JPH0159103B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a textured decorative composite board used for furniture, architectural interior materials, etc., and a method for manufacturing the same.

Furniture, electrical appliance cabinets, doors, architectural interior walls, etc. often have deep uneven patterns.
Most of these are made of a base material such as particle board or plywood that has been processed into a deep uneven pattern, and a vinyl chloride sheet or the like printed with a veneer or wood grain pattern is attached to the base material. To form a deep uneven pattern on a base material such as particle board or plywood, it is possible to easily form a complex uneven pattern using a woodworking machine such as an NC router, but the more complex the shape, the more expensive the machine is required. There are drawbacks such as high processing costs, such as the need for cutting tools and the wear and tear of cutlery compared to wood. In addition, when using veneer as a surface decorative material, the veneer and thin paper are glued together and pasted on the base material with the uneven pattern described above, but after temporary adhesion while following the uneven pattern of the core material. Not only is productivity low as it requires many steps to prevent the veneer from tearing, such as pressurized adhesive bonding, but it is also very expensive as it requires finishing such as painting on the product after the actual adhesive bonding. becomes. On the other hand, when using a vinyl chloride sheet as a surface decorative material, it can be easily bonded using a vacuum forming press, but the processed surface of the base material is likely to appear on the product, and the hardness, heat resistance, and abrasion resistance There are disadvantages such as poor surface performance of other products.

On the other hand, thermosetting resin decorative boards used as surface decorative materials generally have an uneven pattern formed during the manufacturing process, and an uneven pattern that matches the design or a delicate uneven pattern that covers the entire surface can be expressed. However, the depth of the uneven pattern is about 300 μm at maximum, making it difficult to create a deep uneven pattern. In addition, when thermosetting resin decorative laminates for post forms are used as surface decorative materials, it is also known to apply a drawing process to the sink attachment part of a sink, for example. Alternatively, the method is essentially no different from the method of pasting a vinyl chloride sheet.

The present invention uses a thermosetting resin decorative board as a surface decorative material, interposes a synthetic resin foam between it and the base material, and when laminating and integrating with an adhesive layer, the surface of the thermosetting resin decorative board is By applying an irregularity-imparting material of an arbitrary shape and hot-pressing it, the elasticity, heat deformability, and other characteristics of the synthetic resin foam of the intermediate layer can be effectively used, and the surface layer can be formed without creating an irregular pattern on the base material. A deep drawing pattern of an arbitrary shape is added to a thermosetting resin decorative board.

Hereinafter, the present invention will be explained in detail based on the drawings.

Thermosetting resin decorative board 1 refers to a decorative board made of melamine resin, diallyl phthalate resin, polyester resin, phenol resin, modified resin of these resins, etc., and is divided into general products used as flat boards and curved parts depending on the purpose. The latter is more suitable for the purpose of the present invention, but is not particularly limited. The thickness of this thermosetting resin decorative board 1 is also not particularly limited; if you want a deep uneven pattern, you will need a thin one, and if you want to improve the surface performance of the product, you will need a thick one. The properties are determined depending on the intended use of the uneven decorative composite board of the invention. Therefore, the thermosetting resin decorative board 1 that can be used in the present invention includes a wide range of thicknesses, from the so-called flexible type with a thickness of about 0.2 to 0.3 mm to a high-pressure melamine decorative board with a thickness of about 1.2 mm. In addition, the synthetic resin foam 2 is made of thermoplastic resins such as polystyrene resin, polyethylene resin, polypropylene resin, polyvinyl chloride resin, etc., and thermosetting resins such as phenolic resin, polyurethane resin, urea resin, etc. Although it is broadly divided into two types, it includes both of these.
The hardness and density of this synthetic resin foam 2 are appropriately selected depending on the desired values such as the cushioning properties of the product obtained by integrally molding by hot pressure molding, and are not particularly limited. It goes without saying that it needs to be thicker than the depth of the unevenness of the desired product, but is not particularly limited in other respects. Furthermore, as for the base material 4, various materials can be used depending on the purpose of the uneven decorative composite board of the present invention, and in addition to wood-based materials such as plywood, hardboard, particle board, and insulation board, fiber-reinforced inorganic board, Metal plates etc. can also be used.

