JP2015044407A - Melamine decorative sheet and manufacturing method of melamine decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a melamine decorative sheet excellent in terms of non-combustibility and flexural workability and possessing a design surface having undergone a mirror-finishing treatment and a manufacturing method of a melamine decorative sheet capable of easily manufacturing such a melamine decorative sheet.SOLUTION: A melamine decorative sheet 100 is constituted by a laminate obtained by laminating a surface layer 11, an intermediate layer 13, and a core material layer 12 in proper order. The surface layer 11 is constituted by a surface layer material comprising a surface layer substrate provided by supporting, on the side of a first surface 111 thereof, a melamine resin-containing resin and by supporting, on the side of a second surface 112 contiguous to the intermediate layer 13, the solid content of a thermoplastic emulsion resin. The intermediate layer 13 is constituted by an intermediate layer formation resin. The core material layer 12 is constituted by a core material layer material consisting of a glass cloth or a prepreg possessing a glass cloth as a substrate. The average thickness of the intermediate layer 13 is greater than the arithmetic average roughness Ra1 of the surface of the core material layer 12 on the intermediate layer side.

Description

  The present invention relates to a melamine decorative board and a method for producing a melamine decorative board.

  A melamine decorative board is a decorative board that uses melamine resin for the surface layer. It is used when applying.

  In recent years, incombustible melamine decorative boards composed of a surface layer using a melamine resin and a glass fiber substrate have become mainstream.

  As such an incombustible melamine decorative board, a decorative board that can be easily bent is known (for example, see Patent Document 1).

  The melamine decorative board described in Patent Document 1 can be made thin and can be easily bent.

  By the way, the design surface of the melamine decorative board may be mirror-finished to give a high-class feeling. However, since the melamine decorative board described in Patent Document 1 has a thin surface layer, the surface layer is affected by the surface shape of the glass fiber base material even if it is mirror-finished. It is difficult to make a specular surface.

Patent No. 5099206

  An object of the present invention is to provide a melamine decorative board having a non-flammability and bending workability, and having a mirror-finished design surface, and a melamine decorative board capable of easily producing such a melamine decorative board. It is to provide a manufacturing method.

  Such an object is achieved by the present inventions (1) to (12) below.

(1) It is composed of a laminate in which a surface layer, an intermediate layer, and a core material layer are laminated in order,
The surface layer comprises a surface layer base material carrying a resin containing a melamine resin on the first surface side which is a design surface and carrying a thermoplastic resin on the second surface side in contact with the intermediate layer. Composed of material, the first surface of the surface layer is a mirror surface,
The core material layer is made of a core material made of a glass cloth or a prepreg based on glass cloth,
The said intermediate | middle layer is comprised with resin for intermediate | middle layer formation, The average thickness is larger than arithmetic mean roughness Ra1 of the surface by the side of the said intermediate | middle layer of the said core material layer, The melamine decorative board characterized by the above-mentioned.

  (2) The melamine decorative board according to (1), wherein the arithmetic average roughness Ra2 of the first surface of the surface layer is 300 nm or less.

  (3) The average thickness of the said intermediate | middle layer is a melamine decorative board as described in said (1) or (2) which is 5 micrometers or more.

  (4) The melamine decorative board according to any one of (1) to (3), wherein the arithmetic average roughness Ra1 is 0.1 to 10 μm.

  (5) The melamine decorative board according to any one of (1) to (4), wherein the average thickness of the melamine decorative board is 0.4 mm or less.

(6) The method for producing a melamine decorative board according to any one of (1) to (5) above,
A first substrate having the first layer made of the surface layer material and the second layer made of the intermediate layer forming resin; and a second substrate made of the core material layer material. And a process of preparing
Disposing the second base so as to face the surface of the first base on the second layer side;
A contact plate having a mirror-finished contact surface is disposed so that the contact surface faces the surface of the first base on the first layer side, and an elastic modulus at 140 ° C. is 1 Arranging a base film of ˜50 GPa so as to face the second base;
The melamine decorative board is obtained by thermocompression bonding the first substrate and the second substrate by bringing the abutment plate and the base film close together while heating at least the first substrate. Process,
The manufacturing method of the melamine decorative board characterized by including the process of removing the said board and the said base film from the said melamine decorative board.

  (7) The first layer supplies a resin varnish containing a resin containing the melamine resin to the first surface side of the surface layer base material, and the second layer of the surface layer base material. The melamine makeup according to (6) above, which is formed by supplying a resin varnish having particles having an average particle size smaller than the arithmetic average roughness Ra1 and including the thermoplastic resin on the surface side. A manufacturing method of a board.

  (8) The second layer has an average particle size that is larger than the average particle size of the particles composed of the thermoplastic resin and smaller than the arithmetic average roughness Ra1, and the intermediate layer forming resin. The manufacturing method of the melamine decorative board as described in said (7) formed using the resin varnish containing the particle | grains comprised by this.

  (9) The second layer (6) to (8), wherein the second layer has an average particle diameter of 150 nm or more and is formed using a resin varnish containing particles composed of the intermediate layer forming resin. The manufacturing method of the melamine decorative board in any one of.

  (10) The method for producing a melamine decorative board according to any one of (6) to (9), wherein the base film has an average thickness of 0.1 to 1.0 mm.

  (11) The said base film is a manufacturing method of the melamine decorative board in any one of said (6) thru | or (10) comprised by the thermoplastic resin whose softening temperature is 120-160 degreeC.

  (12) The method for producing a melamine decorative board according to any one of (6) to (11), wherein a heating temperature in the thermocompression bonding is 130 to 150 ° C. and a pressure is 2 to 8 MPa.

  ADVANTAGE OF THE INVENTION According to this invention, while being excellent in a nonflammability and bending workability, the melamine decorative board provided with the design surface in which the mirror surface process was given can be provided.

