JP2002166401A - Manufacturing method of reinforced decorative board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method capable of efficiently producing a resin-impregnated reinforced decorative board having an excellent appearance, exhibiting good cosmetic properties and having a large surface hardness. SOLUTION: After forming a barrier layer on a surface of a porous substrate such as a plywood for preventing seepage of an adhesive, a film forming adhesive layer is formed on the barrier layer, and thereafter, the film forming adhesive is formed. A decorative thin sheet material consisting of a thin dry veneer veneer having a thickness of 0.5 mm or less is placed on the layer and adhered together by the above-mentioned film-forming adhesive layer. The reinforced synthetic resin liquid is impregnated into the decorative thin sheet material and is cured by applying the liquid and applying heat and pressure with a hot press.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a reinforced decorative board excellent in decorativeness and surface hardness.

[0002]

2. Description of the Related Art Conventionally, a synthetic resin reinforced thin sheet material obtained by impregnating a decorative thin sheet material made of a decorative wood veneer (a veneer) with a synthetic resin liquid and reinforcing the same is integrally laminated on a substrate surface such as a plywood. Such a resin-reinforced decorative board is manufactured by the method described below.

[0003] The first method is to put a dry veneer veneer (a veneer) into a pouring pot, inject the synthetic resin liquid into the pouring pot, and then apply a reduced pressure method or a reduced pressure method to the wood veneer veneer. Impregnated with a synthetic resin liquid, and then heat and press the synthetic resin liquid impregnated wood decorative veneer with a hot press to cure the synthetic resin liquid to produce a synthetic resin reinforced decorative veneer,
This is a method of manufacturing a resin-reinforced decorative board by bonding this synthetic resin-reinforced decorative veneer to the surface of a substrate such as plywood using an adhesive.

A second method is to impregnate a dried wood veneer with a synthetic resin solution in the same manner as in the first method,
The synthetic resin liquid is laminated on the surface of a substrate such as plywood in an uncured state. Thereafter, the laminate is heated and pressed by a hot press to cure the synthetic resin liquid, and the cured resin impregnated wood on the substrate. This is a method for producing a resin-reinforced decorative board in which decorative veneers are integrally layered.

A third method is to bond a decorative wood veneer to the surface of a substrate such as a plywood with an adhesive, and then apply a synthetic resin solution to the surface of the decorative wood veneer to apply the decorative wood veneer. This is a method of manufacturing a resin-reinforced decorative board by impregnating the board with a synthetic resin liquid and then heating and pressurizing the synthetic resin-impregnated wood veneer with a hot press or the like to cure the synthetic resin liquid. In any of the above first to third manufacturing methods, after finishing the surface of the resin-reinforced decorative board by sanding, a transparent synthetic resin paint is applied to finish.

[0006]

However, according to the first and second manufacturing methods, the synthetic resin liquid can be impregnated using a relatively thick wood decorative veneer having a thickness of 0.5 mm or more. From the above, it is possible to obtain a resin-reinforced decorative board with good decorativeness and excellent high-grade and scratch resistance, but on the other hand, requires large-scale resin impregnation equipment such as an injection pot and many manufacturing steps, and thus requires high workability and productivity. However, it is not suitable for mass production and the production cost is high.

Further, in recent years, wood resources having a high decorative value are scarce and expensive, so that thin wood decorative veneers having a thickness of about 0.15 mm to 0.50 mm are often used as decorative wood veneers. However, such thin veneer veneers are undried because they are obtained by slicing wet flitches of wood. There is a problem that water is mixed in the synthetic resin liquid injected into the wood decorative veneer due to the influence, and when the wood decorative veneer impregnated with the synthetic resin liquid is cured, the moisture remaining in the wood decorative veneer is reduced. Accordingly, there is a problem that cracks easily occur in the decorative wood veneer or the decorative wood veneer may be damaged.

Accordingly, it is desirable to dry the decorative veneer veneer in advance, but not only does the drying process take a long time to lower the productivity but also the decorative veneer veneer cracks due to drying. There is a possibility that it will be impossible to use it.