The thermosetting resin decorative board 1, synthetic resin foam 2
and an adhesive layer 3 for adhering these layers of the uneven decorative composite board of the present invention having the base material 4 as its main component.
All kinds of adhesives, such as thermosetting resins, thermoplastic resins, and rubber adhesives, can be used as adhesives, but they are limited by factors such as the cushioning properties of the product to be obtained and the hot-press molding conditions.

In the uneven decorative composite board of the present invention, the thermosetting resin decorative board 1 on the surface layer is deep-drawn in an arbitrary pattern, and is formed into an uneven shape in complete synchronization with the deep drawing pattern of the thermosetting resin decorative board 1. The synthetic resin foam 2 is bonded via the adhesive layer 3, and these are further bonded to the base material 4 via the adhesive layer 3, thereby forming the thermosetting resin decorative board 1, the synthetic resin foam 2, and the base material. 4 are integrated. This uneven decorative composite board is made of synthetic resin foam that is elastic and easily follows complex and large deformations, and has a density that is smaller than that of base materials such as particle board or plywood, and can be easily deformed with a fairly small force. Since the body 2 is used as an intermediate layer, it is molded into an uneven shape that perfectly matches the deep drawing pattern of the thermosetting resin decorative board 1 on the surface layer, and the synthetic resin is used for the adhesive layer 3 on both layers. foam 2
The repulsion elastic force is constantly acting to strengthen the bond. In addition, if the thickness of the synthetic resin foam 2 is selected to be thicker than the depth of the desired unevenness of the product, the deep drawing pattern of the thermosetting resin decorative board 1 on the surface layer can be formed. The corresponding uneven pattern is only formed on the synthetic resin foam 2 of the intermediate layer, and the base material 4 is not affected in any way. Adhesion between the synthetic resin foam 2 and the base material 4 is performed via the adhesive layer 3,
The type of adhesive layer 3 does not necessarily have to be the same as the adhesive layer 3 between the thermosetting resin decorative board 1 and the synthetic resin foam 2, and can be freely selected depending on the type of the base material 4. Can be done.

As described above, the uneven decorative composite board of the present invention is
The thermosetting resin decorative board 1, which has excellent performance as a surface decorative material and does not require finishing processes such as painting, is used, and an uneven pattern is not applied to the base material 4, making it possible to easily create complex patterns with extremely low pressure. By applying this to the synthetic resin foam 2 that freely follows the shape, the trouble of roughening the base material 4 can be eliminated, and by changing the type of the synthetic resin foam 2, it can be applied to the product. When using net-like bodies or perforated plate-like bodies to impart cushioning properties or as an embossing material during hot-press molding as described later, soft curved surfaces can be freely expressed from concave parts to convex parts. It has many excellent features.

Next, a method for manufacturing the uneven decorative composite board of the present invention will be explained.

First, the synthetic resin foam 2 and the thermosetting resin decorative board 1 are sequentially laminated on the base material 4 via the adhesive layer 3, and the adhesive layer 3 can be made of various resins as described above. Furthermore, various methods are possible for forming this adhesive layer. 1st
In the second step, a sheet-like material made of thermosetting resin or thermoplastic resin is directly used as a thermosetting resin decorative board 1.
In this method, the adhesive layer 3 is inserted between the layers of the synthetic resin foam 2 and the synthetic resin foam 2 and between the synthetic resin foam 2 and the base material 4. This method is easy to handle and guarantees stable adhesive strength as long as the hot-press molding conditions are constant. The second step is to apply a thermosetting resin, thermoplastic resin, rubber adhesive, etc. to the surfaces of the thermosetting resin decorative board 1, synthetic resin foam 2, and base material 4 to be bonded, and apply this to the adhesive layer 3. This is the method to do so. Depending on the type of adhesive, this method may be a little cumbersome in terms of operation, as it may be necessary to apply adhesive to both sides of the adhesive surface, but since there are many types of adhesives, it is difficult to use depending on the type of base. A material having good adhesion to the material 4 can also be selected. The third method is to use a synthetic resin foam 2 for the intermediate layer that has been impregnated with a thermosetting resin or a thermoplastic resin. A portion of the resin oozes out onto the surface of the synthetic resin foam 2, and this resin becomes the adhesive layer 3. In this method, the synthetic resin foam 2, the thermosetting resin decorative board 1, and the base material 4 must be bonded with one type of resin, and the type of adhesive that can be used depends on the type of the base material 4. Although limited, it has the characteristic that the properties of the synthetic resin foam 2 can be significantly modified by impregnating the synthetic resin foam 2 with a resin.