  Moreover, the manufacturing method of the melamine decorative board which can manufacture such a melamine decorative board easily can be provided.

FIG. 1 is a cross-sectional view showing an embodiment of the melamine decorative board of the present invention. FIG. 2 is a process diagram showing an example of a method for producing a melamine decorative board according to the present invention. FIG. 3 is a conceptual diagram showing another example of the configuration of the decorative melamine board of the present invention. FIG. 4 is a conceptual diagram showing another example of the configuration of the melamine decorative board of the present invention.

  Hereinafter, the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.

《Melamine decorative board》
First, a preferred embodiment of the melamine decorative board of the present invention will be described.

  The melamine decorative board of the present invention can impart aesthetics and a high-class feeling by being attached to the wall surface of a building, the inner wall surface of an elevator or a train vehicle, the surface of furniture such as a desk or a bookshelf. Moreover, the melamine decorative board of this invention has nonflammability.

  FIG. 1 is a cross-sectional view showing an embodiment of the melamine decorative board of the present invention.

  In the following description, the upper side in FIG. 1 is referred to as “upper”, and the lower side in FIG. 1 is referred to as “lower”.

  As shown in FIG. 1, the melamine decorative board 100 is comprised by the laminated body on which the surface layer 11, the intermediate | middle layer 13, and the core material layer 12 were laminated | stacked. That is, the melamine decorative board 100 has a configuration in which the surface layer 11 and the core material layer 12 are joined via the intermediate layer 13.

  Hereinafter, each layer will be described in detail.

<1. Surface layer>
The surface layer 11 includes a first surface 111 (upper surface) serving as a design surface, and a second surface 112 (lower surface) in contact with the intermediate layer 13 on the side opposite to the first surface 111. The surface layer 11 was supported on the surface layer base material, a resin containing a melamine resin supported on the first surface 111 side of the surface layer base material, and the second surface 112 side of the surface layer base material. It is comprised with the surface layer material which consists of a thermoplastic resin. Further, the surface layer 11 has a design surface (first surface 111) as a mirror surface.

  In the present specification, the surface layer base material carrying the resin means that the resin adheres to the surface of the surface layer base material (carrier) or is impregnated in the voids inside the surface layer base material. means. In this state, after molding the surface layer material, the resin carried on the surface layer base material exhibits its performance. The resin may not be uniformly distributed on the surface of the surface layer base material and the inside of the surface layer base material.

  The surface layer base material is a sheet-like base material, and a design surface is formed on the first surface 111 of the surface layer 11 by supporting a resin containing a melamine resin on the first surface 111 side. . The material of the surface layer base material is not particularly limited. As the surface layer base material, for example, various fiber base materials such as pulp, linter, synthetic fiber, and glass fiber can be used. Further, as the surface layer base material, a titanium oxide-containing decorative paper containing a pigment such as titanium oxide can be used as necessary.

Although the basic weight of a surface layer base material is not specifically limited, It is preferable that it is 40-150 g / m < ² >. If the basis weight is less than the lower limit value, the resin impregnation step may cause the resin to break or the surface layer material (surface layer 11) to be obtained is likely to be wrinkled. Therefore, impregnation treatment (for example, coating treatment) ) May be difficult. Furthermore, it may be difficult to adjust the amount of resin carried on each of the first surface 111 side and the second surface 112 side of the surface layer base material. On the other hand, when the basis weight exceeds the upper limit, unevenness occurs in the amount of the resin carried by the surface layer base material, and the flexibility of the melamine decorative board 100 is lowered, and the productivity is lowered and the cost is increased. It may be a cause.

  The surface layer material carries a resin containing a melamine resin on the upper surface side (first surface 111 side) of the surface layer base material. Thereby, suitable surface hardness can be provided to the upper surface of the surface layer 11, that is, the first surface 111 (design surface) of the surface layer 11.

  The melamine resin is not particularly limited, and for example, a polymer obtained by reacting melamine and formaldehyde in a neutral or weak alkali can be used.

  The reaction molar ratio of formaldehyde to melamine (hereinafter also simply referred to as “reaction molar ratio”) is a value of (molar amount of formaldehyde) / (molar amount of melamine). The reaction molar ratio is not particularly limited, but is preferably 1.0 to 4.0, more preferably 1.0 to 2.0, and further preferably 1.1 to 1.8. preferable. A melamine resin obtained by reacting melamine and formaldehyde at such a reaction molar ratio can be suitably used. When the reaction molar ratio is less than the lower limit, unreacted melamine increases, the storage stability of the resin decreases, and the cost may increase. Moreover, when the said upper limit is exceeded, the fall of the softness | flexibility of resin after hardening may become remarkable. In addition, the resin carried on the upper surface side of the surface layer base material can be a resin containing one kind of melamine resin alone, or two or more kinds of melamine resins having different reaction molar ratios, weight average molecular weights, and the like. A resin containing can also be used.

  Moreover, as this melamine resin, commercial items, such as a melamine resin by Sumitomo Chemical Co., Ltd., can also be used.

  Although the weight average molecular weight of a melamine resin is not specifically limited, It is preferable that it is 200-500, and it is more preferable that it is 250-350. When the weight average molecular weight of a melamine resin is smaller than the said lower limit, the unreacted melamine contained in resin increases, and the preservability of resin may fall. Moreover, when larger than the said upper limit, the impregnation property to the base material of resin may fall. The weight average molecular weight can be measured, for example, by GPC (gel permeation chromatography, standard substance: converted to polystyrene).

  The amount of the melamine resin contained in the resin supported on the upper surface (first surface 111) side of the surface layer base material is not particularly limited, but is preferably 80 to 100% by mass, and 95 to 100% by mass. % Is more preferred. When the amount of the melamine resin contained in the resin carried on the upper surface side of the surface layer base material is less than the lower limit value, the hardness of the surface of the surface layer 11 (first surface 111) decreases, Contamination resistance may be reduced.

