JPH0432183B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field] The present invention relates to a decorative board used as a decorative material for interior building materials, and a method for manufacturing the same. The decorative laminate of the present invention is made by pasting a resin-impregnated nonwoven fabric sheet on the surface of the artificial decorative veneer through which the surface pattern of the veneer can be seen, and does not have a base material on the back side of the artificial decorative veneer. (resin-impregnated nonwoven fabric sheet pasted decorative veneer) or has a base material.

[Background technology]

Artificial decorative veneers are usually made as follows. That is, the veneers obtained by rotary slicing are degreased, bleached, and dyed, and the resulting dyed veneers are laminated via adhesive, pressure molded to obtain a composite frit, and this is sliced. I am gaining from this. After this, the surface is usually coated with resin and finished with paint to create a sense of transparency and depth.

However, although such artificially decorated veneers can achieve a sense of transparency and depth by coating with resin, they have the drawback of being extremely thin and having poor strength and brittleness. For this reason, the decorative veneer obtained from such a decorative veneer has the disadvantage that it is easily damaged during construction or use.

[Purpose of the invention]

This invention was made in view of the above circumstances, and an object thereof is to improve the strength of a veneer without reducing the transparency and depth of the veneer surface.

[Disclosure of the invention]

The inventors have made extensive studies to achieve the above object. As a result, this invention was completed.

This invention provides a decorative veneer in which a resin-impregnated nonwoven fabric sheet through which the surface pattern of the veneer can be seen is adhered to the surface of the artificial decorative veneer, which may have a base material on the back side.

The present invention also provides a method for manufacturing a decorative laminate, characterized in that, in obtaining the decorative laminate, a transparent resin-impregnated nonwoven fabric sheet made by impregnating a nonwoven fabric with a resin is adhered to the surface of the artificial decorative veneer.

This invention also provides a resin-impregnated nonwoven fabric sheet that allows the surface pattern of the veneer to be seen through the surface of the artificial decorative veneer as a decorative veneer, when a base material is attached to the back side of the decorative veneer to obtain a decorative veneer. To provide a method for manufacturing a decorative board, characterized in that a decorative board is used.

This invention furthermore provides that when a decorative veneer is obtained by pasting a base material on the back side of a decorative veneer, an artificial decorative veneer is layered on the surface of the base material via an adhesive, and the same artificial decorative veneer is placed on top of the artificial decorative veneer. To provide a method for producing a decorative board, which is characterized by placing a resin-impregnated nonwoven fabric sheet with a transparent surface pattern and bonding it under heat.

These will be explained in detail below.

The decorative board according to this invention strengthens the artificial decorative veneer without reducing the transparency and depth.
It is characterized in that a resin-impregnated nonwoven fabric sheet is adhered to the surface of the artificial decorative veneer.

FIG. 1 shows a case where the decorative laminate according to the present invention is a decorative veneer pasted with a resin-impregnated nonwoven fabric sheet, that is, an artificial decorative veneer that does not have a base material on the back side.
It is a perspective view showing an example. In the resin-impregnated nonwoven fabric sheet-attached decorative veneer 1 shown in FIG. 1, a resin-impregnated nonwoven fabric sheet 2 is adhered to the surface of an artificial decorative veneer 3 obtained by a known method. Although the resin-impregnated nonwoven fabric sheet 2 appears opaque in the figure, it is actually highly transparent, and the surface pattern (wood grain) of the artificial decorative veneer 3 can be seen through it. Therefore, it is possible to create a sense of transparency and depth. In order to enhance this effect, it is preferable that the resin has a refractive index similar to that of the nonwoven fabric material. Note that the resin here includes transparent resins such as polyester resins,
Diaryl phthalate resin, polyurethane resin, etc. are preferably used. In addition, the nonwoven fabric referred to here is a fiber whose nonwoven material is a resin with low heat resistance (preferably a fiber whose ingredient is a resin that melts at a certain temperature or higher), such as rayon. Regenerated fibers, polyvinyl alcohol fibers, polyester fibers, etc. are preferably used.

The present invention is also a method for manufacturing such a decorative veneer with a resin-impregnated nonwoven fabric sheet, and is characterized in that the resin-impregnated nonwoven fabric sheet is adhered to the surface of the artificial decorative veneer by thermocompression bonding or the like. FIG. 2 is a perspective view showing the nonwoven fabric sheet used in this invention;
FIG. 3 is a perspective view showing a resin-impregnated nonwoven fabric sheet. The decorative veneer 1 covered with a resin-impregnated nonwoven fabric sheet shown in FIG. 1 is produced as follows. That is, the nonwoven fabric sheet 4 shown in FIG. 2 is impregnated with the resin as described above and dried to a semi-cured state (B stage). Note that the impregnation in this case may be performed by dipping or coating, but in order to uniformly mix the resin and the nonwoven fabric, dipping is preferable. As a result, as shown in FIG. 3, a resin-impregnated nonwoven fabric sheet 2 in which the nonwoven fabric 4 is impregnated with the resin 5 is obtained.