On the other hand, in the third method, since there is no need to use an injection pot, productivity is high, and further, the thickness is small.
If it is a thin wood decorative veneer of about 0.15 mm to 0.50 mm, there is an advantage that synthetic resin liquid can be penetrated and impregnated, but when bonding such a thin wood decorative veneer on a substrate such as plywood Since a part of the adhesive is bonded and integrated in a state in which the wood decorative veneer permeates into the veneer veneer, when the surface of the veneer veneer is coated and impregnated with a synthetic resin liquid, A situation in which the synthetic resin liquid cannot be sufficiently penetrated and impregnated into the veneer by the adhesive occurs, resulting in uneven impregnation, resulting in a reduction in decorativeness and obtaining sufficient strength as a veneer veneer treated with resin. Is no longer possible.

These problems can be alleviated by using a film-forming adhesive as the adhesive applied to the surface of a substrate such as plywood, but the amount of the film-forming adhesive applied is small. When the synthetic resin impregnated wood veneer laminated on the substrate surface is heated and pressed by a hot press or the like to bond the wood veneer veneer to the substrate, most of the adhesive seeps into the substrate surface and There is a problem that the adhesive strength between the decorative veneer and the substrate is insufficient. Also, if the amount of adhesive applied to the substrate surface becomes excessive, the adhesive force between the wood decorative veneer and the substrate can be sufficiently ensured, but a part of the applied film-forming adhesive becomes thin in the wooden decorative veneer. As described above, there is a problem in that the decorativeness deteriorates due to the uneven impregnation of the synthetic resin liquid.

Further, since the wood veneer veneer reinforced by impregnation and hardening of the synthetic resin liquid is thin, it has a poor effect of improving the hardness of a porous substrate such as a plywood and the like. It was not possible to improve the scratch resistance sufficient to suppress the occurrence of scratches and the like.

The present invention has been made in view of these problems. It is an object of the present invention to provide not only excellent decorativeness but also sufficient surface hardness and efficient production. It is an object of the present invention to provide a method for producing a reinforced decorative sheet which can be made.

[0013]

In order to achieve the above object, a method for manufacturing a reinforced decorative sheet according to the present invention is characterized in that an adhesive spreads on the surface of a porous substrate. After forming a barrier layer for preventing the penetration of the film, a film forming adhesive is applied to the surface of the barrier layer to form a film forming adhesive layer, and a porous decorative thin film is formed on the surface of the film forming adhesive layer. A sheet material is placed, and the decorative thin sheet material is integrally adhered to the barrier layer via a film forming adhesive layer, and thereafter, a reinforced synthetic resin liquid is applied to the surface of the decorative thin sheet material, It is characterized in that the reinforced synthetic resin liquid is impregnated into the decorative thin sheet material and cured.

Further, the invention according to claim 2 is the method for forming a barrier layer according to the above, wherein the synthetic resin liquid is applied to the surface of the porous substrate, and the impregnating sheet material is placed thereon. The barrier layer is formed by impregnating and hardening the above synthetic resin liquid to bond and integrate with the porous substrate.

In the invention according to claim 2, the invention according to claim 3 is characterized in that the synthetic resin liquid applied to the surface of the porous substrate is a water-based synthetic resin having a resin content of 55% by weight to 80% by weight. Liquid on the surface of the porous substrate.
It is characterized by being applied at 250 to 600 g / m ² .

[0016] Further, in the invention according to the second or third aspect, the invention according to the fourth aspect is characterized in that an acryl-modified trimethylolmelamine is used as the synthetic resin liquid.

According to a fifth aspect of the present invention, in the second aspect of the present invention, the sheet material for impregnation has a thickness of 0.15 mm or more.
It is characterized by using paper of 0.4 mm and density of 0.4 g / m ^{3 to} 0.6 g / m ³ .

Further, in the invention according to the first aspect, the invention according to the sixth aspect is characterized in that the film-forming adhesive layer has a thickness of 10 to 30 μm. The moisture in the undried decorative veneer is evaporated by bonding the barrier layer and the undried decorative veneer under heat and pressure by using an undried decorative veneer having a thickness of 0.5 mm or less as the decorative thin sheet material. It is characterized by the following.