Next, an irregularity-imparting material having an arbitrary shape is applied to the surface of the laminate in which the thermosetting resin decorative board 1, the synthetic resin foam 2, and the base material 4 are laminated with the adhesive layer 3 interposed therebetween, and hot-press molding is performed. The irregularity-imparting material of any shape used here is selected depending on the desired irregularity pattern on the surface thermosetting resin decorative board 1, and the material can withstand the heat and pressure during thermoforming. Anything can be used, such as phenolic resin used in the production of conventional uneven decorative boards, shaped plates such as aluminum plates and stainless steel plates, wire mesh, expanded metal, net-like bodies such as cloth, and perforated plates such as punched metal. You can use your body etc. When using a forming plate with relatively shallow irregularities, which is used in the production of conventional uneven decorative boards, etc., the surface thermosetting resin decorative board 1 comes into contact with the entire surface of the forming plate during hot-press molding. Therefore, it is only possible to express an uneven pattern that is exactly the same as the uneven pattern of the forming plate. On the other hand, when using a net-like body, a perforated plate-like body, etc., there are parts where pressure is applied to the surface layer thermosetting resin decorative board 1 and parts where no pressure is applied at all during thermoforming. In the areas where pressure is applied, the synthetic resin foam 2 of the intermediate layer is compressed to form a concave part, whereas in the areas where no pressure is applied, a convex part is formed, but the transition from the concave part to the convex part is caused by the forming plate. Unlike the case where the curved surface is constrained by, for example, the curved surface is not constrained, it has the excellent feature of expressing a soft curved surface that cannot be created artificially. In addition, when using a net-like material such as expanded metal whose cut surfaces are asymmetrical, the resulting decorative composite board with an uneven pattern will naturally have an asymmetrical uneven pattern and will have a varied appearance when viewed from a different perspective. You can enjoy something extremely unique. Furthermore, even when using a forming plate, the depth of the unevenness of the forming plate is sufficiently deep, so that only the convex portions of the forming plate are the surface layer of the thermosetting resin decorative board 1 during hot press forming. Under conditions in which the recessed portion of the forming plate does not come into contact with the surface thermosetting resin decorative board 1 at all, the same phenomenon as in the case of using the above-mentioned net-like body, perforated plate-like body, etc. occurs. It goes without saying that this will happen. In this way, various materials can be used as the irregularity-imparting material having an arbitrary shape, but it is possible to provide a unique texture with an irregular pattern by effectively utilizing the repulsion elastic force of the synthetic resin foam 2 of the intermediate layer. In addition, it is optimal for the textured decorative composite board of the present invention to use a net-like body or a perforated plate-like body, which are available as ready-made products. In addition, the thickness of the unevenness-imparting material having an arbitrary shape is automatically determined according to the desired depth of unevenness in the present invention, and it is naturally impossible to obtain an unevenness depth greater than the thickness of the unevenness-imparting material having an arbitrary shape. It is necessary to select an irregularity imparting material having an arbitrary shape and a thickness equal to or greater than the desired depth of the irregularities.

