【発明の詳細な説明】産業上の利用分野この発明は耐摩耗性化粧板の製造方法、特に床材として
好適に使用されるような表面部に高度の耐摩耗性塗膜を
有する木質化粧板の製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application This invention relates to a method for producing a wear-resistant decorative laminate, particularly a wood decorative laminate having a highly abrasion-resistant coating on its surface, which is suitable for use as a flooring material. Relating to a manufacturing method.
従来の技術従来、床材として使用されるような耐摩耗性木質化粧板
として、例えば特公昭４９−１９８４９号公報、同４９
−４８４９７号公報等に見られる如く、ベニヤ合板、ハ
ードボード、パーティクルボード等の木質基板に木目模
様等の印刷を施し、あるいは化粧単板、パターン紙等の
化粧材を貼着して化粧層を形成したのち、該木質基板表
面に、α−アルミナ、炭化硅素等の無機結晶質の硬質微
粉末で、粒度１０〜７０μのものを、樹脂固形分に対し
５〜４０重量％含有せしめた透明または半透明の合成樹
脂塗料を塗着して耐摩耗性表層塗膜を形成せしめたもの
が知られている。BACKGROUND OF THE INVENTION Conventionally, abrasion-resistant wooden decorative boards used as flooring materials have been disclosed, for example, in Japanese Patent Publication No. 19849-1984;
As seen in Publication No. 48497, a decorative layer is formed by printing a wood grain pattern on a wooden substrate such as veneer plywood, hardboard, or particle board, or by pasting decorative materials such as decorative veneer or patterned paper. After forming, a transparent or transparent resin containing 5 to 40% by weight of inorganic crystalline hard fine powder such as α-alumina or silicon carbide with a particle size of 10 to 70μ based on the resin solid content is applied to the surface of the wooden substrate. It is known that a translucent synthetic resin paint is applied to form a wear-resistant surface layer coating.
発明が解決しようとする問題点しかしながら、従来既知の上記のような化粧板は、表面
の耐摩耗性、従って耐久性の点で未だ充分な満足が得ら
れるものではなかった。このため一般的にはせいぜい住
居の上履き用床材としての用途において実用化されてい
るにすぎないものであった。ちなみに、従来の上記床材
は、フローリングの日本農林規格に定める摩耗Ａ試験に
おいて塗膜下の下地層が消滅しはじめるまでの回転数が
５００〜１０００回を少々上まわる程度の耐摩耗性が得
られるものであるにすぎず、一段と苛酷な使用条件下、
例えば近時益々要請の強い土足床用木質化粧床材として
の使用条件下にあっては、耐摩耗性の点で未だ充分な適
合性を具有し得ないものであった。Problems to be Solved by the Invention However, the conventionally known decorative laminates as described above have not yet been fully satisfactory in terms of surface abrasion resistance and therefore durability. For this reason, it has generally only been put to practical use as a flooring material for indoor shoes. By the way, the above-mentioned conventional flooring materials have such abrasion resistance that in the abrasion A test specified by the Japanese Agricultural Standards for flooring, the number of rotations before the base layer under the coating begins to disappear is slightly over 500 to 1000 times. However, under even more severe usage conditions,
For example, under the conditions of use as a wooden decorative flooring material for clay floors, which is increasingly in demand these days, it has not yet been able to provide sufficient compatibility in terms of wear resistance.
上記のような問題点に対し、塗膜の耐摩耗性を可及的に
向上するための手段として、塗料中の硬質微粉末含有量
を増大することが考慮される。しかしながら、この含有
量は、塗料中の樹脂成分の量との関係で、該樹脂が粉末
微粒子に対し充分に強固な保持能力を発揮しうる範囲の
量に制限されることから、徒らに増大することはできな
い。In order to address the above-mentioned problems, increasing the content of hard fine powder in the paint is considered as a means to improve the abrasion resistance of the paint film as much as possible. However, this content is limited to a range in which the resin can exhibit a sufficiently strong holding ability for powder particles due to the amount of resin components in the paint, so it is unnecessarily increased. I can't.
そこで、硬質微粉末の許容値以下の含有量の範囲内で耐
摩耗性を上げるためには、次に塗膜厚を増大することが
考慮される。Therefore, in order to increase the wear resistance within the range of the hard fine powder content being below the permissible value, increasing the coating film thickness is next considered.
