JP3152880B2 - Manufacturing method of decorative board - Google Patents
Manufacturing method of decorative boardInfo
- Publication number
- JP3152880B2 JP3152880B2 JP26337296A JP26337296A JP3152880B2 JP 3152880 B2 JP3152880 B2 JP 3152880B2 JP 26337296 A JP26337296 A JP 26337296A JP 26337296 A JP26337296 A JP 26337296A JP 3152880 B2 JP3152880 B2 JP 3152880B2
- Authority
- JP
- Japan
- Prior art keywords
- sheet material
- decorative
- decorative board
- coater
- manufacturing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Application Of Or Painting With Fluid Materials (AREA)
- Laminated Bodies (AREA)
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、主に内装材として
様々な用途に使用される化粧板の製造方法に関するもの
である。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative board mainly used as an interior material for various uses.
【０００２】[0002]
【従来の技術】内装材として使用される化粧板は、市場
において不燃及び準不燃化粧板の需要が高まっており、
それに用いられる化粧板には、珪酸カルシウム板等の不
燃性基材の表面に化粧層を施したものや、ガラス不織布
やガラス織布を基材として水酸化アルミニウム等の無機
フィラーと樹脂を含有する配合物を含浸させたものを積
層して加熱加圧成形したものが殆どである。珪カル板等
の不燃性基材の表面に化粧層を施したものは軽量で且つ
安価であるが脆く、ガラス不織布やガラス織布を基材と
して水酸化アルミニウム等の無機フィラーと樹脂を含有
する配合物を含浸させたものを積層して加熱加圧成形し
たものはガラス不織布やガラス織布基材への配合物の含
浸処理率に限界があり、化粧板中ガラス基材比率が高く
なるため高強度ではあるがコスト的に高いものとなって
しまう。2. Description of the Related Art The demand for non-combustible and semi-non-combustible decorative panels in the market for decorative panels used as interior materials is increasing.
The decorative plate used for it contains a decorative layer on the surface of a non-combustible substrate such as a calcium silicate plate, or contains a glass nonwoven fabric or a glass woven fabric as a base material and contains an inorganic filler such as aluminum hydroxide and a resin. In most cases, the products impregnated with the compound are laminated and heated and pressed. A non-combustible substrate such as a silica plate provided with a decorative layer on its surface is lightweight and inexpensive but brittle, and contains an inorganic filler such as aluminum hydroxide and a resin based on a glass nonwoven fabric or a glass woven fabric. Heat-press molding of the compound impregnated laminate is limited in the rate of impregnation of the compound into the glass nonwoven fabric or glass woven fabric substrate, and the ratio of the glass substrate in the decorative plate increases. Although it has high strength, it is expensive.
【０００３】[0003]
【発明が解決しようとする課題】本発明は、ガラス不織
布やガラス織布を基材とし、これに水酸化アルミニウム
等の無機充填材と樹脂を含有する配合物を塗工する工程
において、従来の方式では困難であった膜厚の厚い塗工
を実現することにより、安価な化粧板を提供するもので
ある。SUMMARY OF THE INVENTION The present invention relates to a process for applying a compound containing an inorganic filler such as aluminum hydroxide and a resin to a glass nonwoven fabric or a glass woven fabric as a base material. It is intended to provide an inexpensive decorative board by realizing a thick coating, which was difficult in the method.
【０００４】[0004]
【問題を解決するための手段】本発明は、長尺の繊維基
材の片面側から、無機充填材を含有する配合物を、コン
マロールコーター又はナイフコーターにより、塗工厚み
０．３〜２．０ｍｍに塗工し、加熱乾燥して芯材層用シ
ート材料を作製し、この芯材層用成形素材を加熱加圧成
形する工程を有することを特徴とする化粧板の製造方法
に関するものであり、製造工程が簡単であり、かつ連続
生産が可能であり、性能上も従来の化粧板と同等以上の
ものを得ることができる。According to the present invention, a composition containing an inorganic filler is supplied from one side of a long fiber base material to a contaminant.
Coating thickness with a marol coater or knife coater
0.3 to 2.0 mm , heating and drying to produce a core material layer sheet material, and a step of heating and pressing the core material forming material. The present invention relates to a production method, in which a production process is simple, continuous production is possible, and a product having a performance equivalent to or higher than that of a conventional decorative plate can be obtained.
