthermore, a separate area must be provided for the paper pasting process, which makes the process complicated.

In order to solve these drawbacks of the prior art, the present invention simultaneously adheres paper during hot pressing.
The idea is to make use of the high temperature of the hot press to allow the adhesive to sufficiently penetrate into the paper, and to remove the areas that do not penetrate, thereby strengthening the paper and eliminating uneven coating.

(Description of Examples) Examples of the method of the present invention illustrated in the drawings will be described below.

(1) A thin paper 3 is adhered to the surface of the veneer 1 that is to become the front veneer via an adhesive 2 to form a paper-attached front veneer 4.

The adhesive is a thermosetting adhesive such as urea resin, melamine resin, phenolic resin, vinyl acetate resin, or vinyl acetate-ethylene resin, which is generally used for manufacturing plywood or pasting paper.

Thin paper is 30 to 150 g/ ^m2 , rayon paper,
Manila paper, synthetic paper, parchment paper, waraf paper, non-woven fabric, etc. are used.

(2) Next, paper pasted front veneer 4, middle veneer 5, back veneer 6
is deposited, the deposited body is cold-pressed, the adhesive is impregnated into the veneers and the thin paper, and temporary bonding is performed to form a laminate of the veneers 4, 5, and 6.

The amount of adhesive to be applied is appropriately determined depending on the type and viscosity of the adhesive, as well as the type and thickness of the thin paper. The adhesive used here is one commonly used in plywood production, such as urea resin, melamine resin, and phenol resin.

The front veneer and the veneer may be laminated in either an even number or an odd number, and the fiber directions of the veneers may be parallel or orthogonal.

(3) Next, the temporarily bonded laminate is simultaneously hot-press molded according to the plywood manufacturing conditions. In this way, a paper-laminated plywood board 7 having the thin paper 3 adhered to its surface is obtained.

(The thin paper and multiple veneers may be laminated with an adhesive so that the thin paper is on the top surface, followed by cold press temporary adhesion and then hot pressure molding to form plywood.) The resulting paper-laminated plywood In 7, the adhesive 2 sufficiently penetrates into the veneer 1 or the thin paper 3 and is cured, so that the veneer 1 and the thin paper 3 are firmly bonded.

(4) Next, the surface of the paper-bound plywood 7 is ground with a grinder 8 to remove the surface paper that is not impregnated with the adhesive 2 in the thin paper 3 portion. In this way, a decorative board base plate Q whose surface is pasted with paper is formed.
This baseboard is paper-pasted at the same time as the plywood is manufactured, so the process does not become complicated. In addition, after cold press temporary adhesion, thin paper pasting is performed by hot pressure molding, and the adhesive sufficiently penetrates into the veneer or thin paper, hardening the adhesive, and improving adhesive strength.

Furthermore, in order to remove the surface paper that is not impregnated with the adhesive 2 of the thin paper 3 as described above,
The surface is smoothed, and the reinforced part impregnated and hardened with the adhesive 2 appears on the surface, improving the surface strength.

Furthermore, since the paper material is removed by grinding down to the reinforced portion where the adhesive 2 has been impregnated and hardened, there is no occurrence of fuzzing due to grinding, and there is no occurrence of paper peeling in the thin paper left on the surface.

(5) Next, a urethane sealer is applied and impregnated onto the surface of the decorative board base plate Q to form a sealer coating layer 9.

(6) Next, an acrylic urethane resin paint is applied and dried on the sealer coating layer 9, and a base coating 10 is applied. A pattern 11 is printed on this by appropriate printing such as gravure printing, offset printing, or gravure offset printing.

(7) Next, using a recessed roll G on which a patterned pattern recess g is engraved in synchronization with or not in synchronization with the patterned pattern 11 on the surface on which the patterned pattern 11 is formed,
(Fig. 3) After filling the patterned concave portion g of the intaglio roll G with a transparent urethane resin or transparent acrylic resin paint and pressing to transfer the paint in the concave portion g, a transparent raised pattern 12 is formed. ,
Dry immediately.

It should be noted that if the patterned concave portions g are arbitrarily provided with different depths, the raised patterns 12 will also be formed with different heights as shown in FIG.

