JP2545652B2 - Decorative board and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board and a method for producing the same, and particularly to provide a beautiful decorative surface which has a good adhesive force with a decorative sheet while using a substrate having a defect recess on the surface. The present invention relates to a decorative board and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, a decorative plate in which a sheet material such as paper, cloth, synthetic resin, etc. is pasted on the surface of a substrate such as plywood, fiberboard or the like has been widely put into practical use and they are adhered to the surface of the substrate. It was manufactured by sticking a sheet-like material with the agent.

However, there are defects in the surface of the substrate used, such as conduit grooves, knot holes, and wormholes on the surface of plywood.
If there is a crack or the like, a recess appears on the surface of the attached sheet-like material, impairing the appearance, and those portions are easily damaged by an external force.

For this reason, in the case where there are defect recesses on the surface of the substrate, the sheet-like material has been attached after the surface of the substrate has been subjected to sealing treatment.

[0005]

Various types of water-based and oil-based sealing agents are generally used as the sealing agent used in the above sealing treatment, but the oil-based sealing agent is generally expensive and slow to dry. Therefore, it has a drawback of lowering productivity. Aqueous fillers are relatively inexpensive and dry quickly, but have the drawback of increasing the water content of the substrate.

[0006] Furthermore, since the purpose of the sealing agent is to fill in the recesses of defects, regardless of whether it is water-based or oil-based, it contains a pigment component. If the content of pigment is high, the viscosity of the sealing agent becomes high and the fluidity becomes low, making it difficult to completely fill the sealing agent in the defect recesses with narrow mouths and deep defect recesses, and it is necessary to apply it once. In that case, it was not possible to completely stop the filling, and since water and oil were also dissipated, it was necessary to apply and fill the coating several times. Further, if the pigment content is reduced, coating and filling in the defect recesses will be facilitated, but eye loss will be noticeable, and in this case as well, multiple coatings are required.

For the purpose of reducing the number of times of application of the sealing agent and preventing the loss of eyesight, a foaming agent which foams by heating is mixed in the sealing agent, and this is coated and filled in the defect concave portion of the substrate.
A method of heating and foaming, and then scraping off the protruding part from the substrate surface by sanding, etc. was also proposed, but since the number of steps is increased and the sealing agent is porous, it is not possible to attach the decorative sheet. As a result, the amount of penetration of the adhesive increases, and there is a drawback that the adhesion at that portion becomes insufficient.

[0008]

In view of the above-mentioned conventional techniques, the present invention provides a novel decorative surface which is excellent in adhesive strength to a decorative sheet while using a substrate having a defective recess. It is an object of the present invention to provide a decorative board and a method for manufacturing the same.

That is, in the decorative plate according to the present invention, a flat film-like portion is formed in the upper layer portion in the defect concave portion of the substrate surface, and the lower layer portion is a foaming portion due to activation of the foaming agent. It is characterized in that it is filled with a curable resin, and a decorative sheet is attached to the entire surface of the substrate including the surface of the filled portion via an adhesive. The filling portion in the concave portion of the substrate surface of the decorative plate according to the present invention is filled with the resin all the way to the defective concave portion due to the foaming action by the activation of the foaming agent, and the upper layer portion thereof is Since the hard and flat film-like part is formed, the decorative sheet is surely and evenly adhered to the surface of the substrate, giving a perfect appearance and making the decorative sheet on the filling part less likely to be damaged. Is greatly improved.

The method for manufacturing a decorative board according to the present invention is
Defects on the surface of the substrate After the thermosetting resin containing the foaming agent is applied and filled in the recess, it is immediately heated to a high temperature to cure the surface portion of the filled thermosetting resin to form a film, and the inside At this point, the foaming agent in the resin is activated so that the resin is completely filled in the defect recesses and is semi-cured in a state of being raised on the substrate, and then the whole of the substrate including the raised filling portion is Apply an adhesive to the surface, place a decorative sheet on the applied adhesive and heat it to form a resin film while smoothing the upper layer part of the thermosetting resin with foaming protrusion, and then applying It is characterized in that the decorative sheet is also adhered by curing the formed adhesive. According to such a method, the application of the sealing agent (thermosetting resin containing the foaming agent) is required only once, and each step can be continuously performed without worrying about blindness. It is possible to obtain a decorative board having good quality and improved quality as described above.

[0011]

EXAMPLE As shown in FIG. 1, a plywood substrate 1 used in this example has defect recesses 2 such as conduit grooves, knot holes, wormholes and cracks on its surface.

A thermosetting resin 3 containing a foaming agent is applied and filled in the defect recesses 2 by using a coating device such as a roll coater or a reverse coater. This process is shown in FIG.