Next, a method of applying the unevenness imparting material of an arbitrary shape to the surface of the laminate and hot-pressing it will be described. This thermoforming is generally carried out using a flat plate press, and a cushion material, a backing plate, etc. are placed between the arbitrarily shaped unevenness imparting material and the base material 4 and the pressing plate facing each other, as necessary. However, the thermoforming of the present invention is not limited to only flat press.
The first thing to mention about the heating temperature in the hot-press molding method is that this heating temperature has a large effect on the elongation rate and flexibility of the surface layer thermosetting resin decorative laminate 1. For example, in the case of a melamine resin decorative laminate,
80~180℃, for diallyl phthalate resin decorative board
60~160℃, 60~140℃ for polyester resin decorative board
A temperature range of ℃ is suitable. When applying an unevenness imparting material of an arbitrary shape onto the surface layer thermosetting resin decorative board 1 and performing hot pressure molding, the surface layer thermosetting resin decorative board 1 is pressed by the convex portions of the unevenness imparting material of an arbitrary shape. The thermosetting resin decorative board 1 of the surface layer is in a state where it has largely dug into the synthetic resin foam 2 of the intermediate layer, and on the other hand, the part where no pressure is applied at all due to the unevenness imparting material of an arbitrary shape is the synthetic resin foam of the intermediate layer. If the hardness of the synthetic resin foam 2 is large, the amount of compression of the synthetic resin foam 2 is small, but if the hardness of the synthetic resin foam 2 is small, the composition of the thermosetting resin decorative board 1 at the convex portion of the irregularity imparting material of an arbitrary shape is reduced. The state is close to digging into the resin foam 2. In this state, when the surface layer thermosetting resin decorative board 1 is heated to the above-mentioned temperature, the flexibility of the thermosetting resin decorative board 1 increases, and the rebound resilience of the intermediate layer synthetic resin foam 2 increases. The force causes the thermosetting resin decorative board 1 to elongate, and the surface layer of the thermosetting resin decorative board 1 in the areas where no pressure is applied is raised due to the unevenness imparting material having an arbitrary shape, and as a result, a deep drawing process is performed. will be done.
The fact that the unevenness is achieved by the production method of the present invention based on the above-mentioned principle is that compressive force is always applied to the adhesive layer 3 between the surface layer thermosetting resin decorative board 1 and the intermediate layer synthetic resin foam 2. This is closely related to the fact that this ensures a strong adhesive force, and that the transition from the convex part to the concave part is very smooth and provides a soft curved surface. In addition, the relationship between the hot press molding conditions and the type of synthetic resin foam 2 of the intermediate layer will be described here. Synthetic resin foam 2 used for intermediate layer
If it is made of a thermoplastic resin, not only the surface layer thermosetting resin decorative board 1 is heated by the hot-press molding, but also the intermediate layer synthetic resin foam 2 is also heated. As a result, the synthetic resin foam 2 made of thermoplastic resin is softened by heating and has a certain degree of fluidity, and the synthetic resin foam 2 is formed in the areas pressurized by the convex portions of the unevenness imparting material having an arbitrary shape. Since the body 2 flows to a part where no pressure is applied due to the unevenness imparting material having an arbitrary shape, the above-mentioned repulsion elastic force of the synthetic resin foam 2 is combined with the deep drawing process of the surface layer thermosetting resin decorative board 1. will be administered. Next, if the synthetic resin foam 2 used for the intermediate layer is made of thermosetting resin, even if it is hot-press molded, the rebound elastic force of the synthetic resin foam 2 will be large when released from the hot-pressure state. Although it is difficult to perform a deeper drawing process than in the case of a synthetic resin foam made of thermoplastic resin, by using a thermosetting resin such as melamine resin, phenol resin, urea resin, or epoxy resin as the adhesive layer 3, Deep drawing is possible because the synthetic resin foam 2 is fixed to the surface thermosetting resin decorative board 1 in the state of deep drawing by thermopress molding. Regarding the magnitude of the pressure applied in the second step in the thermoforming method, the magnitude of this pressure is the same as the thermosetting resin decorative board 1 used for the uneven decorative composite board of the present invention.
The properties are automatically determined depending on factors such as the type of synthetic resin foam 2, the desired depth of deep drawing, and the temperature during hot press molding. Conversely, if the temperature of the thermosetting resin decorative board 1, the synthetic resin foam 2, and the temperature during hot-pressing molding are kept constant, the product can be obtained by changing the magnitude of the pressure during hot-pressing molding. It is possible to adjust the depth of deep drawing. In addition, the temperature of the surface layer of the decorative thermosetting resin laminate 1 when applying pressure is not particularly limited and may be at room temperature, but it may be around 60 to 100°C depending on the type of the decorative thermosetting resin laminate. It is important to carry out the process when the material is heated to a certain temperature, especially when performing deep drawing. In the thermo-press molding method, the last thing to mention is the presence or absence of cooling after heating. This is a property determined by the type of synthetic resin foam 2 of the intermediate layer and/or the type of adhesive layer 3, and is particularly applicable to the present invention. It does not affect the finish such as the deep drawing pattern of the textured decorative composite board.