  The method for supporting the resin containing the melamine resin on the upper surface side (first surface 111 side) of the surface layer base material is not particularly limited. As such a method, for example, a resin varnish obtained by dissolving the resin in a solvent is applied to a surface layer substrate using a known device such as a spray device, a shower device, a kiss coater, a comma coater, A method of heating and drying at about 80 to 130 ° C. can be used. Thereby, a surface layer base material (hereinafter, also referred to as “resin-supporting base material”) carrying a resin on the upper surface side is obtained.

  The resin-supported substrate (for example, resin-impregnated paper) after heat drying has 2 to 6% by mass of a volatile component (solvent) when the total weight of the resin-supported substrate is 100% by mass. It is preferable to remain. This facilitates handling of the resin-carrying substrate. Moreover, when manufacturing the melamine decorative board 100 using such a resin support base material, when heating and pressurizing (heating molding), the upper surface side (first surface 111 side) of the surface layer base material The resin flow of the resin containing the melamine resin supported on is improved. Therefore, the design appearance and surface glossiness of the surface layer 11 are improved. On the other hand, when the volatile component is less than 2% by mass, the resin is easily broken, and thus handling becomes difficult. Further, since the resin flow is lowered, the appearance of the surface layer 11 is hindered. Moreover, when manufacturing the melamine decorative board 100 using resin with a volatile component exceeding 6%, depending on the dry environment after shaping | molding, the curvature (sheet curl) of the melamine decorative board 100 tends to increase. Further, when the volatile component is 7.5% or more, the volatile component affects the gloss transfer property of the appearance of the melamine decorative board 100.

  It does not specifically limit as a solvent for melt | dissolving resin containing a melamine resin (adjusting a resin varnish), For example, water, methanol, etc. are mentioned. As such a solvent, water is particularly preferable. In addition, a poor solvent can be used in combination as long as it does not adversely affect the coatability of the resin varnish. The amount of solid content (all components excluding the solvent) contained in the resin varnish is not particularly limited, but is preferably 30 to 70% by mass of the entire resin varnish, and 45 to 60% by mass. More preferred. Thereby, the impregnation property to the surface layer base material of the resin varnish can be improved.

  The surface layer material is formed by supporting a thermoplastic resin on the second surface 112 side opposite to the first surface 111 (design surface) side of the surface layer base material.

  The thermoplastic resin supported on the surface layer base material may be in the form of particles, bulk, or a combination thereof, but is preferably included in the form of particles. In addition, particulate thermoplastic resin (thermoplastic resin particles) can be easily obtained by using a thermoplastic emulsion resin (resin varnish) in which the thermoplastic resin is dispersed in a solvent to form an emulsion and drying it. And it can be obtained reliably.

  Thermoplastic resin particles have excellent adhesive properties with metals and various materials. For this reason, the thermoplastic resin particles are supported on the surface layer base material with high adhesive strength. In particular, even if the surface layer base material is deformed by applying a stress such as bending, the high adhesive strength makes it difficult for the thermoplastic resin to peel from the surface layer base material. Furthermore, since the thermoplastic resin particles carried on the surface layer base material are in point contact with each other, they reliably follow the deformation of the surface layer base material. Therefore, flexibility is imparted to the melamine decorative board 100. As a result, the bending workability of the melamine decorative board 100 can be improved.

  The thermoplastic resin is not particularly limited, and examples thereof include various thermoplastic resins such as acrylic resin, urethane resin, vinyl acetate copolymer, urethane acrylic composite resin, styrene butadiene rubber (SBR), and nitrile rubber (NBR). Can be mentioned. Among these, as the thermoplastic resin, a thermoplastic resin containing urethane acrylic composite particles is preferable.

  Urethane resins are particularly excellent in toughness, elasticity and flexibility, and acrylic resins are particularly excellent in transparency, durability, weather resistance, chemical resistance and film-forming properties. Therefore, when a urethane acrylic composite resin is used as the thermoplastic resin, the thermoplastic resin carried on the surface layer base material can have both the characteristics of the urethane resin and the acrylic resin described above.

  From the above, it is preferable that the thermoplastic resin supported on the second surface 112 side of the surface layer base material includes particles made of urethane acrylic composite resin, that is, urethane acrylic composite particles. .

  In addition, in this specification, a urethane acrylic composite particle means the particle | grains which have the heterophasic structure of an acrylic resin and a urethane resin in a single particle. Further, in the present specification, the “heterophasic structure” means a structure in which a plurality of phases composed of different types of resins are present in one particle. Examples of such a structure include a core-shell structure, a localized structure, and a sea-island structure.

  Such urethane acrylic composite particles preferably have a core-shell structure in which each particle has an acrylic resin as a core and a urethane resin as a shell. When urethane acryl composite particles having the above core-shell structure are supported on the surface layer base material, the surface outline becomes urethane resin. Therefore, the characteristics of the urethane resin can be imparted to the outer shell while giving the characteristics of both the urethane resin and the acrylic resin to the second surface 112 side of the surface layer base material.

  Moreover, the arrangement state of the particles when the urethane acrylic composite particles are carried on the second surface 112 side of the surface layer base material is not particularly limited. Such particles, for example, can be arranged in a straight line to form a straight chain structure or take other various arrangement states. The structure of the particles and the arrangement state of the particles can be confirmed by, for example, a scanning electron microscope (SEM).

  In addition, as a thermoplastic resin, one type in the thermoplastic resin mentioned above may be included independently, and 2 or more types of different thermoplastic resins may be mixed and included.

  Moreover, the thermoplastic resin may contain a small amount of a thickener, a penetration accelerator, an antifoaming agent, and the like as necessary, in addition to the resin particles of the thermoplastic resin.