ところが、本発明者らの研究によれば、単に塗膜厚を増
大するだけでは、それに見合うだけの比例的な耐摩耗性
の向上効果を実現することができないのみならず、化粧
板の表面の良好な仕上り状態を得ることもできない。こ
の原因について考究するところ、次のようなことが考え
られる。即ち、第６図（イ）に示すように、基板（１１
）上に、比較的多量の硬質微粉末（１２）を添加した塗
料（１３）を多量に厚く塗布すると、その樹脂成分が硬
化するまでの過程で比重の大きい硬質微粉末（１２）の
粒子が塗層内で沈降し、その下層部分に集中して局部的
に高密度に分布することになる。このため、また塗層の
乾燥後においても、第６図（ロ）に示すように、塗膜の
下層部分において硬質微粉末（１２）の粒子が過密度に
偏在することになり、該部分においての塗膜中の樹脂成
分による硬質微粉末（１２）の粒子に対する保持力が不
充分なものとなる。そして結果的に微粉末のあまり存在
しない表層部の早期摩耗後において、上記微粉末（１２
）が脱落し易い状態を露呈し、該微粉末が充分に耐摩耗
性の向上に有効に寄与し得ないためと考えられる。加え
て、塗層が厚いためにその乾燥過程で気泡が抜けにり＜
、第６図（ロ）に示すように塗膜中に発泡（１４）やピ
ンホールを生じるのみならず、微粉末の下層部集中と相
俟って塗膜の透明性をも悪化し、白濁等の現象を呈して
基板面上の化粧層の木目模様等の顕示性を劣化するとい
う欠点の派生も見られる。However, according to the research conducted by the present inventors, simply increasing the coating film thickness not only fails to achieve a commensurate proportional improvement in wear resistance, but also increases the wear resistance of the decorative board surface. It is also impossible to obtain a good finish. When investigating the causes of this, the following may be considered. That is, as shown in FIG. 6(a), the substrate (11
), when a paint (13) containing a relatively large amount of hard fine powder (12) is applied thickly in a large amount, particles of hard fine powder (12) with a high specific gravity are formed in the process until the resin component hardens. It settles within the coating layer and is concentrated in the lower layer and locally distributed at high density. For this reason, even after the coating layer dries, the particles of the hard fine powder (12) are concentrated and unevenly distributed in the lower part of the coating film, as shown in Figure 6 (b). The holding power of the resin component in the coating film to the particles of the hard fine powder (12) becomes insufficient. As a result, after early wear of the surface layer where there is not much fine powder, the fine powder (12
) is likely to fall off, and this is considered to be because the fine powder cannot effectively contribute to the improvement of wear resistance. In addition, because the coating layer is thick, air bubbles are difficult to escape during the drying process.
As shown in Figure 6 (b), not only do foaming (14) and pinholes occur in the coating film, but also the transparency of the coating film deteriorates due to the concentration of fine powder in the lower layer, causing cloudiness. There are also problems such as deterioration of visibility of the wood grain pattern of the decorative layer on the substrate surface.
この発明は、上記のような技術的背景に基づき、耐摩耗
性塗膜の形成方法、即ち塗料の塗布工程の改善により、
土足床用床材としての実用にも耐え得るような従来品よ
り更に一段と優れた耐摩耗性を有し、しかも表面に有害
なザラツキ、白濁等を有しない高耐摩耗性化粧板を提供
することに成功をおさめたものである。Based on the above-mentioned technical background, this invention aims to improve the method of forming a wear-resistant coating film, that is, the coating process of the coating material.
To provide a highly abrasion-resistant decorative board that has even better abrasion resistance than conventional products and can withstand practical use as a flooring material for shoes with shoes on, and has no harmful roughness, cloudiness, etc. on the surface. It was a success.
問題点を解決するための手段而して、この発明は、乾燥後の単位塗膜の実質膜厚が、
硬質微粉末の平均粒径の３０〜８０％になる塗布量にお
いて前記塗料の塗布および乾燥を行う塗装工程を１回の
単位塗装工程とし、該単位塗装工程を複数回繰返して行
うことにより重ね塗り状の所定膜厚の耐摩耗性塗膜を形
成することを特徴とする耐摩耗性化粧板の製造方法を要
旨とするものである。As a means for solving the problem, the present invention provides that the substantial film thickness of a unit coating film after drying is
The coating process of applying and drying the paint at a coating amount of 30 to 80% of the average particle diameter of the hard fine powder is one unit coating process, and this unit coating process is repeated multiple times to achieve overcoating. The gist of the present invention is a method for manufacturing a wear-resistant decorative board, which is characterized by forming a wear-resistant coating film having a predetermined thickness.
第５図に示す化粧板において、（１）は基板、（２）は
その表面部の化粧層、（３）はこの発明の方法によって
上記基板（１）上に形成される耐摩耗性塗膜である。In the decorative board shown in FIG. 5, (1) is a substrate, (2) is a decorative layer on the surface thereof, and (3) is an abrasion-resistant coating film formed on the substrate (1) by the method of the present invention. It is.