[0019]

According to the first aspect of the present invention, after forming a barrier layer on the surface of the porous substrate to prevent the adhesive from seeping into the porous substrate, a film forming property is formed on the surface of the barrier layer. An adhesive is applied to form a film forming adhesive layer, and a porous decorative thin sheet material is placed on the surface of the film forming adhesive layer, and the decorative thin sheet material is applied to the barrier layer. It is characterized by being integrally bonded through a layer, and thereafter, by applying a reinforced synthetic resin liquid to the surface of the decorative thin sheet material and impregnating it into the decorative thin sheet material, and curing, After forming the barrier layer on the surface of the substrate, the film forming adhesive is applied, so that a predetermined amount of the film forming adhesive can be applied without being affected by the material of the substrate,
Further, when the decorative thin sheet material is placed on the film-forming adhesive layer applied to the surface of the barrier layer and heated and pressed by a hot press or the like, the presence of the barrier layer formed on the surface of the porous substrate can be prevented. Accordingly, the film-forming adhesive layer is prevented from seeping into the porous substrate, and therefore, the decorative thin sheet material is applied to the film-forming adhesive layer without excessively applying the film-forming adhesive layer on the barrier layer. It is possible to securely and firmly adhere.

In addition, since it is not necessary to apply an excessive film-forming adhesive layer on the barrier layer as described above, a decorative thin sheet material such as a decorative veneer placed on the film-forming adhesive layer can be used. Since the excess amount of the film-forming adhesive layer does not permeate, even if the reinforced synthetic resin liquid is applied to the surface of the decorative thin sheet material, the reinforced synthetic resin liquid is uniformly applied throughout the interior of the decorative thin sheet material. In addition, it can be sufficiently penetrated and impregnated, and it is possible to obtain a reinforced decorative board having excellent decorativeness and a large surface hardness without impregnation unevenness which deteriorates performance such as decorativeness and hardness. In addition to this, the process of impregnating a veneer veneer with a synthetic resin solution in advance and drying it in a semi-cured state as in the conventional manufacturing method can be omitted, thereby improving production efficiency. .

According to the second aspect of the present invention, the synthetic resin liquid is applied to the surface of the porous substrate after the synthetic resin liquid is applied to the surface of the porous substrate and the impregnating sheet material is placed thereon and applied to the surface of the porous substrate. Is impregnated into the impregnating sheet material and cured to form a barrier layer by bonding and integrating the sheet material and the porous substrate. A resin-reinforced decorative plate excellent in surface hardness and scratch resistance can be obtained.

According to a third aspect of the present invention, in the second aspect of the present invention, the synthetic resin liquid applied to the surface of the porous substrate has a resin content of 55 to 80% by weight. And apply this synthetic resin liquid to the surface of the porous substrate for 250 minutes.
600600 m ^{2 is} applied, so that the synthetic resin liquid can be smoothly impregnated into the impregnating sheet material placed on the porous substrate because there is little excess water, and the synthetic resin liquid impregnated sheet material Can be securely and firmly bonded and integrated with the porous substrate, and it is excellent in handleability and working environment.

In the invention according to the second or third aspect, the invention according to the fourth aspect uses a water-based acrylic-modified trimethylolmelamine resin solution as a synthetic resin solution, so that good toughness and hardness can be obtained. A barrier layer having a thickness can be formed.

The invention according to claim 5 is the invention according to claim 2, wherein the sheet material for impregnation has a thickness.
Since 0.15 mm to 0.4 mm paper and density of 0.4 g / m ^{3 to} 0.6 g / m ³ are used, the impregnation and adhesion of the synthetic resin liquid are better than those of sheet materials such as non-woven fabrics. The hardness of the surface of the porous substrate can be increased, and a reinforced decorative sheet excellent in strength and scratch resistance can be obtained. Incidentally, if the thickness of the impregnating sheet material is less than 0.15 mm, the effect of improving the hardness of the surface of the porous substrate is reduced, and if it exceeds 0.4 mm, it is only uneconomical.