  The average particle diameter of the thermoplastic resin particles is not particularly limited, but is preferably smaller than the arithmetic average roughness Ra1 of the surface (upper surface) of the core layer 12 described later on the intermediate layer 13 side. Furthermore, the average particle diameter of the thermoplastic resin particles is preferably 30 to 100 nm, and more preferably 60 to 90 nm.

  When the average particle diameter of the thermoplastic resin particles satisfies the above conditions, the impregnation property of the thermoplastic resin particles between the fibers of the surface layer base material is improved, and the thermoplastic resin particles are further impregnated inside the surface layer base material. Can be made. For this reason, the surface layer 11 can be given good flexibility. Further, if the average particle diameter of the thermoplastic resin particles is within the above range, the design of the design surface of the surface layer 11 is sufficiently smaller than the arithmetic average roughness Ra1 of the surface of the core layer 12 on the intermediate layer 13 side. Appearance and surface gloss are further improved.

  The thermoplastic resin is preferably water-insoluble. Thereby, it can prevent that a thermoplastic resin transfers to the 1st surface 111 side of a surface layer base material, and mixes with the melamine resin currently carry | supported by the 1st surface 111 side. Therefore, it can prevent impairing the surface performance by the melamine resin on the first surface 111 side.

  The method for supporting the thermoplastic resin on the second surface 112 side of the surface layer base material is not particularly limited, and the above-described method for supporting the resin containing the melamine resin on the first surface 111 side of the surface layer base material Similar methods can be used.

  In particular, when a thermoplastic emulsion resin (resin varnish) is used as a raw material, a method in which a thermoplastic emulsion resin is applied to a surface layer substrate using a known method and heated and dried can be used.

  The thermoplastic emulsion resin in which the urethane acrylic composite resin is dispersed in a solvent to become an emulsion is particularly preferably an aqueous clear type.

  The water-based clear thermoplastic emulsion resin is water-soluble, its solid content (coating film) after water removal is water-insoluble, and transparent enough to clearly identify the underlying pattern have. Therefore, in this specification, the aqueous clear type thermoplastic emulsion resin means an aqueous resin solution having such characteristics. By using such an aqueous clear type thermoplastic emulsion resin as a raw material of the thermoplastic resin carried on the second surface 112 side of the surface layer base material, the influence on the color tone of the design surface of the surface layer is exerted. Can be suppressed.

  In addition, 2-6 mass% of volatile components remain in the resin-supported substrate (for example, resin-impregnated paper) after the heat drying when the weight of the entire resin-supported substrate is 100 mass%. It is preferable. This facilitates handling of the resin-carrying substrate. Moreover, when manufacturing the melamine decorative board 100 using such a resin support base material, when heating and pressurizing (heating molding), the upper surface side (first surface 111 side) of the surface layer base material The resin flow of the resin containing the melamine resin supported on is improved. Therefore, the design appearance and surface glossiness of the melamine decorative board 100 are improved.

  It does not specifically limit as a solvent for melt | dissolving a thermoplastic resin (adjusting a thermoplastic emulsion resin), For example, water etc. are mentioned. The solvent may be used in combination with a poor solvent as long as the coating property and the like are not adversely affected. The amount of solid content (all components excluding the solvent) contained in the resin is not particularly limited, but is preferably 25 to 60% by mass, more preferably 30 to 45% by mass of the entire resin. . Thereby, the impregnation property to the surface layer base material of resin can be improved.

  As described above, the design surface (first surface 111) of the surface layer 11 is a mirror surface, and the arithmetic average roughness Ra2 is preferably 300 nm or less, more preferably 150 nm or less. preferable. Thereby, the 1st surface 111 of the surface layer 11 becomes smoother, and the high-class feeling of the melamine decorative board 100 can be made higher.

<2. Core material layer>
The core material layer 12 is bonded to the lower surface (second surface 112) side of the surface layer 11 via the intermediate layer 13.

  The core material layer 12 is composed of a core material made of glass cloth or a prepreg containing glass cloth as a base material. Thereby, heat resistance, nonflammability, rigidity, etc. can be provided to the melamine decorative board 100.

  Further, irregularities are formed on the upper surface of the core material layer 12. Since the irregularities of the core material layer 12 are embedded in the intermediate layer 13, the core material layer 12 and the intermediate layer 13 are firmly bonded (adhered) by the anchor effect. That is, the interlayer adhesive strength between the core material layer 12 and the intermediate layer 13 can be increased. Thereby, when bending the melamine decorative board 100, it can prevent reliably that the core material layer 12 and the intermediate | middle layer 13 peel.

  The arithmetic average roughness Ra1 of the upper surface of the core material layer 12 (the surface on the intermediate layer 13 side) is not particularly limited, but is preferably 0.1 to 10 μm, and more preferably 1 to 7 μm. Thereby, the interlayer adhesive strength of the core material layer 12 and the intermediate | middle layer 13 can be made higher.

  Moreover, as glass which comprises a glass cloth, E glass, C glass, A glass, S glass, D glass, NE glass, T glass, H glass etc. are mentioned, for example. Among these, T glass is preferable. Since T glass is a material having a relatively small thermal expansion coefficient, the thermal expansion coefficient of the glass cloth can be reduced by using it as a constituent material of the glass cloth.

The weight of the glass cloth is not particularly limited, but if it is necessary to satisfy the “non-combustible crack / penetration after combustion” requirement of Article 2-9 of the Building Standards Act, the basis weight It is preferable to be 100 g / m ² or more. The upper limit of the weight is not particularly limited, but a basis weight of 250 g / m ² or less is preferable in consideration of material cost and workability.

  The prepreg is not particularly limited, and for example, the above glass cloth can be impregnated with a resin composition containing a thermoplastic resin, a thermosetting resin, or the like.

