JPH03231A - Decoration panel and manufacture thereof - Google Patents

Abstract

PURPOSE:To perform the simplification of processes and the rationalization of preparatory processes by laminating and integrating a thermosetting resin decoration board and cushioning material via an adhesive paper, and giving a curved surface work wherein recesses are made from the thermosetting resin decoration board to the cushioning material. CONSTITUTION:A diallylphthalate resin decoration board 2 and phenol resin foaming 4 being ten times in expansion ratio are laminated on a plate 5 via a diallylphthalate resin infiltrated adhesive paper which is infiltrated in a vinylon non-woven fabric. Next, a mold 6 made of aluminum is pressed thereon, and then, a whole part except the curved surfaces is integrated by means of a press or roll and the like, thereby manufacturing a decoration panel 1 having curved surfaces wherein the diallylphthalate resin decoration board 2 and phenol resin foaming 4 are laminated and integrated via the adhesive paper 3. Since the decoration panel is covered in its surface with a thermosetting resin decoration board which is excellent in wear resistance, anti-pollution, scratch hardness or the like, it has an excellent surface material and durability.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to decorative panels used as construction materials such as furniture, doors of system kitchens, wainscoting, wall coverings of houses, stores, offices, etc. [Prior Art] Conventionally, a decorative panel (hereinafter referred to as a decorative panel) in which a thermosetting resin decorative board is processed into a curved shape has a structure in which the heat is transmitted along a core material having a curved shape. It is known that the curable resin decorative laminate is postform-processed, or that the impregnated paper of the thermosetting resin decorative laminate is hot-press-molded or vacuum-formed in a curved mold.

[Purpose of the invention]

Conventionally, decorative panels with curved shapes obtained by post-form processing, vacuum press processing, etc. have been made using core materials such as plywood or verticle board processed into various shapes, molds and treatments of the same size as the desired product size. Tools and the like are required, and when making preparations for type change within the manufacturing process, there are problems such as it is time consuming and time consuming.゛Also, decorative materials such as thermosetting resins such as soft vinyl chloride resin, paper, and cloth conventionally used for wall decoration etc. have problems such as poor surface properties and easy staining and scratching. be.

The present invention was invented in view of the above-mentioned problems of the prior art, and provides a decorative panel that simplifies the setup process and has a curved surface with excellent surface properties, and a method for manufacturing the same. Our goal is to provide the following.

[Means to achieve the purpose]

In order to achieve the above object, the decorative panel of the present invention has a thermosetting resin decorative board with a thickness of 0.2 to 2.01 lII made of melamine resin, diallyl phthalate resin, polyester resin, etc., and urethane resin foam, polyethylene resin foam. Cushioning materials are made of synthetic resin foams such as body, phenolic resin foam, and wood materials such as valve materials, and are elastic bodies that do not have restoring force even when compressed, and epoxy resins, diallyl phthalate resins, and melamine resins. , nonwoven fabrics made of organic or inorganic materials such as cellulose, vinylon, polyester, and glass fibers impregnated with thermosetting resins such as unsaturated polyester resins, woven fabrics, and adhesive paper such as paper.

Next, a curved mold made of metal materials such as iron, aluminum, and brass, hard plastic materials such as melamine resin and phenolic resin, and hard wood materials with a specific gravity of 0.6 or more is used to form the thermosetting resin decorative board. After being embossed from above or after being embossed, the thermosetting resin decorative board and the cushioning material are integrated to obtain the curved decorative panel of the present invention. The pattern may cover the entire surface of the nuclear thermosetting resin decorative board, or it may cover only the portion where the curved surface is to be processed. The buffer material is preferably one with a high flame retardant effect, such as a phenol resin foam which can be used as a quasi-noncombustible material.

Further, the adhesive paper may be paper impregnated with an adhesive such as an epoxy resin adhesive, a urethane resin adhesive, or a synthetic rubber adhesive, or a nonwoven fabric or a woven fabric. The adhesive paper serves as an adhesive layer between the thermosetting resin decorative board and the cushioning material,
Because the adhesive layer is made of non-woven fabric, woven fabric, paper, etc. other than resin, it is less likely to break than when the adhesive is alone;
To prevent separation of the thermosetting resin decorative board and the cushioning material at the embossed portion.

〔Example〕

Examples will be described with reference to the drawings.