基板（１）としては、最も一般的にはベニヤ合板が用い
られるが、その他パーティクルボード、ハードボード等
の主として木質板が用いられる。基板の表面の化粧層（
２）は、補材、桜、欅材等の美麗な木目模様を有する天
然木化粧単板の貼着によって形成するのが一般的である
が、木目模様印刷紙の貼着、木目模様等の直接印刷層の
形成等、既知のいかなる手法によって形成したものであ
っても良い。As the substrate (1), veneer plywood is most commonly used, but other materials such as particle board and hardboard are mainly used. Decorative layer on the surface of the substrate (
2) is generally formed by attaching a decorative natural wood veneer with a beautiful wood grain pattern such as supplementary wood, cherry wood, or zelkova wood, but it is also possible to attach a wood grain pattern printed paper or a wood grain pattern etc. It may be formed by any known method such as direct printing layer formation.
耐摩耗性塗膜（３）は、上記化粧層を有する基板上に、
要すれば下地着色層、及び吸込み防止用下塗り層を介し
て形成されるものであり、透明または半透明の樹脂塗料
に無機結晶質の硬質微粉末を添加含有せしめた耐摩耗性
樹脂塗料により形成されるものである。The wear-resistant coating film (3) is formed on the substrate having the above-mentioned decorative layer,
If necessary, it is formed through a colored base layer and an undercoat layer for preventing suction, and is formed from a wear-resistant resin paint made by adding and containing inorganic crystalline hard fine powder to a transparent or translucent resin paint. It is something that will be done.
ここに用いられる硬質微粉末は、α−アルミナ、炭化硅
素を代表的なものとして、その他例えば炭素、ホウ素等
の化合物微粉末等が用いられる。もちろんこれらに限定
されるものではなく、工業的に研磨材として使用される
ような種類の硬度の高い各種鉱物質微粉末を好適に用い
うるが、その粒度は、一般的に１０〜１５０μの範囲の
ものが用いられる。The hard fine powder used here is typically α-alumina and silicon carbide, and other fine powders of compounds such as carbon and boron are also used. Of course, the invention is not limited to these, and various fine mineral powders with high hardness of the type used industrially as abrasives can be suitably used, but the particle size is generally in the range of 10 to 150μ. are used.
一方、上記硬質粉末を添加して塗膜形成に使用される樹
脂塗料は、化粧基板（１）上の化粧層（２）の木目模様
その他の模様を塗膜（３）下に透視可能なものとするべ
く、透明または少なくとも半透明のものが用いられるが
、そのビヒクルとしての樹脂成分の種類は特に限定され
るものではなく、求める塗膜性能、塗装作業性、乾燥性
、価格等を考慮して公知の樹脂塗料の中から任意に選択
使用される。一般的には微粉末粒子の保持力に可及的優
れ、かつそれ自体の耐摩耗性にも優れた樹脂からなる塗
料を選択使用すべきであり、その具体的な例示としては
、一液性ポリウレタン樹脂塗料、および二液性ポリウレ
タン樹脂塗料のうちの１種または２種を最も好適なもの
として挙示することができる。その他エポキシ系樹脂塗
料、ポリエステル系樹脂塗料の使用も可能であるし、更
にはそれらの樹脂の複合樹脂塗料はもちろん、紫外線硬
化あるいは電子線硬化樹脂塗料を用いても良い。On the other hand, the resin paint to which the above-mentioned hard powder is added and used to form a paint film is one that allows the wood grain pattern and other patterns of the decorative layer (2) on the decorative substrate (1) to be seen through the paint film (3). In order to achieve this, a transparent or at least translucent vehicle is used, but the type of resin component used as the vehicle is not particularly limited, and may be determined based on the desired coating performance, painting workability, drying properties, price, etc. Any one of the known resin paints may be used. In general, paints made of resins that have the best possible holding power for fine powder particles and have excellent abrasion resistance themselves should be selected. One or two of polyurethane resin paints and two-component polyurethane resin paints are most preferred. It is also possible to use other epoxy resin paints and polyester resin paints, as well as composite resin paints of these resins, as well as ultraviolet curing or electron beam curing resin paints.
また、塗料中への硬質微粉末の含有量は、良好な耐摩耗
性を上げるために樹脂固形分に対して１０〜６０％とす
るのが一般的である。下限値未満では塗膜に良好な耐摩
耗性を得ることができず、逆に上限値をこえると塗膜に
ザラツキを生じる。最も好ましい上記含有量は概ね２０
〜５０％程度である。Further, the content of hard fine powder in the paint is generally 10 to 60% based on the resin solid content in order to improve wear resistance. If it is less than the lower limit, good abrasion resistance cannot be obtained in the coating film, and on the other hand, if it exceeds the upper limit, the coating film will become rough. The most preferable content is approximately 20
It is about 50%.