  The amount of the resin composition contained in the prepreg is not particularly limited as long as the interlayer adhesive strength with the intermediate layer 13 is sufficient for forming the melamine decorative board 100. When a thermoplastic resin is used as the resin composition, the amount of the thermoplastic resin (solid content) contained in the prepreg is preferably 1% by mass or more and 20% by mass or less, and preferably 1% by mass or more and 10% by mass. % Or less is more preferable. Thereby, the interlayer adhesive strength of the intermediate | middle layer 13 and the core material layer 12 can be improved more.

  Moreover, when using a thermosetting resin as a resin composition, it is preferable that the quantity of the thermosetting resin (solid content) contained in a prepreg is 1 mass% or more and 20 mass% or less, and 2 mass%. More preferably, it is 10 mass% or less. Thereby, the interlayer adhesive strength of the intermediate | middle layer 13 and the core material layer 12 can be improved more.

  The thermoplastic resin is not particularly limited, and examples thereof include an acrylic resin, a urethane resin, an ethylene vinyl acetate resin, and a styrene butadiene rubber (SBR). Among these, it is preferable to use an acrylic resin and / or a urethane resin as the thermoplastic resin.

  The thermosetting resin is not particularly limited, and examples thereof include phenol resin, epoxy resin, oxetane resin, (meth) acrylate resin, unsaturated polyester resin, diallyl phthalate resin, urea resin, and maleimide resin. Especially, it is preferable to use a phenol resin as a thermosetting resin from a nonflammability, heat resistance, and adhesive viewpoint. These resins can be used alone or in combination.

  The prepreg can be produced by a conventionally known method. For example, it can be obtained by impregnating the above-described glass cloth with a resin varnish obtained by dissolving a resin composition in a solvent and then drying the resin varnish.

  The core material layer 12 may further carry a thermoplastic resin on the upper surface side in contact with the intermediate layer 13. As such a thermoplastic resin, a thermoplastic resin similar to the thermoplastic resin carried on the second surface 112 side of the surface layer base material can be used. Moreover, when this thermoplastic resin contains a thermoplastic resin particle, the adhesive strength of the core material layer 12 and the intermediate | middle layer 13 is improved further, and the high bending workability in the normal temperature of the melamine decorative board 100 is achieved. be able to. The average particle diameter of the thermoplastic resin particles is not particularly limited. Such thermoplastic resin particles may be water-soluble or water-insoluble.

  The thermoplastic resin carried on the side of the core material layer 12 in contact with the intermediate layer 13 is not particularly limited as long as it imparts flexibility to the core material layer 12 and does not affect the calorific value and gas toxicity during combustion.

  The thickness of the core material layer 12 is preferably 100 μm or more. Thereby, sufficient heat resistance and nonflammability can be imparted to the melamine decorative board 100. Further, the upper limit of the thickness is not particularly limited. However, as the thickness increases, the thickness and weight of the melamine decorative board 100 increase and the cost also increases. For this reason, it is preferable to set the thickness of the core material layer 12 in an allowable range in the design of the final product (melamine decorative board 100), and more preferably 350 μm or less.

<3. Intermediate layer>
The intermediate layer 13 is a resin layer disposed between the surface layer 11 and the core material layer 12, and the upper surface thereof is in contact with the surface layer 11, and the lower surface thereof is in contact with the core material layer 12 to join them. To do. The intermediate layer 13 is a layer having a function of reducing the influence of the surface shape (unevenness) of the upper surface of the core material layer 12 on the surface layer 11.

  As described above, the present invention is characterized in that the intermediate layer 13 is provided between the surface layer 11 and the core material layer 12.

  By having such a feature, the influence of the surface shape (unevenness) of the upper surface of the core material layer 12 derived from the glass cloth on the design surface (first surface 111) of the surface layer 11 can be reduced. Thereby, the smoothness of the design surface of the surface layer 11 can be improved. As a result, it is possible to provide the melamine decorative board 100 which is excellent in nonflammability and bending workability and has a high-class feeling by mirror finishing.

  Moreover, in this melamine decorative board 100, the average thickness of the intermediate | middle layer 13 is larger than the arithmetic mean roughness Ra1 of the upper surface of the core material layer 12. FIG. Thereby, it can suppress that an unevenness | corrugation arises in the upper surface of the intermediate | middle layer 13 with the unevenness | corrugation of the upper surface of the core material layer 12, and the smoothness improves. As a result, the design appearance and surface glossiness of the design surface of the surface layer 11 can be improved. Moreover, when the average thickness of the intermediate layer 13 satisfies the above conditions, the intermediate layer 13 exhibits a function as a cushion layer and absorbs stress applied to the melamine decorative board 100. For this reason, when bending the melamine decorative board 100, it can prevent reliably that the core material layer 12 and the intermediate | middle layer 13 peel.

  The intermediate layer 13 is made of an intermediate layer forming resin.

  Although it does not specifically limit as resin for intermediate | middle layer formation, It is preferable that the resin particle is included. Such resin particles can be easily and reliably obtained by using, as a raw material, an emulsion resin (resin varnish) obtained by dispersing the resin in a solvent to form an emulsion. When the intermediate layer forming resin contains resin particles, the resin particles are embedded in the concave and convex recesses of the core material layer 12. Thereby, the smoothness of the upper surface of the intermediate layer 13 is further improved. Thereby, the influence of the surface shape of the core material layer 12 derived from the glass cloth on the design surface (first surface 111) of the surface layer 11 can be further reduced.

  The resin particles are not particularly limited. For example, particles of thermoplastic resin such as acrylic resin, urethane resin, vinyl acetate copolymer, urethane acrylic composite resin, styrene butadiene rubber (SBR), and nitrile rubber (NBR) are used. Can be mentioned. Among these, it is preferable to use acrylic resin particles as the resin particles. Thereby, while being able to join the surface layer 11 and the core material layer 12 more firmly, the surface shape of the core material layer 12 derived from the glass cloth with respect to the design surface (first surface 111) of the surface layer 11 The influence of can be further reduced.