(8) Next, a transparent urethane resin or melamine resin paint mixed with a fine powder abrasive 14 is applied to the entire surface including the raised pattern 12 and dried to form a top coat 13. Fine powder abrasive material 14
Examples include gold steel sand with a particle size of 10μ or less, silica stone, garnet, aluminum oxide, aluminum hydroxide, silicon carbide, and hardened thermosetting resin powder such as epoxy resin, melamine resin, and polyethylene resin. These can be used alone or in an appropriate mixture of two or more. The amount added is 10 to 60% by weight based on the resin solid content of the top coat. Since the raised pattern 12 is formed on the surface, the top coat paint is formed thinly on the raised pattern 12 due to its fluidity, and thickly in the recesses other than the raised pattern.

When the particle size 1 of the fine powder abrasive material 14 is 0 μ or more, the abrasive material 14 is exposed to the surface of the top coating film 13 on the raised pattern 12, and the surface coating surface becomes rough or matte. Decrease in design quality.

In this way, the desired decorative board is completed by the method of the present invention.

(Effects of the present invention) Thin paper 3 is applied to the surface of plywood at the same time when the plywood is manufactured.
Since complete adhesion is achieved, paper pasting is easy and the adhesive strength between the thin paper 3 and the veneer 1 is also improved.

Since the surface of the thin paper 3 is ground to remove the paper part that is not impregnated and hardened with the adhesive 2, the surface is smoothed, and the paper quality impregnated and hardened with the adhesive 2 appears on the surface, improving the surface strength. Moreover, peeling of paper does not occur.

Since the sealer coating 9 is applied to the surface of the thin paper 3, even if the adhesive 2 penetrates unevenly, the thin paper 3 is uniformly strengthened and no peeling occurs. Furthermore, the sealer coating 9 suppresses fuzzing on the surface of the thin paper 3, allowing good adhesion of the base coating 10 and allowing beautiful printing of the pattern 11.

By forming the raised pattern 12, the underlying pattern 11 can be seen through, and due to the lens effect, the pattern 11 can be seen floating, giving a rich three-dimensional effect.

By providing the recesses g of the intaglio roll G with different depths, the raised patterns 12 are formed with different heights, which further enhances the three-dimensional effect.

Top coat 1 on the entire surface including the raised pattern 12
3 and mixed with the finely powdered unpolished material 14, the raised pattern 12 and pattern pattern 11 are sufficiently protected.

[Brief explanation of drawings]

Figure 1 a, b, c: Process diagram of the method of the present invention, 2nd
Figure: Cross-sectional view of the decorative board obtained by the method of the present invention, No. 3
Figure: Side view of intaglio roll G, 1...Front veneer, 2...Adhesive, 3...Thin paper, 4
...Paper-bound front veneer, 5...Middle veneer, 6...Back veneer, 7...Paper-bonded plywood, 8...Grinding machine, 9...Sealer coating layer, 10...Base coating, 11... ... Pattern pattern, 12 ... Raised pattern, 13 ... Top coat film,
14... Fine powder abrasive material, Q... Base plate for decorative board.

Claims (1)

[Claims] 1. A thin paper 3 is laminated on the surface of the veneer 1 via an adhesive 2 to form a paper-bound top veneer 4, and the paper-bound top veneer 4 and a plurality of veneers 5, 6 are combined. The laminated paper-laminated top veneer 4 and the plurality of veneers 5 and 6 are then hot-press molded to form a paper-laminated plywood 7 according to the manufacturing conditions for general plywood. The thin paper 3 on the surface is ground to remove the surface paper that is not impregnated with the adhesive 2 to obtain a decorative base plate Q. Next, the thin paper 3 of the decorative base plate Q is penetrated and impregnated with a sealer 9. A base coating 10 is laminated on top, a pattern 11 is printed on it, and then a transparent raised pattern 12 is printed on the surface of the base coating 10, with or without synchronization with the pattern 11.
Next, a transparent top coat mixed with a finely powdered abrasive material 14 is formed on the entire surface including the raised pattern 12, and the raised pattern 12 is formed using an intaglio roll G in which patterned concave portions g are engraved. A method for producing a decorative board, characterized by: