JP2010173202A - Decorative panel and manufacturing method of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a decorative panel of new grain appearance excellent in fanciness by harmonically merging color patterns of a printing layer and a concavo-convex thin veneer layer. <P>SOLUTION: The appearance is made to appear on a surface where the color pattern of a printing layer and the grain of a concavo-convex thin veneer are harmonically merged by preparing: the printing layer to conceal a surface color of a substrate on the substrate surface, a concavo-convex thin veneer with concave early-wood parts and convex late-wood parts on the surface of a printing layer through a transparent adhesive layer and a transparent resin coating layer on the surface of the concavo-convex thin veneer. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  TECHNICAL FIELD The present invention relates to a decorative board excellent in decorativeness and a method for producing the same, which is suitable for use as a flooring material for buildings such as houses, walls and other interior building materials and furniture face materials.

  Conventionally, a natural wood thin veneer is bonded to the surface of a plywood, MDF, or a wood substrate made of a composite board in which the surface of the plywood is reinforced with resin-impregnated paper or thin MDF, and a transparent resin coating is applied to the surface. Decorated decorative panels are well known and are widely used as decorative panels for residential floors and storage furniture. However, such natural name wood thin veneers have become depleted of resources, are difficult to obtain, and have become expensive, and it is necessary to use wood thin veneers that are less decorative than these natural name wood thin veneers. Yes.

  On the other hand, since such a woody thin veneer has also become expensive, recently, a thin object of about 0.2 mm to 0.5 mm is often used. In addition, plywood used for the wood substrate is made of a tree species having many defects such as nodes on the surface of conifers and afforestation trees, instead of the southern hardwoods. Furthermore, the color of MDF is also dark brown. For this reason, if the thin wood thin veneer as described above is bonded to the surface of such a plywood or dark brown MDF with many defects, the defects such as the node of the substrate and the dark surface color will be the surface of the wood thin veneer. The surface appearance of the decorative board is remarkably impaired.

  On the other hand, in Patent Document 1, a colored paper or the like is adhered to a base material, a thin decorative veneer is adhered to the base material via a transparent adhesive, and the surface is covered with a transparent paint layer. A color veneer laminate is shown in which a different color and a wood grain pattern of the veneer are projected and the fine wood texture of the veneer is faithfully expressed.

  According to this, an expensive natural wood veneer can be used very thinly, and the desired color and the wood texture of the veneer can be displayed by concealing the base material color. Those with different shades can be provided.

  However, with this method, it is possible to obtain a decorative plate with a special color tone such as yellow, blue, and gray while taking advantage of the decorative wood texture of the natural wood veneer. It was not possible to enhance the decorativeness of the wood grain, reveal a new wood grain appearance not found in natural wood, or give the wood grain appearance a depth or a three-dimensional feel.

  Moreover, since an extremely thin woody thin veneer is required, there is a problem that production such as slicing and bonding is difficult.

JP-A-3-83601

  The present invention has been made in view of such conventional problems, and is not affected by defects or colors on the substrate surface, has a three-dimensional appearance and depth, and has a new wood-grained decorative board excellent in decorativeness and its production. It aims at providing a manufacturing method with good property.

  In order to achieve the above object, the decorative board of the present invention is provided with a printed layer on the surface of the substrate that has a color pattern that fuses and harmonizes with the color pattern of the grain and conceals the surface color of the substrate, and the surface of the printed layer. A concave / convex thin veneer layer having a concave spring portion and a convex autumn portion is provided via a transparent adhesive layer, and a transparent resin coating layer is provided on the surface of the concave / convex thin single plate layer to provide a printed layer. The main feature is that the appearance that the color pattern of the ruggedness and the color pattern of the grain of thin rugged wood are fused and harmonized appears on the surface.

  In order to achieve the above object, the decorative board manufacturing method of the present invention forms a printed layer on the surface of the substrate with a color pattern that blends and harmonizes with the color pattern of the wood and that conceals the surface color of the substrate. A printing layer forming step, a thin veneer bonding step in which a transparent adhesive is applied to the surface of the printing layer, and a thin veneer having a thickness of 0.2 mm to 0.5 mm is bonded; and the surface of the thin veneer A thin single plate grinding process for forming a concave / convex thin single plate layer having a spring portion as a concave and an autumn eye portion as a convex by shot blasting or brushing, and a transparent resin coating on the surface of the concave / convex thin single plate layer And a resin coating application step of forming a transparent resin coating layer by applying the above.

  According to the decorative board and the method for producing the same of the present invention, the defects such as the nodes of the substrate and the surface color of dark brown are not shielded by the printing layer and appear on the surface, and the color pattern of the printing layer is uneven. A decorative board having a new three-dimensional appearance and deep grain appearance can be obtained in harmony with the color pattern of a single board, and such a decorative board can be manufactured with high productivity.

It is sectional drawing which showed the decorative board A which is embodiment of this invention. It is sectional drawing which showed the decorative board B which is embodiment of this invention. It is sectional drawing which showed the decorative board C which is embodiment of this invention. It is explanatory drawing which showed the manufacturing method of the decorative board A which is embodiment of this invention.

  Hereinafter, embodiments of a decorative board and a manufacturing method thereof according to the present invention will be described with reference to the drawings. Note that the present invention is not limited to the description of the present embodiment.

  FIG. 1 shows a cross-sectional view of a decorative board A according to an embodiment of the present invention. The decorative board A is provided with a printing layer 4 composed of an opaque adhesive layer 2 and a printing paper layer 3 on the surface of the substrate 1 in order from the bottom, and a transparent adhesive layer 5 is provided on the surface of the printing layer 4, An uneven thin single plate layer 6 is provided on the surface of the transparent adhesive layer 5, and a transparent resin coating layer 7 is provided on the surface of the uneven thin single plate layer 6.

  As the substrate 1, a wood board such as plywood, MDF, LVL, particle board, a wood composite board in which thin MDF is laminated and bonded to the surface of these wood boards, or a resin layer or the like on the surface of these wood boards or wood composite boards A wood substrate provided with a resin-impregnated paper layer and having a reinforced surface can be suitably used. Other than such a wooden substrate, an inorganic plate such as an inorganic fiber plate or a volcanic glassy multilayer plate, a synthetic resin plate, or the like can also be used as the substrate 1.

  In the present embodiment, the printing layer 4 is formed of the opaque adhesive layer 2 and the printing paper layer 3. As the opaque adhesive layer 2, a white pigment such as titanium oxide is added to an adhesive that exhibits transparency after curing such as an adhesive such as an ethylene vinyl acetate resin adhesive or a urea melamine resin adhesive, thereby providing concealability. Can be used.

  The printed paper layer 3 may be a pattern printed with a wood grain pattern such as a grain pattern or a grid pattern, a pattern printed with a continuous or intermittent linear stripe pattern, or a continuous or intermittent wave pattern. Printed, printed with ground pattern such as grain pattern, rock texture pattern, spotted pattern, yuzu skin pattern, other irregular curve pattern or fine lattice pattern, and these The printing can be performed entirely or partially with pearly or metallic lustrous or glossy color, or with other colors.

  Such a color pattern of the printing paper layer 3 appears strongly in the spring portion 8 which is the concave portion when the uneven thin veneer layer 6 described later is provided on the surface, and hardly stands out in the autumn portion 9. In consideration of this, it is set to blend and harmonize with the grain and color tone of the uneven thin veneer layer 6 to give the surface of the decorative board A a three-dimensional feeling and depth, and to enhance the new sense of grain appearance. Can be selected.

  In the present embodiment, the adhesive layer 2 is made opaque in order to provide the printing layer 4 with concealing property, but not limited to this, the printing paper layer 3 having concealing property is used. You can also. Specifically, it is possible to use printing paper in which a concealing sheet such as aluminum foil is bonded to the back surface, or printing paper in which a white pigment is internally added. The printing paper in this embodiment is not limited to paper made from so-called vegetable fibers, but is printed on a wide variety of raw materials such as synthetic fiber paper, synthetic resin films, and sheets. Can be used.

  The transparent adhesive layer 5 needs to be transparent or semi-transparent in a cured state and to be able to transmit or semi-transmit the color pattern of the printing layer 4 to the surface. Specifically, such a transparent adhesive layer 5 is a cured product of an adhesive such as urea / melamine resin, melamine resin, ethylene vinyl acetate resin, vinyl urethane resin, or a small amount of a color pigment in these adhesives. A translucent cured body of a mixed colored adhesive or the like can be used.

  As the rugged thin single plate layer 6, one having a float-like appearance in which the concave portion is formed by the spring eye portion 8 and the convex portion is formed by the autumn eye portion 9 can be used. Here, it is preferable that the thickness of the spring part 8 is 0.05 mm or less, and the thickness of the autumn part is preferably about 0.05 mm to 0.5 mm. As a result, the color pattern on the surface of the printed layer 4 that has passed through the transparent adhesive layer 5 is strong in the thin spring portion 8 and weak in the thick autumn portion 8 or uneven in an inconspicuous state. It becomes possible to appear on the surface in harmony with the color pattern of the thin single plate layer 6.

  Here, when the thickness of the spring part 8 that is a concave portion exceeds 0.05 mm, the color pattern of the printed layer 4 is fused and harmonized with the color pattern of the uneven thin single plate layer 6 to appear as a new design appearance. Is unclear. Further, when the thickness of the autumn eye portion 9 which is a convex portion is 0.05 mm or less, the appearance of the color pattern of the printed layer 4 becomes smaller in the spring eye portion 8 and the autumn eye portion 9 and the cosmetic appearance is impaired. This is not preferable because the processing may be difficult.

  As a result, the color pattern of the printed layer 4 and the color pattern of the wood veneer veneer are strong in the spring, even if a veneer veneer veneer that is not so decorative is used for the uneven thin veneer layer 6 It becomes possible to fuse and harmonize the eye part so that it is weak or hardly noticeable.

  The transparent resin paint layer 7 can be provided so that the unevenness of the uneven thin single plate layer 6 is embedded and the surface becomes smooth. As the resin used for the transparent resin coating layer 7, for example, a resin that exhibits transparency after curing, such as a urethane acrylate resin, an epoxy acrylate resin, or a methacrylate resin, can be used. And what becomes translucent after hardening can also be used.

  As a result, the color pattern of the printed layer 4 and the uneven thin single plate layer 6 is strong in the spring part 8 and weak in the autumn part 9, or has a new wood grain appearance fused to a degree that is hardly noticeable. It can appear on the surface through the transparent resin coating layer 7. Here, the surface of the transparent resin coating layer 7 may be further provided with a transparent resin coating layer for overcoating to enhance the surface protection.

  Here, a specific example of the color pattern of the printing layer 4 to be used, the color pattern of the uneven thin single plate layer to be used, and a new wood grain appearance in which these color patterns appear in a fusion and harmony manner. As a first example, as a color pattern of the printing layer 4, a light brown printing paper printed with a fine hairline-like stripe pattern having a width of 0.5 mm to 3 mm is used. As a pattern, a single piece of Sawagurumi with little change is used, and the length of the stripe pattern of the printed layer 4 is oriented in a direction perpendicular to the length direction (vertical direction) of the Sawagurumi single veneer. In the case of providing a single plate, the striped color pattern of the printed layer 4 appears strong on the surface in the spring part of the Sawagurumi single plate, and weakly on the surface in the autumn part. A wild appearance with a natural view like this can appear on the surface.

  As a second example, in the first example, a strip of single piece of walnuts so that the length direction of the stripe pattern of the printing layer 4 is oriented in a direction parallel to the length direction (longitudinal direction) of the single piece of walnut slices in the first example. In the other cases, the stripe-like color pattern of the printed layer 4 appears on the surface strongly in the spring part of the Sawagurumi veneer veneer and weakly in the autumn part. A new wood grain appearance with a natural view like a combination of shine and glazed eyes can be displayed on the surface.

  As a third example, a gold (gold pearl) printing paper having a fine grained ground pattern is used as the color pattern of the printing layer 4, and the color pattern of the grain pattern of the uneven thin veneer layer 6 is the first When using the same Sawagurumi veneer veneer as in the example, the fine wrinkled pattern of gold (gold pearl) on the printed layer 4 is strong in the spring eye portion of the Sawagurumi veneer veneer and weakly in the autumn eye portion. Appearance, with the addition of grainy patterns and their brilliant colors, a new artificial wood grain appearance can appear on the surface.