  The average particle diameter of such resin particles is not particularly limited. When the thermoplastic resin carried on the lower surface side of the surface layer 11 includes thermoplastic resin particles, it is preferably larger than the average particle diameter of the thermoplastic resin particles and smaller than the arithmetic average roughness Ra1 described above. The resin particles having such a size can be embedded in the concave and convex portions of the core material layer 12 to smooth the upper surface of the intermediate layer 13. Further, even if minute irregularities are formed on the surface (upper surface) of the intermediate layer 13 on the surface layer 11 side, the thermoplastic resin particles of a thermoplastic resin having an average particle size smaller than the resin particles in the irregularities of the irregularities. Is embedded. As a result, the first surface 111 (design surface) of the surface layer 11 can be made smoother, and the design appearance and surface glossiness of the design surface of the surface layer 11 are further improved.

  Specifically, the average particle size of the resin particles is preferably 150 nm or more and 0.75 × Ra1 or less, and more preferably 200 nm or more and 0.50 × Ra1 or less. When the average particle diameter of the resin particles contained in the resin for forming the intermediate layer is within the above range, the first surface 111 (design surface) of the surface layer 11 can be made smoother due to the above-described effects. Further, the design appearance and surface glossiness of the design surface of the surface layer 11 are further improved.

  Furthermore, the penetration of the resin particles into the surface layer 11 and the core material layer 12 can be more reliably prevented, and the function as the intermediate layer 13 as described above can be more reliably exhibited. On the other hand, if the average particle size of the resin particles is less than the lower limit, depending on the type of the surface layer base material constituting the surface layer 11 and the type of glass cloth constituting the core material layer 12, the melamine decorative board When 100 is manufactured, resin particles are absorbed by the surface layer 11 and the core material layer 12, and it may be difficult to form the intermediate layer 13.

  As the intermediate layer 13, a film made of an intermediate layer forming resin can also be used.

  Such a film can be composed of a thermoplastic resin such as an acrylic resin, a urethane resin, a polyolefin resin, or a polyester resin. Even when such a film is used as the intermediate layer 13, the influence of the surface shape of the core material layer 12 derived from the glass cloth on the design surface (first surface 111) of the surface layer 11 can be further reduced. . Further, when such a film is used as the intermediate layer 13, it is possible to save materials (solvents and the like) for forming the intermediate layer 13 and time, thereby reducing the cost for manufacturing the melamine decorative board 100. can do.

  The average thickness of the intermediate layer 13 is not particularly limited as long as it is larger than the arithmetic average roughness Ra1 of the upper surface of the core material layer 12, but is preferably 6 μm or more, and more preferably 10 to 50 μm. Thereby, the influence of the surface shape of the core material layer 12 derived from the glass cloth on the design surface (first surface 111) of the surface layer 11 can be reduced more effectively. On the other hand, when the average thickness of the intermediate layer 13 is less than the lower limit, depending on the value of the arithmetic average roughness Ra1, the design surface (first surface 111) of the surface layer 11 is derived from the glass cloth. The influence of the surface shape of the core material layer 12 may increase. Moreover, if the average thickness of the intermediate layer 13 exceeds the upper limit, the calorific value when the intermediate layer 13 burns increases, and the melamine decorative board 100 having the intermediate layer 13 may not be incombustible.

  The melamine decorative board 100 as described above can be bent so that the minimum bending radius at room temperature (usually about 20 to 30 ° C.) is 10 mmR or less, but the degree of bending (the value of the minimum bending radius). Is not limited to this. The minimum bend radius R is the minimum that can be obtained 100% non-defective product without causing defects such as cracking even if the room temperature bending process is repeatedly performed in one direction along a mold having a curved portion with a radius R. Means the radius R of the mold.

  Moreover, it is preferable that the whole thickness of the melamine decorative board 100 is 0.4 mm or less. Thereby, it becomes possible to bend the melamine decorative board 100 more easily.

  In the present embodiment, as a preferred example, the thermoplastic resin carried on the second surface 112 side of the surface layer base material has been described as being in the form of particles, but may not be in the form of particles. That is, for example, when a thermoplastic emulsion resin (resin varnish) is used and supported on the second surface 112 side of the surface layer base material, the thermoplastic resin is in a particulate form after the resin varnish is dried. May not be held.

  Further, in the present embodiment, as a suitable example, the intermediate layer forming resin constituting the intermediate layer 13 has been described as being in the form of particles, but may not be in the form of particles. That is, for example, when the intermediate layer 13 is formed using an emulsion resin (resin varnish), the intermediate layer forming resin does not have to maintain a particulate form after the resin varnish is dried.

<Method for producing melamine decorative board>
Next, the manufacturing method of the melamine decorative board mentioned above is demonstrated.

  FIG. 2 is a process diagram showing an example of a method for producing a melamine decorative board according to the present invention.

  In the following description, the upper side in FIG. 2 is referred to as “upper”, and the lower side in FIG. 2 is referred to as “lower”.

  First, a first layer 11 'made of the surface layer material is formed. The first layer 11 ′ is a layer that becomes the surface layer 11 described above.