FIG. 4 is a perspective view showing an artificial decorative veneer used in the present invention. Artificial decorative veneer 3 shown in the figure
is created as follows. Multiple pieces of dyed veneer are laminated with adhesive and pressed together using an appropriate mold, such as one with a flat mold surface or a mold with irregularities, to create a laminated structure with no irregularities or curves. Obtain a composite flitch with uniform concavity and convexity variations. This assembled fritsch is sliced thinly at a desired angle to reveal the grain or straight grain to obtain an artificial decorative veneer. When the resin-impregnated non-woven fabric sheet 2 shown in FIG. 3 is placed on this artificial decorative veneer 3 and thermocompression bonded, the resin-impregnated non-woven fabric sheet pasted decorative veneer 1 shown in FIG. 1 is obtained. . The resin-impregnated nonwoven fabric sheet-attached decorative veneer is reinforced by the resin-impregnated nonwoven fabric sheet attached to it, and its strength is improved.

As mentioned above, in this artificially decorated veneer, it is preferable that the refractive index of the nonwoven fabric material and the resin used are similar. In this case, even if the resin flows through heat and pressure and mixes with the melted nonwoven fabric, the refractive index is similar, so the surface permeability of the decorative veneer pasted with the resin-impregnated nonwoven fabric sheet ( Transparency) does not decrease. Furthermore, if the refractive indexes are similar, even if the fibers are not melted, the flowing resin will permeate into the fibers and between the fibers, and similar results can be obtained.

Good compatibility between the nonwoven fabric material and the resin is also one of the preferable conditions.

When the above conditions are satisfied, when a resin-impregnated nonwoven fabric sheet is thermocompression bonded to a decorative veneer, the transparency and depth of the surface of the veneer can be further improved. Therefore, it is best to choose a combination of the same type of resin and nonwoven fabric as much as possible, based on the refractive index and
Preferable from the viewpoint of compatibility.

Next, when the decorative laminate according to the present invention has a base material on the back side of the artificial decorative veneer, the resin-impregnated nonwoven fabric sheet obtained as described above is adhered to the surface of the base material. That is.

FIG. 5 is a side sectional view showing one embodiment of the decorative laminate according to the present invention having a base material on the back side of the artificial decorative veneer. This decorative board 6 has a resin-impregnated nonwoven fabric sheet pasted decorative veneer 1 adhered to the surface of a base material (base plate) 7 via an adhesive 8. Therefore, the surface of the decorative board 6 has a transparent appearance and is reinforced by the resin-impregnated nonwoven fabric sheet, resulting in improved strength.

The present invention is also a manufacturing method for obtaining such a decorative laminate, and is characterized in that a resin-impregnated nonwoven fabric sheet-attached decorative veneer is adhered to the surface of a base material via an adhesive. That is, in the manufacturing method of the present invention, the resin-impregnated nonwoven fabric sheet-covered decorative veneer obtained according to the present invention is thermocompression bonded to the surface of the base material via an adhesive such as urea/vinyl acetate. In this case, the adhesive may be applied to either the surface of the base material or the back of the decorative veneer pasted with a resin-impregnated nonwoven fabric sheet. Although there is no particular limitation, considering ease of workability, it is usually not used in the production of artificial decorative laminates. Preferably, it is applied to the surface of the substrate, as is practiced.

The present invention also provides another manufacturing method for obtaining a decorative board, in which an artificial decorative veneer is placed on a base material, and a resin-impregnated nonwoven fabric sheet is further placed on top of the artificial decorative veneer.
It is characterized by being heat-pressed at the same time. That is, in this invention, a resin-impregnated nonwoven fabric sheet, a decorative veneer, and a base material (base plate) are prepared, the decorative veneer is first laid on the surface of the base material via an adhesive, and the resin-impregnated nonwoven fabric sheet is placed on top of the decorative veneer. Then, heat and press the parts together.
In this invention, the resin-impregnated nonwoven fabric sheet, the decorative veneer, and the base material (base plate) are bonded together by thermocompression, so the process of making the decorative veneer pasted with the resin-impregnated nonwoven fabric sheet can be omitted, and the process can be made quickly. but,
Depending on the base material (base plate) used, there may be a tunnel (cavity).
It becomes difficult to apply pressure evenly during thermocompression bonding. In such a case, it is preferable to use the second manufacturing method according to the present invention, that is, the method of attaching a decorative veneer with a resin-impregnated nonwoven fabric sheet to the surface of the base material via an adhesive.