  As a fourth example, as a color pattern of the printing layer 4, a printing paper in which a fine diagonal lattice pattern of about 3 mm interval is printed in a light gray-green color, When the same Sawagurumi veneer veneer as in the first example is used, the diagonal lattice pattern of the printed layer 4 appears on the surface strongly in the spring eye portion of the Sawagurumi veneer veneer and weakly in the autumn eye portion. It is possible to bring out a new artificial wood grain appearance on the surface as if it were calm and embossed with a diagonal lattice.

  FIG. 2 shows a case where a concealing direct print layer is provided on the surface of the substrate 1 as the print layer 4, and the other is a decorative board B configured in the same manner as the decorative board A. According to this, the printed layer 4 can be formed with higher productivity.

  FIG. 3 also shows that the transparent resin coating layer 7 of the decorative board A is provided so as not to lose the floating undulations of the uneven thin veneer so that the surface has a grainy appearance, and other configurations are applied. A decorative board C configured in the same manner as the board A. According to this, since the unevenness of the floating tone actually appears on the surface, it is possible to feel the unevenness tactilely.

  Next, the manufacturing method of the decorative board A is demonstrated according to (a)-(g) of FIG. 4A shows the substrate 1, and in the printing layer forming step, first, as shown in FIG. 4B, an opaque adhesive 2 ′ is applied to the surface of the substrate 1 with a roll coater or a flow coater. To do. Here, as the opaque adhesive 2 ′, a white pigment such as titanium oxide is added to an adhesive that exhibits transparency after curing, such as an ethylene vinyl acetate copolymer resin adhesive or an aqueous urea melamine resin adhesive. Thus, it is possible to use one that is adjusted to be opaque after curing.

  Next, in a state where the applied opaque adhesive 2 ′ is uncured, the printing paper 3 is placed on the surface as shown in FIG. 4C, and the opaque adhesive 2 ′ is cured and bonded. They are integrated to form a printing layer 4 composed of the opaque adhesive layer 2 and the printing paper 3.

  Next, in the thin single plate bonding step, as shown in FIG. 4 (d), the surface of the printed layer 4 is coated with a transparent adhesive 5 ′ that exhibits transparency after curing with a roll coater or a flow coater. To do. Here, as the transparent adhesive 5 ′, an aqueous urea melamine resin adhesive, an aqueous melamine resin adhesive, an aqueous vinyl urethane resin adhesive, or the like can be used.

  Next, the applied transparent adhesive 5 ′ is in an uncured state, and as shown in FIG. 4 (e), a wooden decorative thin veneer 6 ′ having a thickness of 0.2 mm to 0.5 mm on the surface thereof. The transparent adhesive 5 ′ is cured by pressurization or heating and pressurization to form the transparent adhesive layer 5, and the wood decorative thin veneer 6 ′ is bonded and integrated.

  Next, in the thin veneer grinding step, the surface of the wood-decorated thin veneer 6 ′ is ground by brushing or shot blasting, and as shown in FIG. To form. The uneven thin veneer layer 6 having a floating tone is formed as a result of grinding the soft spring part 8 of the wooden veneer veneer 6 'more than the hard autumn part 9, and preferably the spring part. It is preferable that the portion 8 has a thickness of 0.05 mm or less, and the autumn eye portion 9 is ground so that its thickness is in the range of 0.05 mm to 0.5 mm. The spring part can be ground to such an extent that the lower transparent adhesive layer 5 is partially exposed.

  Next, a transparent resin coating is applied to the surface of the uneven thin single plate layer 6 so that the unevenness is completely buried and the surface becomes a smooth surface, and cured by irradiation with ultraviolet rays from the surface. The decorative board A is manufactured by forming the adhesive resin coating layer 7. Here, as the transparent resin paint, ultraviolet curable resins such as urethane acrylate resins, epoxy acrylate resins, and methacrylate resins can be suitably used.