ところで、この発明は、上記耐摩耗性塗膜（３）の塗着
形成手段として、単位塗装工程の繰返し実施による所謂
重ね塗りによって行うこと、及びこの単位塗装工程を、
乾燥後の実質塗膜厚が硬質微粉末の平均粒径の３０〜８
０％になる塗布量において行うこと、を主旨とするもの
である。By the way, the present invention provides that the abrasion-resistant coating film (3) is formed by so-called overcoating by repeating a unit coating process, and that this unit coating process is
The actual coating thickness after drying is 30 to 8 of the average particle size of the hard fine powder.
The main idea is to perform the coating at a coating amount of 0%.
これを添附図面に基づいて更に詳しく説明すると、先ず
、第２図に示すように第１回の単位塗布工程において、
同図左側の図面に示すように、基板（１）上への塗料（
４）の塗布直後の状態では、硬質微粉末粒子（５）は沈
降するが、塗料（４）の塗布量の前記規定により、これ
によって形成される乾燥後の第１単位塗膜（３ａ）にお
いては同図右側の図面に示すように、硬質微粉末粒子（
５）の平均粒径Ｈ２）に対して実質膜厚（１）はその３
０〜８０％の範囲のものとなり、従って該塗膜面上にお
いて多くの微粉末粒子（５）が上方に突出した状態にな
る。ここに、微粉末の平均粒径というのは、個々の異形
の粉末粒子（５）の平均粒径による全含有粉末粒子の平
均粒径をいうものであり、また乾燥後の単位塗膜（３ａ
）の実質膜厚（１）というのは、粒子（５）の突出部分
を除いた粒子間の部分における平均的な膜厚をいうもの
である。To explain this in more detail based on the attached drawings, first, as shown in FIG. 2, in the first unit coating process,
As shown in the drawing on the left side of the figure, paint (
4) Immediately after application, the hard fine powder particles (5) settle, but due to the above-mentioned regulation of the amount of coating material (4), in the first unit coating film (3a) after drying formed by this, the hard fine powder particles (5) settle. As shown in the drawing on the right side of the figure, hard fine powder particles (
The real film thickness (1) is 3 for the average particle diameter H2) of 5).
Therefore, many fine powder particles (5) protrude upward on the coating surface. Here, the average particle size of the fine powder refers to the average particle size of all contained powder particles based on the average particle size of individual irregularly shaped powder particles (5), and also refers to the average particle size of all contained powder particles (3a) after drying.
The real film thickness (1) in ) refers to the average film thickness in the area between the particles excluding the protruding parts of the particles (5).
次に、上記による第１回の単位塗装工程後、その単位塗
膜面上に第１回と同様の塗布量において第２回の単位塗
布工程を実施する。これによって、塗料（４）中に含む
微粉末粒子（５）は、第２図に示すように第１回目の単
位塗装工程による第１単位塗膜（３ａ）面上の凹部、即
ち突出粒子相互間に入り込む傾向を示し、従って乾燥後
の第２回目の単位塗装工程による第２単位塗膜（３ｂ）
面は第１回目の単位塗膜面に比べて若干平滑なものとな
り、相対的にザラツキの減少したものとして形成される
。Next, after the first unit coating process as described above, a second unit coating process is performed on the unit coating surface with the same amount of coating as the first unit coating process. As a result, the fine powder particles (5) contained in the paint (4) are transferred to the recesses on the surface of the first unit coating film (3a) caused by the first unit coating process, that is, the protruding particles interact with each other, as shown in FIG. Therefore, the second unit coating film (3b) from the second unit coating process after drying.
The surface is slightly smoother than the surface of the first unit coating film, and is formed with relatively less roughness.
続いて第３回目の単位塗装工程を同様に実施し、第４図
に示すような第３単位塗膜（３ｃ）を形成する。更に要
すれば続いて第４回目の単位塗装工程も同様に実施して
、第１〜第ｎの単位塗膜（３ａ）、（３ｂ）（３ｃ）（
３ｎ）（７）積層からなる第１図に示すような所要膜厚
の耐摩耗性塗膜（３）を得るものである。Subsequently, a third unit coating process is performed in the same manner to form a third unit coating film (3c) as shown in FIG. Further, if necessary, a fourth unit coating step is similarly carried out to form the first to nth unit coating films (3a), (3b) (3c) (
3n) (7) A wear-resistant coating film (3) of a required thickness as shown in FIG. 1 is obtained by laminating the layers.
上記の各単位塗装工程は、複数個のヘッドを備えたロー
ルコータ−を用いて行うことによって能率良く、最も好
適に行いうるが、これに限定されるものではなく、所要
の単位塗装工程にフローコーターを併用して実施しても
良いし、その他の塗布手段を採用して行っても差支えな
い。Each of the above unit coating processes can be carried out efficiently and most preferably by using a roll coater equipped with multiple heads, but this is not a limitation. The coating may be carried out by using a coater in combination, or by employing other coating means.
また、単位塗装工程の実施回数は、少なくとも２回以上
行うことによってこの発明の効果を得ることができるが
、好ましくは３〜５回、特に好ましくは４回程度の実施
が最も好適である。Further, the effect of the present invention can be obtained by performing the unit coating process at least twice, but it is most suitable to perform the unit coating process preferably about 3 to 5 times, particularly preferably about 4 times.
複数回の単位塗装工程の実施によって形成される所定厚
さの耐摩耗性塗膜（３）は、その好適な条件での実施に
よってその表面は多少のザラツキを有ものとなるが、常
法に従って軽く表面研磨を施すことによって充分平滑に
仕上げることができる。更に塗膜（３）の表面の充分に
平滑な最終仕上げ状態を得るために該塗膜（３）上に、
従来の常法に従い、第１図に鎖線で示すように硬質微粒
子を含まない上塗り用塗料により、薄い上塗り塗層（６
）を形成して製品としての化粧板に仕上げるのが一般的
である。The abrasion-resistant coating film (3) of a predetermined thickness formed by carrying out the unit coating process multiple times may have some roughness on its surface depending on the coating process under suitable conditions. A sufficiently smooth finish can be obtained by lightly polishing the surface. Furthermore, in order to obtain a sufficiently smooth final finish on the surface of the coating film (3), on the coating film (3),
In accordance with the conventional method, a thin top coat layer (6
) to form a decorative board as a product.
この発明による各単位塗装工程における塗料の塗布量が
、乾燥後の単位膜の膜厚（１）において含有硬質微粉末
粒子径（ρ）の３０〜８０％に限定されるのは次の理由
による。即ち、３０％未満の少ない塗布量によるときは
、粉末粒子の突出度合いが大きく、表面に著しいざらつ
きを生じ、しかも該突出粒子の樹脂による保持力も弱い
ものとなるために、微粉末粒子が脱落し易く、また表面
粗さを解消するためにサンディング等の研磨を施すと、
それによって多くの微粉末がとれてしまい、結果的に耐
摩耗性の向上効果を得ることができない。一方、８０％
をこえて多量に塗布するときは、塗膜表面は平滑に仕上
るが、硬質微粉末の塗層内での沈降偏在を生じる傾向が
強くなり、塗膜の厚さ方向においての粉末粒子の均一分
布性が低下する。このため、耐摩耗性の点においてむし
ろ有害であるのみならず、塗膜の全体として所期する耐
摩耗性を得ようとする場合には、塗膜を全体として相対
的に厚いものとせざるを得なくなり、塗料の消費量の増
大による経済的不利益が生じる。The reason why the amount of paint applied in each unit coating process according to the present invention is limited to 30 to 80% of the contained hard fine powder particle size (ρ) at the thickness (1) of the unit film after drying is as follows. . That is, when using a small coating amount of less than 30%, the degree of protrusion of the powder particles is large, resulting in significant roughness on the surface, and the holding power of the protruding particles by the resin is also weak, resulting in the fine powder particles falling off. If you perform polishing such as sanding to make it easier and eliminate surface roughness,
As a result, a large amount of fine powder is removed, and as a result, the effect of improving wear resistance cannot be obtained. On the other hand, 80%
When applying a large amount exceeding 100 mL, the surface of the coating will be smooth, but there is a strong tendency for the hard fine powder to settle and unevenly distribute within the coating layer, resulting in a uniform distribution of powder particles in the thickness direction of the coating. Sexuality decreases. For this reason, it is not only harmful in terms of abrasion resistance, but in order to obtain the desired abrasion resistance of the coating film as a whole, the coating film as a whole must be made relatively thick. This results in an economic disadvantage due to increased paint consumption.
各単位塗装工程における塗布量の好適範囲は、硬質微粉
末の平均粒度Ｎ２）との関係における乾燥単位塗膜厚（
１）の比率において４０〜７０％であり、特に好ましく
は５０〜６０％程度である。これを面積当りの塗布量で
いえば、使用する硬質微粉末の粒度とのＩｌ’１対関係
で一概には特定できないが、概ね４０〜１００ ｇ／ｒ
ｄであり、塗装作業性等も考慮した場合、好適には５０
〜Ｂｏｇｌｒｄ程度の範囲である。The preferred range of coating amount in each unit coating process is the dry unit coating thickness (
The ratio of 1) is 40 to 70%, particularly preferably about 50 to 60%. In terms of the amount of coating per area, it cannot be determined unambiguously depending on the Il' pair relationship with the particle size of the hard fine powder used, but it is approximately 40 to 100 g/r.
d, and when considering painting workability etc., preferably 50
~Boglrd.