After making the decorative board, if necessary, in order to reduce the monotony of the decorative board surface, sanding, etc. is performed, and then coloring is done with urethane flats mixed with stain (coloring agent) to give it depth. You can also create a decorative finish.

Examples will be described below.

Example 1 A nonwoven fabric made of polyvinyl alcohol fibers was impregnated with diallyl phthalate resin, and the resulting resin-impregnated nonwoven fabric sheet was wound up in a semi-cured state (B stage). Next, the resin-impregnated nonwoven fabric sheet was placed on the surface of the thinly sliced artificial decorative veneer, and thermocompression bonded at a temperature of 140 to 150°C for 10 minutes and a pressure of 10 kg/cm ² to paste the resin-impregnated nonwoven fabric sheet. I got a decorative veneer. The resulting decorative veneer with a resin-impregnated nonwoven fabric sheet had improved strength and excellent surface transparency.

Example 2 A 100 μm thick nonwoven fabric made of polyester fibers was impregnated with a polyester resin to form a resin-impregnated nonwoven fabric sheet in a semi-cured state (B stage). The resin-impregnated nonwoven fabric sheet was placed on the surface of a separately prepared artificial decorative veneer with a rosewood grain pattern, and thermocompression bonded at a temperature of 100°C for 5 minutes and a pressure of 7 kg/cm ² to infuse the resin. A decorative veneer with a non-woven sheet pasted was obtained. Next, the decorative veneer with the resin-impregnated non-woven fabric sheet was placed on the plywood coated with urea/vinyl acetate resin adhesive, with the resin-impregnated non-woven fabric sheet facing up, at a temperature of 110°C for 3 minutes. ，
A decorative board was obtained by thermocompression bonding at a pressure of 10 kg/cm ² .
After lightly sanding the surface, it was colored with urethane flat mixed with a brown colorant. The obtained decorative board had a deep coating and no uneven color.

Example 3 A nonwoven fabric having a thickness of 80 μm made of polyester fibers was impregnated with a polyester resin to form a resin-impregnated nonwoven fabric sheet in a semi-cured state (B stage). The resin-impregnated nonwoven fabric sheet is placed on the surface of a separately prepared artificial decorative veneer with a cherries pattern,
A decorative veneer with a resin-impregnated nonwoven fabric sheet was obtained by thermocompression bonding at a temperature of 110° C. for 4 minutes and a pressure of 10 kg/cm ² . Next, the decorative veneer with the resin-impregnated non-woven fabric sheet was placed on the plywood coated with the urea/vinyl acetate resin adhesive, with the resin-impregnated non-woven fabric sheet facing up, and the temperature was 110°C for 3 minutes. pressure 10
A decorative board was obtained by thermocompression bonding under conditions of Kg/cm ² . After lightly sanding the surface, it was colored with urethane flat mixed with an orange colorant. The obtained decorative board had a deep coating and no uneven color.

Experimental Example 4 In the same manner as in Example 2, three materials were prepared: a polyester fiber nonwoven fabric sheet impregnated with a polyester resin, an artificial decorative veneer having a rosewood grain pattern, and plywood. First, after applying a urea/vinyl acetate resin adhesive onto the plywood, the artificial decorative veneer was placed, and the resin-impregnated nonwoven fabric sheet was placed on top of it, and the temperature was 110°C for 5 minutes and pressure was applied. A decorative board was obtained by thermo-compression bonding by three people at the same time under the condition of 10 kg/cm ² . The obtained decorative board had excellent transparency and depth.

〔Effect of the invention〕

The decorative board according to the present invention has a resin-impregnated nonwoven fabric sheet that allows the surface pattern of the veneer to be seen through attached to the surface of the artificial decorative veneer, which does not have a base material on the back side, so the surface has a sense of transparency and depth. It has excellent properties and has improved strength. Therefore, there is no fear of damage, making it easier to handle during work. Moreover, the shelf life of the decorative board is also good.