According to a sixth aspect of the present invention, in the first aspect of the present invention, the film-forming adhesive layer formed on the barrier layer on the surface of the porous substrate has a thickness of 10 to 30 μm. The decorative thin sheet material can be securely adhered to the barrier layer via the film adhesive layer, and an extra film-forming adhesive layer does not seep into the decorative thin sheet material. If the thickness of the film-forming adhesive layer is less than 10 μm, the adhesive strength is insufficient, and if it exceeds 30 μm, an excessive film-forming adhesive layer may undesirably seep into the decorative thin sheet material.

The invention according to claim 7 is characterized in that an undried decorative veneer having a thickness of 0.5 mm or less is used as the decorative thin sheet material,
Since the moisture in the undried decorative veneer is evaporated by bonding the barrier layer and the undried decorative veneer under heat and pressure, a drying process is not required as compared with the case of using a thick dry decorative veneer. Thus, it is possible to manufacture a reinforced decorative board without producing cracks and the like, while having good productivity and excellent workability and economic efficiency.

[0027]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a simplified longitudinal sectional view of a reinforced decorative sheet A manufactured by the method of the present invention. Barrier layer 2 on the surface to prevent penetration of adhesive
The synthetic thin sheet material 4 impregnated with synthetic resin is bonded and integrated on the barrier layer 2 via a film forming adhesive layer 3.

In order to manufacture such a reinforced decorative board, first, as shown in FIG. 2A, a barrier for preventing the adhesive from seeping into the porous substrate 1 on the surface of the porous substrate 1. After the layer 2 is formed, a film forming adhesive is applied to the surface of the barrier layer 2 to form a film forming adhesive layer 3 having a predetermined thickness, as shown in FIG.

As the porous substrate 1, plywood, LVL
(Laminated Veneer Lumber), MDF (medium-density fiberboard), hardwood board, particle board, wood-based board such as glued laminated wood, volcanic glassy multilayer board (product name: Dailite, manufactured by Daiken Kogyo Co., Ltd.), etc. A relatively light-weight porous substrate having strength as a substrate and having numerous voids inside is used, such as an inorganic substrate. In such a porous substrate 1, a composite plate of one or more porous substrates or a composite plate of a porous substrate and a wooden veneer, for example, a thin plate having a thickness of 3 mm or less on the surface of the plywood or on both front and back surfaces. MD
A composite plate obtained by attaching a wood veneer to one or both surfaces of a composite plate obtained by adhering F integrally or a volcanic glassy multilayer plate may be used.

On the other hand, the barrier layer 2 adhered to the surface of the porous substrate 1 is a dense sheet-like material which can prevent the film-forming adhesive layer 3 from seeping into the porous substrate 1. If it is a layer consisting of, it can be adopted regardless of its material type and thickness. In this case, it is more preferable that the barrier layer be made of a sheet-like material that has good adhesion to the porous substrate 1 and can improve the surface hardness of the porous substrate 1 in addition to the bleeding prevention effect. As a sheet-like material, there is a resin-impregnated sheet layer obtained by impregnating a porous resin-impregnated sheet material such as paper, nonwoven fabric, or glass fiber sheet with a synthetic resin liquid, and in particular, a resin impregnation obtained by impregnating paper with a synthetic resin liquid. The paper layer is desirable because it is excellent in productivity and economy as well as the above effects.

As a specific example of forming the barrier layer 2 composed of such a resin-impregnated sheet layer on the surface of the porous substrate 1, first, a synthetic resin liquid is applied to the surface of the porous substrate 1. As the synthetic resin liquid, a thermosetting resin liquid, a modified thermosetting resin liquid, or a mixed resin liquid obtained by mixing a thermosetting resin with a thermosetting resin can be used. For example, melamine resins, urea resins, urea-melamine resins, phenol resins, polyester resins, epoxy resins, acrylic resins, vinyl acetate resins, or modified products or mixtures of these resins it can.
Further, from the viewpoint of handleability and work environment, the synthetic resin liquid is preferably aqueous such as an emulsion or an aqueous solution, and a resin having appropriate toughness and extensibility when cured is preferable. In particular, a mixture of a melamine-based resin and a vinyl acetate-based resin, an ethylene-modified vinyl acetate resin, an acrylic emulsion resin, or a product obtained by modifying the methylol group of methylolmelamine with an acrylic or allyl can be preferably used.