発明の効果この発明の方法によれば、耐摩耗性塗膜の形成を、硬質
微粉末を含む塗料の重ね塗り、即ち単位塗装工程の複数
回の繰返し実施によって所定厚さに形成するものである
がら、塗膜中の全体、特にその厚さ方向に粉末粒子を均
一に分布させることができる。しかも、上記各単位塗装
工程における塗料の塗布量を、乾燥塗膜の実質膜厚が硬
質微粉末粒子の平均粒径の３０〜８０％となる範囲に規
定して行うものであるから、先行実施した単位塗装工程
による単位塗膜面上の凹部内に、順次後続実施する単位
塗装工程時の塗料中に含む微粒子をはまり込み状態に位
置させることができる。このため、最終的な塗膜におい
て、その全体としての膜厚を比較的低く抑えつつ、即ち
塗料の全消費量を節約しながらも、その中に比較的高密
度に硬質微粉末を分布せしめることができる。かつ該粉
末粒子を塗膜面上から大きく突出させることなく、樹脂
成分により該粉末粒子に対する充分に強固な保持力を実
現せしめうる。従って、上記相俟って、極めて優れた耐
摩耗性を付与することができ、上履き用床材としてはも
とより、土足床用床材としても遜色なく使用しうるよう
な高耐摩耗性木質化粧板の提供を可能とする。また、各
単位塗装工程の塗料塗布ｍを前記の如く規定したことに
より、塗膜の表面に著しいザラツキを生じさせることが
ないのはもとより、各単位塗装工程で形成される単位塗
膜は比較的薄いものであるから、塗布後において塗料中
の気泡が抜は易く、気泡の内在とかピンホールの発生に
よる仕上り状態の悪化のおそれもなく、良好な表面性状
をもった化粧板を提供しうる。Effects of the Invention According to the method of the present invention, a wear-resistant coating film is formed to a predetermined thickness by overcoating paint containing hard fine powder, that is, by repeating a unit coating process multiple times. However, the powder particles can be uniformly distributed throughout the coating, especially in the thickness direction. Moreover, since the amount of paint applied in each of the above unit painting steps is determined within a range such that the actual film thickness of the dry coating film is 30 to 80% of the average particle diameter of the hard fine powder particles, advance implementation is necessary. The fine particles contained in the paint in the subsequent unit coating process can be placed in the recesses on the surface of the unit coating film formed by the unit coating process. For this reason, it is possible to distribute the hard fine powder in a relatively high density in the final coating film while keeping the overall film thickness relatively low, that is, while saving the total amount of paint consumed. I can do it. Moreover, the resin component can realize a sufficiently strong holding force for the powder particles without causing the powder particles to protrude significantly from the surface of the coating film. Therefore, in combination with the above, the highly wear-resistant wood decorative board can be imparted with extremely excellent abrasion resistance, and can be used not only as a flooring material for indoor shoes but also as a flooring material for shoes on shoes. It is possible to provide the following. In addition, by specifying the paint application m in each unit painting process as described above, not only does it not cause significant roughness on the surface of the paint film, but the unit paint film formed in each unit painting process is relatively Since it is thin, air bubbles in the paint can be easily removed after application, and there is no risk of deterioration of the finish due to the inclusion of air bubbles or the generation of pinholes, and a decorative board with good surface properties can be provided.
実施例合板に公知接着剤を用いて天然木化粧単板を貼着し、下
地着色塗装を施したものを化粧基板として採用した。そ
して、該基板面に、（耐摩耗性樹脂塗料）湿気硬化型ポリウレタン樹脂 １００重量部（樹脂分
５０％）α−アルミナ ２２．５重量部（平均粒
度５０μ）シンナー １０重量部からなる
塗料を、３ヘツドのロールコータ−を用いて１回の単位
塗装工程当りの塗布量と、その塗装回数を１回〜４回の
範囲で各種に変えて塗装し、所定膜厚の耐摩耗性塗膜を
形成した。EXAMPLE A natural wood decorative veneer was attached to plywood using a known adhesive, and a base coloring coating was applied to the plywood, which was used as a decorative substrate. Then, on the substrate surface, (wear-resistant resin paint) a paint consisting of 100 parts by weight of moisture-curable polyurethane resin (50% resin content), 22.5 parts by weight of α-alumina (average particle size 50μ), and 10 parts by weight of thinner, Using a 3-head roll coater, coating was performed by varying the amount of coating per unit coating process and the number of coatings ranging from 1 to 4 times to form a wear-resistant coating film of a predetermined thickness. Formed.
次いで更に該塗膜面上に、（上塗り塗料）湿気硬化型ポリウレタン樹脂 １００重量部（−波型
、樹脂分５０％）シンナー ２０重量部からなる
上塗り用塗料を、６０ｇ１ｒｄの割合で塗布し乾燥して
各種化粧板の試料を得た。Next, on the coating surface, (top coat) a top coat consisting of 100 parts by weight of moisture-curing polyurethane resin (-corrugated, 50% resin content) and 20 parts by weight of thinner was applied at a ratio of 60g1rd and dried. Samples of various decorative boards were obtained.
そして、この各試料につき、フローリングの日本農林規
格に定める摩耗Ａ試験の条件で摩耗試験を行い下地着色
塗装が消滅しはじめるまでの摩耗回転数（これを耐摩耗
性とする）を測定すると共に、指触法により表面の仕上
がり状態を調べた。その結果を下記の表に示す。Then, each sample was subjected to an abrasion test under the conditions of the abrasion A test specified in the Japanese Agricultural Standards for flooring, and the number of abrasion rotations until the base colored coating began to disappear (this is considered abrasion resistance) was measured. The surface finish was examined using the finger touch method. The results are shown in the table below.
［以下余白］上表の結果から、次のことが判る。[Margin below]From the results in the table above, the following can be seen.
■ 試料Ｎｏ、１４．１７．１９に見られるように、１
回の塗装作業で所要膜厚の塗膜を得る場合には、塗布量
が少ない場合はもちろんのこと、これを充分に多くして
も、高度の耐磨耗性は得られない。かつ１回で塗布量の
多い試料Ｎ１１Ｌ１９のような場合には、塗膜内に気泡
が残存する欠点も派生する。■ As seen in sample No. 14.17.19, 1
In order to obtain a coating film of the required thickness in one coating operation, a high degree of abrasion resistance cannot be obtained even if the coating amount is sufficiently large, let alone if the coating amount is small. In addition, in the case of sample N11L19 where a large amount of coating is applied at one time, there is a drawback that air bubbles remain in the coating film.
■ 端的に試料Ｎｏ、 １１と１９との対比から判るよ
うに、塗料の単位面積当りの全塗布量が同程度であって
も、塗装と複数回の単位塗装工程に分けて重ね塗りの状
態で行う方が、結果的に優れた耐磨耗性が得られる。■ As you can clearly see from the comparison between samples No. 11 and 19, even if the total amount of paint applied per unit area is about the same, the paint is divided into multiple unit painting processes and layered. Doing so will result in superior abrasion resistance.
■ 単位塗装工程の複数回実施による重ね塗りを行う場
合にあっても、その単位塗膜の乾燥膜厚／微粉末平均粒
子径の百分率が３０〜８０％の範囲から逸脱する場合に
は、最終的な塗膜厚をほぼ同じくしても、あるいは塗膜
層が大となるにも拘らず、必ずしもそれに見合った耐磨
耗性の向上効果を得ることはできない。■ Even when overcoating is performed by performing the unit coating process multiple times, if the dry film thickness/fine powder average particle diameter percentage of the unit coating film deviates from the range of 30 to 80%, the final Even if the coating thickness is approximately the same, or even if the coating layer is increased in size, it is not always possible to obtain a corresponding improvement in abrasion resistance.
また、試料Ｎｏ、 １及び２のように１回の塗布量が少
なすぎるときは、重ね塗りするにも拘らず表面仕上り状
態においてザラツキが解消されない。かつ試料２．４の
対比から分かるように、単位面積当りの全塗布量が同じ
でも耐摩耗性も劣る。In addition, when the amount applied at one time is too small as in samples No. 1 and 2, the roughness of the surface finish is not eliminated even though multiple coats are applied. Moreover, as can be seen from the comparison with Sample 2.4, the wear resistance is also inferior even if the total coating amount per unit area is the same.
■ 単位面積当りの塗料の全塗布量との相対関係から見
て、例えば試料Ｎへ９と１５及び１０と１６との各対比
から分かるように、単位塗装工程の実施回数は、２回よ
り３回、３回より４回の方が、耐磨耗性の点で好結果を
得ることができる。■ In terms of the relative relationship with the total amount of paint applied per unit area, for example, as can be seen from the comparison between samples 9 and 15 and 10 and 16, the number of times the unit coating process is performed is 3 times more than 2 times. It is possible to obtain better results in terms of abrasion resistance by applying 4 times than 3 times.