Furthermore, in the decorative laminate according to the present invention, a resin-impregnated nonwoven fabric sheet through which the surface pattern of the veneer can be seen is adhered to the surface of the artificial decorative veneer having a base material on the back side, so that the surface of the decorative veneer is not strengthened. It is less brittle and has an excellent sense of transparency and depth. By having a part on the front side of the decorative veneer that has a resin-impregnated nonwoven fabric sheet that allows the surface pattern of the veneer to be seen through, the finish can be completed with just a top coat, so there is no need to apply an undercoat. Can be omitted. Even if there is uneven coloring on the top coat,
The resin-impregnated nonwoven fabric sheet makes paint unevenness less noticeable. Conventionally, in the production of decorative laminates, when high moisture content decorative veneers were used, cracks could occur due to uneven shrinkage during plywood lamination, but the method for manufacturing decorative laminates according to the present invention Since a resin-impregnated nonwoven fabric sheet that allows the surface pattern of the veneer to be seen through is attached to the decorative veneer, it has a large reinforcing effect and prevents cracking.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing a decorative veneer pasted with a resin-impregnated nonwoven fabric sheet, which is an embodiment of the decorative laminate according to the present invention, which does not have a base material on the back side of the artificial decorative veneer, and FIG. FIG. 3 is a perspective view showing a resin-impregnated nonwoven fabric sheet used in this invention. FIG. 4 is a perspective view showing an artificial decorative veneer used in this invention. FIG. 5 is a perspective view showing a decorative veneer according to this invention. It is a side sectional view showing one example when a board has a base material on the back side of an artificial decorative veneer. 1... Decorative veneer with resin-impregnated nonwoven sheet pasted, 2
...Resin-impregnated nonwoven fabric sheet, 3...Artificial decorative veneer, 4...Nonwoven fabric sheet, 5...Resin, 6...Decorative board, 7...Base material, 8...Adhesive.

Claims (1)

[Scope of Claims] 1. A decorative veneer in which a resin-impregnated nonwoven fabric sheet through which the surface pattern of the veneer can be seen is adhered to the surface of an artificial decorative veneer, which may have a base material on the back side. 2. The decorative board according to claim 1, wherein the nonwoven fabric is at least one selected from recycled fibers, polyvinyl alcohol fibers, and polyester fibers. 3. The decorative board according to claim 1 or 2, wherein the resin is at least one selected from polyester resin, diallyl phthalate resin, and polyurethane resin. 4. The decorative board according to any one of claims 1 to 3, wherein the resin has a refractive index similar to that of the nonwoven fabric material. 5. A method for producing a decorative board, which is characterized in that, in obtaining the decorative board, a transparent resin-impregnated nonwoven fabric sheet made by impregnating a nonwoven fabric with a resin is adhered to the surface of an artificial decorative veneer. 6. The method for producing a decorative board according to claim 5, wherein the adhesion is thermocompression bonding. 7. The method for producing a decorative board according to claim 5 or 6, wherein the nonwoven fabric is at least one selected from recycled fibers, polyvinyl alcohol fibers, and polyester fibers. 8. The method for producing a decorative board according to any one of claims 5 to 7, wherein the resin is at least one selected from polyester resin, diallyl phthalate resin, and polyurethane resin. 9. The method for manufacturing a decorative board according to any one of claims 5 to 8, wherein the resin has a refractive index similar to that of the nonwoven fabric material. 10 When obtaining a decorative veneer by attaching a base material to the back side of the decorative veneer, a resin-impregnated nonwoven fabric sheet that allows the surface pattern of the veneer to be seen through is attached to the surface of the artificial decorative veneer as a decorative veneer. A method of manufacturing decorative boards characterized by the use of 11. The method for producing a decorative board according to claim 10, wherein the nonwoven fabric is at least one selected from recycled fibers, polyvinyl alcohol fibers, and polyester fibers. 12. The method for producing a decorative board according to claim 10 or 11, wherein the resin is at least one selected from polyester resin, diallyl phthalate resin, and polyurethane resin. 13. The method for manufacturing a decorative board according to any one of claims 10 to 12, wherein the resin has a refractive index similar to that of the nonwoven fabric material. 14 In order to obtain a decorative veneer by pasting a base material on the back side of a decorative veneer, the artificial decorative veneer is layered on the surface of the base material via an adhesive, and the surface pattern of the artificial decorative veneer is shown through. A method for producing a decorative board, which is characterized by placing a visible resin-impregnated nonwoven fabric sheet and bonding it under heat. 15. The method for producing a decorative board according to claim 14, wherein the nonwoven fabric is at least one selected from recycled fibers, polyvinyl alcohol fibers, and polyester fibers. 16. The method for producing a decorative board according to claim 14 or 15, wherein the resin is at least one selected from polyester resin, diallyl phthalate resin, and polyurethane resin. 17. The method for manufacturing a decorative board according to any one of claims 14 to 16, wherein the resin has a refractive index similar to that of the nonwoven fabric material.