The synthetic resin liquid applied to the surface of the porous substrate 1 has a resin content of 55% by weight or more. Depending on the type of the resin, it is also possible to use a solventless resin having a resin content of 100%. However, if the resin content is less than 55% by weight, the curing time becomes longer and the productivity becomes worse, and the resin shrinks at the time of curing so that the porous substrate 1 is likely to be warped. If the resin content exceeds 80% by weight, it becomes difficult to uniformly impregnate the resin impregnated sheet material depending on the type of synthetic resin used.
80% by weight is desirable. If the amount of the synthetic resin liquid applied to the surface of the porous substrate 1 is less than 250 g / m ² , the impregnation amount is insufficient, and if it exceeds 600 g / m ² , it is uneconomical and reduces productivity. 250 g / m ² to 600 g
/ M ² is desirably applied.

After the synthetic resin liquid is applied to the surface of the porous substrate 1 as described above, the impregnating sheet material is placed thereon, and the synthetic resin liquid is penetrated and impregnated into the impregnating sheet material. As the impregnating sheet material, as described above, a porous sheet material such as paper, nonwoven fabric, or glass fiber sheet is used, and the thickness is preferably about 0.1 mm to 0.5 mm. A resin-impregnated base paper having a thickness of about 0.15 mm to 0.4 mm and a density of about 0.4 g / m ^{3 to} 0.6 g / m ³ is most practical and preferably has high productivity. The impregnating sheet material is placed on the surface of the porous substrate 1 after the synthetic resin liquid is applied thereto. After the impregnating sheet material is placed on the surface of the porous substrate 1, the impregnating sheet material is placed on the surface. A synthetic resin solution may be applied to the surface of the material to impregnate and impregnate the sheet material for impregnation with the synthetic resin solution.

Next, the surface of the sheet material impregnated with and impregnated with the synthetic resin solution is lightly pressed, if necessary, by a roller means or the like, so that the synthetic resin solution is uniformly spread over the entire sheet material. Penetrate, impregnate, and then
The sheet material is heated by hot-pressing means such as hot press,
By applying pressure, the barrier layer 2 is formed by adhering to the surface of the porous substrate 1 and curing the synthetic resin liquid impregnated in the sheet material. The bonding between the sheet material and the porous substrate 1 is performed by curing a synthetic resin liquid existing between the porous substrate 1 and the sheet material. The barrier layer 2 thus obtained is formed as a dense layer having a specific gravity of 1.2 or more.

After forming the barrier layer 2 on the surface of the porous substrate 1 in this manner, a film forming adhesive is applied to the surface of the barrier layer 2 to form a film forming adhesive layer 3 having a predetermined thickness.
As the film-forming adhesive, a solvent-type adhesive such as a polyester resin can be used, but an emulsion-type adhesive such as a vinyl acetate resin, a vinyl acetate-acrylic copolymer resin, or an acrylic resin, which is easy to apply and handle, can be used. It is preferred to use an agent. After this adhesive is applied to the surface of the barrier layer 2, a film is formed by evaporating water in the adhesive with warm air or the like to form a film-forming adhesive layer 3. The thickness of the film forming adhesive layer 3 is
10 μm in order to secure adhesion to the decorative thin sheet material 4 to be laminated thereon and to suppress seepage into the decorative thin sheet material 4
It is desirable that the thickness be about 30 μm.

After the above-mentioned film-forming adhesive layer 3 is formed on the surface of the film-forming adhesive layer 2, a decorative thin sheet material 4 is placed on the film-forming adhesive layer 3 as shown in FIG. The decorative thin sheet material 4 is integrally bonded to the film forming adhesive layer 3 by heating and pressurizing by means of a hot press such as a hot press. At this time, since the film-forming adhesive layer 3 contains a small amount of water as described above, the decorative thin sheet material 4 can be satisfactorily adhered to the decorative thin sheet material 4 without substantially seeping into it. As such a decorative thin sheet material 4, a decorative wood veneer or decorative printing paper can be used. In this case, if the decorative thin sheet material 4 is a decorative wood veneer, its thickness is 1 mm or less. From the viewpoint of economy, it is preferable to use one having a thickness of 0.15 mm to 0.5 mm, and a undried sliced veneer.

