JPH09262956A - Decorative plate and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a decorative plate in which the color difference between a recession and a projection is made clear to improve design by a method in which a transparent resin layer impregnated with a transparent thermosetting resin is contacted with the surface of a substrate, and a colored resin layer is positioned on the surface of a decorative plate. SOLUTION: This decorative paper sheet impregnated with a transparent thermosetting resin liquid is dried preliminarily, impregnated with a colored thermosetting resin liquid, and dried to prepare a resin-impregnated decorative paper sheet 2. The sheet 2 is mounted on a substrate 1 and heat-pressed on the substrate 1 with the use of an embossing plate 5. The sheet 2 impregnated with the colored resin is placed on the substrate 1, and when the sheet 2 is heat-pressed through the embossing plate 5, the sheet 2 is stuck to the substrate 1 by the self-adhesion effect of the molten resin to be integrated. The rigid substrate 1 is used, such as plywood, particle board, intermediate specific gravity fiber board, calcium silicate plate, slate plate, gypsum plate, and slag gypsum plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermosetting resin decorative board having an uneven pattern on the surface and used as an interior material for houses and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a resin-impregnated decorative paper is placed on a surface of a substrate made of a hard material by placing a decorative paper in which a thermosetting resin is impregnated on a base paper on which a printed pattern has been applied and applying heat. The decorative sheet attached to the surface is widely used as a surface material for houses and housing equipment.

In order to improve the design effect of this thermosetting resin decorative board, an uneven pattern by embossing on the surface (hereinafter,
After arranging the resin-impregnated decorative paper on which a printed pattern that matches the pattern of this substrate has been applied, on the substrate processed with the "embossed pattern", thermocompression bonding is performed via the rubber elastic sheet. Although a method of obtaining a thermosetting resin decorative board with an embossed pattern has been devised and implemented, it was difficult to match the embossed pattern of the substrate with the pattern of the decorative paper.

Therefore, a manufacturing method for easily obtaining a decorative plate having an uneven pattern on the surface and a colored pattern in synchronism with the uneven pattern is disclosed in Japanese Patent Application No. Hei 10 (1999) -242242.
It is proposed in JP-A-3-339426 (Japanese Patent Laid-Open No. 5-147050). In this method, "a thermosetting resin-impregnated paper obtained by impregnating a decorative paper with a colored and opaque thermosetting resin is laminated on a base material (substrate) to form an embossed template having irregularities for giving an uneven pattern. It is characterized in that it is used for hot pressing. ”

When this manufacturing method is used, "a larger pressing pressure is applied to a convex portion of the embossing template, that is, a concave portion in the product than that of the concave portion of the embossing template, so that the resin is removed from the embossing template along the impregnated paper. In parallel with this, the impregnated paper and the base material (substrate) are embossed, so that when the curing of the resin is completed, the impregnated paper with a reduced amount of resin is pushed in. It is said that the product recesses will have a lighter resin color than the product protrusions with an increased amount of resin or the degree of hiding of the decorative paper will decrease, forming a colored pattern that perfectly matches the irregularities.

However, although the above-mentioned method can form a colored pattern which perfectly matches the unevenness, the difference in color between the concave portion and the convex portion of the surface pattern cannot be obtained so much, and a sufficient design effect can be obtained. Was difficult.

[0007]

SUMMARY OF THE INVENTION Therefore, in a method for easily manufacturing a decorative board having a colored pattern formed in synchronism with the surface irregularities, the difference in color between the concave portion and the convex portion is made clear, and the decorativeness of the decorative sheet is improved. Is required to be further improved.

[0008]

As a result of studying the reason why the color difference between the concave portion and the convex portion cannot be sufficiently obtained in the above-mentioned conventionally proposed method, the coloring resin penetrates deep inside the decorative paper. Even if the colored resin moves during embossing, the background color of the decorative paper is difficult to appear on the surface because the decorative paper itself is colored. The flow of the colored resin at the time of embossing is not sufficient, and a large amount of the colored resin remains on the concave portion of the decorative paper, and the background color of the decorative paper is difficult to appear on the surface. Was found to be the main cause. Therefore, the present invention makes it difficult to cause such a phenomenon and clarifies the difference in color between the concave portion and the convex portion.

Specifically, the method for manufacturing a decorative board of the present invention is
The decorative paper is impregnated with a transparent thermosetting resin liquid, then pre-dried, then impregnated with a colored thermosetting resin liquid, and dried to make a resin-impregnated decorative paper (2), which is applied to the substrate (1). The resin-impregnated decorative paper (2) is placed, and the resin-impregnated decorative paper is thermocompression-bonded to the substrate using an embossing plate (5).

Further, the decorative board of the present invention is obtained by the above-mentioned method. Specifically, the decorative paper (2) impregnated with the thermosetting resin liquid is attached to the surface of the substrate (1). The decorative sheet is made of a decorative sheet with irregularities on its surface, and the decorative sheet (2) has a colored resin layer (4) impregnated with a colored thermosetting resin and a transparent thermosetting sheet. Having a transparent resin layer (3) impregnated with a resin layer, the transparent resin layer (3) is in contact with the surface of the substrate (1), and the colored resin layer (4) is located on the surface of the decorative plate. Characterize. Furthermore, in the above, the colored resin layer (4a) located in the peripheral portion of the concave portion on the surface of the decorative plate is characterized in that it is thicker than the colored resin layer located on other portions of the surface of the decorative plate.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Decorative paper is impregnated with an uncolored resin solution and pre-dried. Then, the decorative paper is impregnated with the colored resin, dried and cured to the B stage to obtain a resin-impregnated decorative paper.