【０００５】本発明において、長尺基材への配合物の塗
工工程の一例（概略断面図）を図１に示す。巻き出し装
置（１）から巻き出された長尺基材（２）は、搬送ロー
ラー（３）により移送されながら、その上面に無機充填
材を配合した熱硬化性樹脂ワニス（４）をコーター
（５）により所定の膜厚になるように塗布する。この長
尺基材としては、ガラス繊維織布、ガラス繊維不織布、
合成繊維織布または不織布、クラフト紙、リンター紙な
ど特に限定されないが、耐燃性の点からは無機繊維から
なるガラス繊維織布または不織布が好ましい。一方、加
工性、低コスト化が特に要求される場合は、クラフト紙
やリンター紙などのセルロース系紙基材が好ましく使用
される。[0005] In the present invention, an example (schematic sectional view) of a step of applying a compound to a long substrate is shown in FIG. The long base material (2) unwound from the unwinding device (1) is transferred by a transport roller (3), and a thermosetting resin varnish (4) containing an inorganic filler on the upper surface thereof is coated with a coater ( The coating is performed to a predetermined thickness according to 5). As the long base material, a glass fiber woven fabric, a glass fiber nonwoven fabric,
Although not particularly limited, such as synthetic fiber woven or nonwoven fabric, kraft paper, and linter paper, glass fiber woven or nonwoven fabric made of inorganic fibers is preferable from the viewpoint of flame resistance. On the other hand, when workability and cost reduction are particularly required, a cellulosic paper base such as kraft paper or linter paper is preferably used.
【０００６】コーター（５）としては、コンマロールコ
ーター、ナイフコーター、ダイスコーター、リバースコ
ーター等があるが、塗工厚みが０．３〜２．０ｍｍと厚
いので配合物粘度を高粘度にする必要がある。このため
高粘度配合物の塗工に適した方式、即ち、コンマロール
コーター、ナイフコーターが好ましい。As the coater (5), there are a comma roll coater, a knife coater, a die coater, a reverse coater and the like. However, since the coating thickness is as thick as 0.3 to 2.0 mm, it is necessary to increase the viscosity of the compound. There is. For this reason, the method suitable for coating high viscosity compounds, namely, Coma roll
Coaters and knife coaters are preferred.
【０００７】長尺基材に無機充填材を配合した熱硬化性
樹脂配合物を塗工した後、乾燥装置（６）を通過させて
水分や溶剤を蒸発させ、芯材層用シート材料（プリフレ
グ）（８）を得る。加熱乾燥条件は配合物の樹脂量、揮
発分の成分や量、塗工厚みによって異なるが通常１００
〜１６０℃で５〜１５分間程度である。乾燥後、このプ
リフレグ（８）はカッター（７）により所定長さに切断
される。或いは切断しないで連続成形に供することも可
能である。After applying a thermosetting resin composition in which an inorganic filler is blended into a long base material, it is passed through a drying device (6) to evaporate water and solvent, thereby forming a core material sheet material (prefreg). ) (8) is obtained. The heating and drying conditions vary depending on the amount of resin in the composition, the components and amounts of volatile components, and the thickness of the coating.
Approximately 5 to 15 minutes at １６０160 ° C. After drying, the pre-flag (8) is cut into a predetermined length by a cutter (7). Alternatively, it is also possible to perform continuous molding without cutting.
【０００８】このようにして得られた芯材層用シート材
料は、化粧板の板厚・処方に応じて表面化粧用シート材
料、或いは表面化粧用シート材料及び補強層用シート材
料等と組み合わされて加熱加圧成形される。表面化粧用
シート材料はメラミン樹脂を含浸した化粧紙等である。
この時の成形条件は、得られた芯材層用シート材料の熱
硬化性樹脂配合物の流動性にもよるが、温度１２０〜１
５０℃、圧力６０〜１１０ｋｇ／ｃｍ２ 、時間６０〜
１２０分間が適当である。The core material sheet material thus obtained is combined with a surface decorative sheet material, or a surface decorative sheet material and a reinforcing layer sheet material, depending on the thickness and formulation of the decorative board. It is heated and pressed. The surface decorative sheet material is a decorative paper or the like impregnated with a melamine resin .
The molding conditions at this time depend on the flowability of the thermosetting resin composition of the obtained core material layer sheet material,
50 ° C., pressure 60 to 110 kg / cm 2, time 60 to
120 minutes is appropriate.