Next, a reinforced synthetic resin liquid is applied to the surface of the decorative thin sheet material 4 by an appropriate application means, and is penetrated and impregnated into the decorative thin sheet material 4. At this time, the reinforced synthetic resin liquid applied to the surface of the decorative thin sheet material 4 is pressed against the decorative thin sheet material using a roll or a concavo-convex roll, so that the reinforced synthetic resin liquid Penetration and impregnation can be promoted. The reinforced synthetic resin liquid is not particularly limited, but an addition polymerization type synthetic resin liquid represented by an unsaturated polyester resin can be used.

After the reinforced synthetic resin liquid is impregnated into the decorative thin sheet material 4 as described above, the decorative thin sheet material 4 is inserted into a hot-press means such as a hot press and heated and pressurized to thereby impregnate the reinforced synthetic resin material. The liquid is cured to produce a resin-reinforced decorative board. Next, specific examples and comparative examples of the present invention will be described.

[0039]

EXAMPLE Acrylic-modified trimethylol melamine, which is an aqueous melamine resin having a viscosity of 2500 cps and a non-volatile content (resin ratio) of 70% by weight, was 375 g / m ^{2 on} the surface of a substrate having a thickness of 12 mm made of 5-ply plywood. Then, a resin impregnating base paper having a weight of 115 g / m ² and a thickness of 0.22 mm was overlaid thereon, and the surface thereof was lightly pressed by a roller to allow the synthetic resin liquid to permeate the base paper. In this synthetic resin solution, 0.5% of ammonium chloride as an acid catalyst was added to accelerate the curing. Then, the surface of the synthetic resin liquid impregnated base paper inserted into the hot press and superimposed on the substrate is heated and pressed at 130 ° C. and 10 kgf / cm ² for 2.5 minutes to apply the synthetic resin liquid impregnated base paper to the substrate surface. The synthetic resin liquid that was adhered and impregnated in the base paper was cured to form a barrier layer.

Then, after lightly sanding the surface of the barrier layer, a film forming property obtained by adding a small amount of a concealing pigment (iron oxide or titanium oxide) to a melamine resin-acryl emulsion mixed adhesive having a resin ratio of 45%. The adhesive was applied to the surface of the barrier layer at 100 g / m ² and air-dried at room temperature for 4 hours to form a film-forming adhesive layer having a thickness of about 25 μm. Then
An undried veneer made of oak material having a thickness of 0.3 mm is placed on the surface of the film-forming adhesive layer, and is hot-pressed at 120 ° C. and 10 kgf / cm ² for 1 minute by hot pressing to obtain the veneer. Was adhered onto the barrier layer via a film-forming adhesive layer.

Further, a viscosity of 1500 cps was applied to the surface of the veneer.
BPO as an initiator in a soft unsaturated polyester resin liquid
Of a reinforced synthetic resin prepared by adding a small amount of 1% by weight and an orange oil-based dye for grain enhancement, and applying 150 g / m ² using a reverse coater.
After placing a 0 μm PET resin film, the veneer was impregnated with a reinforced synthetic resin solution in a single plate by heating and pressing at 120 ° C. and 10 kgf / cm ² for 5 minutes with a hot press. Thereafter, the surface of the resin-impregnated veneer is sanded to make it smooth, and then a top coating made of a urethane-based transparent resin is applied to the surface to provide a resin-reinforced decorative plate A.
I got

[0042]

COMPARATIVE EXAMPLE 1 The resin-reinforced decorative board B according to Comparative Example 1 was subjected to the same processing steps and processing conditions as those of the above-described embodiment except for the step of forming a barrier layer on the surface of the substrate used in the above-described embodiment.
I got

[0043]

Comparative Example 2 After forming a barrier layer on the surface of the substrate used in the above example in the same manner as in the above example, instead of forming the film-forming adhesive layer in the above example on the surface of this barrier layer, a conventional method was used. Urea-melamine resin adhesive solution is applied and a undried veneer made of oak material having a thickness of 0.3 mm is placed thereon without forming a film. Plate C was obtained.