The thermosetting resin 3 is an acrylic resin ,
Polyester type, urea or urea melamine type, phenol
Any resin such as a resin , an epoxy resin , a polyurethane resin, or the like can be used.

The foaming agent used in the present invention includes various forms of foaming agent in which a substance which volatilizes or decomposes by heating to generate a gas or sublime is enclosed in a thermoplastic synthetic resin capsule.

Immediately after the resin 3 is applied and filled, it is heated by a heating and drying means such as a hot air dryer or an infrared dryer to semi-cure the upper layer portion of the filled resin to form a coating 3'and its lower layer. In the section, the foaming agent in the resin is activated to foam the resin. This state is shown in FIG. 3, and since the foaming gas is confined inside by the upper coating 3 ′, the foaming resin expands and fills every corner of the defect recess 2 and the substrate 1 Produces bumps on the surface of. The heating conditions at this time are appropriately selected according to the characteristics of the foaming agent used.

Next, the adhesive 4 is applied to the entire surface of the substrate 1 including the raised surface of the filling portion. This state is shown in FIG. As the adhesive 4, an amino resin,
Urea resin, melamine resin, phenol resin, resorcin resin, epoxy resin, polyurethane resin, acrylic resin, vinyl acetate resin, polyvinyl acetal resin, vinyl chloride resin, vinylidene chloride resin, vinyl ether resin, polyethylene resin, polyester resin, polyvinyl alcohol resin, etc. Any of the thermoplastic or thermosetting resin adhesives conventionally used for pasting decorative sheets can be appropriately selected and used.

After applying the adhesive 4, the decorative sheet 5 is applied thereon.
And then heat-pressing it using a heat-pressing means 6 such as a heat roll or a heat plate, and the ironing effect flattens the upper layer part of the resin of the filling part raised by the action of the foaming agent, and also has a fine and hard texture. The film-like portion 3 ′ ″ is formed, and the adhesive agent 4 applied later is also solidified to form the decorative sheet 5
To adhere. At this time, the foamed resin 3 ″ is also thermoset to form a solidified foamed portion 3 ″ ″, and thus the decorative board 1 ′ is obtained. This state is shown in FIG.

[0018]

EFFECT OF THE INVENTION According to the present invention, the application of the sealing agent only needs to be performed once, the step of sanding is not required, and all the subsequent steps can be performed continuously, so that the productivity is remarkably improved Moreover, a flat and dense hard film-like part is formed in the upper layer of the filling part, and a hard foam part that extends to every corner of the defect recess is formed in the lower layer, so that the adhesiveness of the decorative sheet is improved. Good, and the surface property of the decorative surface is significantly improved.

[Brief description of drawings]

FIG. 1 is a schematic view showing a substrate used in an embodiment of the method of the present invention.

FIG. 2 is a schematic view showing a state in which a defect recess on the surface of a substrate is coated and filled with a sealing agent.

FIG. 3 is a schematic view showing a state in which a film is formed by semi-curing a resin on the surface of the filling part by heating and a foam part is formed inside the film.

FIG. 4 is a schematic view showing a state in which an adhesive is applied to the substrate surface.

FIG. 5 is a schematic view showing a step of placing a decorative sheet on an adhesive and hot-pressing it to obtain a decorative plate.

[Explanation of symbols]

 1 Substrate 2 Defect Recess 3 Thermosetting Resin (Filling Agent) Containing Foaming Agent 3'Coating 3 '' Foaming Resin 3 '' 'Membrane 3' '' 'Foaming 4 Adhesive 5 Decorative Sheet 6 Hot pressing means

Claims (2)

(57) [Claims] 1. A thermosetting resin in which a flat film-like portion is formed in an upper layer portion and a lower layer portion is a foamed portion due to activation of a foaming agent is filled in a defect concave portion of a substrate surface. The decorative sheet is characterized in that a decorative sheet is adhered to the entire surface of the substrate including the surface of the filling portion via an adhesive. 2. A thermosetting resin containing a foaming agent is applied and filled in the concave portion of the substrate surface, and then immediately heated at a high temperature to cure the surface portion of the filled thermosetting resin to form a coating film. Formed, and the foaming agent in the resin inside
Allowed semi-curing the at while being raised on the substrate causes completely fill the defect recess by foaming the resin by Rukoto activated, then bonded including a raised filled portion on the entire surface of the substrate The adhesive is applied, and a decorative sheet is placed on the applied adhesive and hot pressed to form a resin film while smoothing the upper layer of the thermosetting resin that has risen due to foaming, and then the applied adhesive is applied. A method for manufacturing a decorative board, which comprises curing the agent and adhering the decorative sheet.