【０００９】[0009]
【実施例】以下、実施例及び比較例により具体的に説明
する。 《実施例１》坪量７５ｇ／ｍ2 のガラス不織布を巻き出
し、続いてこれに次の配合からなる熱硬化性樹脂配合物
Ａをコンマロールコーターにより厚さ１．３ｍｍ（乾燥
後）になるように塗工した。 （配合物Ａ配合） フェノール樹脂 ２０重量部 無機充填材（水酸化アルミニウム） ８０重量部 その後、乾燥装置で１５０℃、１０分間乾燥し芯材層用
シート材料を作製した。一方、坪量８０ｇ／ｍ2 の建材
用化粧原紙に硬化剤を含むメラミン樹脂をディップ方式
で塗布含浸し化粧層用シート材料Ｂを作製し、また坪量
８０ｇ／ｍ2 の化粧原紙に硬化剤を含むメラミン樹脂を
ディップ方式で塗布含浸し化粧層用シート材料Ｃを作製
した。作製した芯材層用シート材料を４枚重ね合わせ、
表面に化粧層用シート材料Ｂを、裏面に化粧層用シート
材料Ｃを重ねて、最高温度１４０℃、圧力７０ｋｇ／ｃ
ｍ2 で９０分間加熱加圧成形して、厚さ３．３ｍｍの化
粧板を得た。The present invention will be specifically described below with reference to examples and comparative examples. << Example 1 >> A glass nonwoven fabric having a basis weight of 75 g / m 2 was unwound, and subsequently, a thermosetting resin composition A having the following composition was formed to a thickness of 1.3 mm (after drying) with a comma roll coater. Coated as follows. (Blend of Compound A) 20 parts by weight of phenolic resin 80 parts by weight of inorganic filler (aluminum hydroxide) Thereafter, it was dried at 150 ° C. for 10 minutes with a drying apparatus to prepare a core material layer sheet material. On the other hand, a basis weight of 80 g / m 2 of building materials cosmetic base paper melamine resin containing a curing agent to prepare a coating impregnated with dipping decorative layer sheet material B, also curing agent in cosmetic base paper having a basis weight of 80 g / m 2 Was applied and impregnated with a melamine resin containing dipping by a dipping method to prepare a sheet material C for a decorative layer. Four sheets of the prepared core material sheet are laminated,
The sheet material B for a decorative layer is layered on the front surface and the sheet material C for a decorative layer is layered on the rear surface.
and heat pressure molded 90 minutes at m 2, and to obtain a decorative plate having a thickness of 3.3 mm.
【００１０】《比較例１》実施例１の熱硬化性樹脂配合
物Ａに水を加えて１．５倍に希釈し、坪量７５ｇ／ｍ2
のガラス不織布を基材としてディップ方式で塗布・含浸
して芯材層用シート材料を得た。作製した芯材層用シー
ト材料を６枚重ね合わせ、表面に化粧層用シート材料Ｂ
を、裏面に化粧層用シート材料Ｃを重ねて、実施例１と
同条件で加熱加圧成形して厚さ３．２ｍｍの化粧板を得
た。Comparative Example 1 The thermosetting resin composition A of Example 1 was diluted 1.5 times with water by adding water, and the basis weight was 75 g / m 2.
The glass nonwoven fabric was applied and impregnated by a dipping method using a glass nonwoven fabric as a base material to obtain a core material layer sheet material. Six sheets of the prepared core material sheet material are laminated, and the decorative material sheet material B is formed on the surface.
Was laminated with a sheet material C for decorative layer on the back surface, and heated and pressed under the same conditions as in Example 1 to obtain a decorative plate having a thickness of 3.2 mm.
【００１１】以上、実施例及び比較例で得られた化粧板
の製造コストについて、実施例の製造方法は工程が単純
であり、またコストの高いガラス繊維不織布の使用枚数
が少ないため、比較例で得られた化粧板に比べ３０％程
度低コスト化することができた。As described above, regarding the manufacturing cost of the decorative board obtained in the examples and the comparative examples, the manufacturing method of the examples is simple in the process and the number of expensive glass fiber nonwoven fabrics used is small. The cost was reduced by about 30% as compared with the obtained decorative board.
【００１２】[0012]
【発明の効果】本発明の化粧板の製造方法は、高粘度で
の塗工が可能であるので、配合物を溶剤・水等で希釈す
る必要がなく、また配合物の厚塗りが可能なことから化
粧板中のガラス基材比率を低くできるなど、低コスト化
の点で優れており、また製造工程も簡単であるので、工
業的な化粧板の製造方法として好適である。According to the method for producing a decorative board of the present invention, coating with high viscosity is possible, so that it is not necessary to dilute the composition with a solvent, water or the like, and it is possible to apply the composition thickly. Therefore, it is excellent in terms of cost reduction, for example, the ratio of the glass base material in the decorative board can be reduced, and the manufacturing process is simple, so that it is suitable as an industrial decorative board manufacturing method.