  The first layer 11 ′ carries a resin containing a melamine resin on one surface (first surface 111 serving as a design surface) side (upper surface side) of the surface layer base material, and the other surface (second surface). It is formed by supporting a thermoplastic resin on the surface 112) side (lower surface side). More specifically, a resin varnish containing a resin containing a melamine resin is supplied to the first surface 111 side of the surface layer base material, and a thermoplastic resin is supplied to the second surface 112 side of the surface layer base material. It is formed by supplying a resin varnish containing particles (thermoplastic resin particles) composed of

  In addition, in the resin varnish used when supporting the thermoplastic resin on the second surface 112 side of the surface layer base material, the average particle diameter of the thermoplastic resin particles contained in the resin varnish is 30 to 100 nm. It is preferable that it is 60-90 nm. When the average particle diameter of the thermoplastic resin particles satisfies the above conditions, the impregnation property of the thermoplastic resin particles between the fibers of the surface layer base material is improved, and the thermoplastic resin particles are further impregnated inside the surface layer base material. Can be made. For this reason, the surface layer 11 can be given good flexibility. Further, if the average particle diameter of the thermoplastic resin particles is within the above range, the design of the design surface of the surface layer 11 is sufficiently smaller than the arithmetic average roughness Ra1 of the surface of the core layer 12 on the intermediate layer 13 side. Appearance and surface gloss are further improved.

  Next, an intermediate layer forming resin is applied to the lower surface (the other surface) of the first layer 11 ′ to form a second layer 13 ′ composed of the intermediate layer forming resin. More specifically, the second layer 13 ′ is formed by supplying a resin varnish containing particles (resin particles) made of an intermediate layer forming resin to the lower surface of the first layer 11 ′. The second layer 13 ′ is a layer that becomes the intermediate layer 13 described above.

  In the resin varnish used when forming the second layer 13 ′, the average particle diameter of the resin particles contained in the resin varnish is preferably 150 nm or more, and more preferably 200 nm or more. . When the average particle diameter of the resin particles contained in the resin for forming the intermediate layer is within the above range, the first surface 111 (design surface) of the surface layer 11 can be made smoother due to the above-described effects. Further, the design appearance and surface glossiness of the design surface of the surface layer 11 are further improved. Furthermore, the penetration of the resin particles into the surface layer 11 and the core material layer 12 can be more reliably prevented, and the function as the intermediate layer 13 as described above can be more reliably exhibited.

  As described above, the first base body 10 having the first layer 11 ′ made of the surface layer material and the second layer 13 ′ made of the intermediate layer forming resin is obtained (see FIG. 2A). ).

  Note that the formation of the second layer 13 ′ may be performed simultaneously with supporting the thermoplastic resin on the lower surface (the other surface) side of the first layer 11 ′. The resin particles of the intermediate layer forming resin have a larger particle diameter than the resin particles of the thermoplastic resin constituting the surface layer 11 and are less likely to enter the surface layer 11. In other words, the resin particles of the intermediate layer forming resin are not easily supported on the surface layer base material. For this reason, it is possible to simultaneously carry the thermoplastic resin on the lower surface (second surface 112) side of the surface layer base material and to form the intermediate layer. Thereby, a drying process can be implemented at once, and a simplification of a production process and also a cost reduction can be aimed at.

  Next, a second base 12 'made of a core material layer material is prepared. The second base 12 ′ is a layer that becomes the core material layer 12 described above.

  Next, the second substrate 12 ′ is disposed so as to face the lower surface of the first substrate 10 (the surface on the second layer 13 ′ side) (see FIG. 2B).

  Next, the base film 20 having an elastic modulus at 140 ° C. of 1 to 50 GPa is prepared.

  In addition, two contact plates (mirror finish contact plates) 30 having a contact surface subjected to mirror finishing are prepared.

  Next, as shown in FIG. 2 (c), two sets of laminated bodies of the first base body 10 and the second base body 12 ′ arranged to face each other are prepared, and between the second base bodies 12 ′ of the laminated body. It arrange | positions so that the base film 20 may be pinched | interposed. That is, it arrange | positions so that the 2nd base | substrate 12 'of each laminated body may be located in the base film 20 side.

  Further, as shown in FIG. 2 (c), the two mirror finish finishing plates 30 are arranged so that the respective contact surfaces face the first substrate 10 (first layer 11 ′) of each laminate. .

  Thereafter, the mirror finishing touch plates 30 are brought close to each other while heating the first base 10 (the first layer 11 ′) with the mirror finishing touch plate 30. Thereby, when the mirror finish plate 30 and the base film 20 come close to each other, each laminate is pressed and the first base 10 and the second base 12 ′ are thermocompression bonded. Thereby, two melamine decorative boards 100 are obtained.

  According to the manufacturing method as described above, it is possible to easily manufacture the melamine decorative board 100 having a non-flammability and bending workability and having a design surface subjected to mirror finishing.

  Further, by arranging the base film 20 on the second base 12 ′ side, the force with which the second base 12 ′ presses the first base 10 against the mirror finish abutting plate 30 when thermocompression bonding is eased. can do. Thereby, the influence of the surface shape of the glass cloth which comprises 2nd base | substrate 12 'with respect to the surface (design surface of the surface layer 11) of the 1st base | substrate 10 can be made smaller. As a result, the design surface of the melamine decorative board 100 can be a smoother mirror surface.

  In addition, although the elasticity modulus in 140 degreeC of the base film 20 is 1-50 GPa, it is preferable that it is 15-40 GPa. Thereby, the influence of the surface shape of the glass cloth which comprises 2nd base | substrate 12 'with respect to the surface (design surface of the surface layer 11) of the 1st base | substrate 10 can be made still smaller.

  Although it will not specifically limit if it satisfies the said characteristic as a material which comprises the base film 20, It is preferable that it is comprised with the thermoplastic resin, and it is comprised with the thermoplastic resin whose softening temperature is 120-160 degreeC. More preferably. Thereby, when thermocompression bonding, the influence of the surface shape of the glass cloth constituting the second substrate 12 ′ on the surface of the first substrate 10 (design surface of the surface layer 11) can be further reduced.

  Moreover, it is preferable that it is 0.1-1.0 mm, and, as for the average thickness of the base film 20, it is more preferable that it is 0.1-0.5 mm. Thereby, the influence of the surface shape of the glass cloth which comprises 2nd base | substrate 12 'with respect to the surface (design surface of the surface layer 11) of the 1st base | substrate 10 can be made smaller.