When the decorative appearance of the resin-reinforced decorative panel A obtained in the above example and the resin-reinforced decorative panels B and C obtained in Comparative Examples 1 and 2 are compared, the resin-reinforced decorative panel A obtained in the example is reinforced. While the resin-reinforced decorative board B obtained in Comparative Example 1 had a good appearance without any impregnation unevenness of the synthetic resin liquid, the resin-reinforced decorative board B was directly formed into a film-forming adhesive without forming a barrier layer on the substrate surface. Is applied, the adhesive seeps into the substrate, and the adhesive strength between the substrate and the decorative veneer is reduced, resulting in poor strength. When the amount of the film-forming adhesive applied was larger than that in the example, the film-forming adhesive permeated into cell voids such as a conduit of a veneer veneer, resulting in uneven impregnation of the reinforced synthetic resin solution. Was. In the resin-reinforced decorative board C of Comparative Example 2,
Since the adhesive did not form a film, a part of the adhesive penetrated into cell voids such as a conduit of a decorative veneer and was mixed with the reinforced synthetic resin liquid, and appeared as a non-uniform makeup.

Next, Table 1 shows the results of the surface hardness and the caster test of the resin-reinforced decorative board A in the above example and the resin-reinforced decorative board B in Comparative Example 1. The surface hardness was tested by Brinell hardness (JIS Z 2243), and the caster test applied a test method in which a load of 30 kg was applied to a plastic single wheel caster and a load of 3,000 reciprocations was applied at a sliding distance of 30 cm. did.

[0046]

[Table 1]

As is clear from this table, in the resin-reinforced decorative board obtained in the example of the present invention, the hardness and the resistance to scratching are remarkably improved by forming a barrier layer on the surface of the substrate. Was.

[Brief description of the drawings]

FIG. 1 is a simplified longitudinal sectional view of a resin-reinforced decorative board,

FIG. 2 is a simplified diagram showing a manufacturing process.

[Explanation of symbols]

 Reference Signs List 1 porous substrate 2 barrier layer 3 film forming adhesive layer 4 decorative thin sheet material

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[Procedure amendment]

[Submission date] June 11, 2001 (2001.6.1)
1)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claim 5

[Correction method] Change

[Correction contents]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0017

[Correction method] Change

[Correction contents]

According to a fifth aspect of the present invention, in the second aspect of the present invention, the impregnating sheet material has a thickness of 0.15 mm or more.
It is characterized by using paper of 0.4 mm and density of 0.4 g / cm ^{3 to} 0.6 g / cm ³ .

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0022

[Correction method] Change

[Correction contents]

According to a third aspect of the present invention, in the second aspect of the present invention, the synthetic resin liquid applied to the surface of the porous substrate has a resin content of 55 to 80% by weight. And apply this synthetic resin liquid to the surface of the porous substrate for 250 minutes.
600600 g / m ^{2 is} applied, so that there is little excess water, so that the impregnating sheet material placed on the porous substrate can be smoothly impregnated with the synthetic resin liquid and impregnated with the synthetic resin liquid. The sheet material can be securely and firmly bonded and integrated with the porous substrate, and is excellent in handleability and working environment.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0024

[Correction method] Change

[Correction contents]

The invention according to claim 5 is the invention according to claim 2, wherein the sheet material for impregnation has a thickness.
0.15 mm to 0.4 mm, the density is used paper ^{0.4 g / cm 3 ~0.6 g /} cm 3, the impregnation of the synthetic resin solution as compared to sheet material such as a nonwoven fabric, good adhesion, thereon, The hardness of the surface of the porous substrate can be increased, and a reinforced decorative sheet excellent in strength and scratch resistance can be obtained. Incidentally, if the thickness of the impregnating sheet material is less than 0.15 mm, the effect of improving the hardness of the surface of the porous substrate is reduced, and if it exceeds 0.4 mm, it is only uneconomical.