【図１】 本発明の製造工程において、芯材層用シート
材料を作製する迄の工程を示す概略断面図。FIG. 1 is a schematic cross-sectional view showing a process of manufacturing a core material sheet in a manufacturing process of the present invention.
１ 巻き出し装置 ２ 長尺基材 ３ 搬送ローラー ４ （無機充填材入り）ワニス ５ コーター ６ 乾燥装置 ７ カッター ８ プリプレグ DESCRIPTION OF SYMBOLS 1 Unwinder 2 Long base material 3 Transport roller 4 Varnish (with inorganic filler) 5 Coater 6 Drying device 7 Cutter 8 Prepreg
───────────────────────────────────────────────────── フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) B32B 1/00 - 35/00 ＥＰＡＴ（ＱＵＥＳＴＥＬ) ＷＰＩ／Ｌ（ＱＵＥＳＴＥＬ)────────────────────────────────────────────────── ─── Continued on the front page (58) Fields surveyed (Int. Cl. 7 , DB name) B32B 1/00-35/00 EPAT (QUESTEL) WPI / L (QUESTEL)
Claims (2)
材を含有する熱硬化性樹脂を、コンマロールコーター又
はナイフコーターにより、塗工厚み０．３〜２．０ｍｍ
に塗工し、加熱乾燥して芯材層用シート材料を作製し、
この芯材層用シート材料に表面化粧用シート材料を重ね
合わせ、加熱加圧成形することを特徴とする化粧板の製
造方法。1. A thermosetting resin containing an inorganic filler is coated on one side of a long fiber base material with a comma roll coater or a thermosetting resin.
Is coated by knife coater with a coating thickness of 0.3 to 2.0 mm
And dried by heating to produce a core material sheet.
A method for producing a decorative sheet, comprising superposing a sheet material for surface decoration on the sheet material for the core layer, and subjecting the sheet material to heating and pressure molding.
を含浸した化粧紙である請求項１記載の化粧板の製造方
法。2. The method according to claim 1, wherein the surface decorative sheet material is a decorative paper impregnated with a melamine resin.
Priority Applications (8)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26337296A JP3152880B2 (en) | 1996-10-03 | 1996-10-03 | Manufacturing method of decorative board |
| TW86112509A TW455538B (en) | 1996-09-04 | 1997-09-01 | Flame-retardant or incombustible decorative laminated sheet |
| CN97191196A CN1090563C (en) | 1996-09-04 | 1997-09-03 | Flame-retardant or incombustible decorative laminated sheet |
| KR10-1998-0702990A KR100493535B1 (en) | 1996-09-04 | 1997-09-03 | Flame-retardant or incombustible decorative laminated sheet |
| DE1997605513 DE69705513T2 (en) | 1996-09-04 | 1997-09-03 | FIRE-RETARDANT OR INFLAMMABLE DECORATIVE LAMINATE PANEL |
| EP19970939150 EP0899092B1 (en) | 1996-09-04 | 1997-09-03 | Flame-retardant or incombustible decorative laminated sheet |
| US09/051,279 US6333280B1 (en) | 1996-09-04 | 1997-09-03 | Flame-retardant or incombustible decorative laminated sheet |
| PCT/JP1997/003082 WO1998009816A1 (en) | 1996-09-04 | 1997-09-03 | Flame-retardant or incombustible decorative laminated sheet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26337296A JP3152880B2 (en) | 1996-10-03 | 1996-10-03 | Manufacturing method of decorative board |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH10109383A JPH10109383A (en) | 1998-04-28 |
| JP3152880B2 true JP3152880B2 (en) | 2001-04-03 |
Family
ID=17388583
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP26337296A Expired - Fee Related JP3152880B2 (en) | 1996-09-04 | 1996-10-03 | Manufacturing method of decorative board |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3152880B2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20060234027A1 (en) * | 2005-04-18 | 2006-10-19 | Huusken Robert W | Fire retardant laminate |
| CN102152550A (en) * | 2010-12-13 | 2011-08-17 | 东北林业大学 | Method for preparing overlaid artificial board composite material of functional polymerizing monomer modified wooden veneer |
| JP5712704B2 (en) * | 2011-03-14 | 2015-05-07 | 株式会社リコー | High voltage inverter device |
-
1996
- 1996-10-03 JP JP26337296A patent/JP3152880B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH10109383A (en) | 1998-04-28 |
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