By the hot-pressing method described above, the surface layer thermosetting resin decorative board 1 is deep-drawn using an irregularity imparting material of an arbitrary shape, and at the same time, the intermediate layer synthetic resin foam 2 is formed. An uneven shape is formed that is completely in sync with the deep-drawn pattern of the thermosetting resin decorative board 1 on the surface layer, and both layers are firmly adhered to each other through the adhesive layer 3, and are also bonded to the base material 4 through the adhesive layer 3. To provide an uneven decorative composite board that is integrated with adhesive. In this way, the method for manufacturing a textured decorative composite board of the present invention rationally combines the thermosetting resin decorative board 1, the synthetic resin foam 2, and the base material 4, and furthermore, effectively improves the thermal and mechanical properties. It's an extremely good thing to have used.

Note that, so far, only the case in which the synthetic resin foam 2 and the thermosetting resin decorative board 1 are laminated on the base material 4 has been described, but the present invention has a structure in which the synthetic resin foam 2 and the thermosetting resin decorative board 1 are laminated on both sides of the base material 4. Naturally, it also includes one in which a decorative resin board 1 is laminated and both sides are deep drawn.

Next, embodiments of the present invention will be described.

Example 1 A 4 mm thick polyethylene foam (density 0.14 g/cm ³ ) and a 0.5 mm thick diallyl phthalate resin decorative board were laminated on a 20 mm thick particle board with a polyolefin adhesive sheet interposed between each layer.

A flat top type wire mesh with a wire diameter of 3 mm and an opening of 35 mm was placed on the surface of this laminate, and a stainless steel backing plate and several sheets of cushion paper were placed on top of this.
Place a stainless steel plate and several pieces of cushion paper under the laminate.

This set of laminates is inserted between the hot discs of a flat press so that the laminates and the press hot discs are in slight contact with each other.

Next, heating is started and when the surface temperature of the diallyl phthalate resin decorative board reaches 80°C, pressure is applied until the flat top wire mesh, which is the unevenness imparting material, forms a deep drawing pattern with a depth of 3 mm on the diallyl phthalate resin decorative board. In this state, when the surface temperature of the diallyl phthalate resin decorative board reaches approximately 130°C, heating is stopped, forced cooling is performed, and when the surface temperature of the diallyl phthalate resin decorative board reaches 50°C, the pressure is released.

The surface of the textured decorative composite board obtained in this way has deep depressions formed in 35 mm squares, and the protrusions surrounded by the depressions show a smooth rise toward the center, giving only a visually soft appearance. It is extremely unique in that it also has tactile elasticity due to the polyethylene foam in the middle layer.

Example 2 Melamine resin for adhesive (solid content 40%) was applied to the surface of 20 mm thick particle board, both sides of 5 mm thick soft polyurethane foam (density 0.03 g/cm ³ ), and the back side of 0.6 mm thick modified melamine resin decorative board. and stack them in that order.