A and B in FIG. 2 show the manufacturing process of the decorative panel of the present invention shown in FIG. 1, and the decorative panel is manufactured as follows.

A 0.3fl thick diallyl phthalate resin decorative board (2) and a phenolic resin foam (4) with an expansion ratio of 10 times and a thickness of 8jIIIg were impregnated into a vinylon nonwoven fabric with a basis weight of 50g/- at an impregnation amount of 60% by weight. The adhesive paper (3) impregnated with diallylphthalate resin is laminated onto a flat plate (5).

Next, an aluminum gold hood (6) having a diameter of 5jEIIR was pressed at a temperature of 120° C. and a pressure of LO kg/d, and then rolled by a press or roll at a temperature of 130 a.
5ffR, in which the diallyl phthalate resin decorative board (2) and the phenolic resin foam (4) are laminated and integrated through the adhesive paper (3), by integrating the parts other than the curved surface under heat and pressure conditions of C1 pressure 3 kti 7 ci. A decorative panel (〃) of the present invention having a curved surface is manufactured.

The flat plate (5) is made of a wooden material such as particle board or plywood, or a metal material such as iron or aluminum. After pasting, pressing may be applied.

The expansion ratio of the phenolic resin foam (4) is 6 times to 1
It is preferable that the foaming ratio be around 5 times; if the foaming ratio is low, embossing will not be possible, and if it is high, dents may occur even with the pressure of pressing with a finger, or the foam may become brittle. Undesirable.

The core decorative panel (9 is a panel used as a decorative decorative panel by pasting it to the crosspiece (8) provided on the wall base material as shown in Figure 4, and the concave part pressed into a hole as shown in Figure 5) Part (7)
It is cut into pieces and used as doors for furniture, etc.

〔effect〕

Since the decorative panel of the present invention is manufactured as described above, there is no need to prepare various types of core materials processed into curved shapes as in postform processing, and it is not necessary to prepare various types of core materials processed into curved shapes as in postform processing, and it is not necessary to prepare core materials of various types that are processed into curved shapes as in postform processing. There is no need for a mold; a mold is sufficient for only the part where the curved surface is to be processed, and the thermosetting resin decorative board, adhesive paper, and cushioning material that make up the decorative panel are handled in sheet form. Because it is easy to use, it can be expected to simplify processes and rationalize multi-step setups.

As mentioned above, since the decorative panel is laminated and integrated with the cushioning material through the adhesive paper, the thermosetting resin decorative material on the surface remains intact even when stamped at an acute angle, compared to the case of adhesive alone. and the cushioning material will not peel off and the appearance will not be impaired.

In addition, the surface of the decorative panel is covered with a thermosetting resin decorative board that has excellent abrasion resistance, stain resistance, scratch hardness, etc., so it can be By using phenolic resin foam as a cushioning material, the decorative panel is not a flammable or quasi-nonflammable material. In combination with the advantageous properties of foam, such as heat insulation and sound insulation, it becomes more desirable as a building material.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional view of the structure of an embodiment of the decorative panel of the present invention, Fig. 2 is a state diagram showing the manufacturing process of the decorative panel of the present invention, and Fig. 3 is the process of integrating with embossing in another embodiment. FIG. 4 is a perspective view showing the decorative panel used as a wall decorative material, and FIG. 5 is a perspective view showing the decorative panel used as a door for furniture. 1... Decorative panel 2... Diaryl phthalate resin decorative board 3... Adhesive paper 4... Phenol resin foam 5... Flat plate 6... Mold 7... Concave portion 8... Patent applicant for crosspieces on wall base material Aikanigyo Co., Ltd.

Claims (1)

[Scope of Claims] 1. A thermosetting resin decorative board and a cushioning material are laminated together via adhesive paper, and a curved surface is recessed from the surface of the thermosetting resin decorative board into the cushioning material. A decorative panel characterized by being processed. 2. The decorative panel according to claim 1, wherein the cushioning material is a phenolic resin foam. 3. After laminating the thermosetting resin decorative board and the cushioning material via adhesive paper, press with a curved mold to form a curved surface, or after forming the curved surface, apply the heat A method for manufacturing a decorative panel, comprising integrating a curable resin decorative board and the cushioning material. 4. The method for manufacturing a decorative panel according to claim 3, wherein the cushioning material is a phenolic resin foam.