A wood composite board formed by adhering 3 mm thick MDF to the surface of 9 mm thick softwood plywood was prepared as a substrate. The surface color of this substrate was dark brown, which is the color of MDF. Next, an opaque adhesive prepared by adding 10 parts by weight of a white pigment made of titanium oxide to the solid content of the ethylene vinyl acetate resin emulsion adhesive on the surface of the substrate is 50 g / m ^{2 in} terms of solid content. It was applied as follows. Next, on this adhesive-coated surface, a thin paper with a basis weight of 23 g is laminated with a printed paper on which a pearl-colored brilliant 0.5 mm to 3 mm wide hairline-like stripe pattern is printed, and then dried by adhesion. A printed layer was formed. As a result, the dark brown color of MDF on the substrate surface was concealed by the printing layer comprising this opaque adhesive and printing paper, and did not appear on the surface of the printing layer.

Next, an aqueous urea melamine resin adhesive that exhibits transparency after curing is applied to the surface of the printed layer so as to be 35 g / m ^{2 in} terms of solid content. The thin sheet single plate was placed so that the length direction of the plate faced the length direction of the stripe pattern of the printed layer, and was bonded by heat and pressure. Next, the surface of this thin veneer is shot blasted with glass particles having an average particle diameter of 60 μm, the thickness of the soft spring part becomes 0.05 mm or less, and the thickness of the hard autumn part becomes thicker than that. Were formed into a float-like concavo-convex thin single plate.

Next, an ultraviolet curable transparent urethane acrylate resin coating is applied to the surface of the uneven thin plate, and 150 g / m ^{2 in} terms of solid content is applied so that the uneven surface is completely buried and the surface becomes a smooth surface. A decorative board according to Example 1 was obtained. In addition, by this application | coating, a part of said transparent resin coating osmose | permeated many to the uneven | corrugated wooden thin veneer, especially its soft spring part, and further improved the permeability of the spring part.

  The decorative board obtained in this way has a grainy appearance with little change in the single piece of Sawagurumi veneer, and the fine stripes of the printed layer are strong in the spring and weak in the autumn. Harmonious, transparent urethane acrylate resin paint layer is added to add a three-dimensional effect, depth and luster, and it appears on the surface as a natural new wood grain appearance that makes a striped pattern feel like a striped pattern. It was.

  In Example 1, when heat-pressure bonding of a thin slice of Sawagurumi to the surface of the printing layer, the length direction of the thin slice of Sawagurumi is the length direction of the stripe pattern of the printing layer. The decorative board according to Example 2 was obtained in the same manner as in Example 1 except that the decorative plate was mounted in a direction orthogonal to the above.

  The decorative board obtained in this way has a fine stripe-like color pattern on the printed layer, which is strong in the spring and weak in the autumn, and harmonizes weakly. The rough thorn pattern tones that feel the traces appeared on the surface with a natural and wild appearance completely different from that of Example 1.

  In Example 1, the decorative board according to Example 3 was obtained in the same manner as in Example 1 except that gold-colored printing paper on which fine and irregular spots were printed was used as the color pattern of the printed layer. .

  The decorative board obtained in this way has a fine and irregular gold-colored pattern on the printed paper, which is strong in the uneven thin veneer of Sawagurumi and in the spring part, and in the autumn part. It was weakly fused and harmonized, and it appeared on the surface as a new grained appearance with glitter, three-dimensionality, and natural feeling, with the spring part highlighted by a golden spotted pattern.

In Example 1, an ultraviolet curable transparent urethane acrylate resin coating is applied to the surface of the uneven wooden thin veneer so that the uneven surface of the uneven wooden thin veneer remains 150 g / m ^{2 in} terms of solid content. The decorative board according to Example 4 was obtained in the same manner as in Example 1 except that coating was performed.

  In addition to the wood grain appearance of the decorative board according to Example 1, the decorative board obtained in this way can feel irregularities in the tactile sensation with the actual appearance of floating irregularities appearing on the surface. It was.