The surface of this laminate has a wire diameter of 1.5 mm and an opening of 13 mm.
Apply 28mm expanded metal, then place a stainless steel plate and several pieces of cushion paper on top of it.
Place a stainless steel plate and several pieces of cushion paper under the laminate.

This set of laminates is hot-pressed in the same manner as in Example 1. However, when the surface temperature of the modified melamine resin decorative board is 100℃, pressurize, and the maximum temperature is 140℃,
Depressurize at 50℃.

The surface of the uneven decorative composite board obtained in this way has a deep diamond-shaped recess of 13 mm x 28 mm, and the convex part surrounded by the recess not only draws a smooth curved surface toward the center, but also Since the unique asymmetric cut plane is projected as is, changing the viewpoint from side to side gives a different sense of unevenness.
Possible uses include wall covering materials. Furthermore, as the melamine resin used as the adhesive hardens, the rebound modulus of the soft polyurethane foam is suppressed to some extent, so the cushioning properties of the textured decorative composite board after hot-press molding are considerably reduced.

Example 3 A 3 mm thick soft polyurethane foam (density 0.07 g/cm ³ ) impregnated with an adhesive urea resin (solid content 50%) and a 0.4 mm thick polyester resin decorative board were laminated on a 20 mm thick particle board.

A 5 mm thick stainless steel plate with many holes with an inner diameter of 50 mm is placed on the surface of this laminate, a stainless steel backing plate and several pieces of cushion paper are placed on top of this, and a stainless steel backing plate and cushion paper are placed under the laminate. Apply paper.

This set of laminates is hot-pressed in the same manner as in Example 1. However, when the surface temperature of the polyester resin decorative board is 60℃, pressurize it, and the maximum temperature is 100℃,
When the temperature is 50°C, the pressure is released and the pressure is applied until a deep drawing pattern with a depth of 2 mm is formed on the polyester decorative board.

The surface of the textured decorative composite board obtained in this way has many circles with a diameter of 50 mm and a height of about 1.5 mm emerging, creating a visually soft deep-drawn pattern. However, as the urea resin impregnated into the soft polyurethane foam hardens during hot press molding, the softness of the soft polyurethane foam is completely suppressed, and tactile cushioning properties are almost completely lost.

[Brief explanation of drawings]

The drawing is a sectional view of the uneven decorative composite board of the present invention, where 1 represents a thermosetting resin decorative board, 2 represents a synthetic resin foam, 3 represents an adhesive layer, and 4 represents a base material.

Claims (1)

[Scope of Claims] 1. A surface layer consisting of a thermosetting resin decorative board 1 deep-drawn in an arbitrary pattern in which a convex part surrounded by a concave part curves smoothly toward the center, and the thermosetting resin This uneven decorative composite board is formed by laminating and integrating an intermediate layer made of a synthetic resin foam 2 formed into an uneven shape according to the deep drawing pattern of the decorative board on a base material 4 via an adhesive layer 3. 2. The synthetic resin foam 2 and the thermosetting resin decorative board 1 are sequentially laminated on the base material 4 via the adhesive layer 3, and the surface of the laminated set of these is coated with a net-like body or a perforated plate-like body. An unevenness imparting material of an arbitrary shape is applied and hot-press molded, and at the same time deep drawing is applied to the surface thermosetting resin decorative board 1 so that the convex part surrounded by concave parts forms a smooth curve toward the center. A method for manufacturing a textured decorative composite board, characterized in that a layer of synthetic resin foam 2 is formed into an uneven shape corresponding to the deep drawing pattern of the thermosetting resin decorative board 1. 3. Claim 2, characterized in that the synthetic resin foam 2 of the intermediate layer is a thermosetting resin or a thermoplastic resin foam, and the adhesive layer 3 is a thermosetting resin or a thermoplastic resin. A method for manufacturing a textured decorative composite board.