By thus impregnating in two stages, the layer of impregnated thermosetting resin becomes two layers, and the transparent thermosetting resin layer is formed below the colored thermosetting resin layer. It is possible to prevent the colorant from being absorbed deep inside the decorative paper.

As the impregnating resin, thermosetting resins such as melamine, phenol, epoxy, DAP (diallyl phthalate) and polyester are used, and as the colorant, a pigment which is insoluble in these resin liquids and has weather resistance and heat resistance. Is preferably used.

As shown in FIG. 1, when a resin-impregnated decorative paper impregnated with a colored resin is placed on a substrate and heat-pressed through an embossing plate, the decorative paper is attached to the substrate by a self-adhesive action by heating and melting the impregnated resin. It is attached together with. As the substrate, hard substrates such as plywood, particle board, medium-density fiber board, calcium silicate board, slate board, gypsum board, and slag gypsum board are used.

The heating causes fluidization of the resin. At the convex portion of the embossed plate (recessed portion of the decorative sheet), the colored resin in the vicinity of the surface layer of the decorative sheet is washed away, so the amount becomes small (thin thickness) and the background color of the decorative sheet becomes visible. Further, when the decorative paper is translucent, the background color of the substrate becomes visible.

Further, since the colored resin is unevenly distributed in the vicinity of the surface layer of the impregnated decorative paper, the colored resin easily flows at the embossing press, and the amount of the colored resin extruded around the concave portion of the decorative plate increases. It becomes a state where it is raised more than other convex portions. The decorative plate obtained in this manner has a three-dimensional design with a natural texture such that the convex portions are raised with respect to the concave portions. Shortly thereafter, the resin will cure,
After that, even if it is reheated, it remains in an unmelted state and exhibits physical properties such as water resistance and stain resistance.

The present invention will be described below with reference to preferred embodiments. [Example] Decorative paper was impregnated with uncolored diallyl phthalate resin and pre-dried. Then, a diallyl phthalate resin colored with a titanium oxide pigment was impregnated and dried to obtain a resin-impregnated decorative paper.

The resin-impregnated decorative paper thus obtained is placed on a substrate made of fiber-containing slag gypsum board and heated at a heating temperature of 135 with a hot plate press equipped with a stainless embossing plate.
The decorative board of the present invention was obtained by heat-compressing for 15 minutes under the condition of ° C and a pressure of 12 kg / cm ² .

[Comparative Example] For comparison, the same materials and conditions as those of the Examples were used except that the decorative paper was not impregnated with the uncolored diallyl phthalate resin, but was immediately impregnated with the diallyl phthalate resin colored with the titanium oxide pigment. I made a veneer.

In each of the examples and the comparative examples, a colored pattern was obtained in synchronism with the concavities and convexities, but the decorative plate of the examples clearly showed a difference in color between the concave and convex portions. In addition, in the examples, since the amount of movement of the colored resin was large, the colored resin extruded from the concave portion was raised in the convex portion around the concave portion, and the color was darker than the other convex portions. As a result, a natural three-dimensional effect that cannot be obtained by simple unevenness is expressed, and the design effect is further enhanced.

[0021]

As described above, according to the present invention, in the decorative plate on which the colored pattern is formed in synchronization with the concave-convex pattern on the surface, the difference in color between the concave portion and the convex portion is clarified to further improve the design of the decorative sheet. I was able to improve.

[Brief description of drawings]

FIG. 1 is a sectional view showing a substrate and a resin-impregnated decorative paper before embossing press.

FIG. 2 is a cross-sectional view of a decorative board.

[Explanation of symbols]

 (1) Substrate (2) Decorative paper (3) Transparent resin impregnated layer (4) Colored resin impregnated layer (4a) Raised colored resin (5) Embossed board

Claims (3)

[Claims] 1. A decorative board having a surface of a substrate and a decorative paper impregnated with a thermosetting resin liquid adhered thereto, wherein the surface of the decorative board is uneven, and the decorative paper is colored. It has a colored resin layer impregnated with a thermosetting resin and a transparent resin layer impregnated with a transparent thermosetting resin layer, the transparent resin layer is in contact with the substrate surface, and the colored resin layer is on the decorative plate surface. A veneer characterized by being located. 2. The makeup according to claim 1, wherein the colored resin layer located around the concave portion on the surface of the decorative plate has a larger thickness than the colored resin layer located on other portions of the surface of the decorative plate. Board. 3. A decorative paper is impregnated with a transparent thermosetting resin liquid and then pre-dried, then a colored thermosetting resin liquid is impregnated and dried to form a resin-impregnated decorative paper, and the substrate is coated with the above-mentioned material. A method for manufacturing a decorative board, comprising placing a resin-impregnated decorative paper and thermocompressively bonding the resin-impregnated decorative paper to the substrate using an embossing plate.