[Procedure amendment 5]

[Document name to be amended] Statement

[Correction target item name] 0033

[Correction method] Change

[Correction contents]

After the synthetic resin liquid is applied to the surface of the porous substrate 1 as described above, the impregnating sheet material is placed thereon, and the synthetic resin liquid is penetrated and impregnated into the impregnating sheet material. As the impregnating sheet material, as described above, a porous sheet material such as paper, nonwoven fabric, or glass fiber sheet is used, and the thickness is preferably about 0.1 mm to 0.5 mm. A resin-impregnated base paper having a thickness of about 0.15 mm to 0.4 mm and a density of about 0.4 g / cm ^{3 to} 0.6 g / cm ³ is most practical and preferred in terms of productivity. The impregnating sheet material is placed on the surface of the porous substrate 1 after the synthetic resin liquid is applied thereto. After the impregnating sheet material is placed on the surface of the porous substrate 1, the impregnating sheet material is placed on the surface. A synthetic resin solution may be applied to the surface of the material to impregnate and impregnate the sheet material for impregnation with the synthetic resin solution.

[Procedure amendment 6]

[Document name to be amended] Statement

[Correction target item name] 0046

[Correction method] Change

[Correction contents]

[0046]

[Table 1]

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Junzo Oikawa 1F, Inami-cho, Inami-cho, Higashi-Tonami-gun, Toyama F-term (reference) 2B002 AA05 AA10 BA01 BB04 BB06 BB12 2B250 BA03 BA05 BA11 CA11 DA04 EA02 EA13 FA21 FA28 FA31 FA33 FA37 FA53 GA03 HA01 4F100 AK01B AK01D AK01E AK36D AK36E AK51 AP01D AR00A AR00B AR00C AR00D BA04 BA05 BA07 BA10A BA10D BA10E DG10B DJ00A DJ00B DJ00D EC182 EH462 EJ202 EJ422 EJ82B EJ82D EJ821 HB00D JA13B JB05D JB05E JD01B JL11C JM01D JM01E YY00B YY00C YY00E

Claims (7)

[Claims] 1. After forming a barrier layer on the surface of a porous substrate for preventing an adhesive from seeping into the porous substrate,
A film forming adhesive is applied to the surface of the barrier layer to form a film forming adhesive layer, and then a porous decorative sheet material is placed on the surface of the film forming adhesive layer to form the decorative film. Adhering the sheet material integrally to the barrier layer via a film-forming adhesive layer, and then applying a reinforced synthetic resin liquid to the surface of the decorative thin sheet material to impregnate and cure the decorative thin sheet material. A method for producing a reinforced decorative sheet, characterized by the following. 2. The barrier layer is formed by coating a synthetic resin liquid on the surface of a porous substrate, placing a sheet material for impregnation thereon, impregnating the impregnated sheet material with the synthetic resin liquid, and curing the impregnated sheet material. The method for manufacturing a reinforced decorative board according to claim 1, wherein the reinforced decorative board is formed by bonding and integrating with a substrate. 3. The synthetic resin liquid has a resin content of 55% by weight or less.
3. The method for producing a reinforced decorative board according to claim 2, wherein the aqueous synthetic resin solution is 80% by weight, and the synthetic resin solution is applied to the surface of the porous substrate in an amount of 250 to 600 g / m < ² >. 4. The method for producing a reinforced decorative board according to claim 2, wherein the synthetic resin liquid is an acrylic-modified trimethylolmelamine. 5. The sheet material for impregnation has a thickness of 0.15 mm to 0.4 m.
^3. The method for producing a reinforced decorative sheet according to claim 2, wherein the paper is m and the density is 0.4 g / m < ³ > to 0.6 g / m < ³ >. 6. The method for producing a reinforced decorative sheet according to claim 1, wherein the film-forming adhesive layer has a thickness of 10 to 30 μm. 7. The decorative thin sheet material is an undried veneer veneer having a thickness of 0.5 mm or less, and the barrier layer and the undried veneer veneer are bonded by heating and pressurizing. The method for producing a decorative veneer according to claim 1, wherein the moisture is evaporated.