In Example 1, as the color pattern of the printing layer, printing paper on which a grain pattern of 1-5 mm intervals was printed was used, and the aqueous urea melamine resin adhesive used in Example 1 was applied to the surface of this printing layer. It was applied so that the solid content was 35 g / m ^2, and the surface of the 0.25 mm thick Sawagurumi thin single plate similarly used in Example 1 was printed on the surface in the length direction of the plate. The decorative board according to Example 5 was obtained in the same manner as in Example 1 except that it was placed so as to face the length direction of the wood grain pattern of the layer and heat-pressure bonded.

  The decorative board obtained in this way has a grain pattern of the decorative paper, which is strong in the Sawagurumi board, and strong in the spring part, weak in the autumn part, and weakly harmonized with the depth. It appeared on the surface as a new wood grain appearance with a natural feeling.

Comparative example

  In Example 1, the decorative sheet according to the comparative example was obtained in the same manner as in Example 1 except that the thin single plate grinding step by shot blasting was not performed.

  The decorative board thus obtained does not appear as a decorative pattern such that the stripe pattern of the printed paper is unclear and intended at the spring part of the decorative board surface. As the product value was poor.

  By combining the color pattern of the printed paper with the grain pattern of the woody thin veneer, it can be formed into a decorative board with a new design that is artificial and excellent in decorativeness. It can be applied to a wide range of applications such as vehicular cosmetics, umbrellas and tools, doll cases, and wood-grained cosmetics such as picture frames.

A, B, C Decorative plate 1 Substrate 2 Opaque adhesive layer 3 Printing paper layer 4 Printing layer 5 Transparent adhesive layer 6 Uneven thin single plate layer 7 Transparent resin coating layer 8 Spring eyes 9 Autumn eyes

Claims (12)

  A printed layer is provided on the surface of the substrate that has a color pattern that blends and harmonizes with the color pattern of the wood, and conceals the surface color of the substrate, and the spring layer is recessed on the surface of the printed layer via a transparent adhesive layer. An uneven thin veneer layer having a convex portion at the autumn eyes is provided, and a transparent resin coating layer is provided on the surface of the uneven thin veneer layer so that the color pattern of the printed layer and the grain pattern of the uneven thin veneer A decorative board with a fusion and harmonious appearance on the surface.   The decorative board according to claim 1, wherein the thickness of the spring eyes of the uneven thin single plate layer is 0.05 mm or less.   The decorative board according to claim 1 or 2, wherein the printed layer is a pearl-like printed layer.   The decorative board according to any one of claims 1 to 3, wherein the uneven thin single plate layer is impregnated with a part of the transparent resin paint.   The decorative board according to any one of claims 1 to 4, wherein the transparent resin coating layer is provided so as to have a smooth surface by embedding an uneven thin veneer layer.   Applying a transparent adhesive on the surface of the printed layer, a printed layer forming step of forming a printed layer that conceals and blends with the color pattern of the grain on the surface of the substrate, and conceals the surface color of the substrate, A thin veneer bonding process for bonding thin veneers with a thickness of 0.2 mm or more and 0.5 mm or less, and the surface of the thin veneer is ground by shot blasting or brushing to make the spring eyes concave and the autumn eyes convex A thin veneer grinding process for forming an uneven thin veneer layer, and a resin paint application step for forming a transparent resin paint layer by applying a transparent resin paint on the surface of the uneven thin veneer layer. A method for producing a decorative board, comprising:   The method for producing a decorative board according to claim 6, wherein the printed layer is formed by applying an opaque adhesive to the surface of the substrate and laminating the printed paper on the surface.   The method for producing a decorative board according to claim 6, wherein the printed layer is formed by direct printing so as to conceal the surface color on the surface of the substrate.   The method for producing a decorative board according to any one of claims 6 to 8, wherein grinding is performed so that a thickness of a spring portion of the uneven thin single plate layer is 0.05 mm or less.   The method for producing a decorative board according to claim 6, wherein the printed layer is a pearl-like printed layer.   The method for producing a decorative board according to claim 6, wherein a part of the transparent resin coating is impregnated in the spring part of the uneven thin single plate layer.   The method for producing a decorative board according to any one of claims 6 to 11, wherein the transparent resin coating layer is applied so that the uneven thin single plate layer is embedded and the surface becomes smooth.

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