第１図はこの発明の実施によって形成される耐磨耗性樹
脂塗膜の模式図、第２図は上記塗膜を得るため第１回の
単位塗装工程の実施時ｔこおける塗膜乾燥前と乾燥後の
状態を示す模式図、第３図及び第４図は同じく第２回及
び第３回の単位塗装工程実施時における上記同様の模式
図、第５図はこの発明によって作製される化粧板の斜視
図、第６図は耐磨耗性樹脂塗膜を塗料の１回の塗布作業
で形成する場合における塗膜乾燥前と乾燥後の状態を示
す模式図である。（１）・・・基板、（２）・・・化粧層、（３）・・・
耐摩耗性塗膜、（３ａ）・・・第１単位塗膜、（３ｂ）
・・・第２単位塗膜、（３Ｃ）・・・第３単位塗膜、（
３ｎ）・・・第ｎ単位塗膜、（４）・・・塗料。以 上性３Ｆ；；ζ第５ｒｌＡ第６図手続補正書昭和 ６０年１１月１５ 日特許庁長官 宇 賀 道 部 殿１、事件の表示 １．゛
、。昭和６０年 特許願第２２５９０４号２、発明の名称耐摩耗性化粧板の製造方法３、補正をする者事件との関係 特許出願人住 所 大阪市東区横堀５丁目７番地名 称
朝日特殊合板 株式会社代表者 海 堀 寅 −４、代理人住 所 大阪市南区鰻谷中之町７２−４８、補正
の内容（１） 明細書第６頁第６行の「発泡」を「気泡」と訂
正し、第７行の「ピンホール」の次にｒ （１４ａ ）
Ｊを加入する。（２） 同書第１７頁第１４行の「指触法により」を削
除し、第１５行の「調べた。」の前に「手ざわりで」を
加入する。（３） 図面中の第６図を別紙のとおり補正する。以上Fig. 1 is a schematic diagram of an abrasion-resistant resin coating film formed by carrying out the present invention, and Fig. 2 is a diagram showing the coating film before drying at the time of carrying out the first unit coating process to obtain the above coating film. FIG. 3 and FIG. 4 are schematic diagrams similar to those described above during the second and third unit painting steps, and FIG. 5 is a schematic diagram showing the state after drying. FIG. 5 is a schematic diagram showing the state after drying. The perspective view of the plate, FIG. 6, is a schematic diagram showing the state before and after drying of the coating film when the abrasion-resistant resin coating film is formed by one coating operation. (1)... Substrate, (2)... Decorative layer, (3)...
Abrasion-resistant coating film, (3a)...first unit coating film, (3b)
...Second unit coating film, (3C)...Third unit coating film, (
3n)...nth unit coating film, (4)...paint. 3F;; ζ 5rlA Figure 6 Procedural Amendments November 15, 1950 Director General of the Patent Office Michibu Uga 1. Indication of the case 1.゛、. 1985 Patent Application No. 225904 2 Name of the invention Method for manufacturing wear-resistant decorative laminates 3 Relationship with the case of the person making the amendment Patent applicant address 5-7 Yokobori, Higashi-ku, Osaka Name Name
Asahi Special Plywood Co., Ltd. Representative: Tora Umihori - 4, Agent address: 72-48 Unagidani Nakano-cho, Minami-ku, Osaka, Contents of amendment (1) Changed “foaming” from line 6 on page 6 of the specification to “foaming” ”, and next to “pinhole” in the 7th line, r (14a)
Join J. (2) Delete "by touch" in line 14 of page 17 of the same book, and add "by touch" in line 15 before "I investigated." (3) Figure 6 in the drawings will be amended as shown in the attached sheet. that's all
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP22590485AJPS6283068A (en) | 1985-10-08 | 1985-10-08 | Preparation of abrasion resistant dressed board |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP22590485AJPS6283068A (en) | 1985-10-08 | 1985-10-08 | Preparation of abrasion resistant dressed board |
| Publication Number | Publication Date |
|---|---|
| JPS6283068Atrue JPS6283068A (en) | 1987-04-16 |
| JPH0346185B2 JPH0346185B2 (en) | 1991-07-15 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP22590485AGrantedJPS6283068A (en) | 1985-10-08 | 1985-10-08 | Preparation of abrasion resistant dressed board |
| Country | Link |
|---|---|
| JP (1) | JPS6283068A (en) |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02214573A (en)* | 1989-02-14 | 1990-08-27 | Eidai Co Ltd | Decorative materials and their manufacturing methods |
| JPH04201446A (en)* | 1990-11-30 | 1992-07-22 | Tomoharu Arisawa | Preparation of decorative interior material |
| JP2001315259A (en)* | 2000-05-11 | 2001-11-13 | Toppan Printing Co Ltd | Decorative board |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02214573A (en)* | 1989-02-14 | 1990-08-27 | Eidai Co Ltd | Decorative materials and their manufacturing methods |
| JPH04201446A (en)* | 1990-11-30 | 1992-07-22 | Tomoharu Arisawa | Preparation of decorative interior material |
| JP2001315259A (en)* | 2000-05-11 | 2001-11-13 | Toppan Printing Co Ltd | Decorative board |
| Publication number | Publication date |
|---|---|
| JPH0346185B2 (en) | 1991-07-15 |
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|---|---|---|
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