  A plurality of base film 20 may be used as necessary.

  Moreover, it does not specifically limit as conditions to heat-press-mold (thermocompression bonding) the melamine decorative board 100, However, It is preferable to carry out with the heating temperature of 130-150 degreeC, and the pressure of 2-8 MPa. The time for thermocompression bonding is preferably 10 to 60 minutes. Thereby, the influence of the surface shape of the glass cloth which comprises 2nd base | substrate 12 'with respect to the surface (design surface of the surface layer 11) of the 1st base | substrate 10 can be made still smaller.

  In addition to the method of heating and pressurizing the first base 10 with the mirror finish plate 30, the following method can be used for the thermocompression bonding of the melamine decorative board 100. For example, the melamine decorative board 100 can be obtained by pressing each laminated body with the mirror finish plate 30 while blowing hot air on each laminated body or performing laser irradiation.

  Note that a release film may be sandwiched between the base film 20 and the second substrate 12 'as necessary. As the release film, a known release film can be used.

  As mentioned above, although preferred embodiment of the melamine decorative board of this invention was described, this invention is not limited to this.

  For example, the melamine decorative board of the present invention is not limited to the form of the melamine decorative board 100 shown in FIG. For example, when it is desired to improve the mechanical strength of the melamine decorative board, as shown in FIG. 3, another core material layer made of another core material layer material is laminated below the core material layer. May be. That is, it is good also as a four-layer structure of the surface layer 11, the intermediate | middle layer 13, the core material layer 12, and the core material layer 14 by laminating | stacking two core material layers. Moreover, you may have other layers other than a surface layer, an intermediate | middle layer, and a core material layer, for example, as shown in FIG. 4, the protective layer 15 is formed in the outermost layer of the design surface side (upper side in FIG. 4). Or the support layer 16 may be provided in the outermost layer on the core layer side (lower side in FIG. 4).

The protective layer 15 is not particularly limited, and for example, an inorganic material selected from a paper substrate having a basis weight of 10 to 50 g / m ² , a melamine resin alone, or a melamine resin from aluminum hydroxide, magnesium hydroxide, or silica. It can be obtained by impregnating a resin composition containing a filler and drying it.

  The support layer 16 is not particularly limited. For example, the support layer 16 is supported on the same substrate as the above-described surface layer substrate on the upper side (first surface side) or the lower side (second surface side) of the surface layer. A prepreg obtained by impregnating a glass cloth or the like with a resin that can be used, a metal foil, or the like can be used.

  In addition, although embodiment mentioned above demonstrated the method of manufacturing two melamine decorative boards simultaneously as a manufacturing method, it is not limited to this, The method of manufacturing one by one may be sufficient.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail based on an Example and a comparative example, this invention is not limited to this.

1. Production of melamine decorative board (Example 1)
Titanium oxide-containing decorative paper (Dai Nippon Printing Co., Ltd.) having a basis weight of 80 g / m ² was prepared as a surface layer base material.

Next, on one side (second side) of the titanium oxide-containing decorative paper, an emulsion of urethane acrylic composite resin (manufactured by Chuo Rika Kogyo Co., Ltd., trade name “SU-100”, average particle size: 84 nm, dispersion medium: water) was applied so that the solid content was 40 g / m ² .

Subsequently, melamine resin (reaction molar ratio: 1.4, resin solid content: 50% by mass) is 50 g / m ² on the other surface side (first surface side (design surface side)) of the titanium oxide-containing decorative paper. It was coated so that

  After that, they were dried for 90 seconds with a 120 ° C. hot air dryer. In this way, the urethane acrylic composite particles are supported on the second surface side of the titanium oxide-containing decorative paper, and the melamine resin is supported on the first surface side (design surface side) of the titanium oxide-containing decorative paper. A first layer having a resin ratio of 53% and a volatile content ratio of 3% was obtained.

  In addition, the said melamine resin mix | blended raw material melamine and formalin with the predetermined | prescribed mixture ratio (preparation) to the reaction kettle, and after carrying out catalyst addition, it heated up to the boiling point and made it reflux-react. Then, after confirming that melamine dissolution was completed, when the reaction end point was reached, the resin solid content was adjusted by dehydration and synthesized by a method of cooling.

Next, an acrylic resin emulsion (manufactured by Nippon Zeon Co., Ltd., trade name “Nipol LX-851E”, average particle diameter: 200 nm, dispersion medium: water) is adjusted to the above-mentioned first so that the solid content is 20 g / m ² . The coating was performed on the second surface side of the first layer.

  Then, it dried for 90 seconds with a 120 degreeC hot-air dryer, and formed the 2nd layer (intermediate layer). As a result, a first substrate having a first layer and a second layer and having a resin ratio of 58% and a volatile content of 4% was obtained.

A glass cloth having a grammage of 104 g / m ² (made by Taiwan Nanya Co., Ltd., trade name “Nanya-2116”) is overlaid on the second surface side of the obtained first substrate as a second substrate (core material layer). In addition, a laminate of the first substrate and the second substrate was produced. Furthermore, the above procedure was repeated to create another laminate in which the first substrate and the second substrate were superposed, and two sets of laminates were prepared.

  Next, two base films (manufactured by Sumitomo Bakelite Co., Ltd., trade name “CEL E911B”, thickness: 0.12 mm, softening temperature: 140 ° C.) and two release films (manufactured by Toray Industries, Inc., The product name “Trephan SRP”) was prepared.

  After arranging the two release films so as to sandwich the two base films, the release films and the base films were disposed between the second bases of the laminate. Next, two mirror-finished abutting plates (mirror-finished stainless steel plates having a glossiness meter measurement value of 300 or more as stainless steel plates) each provided with a mirror-finished contact surface are provided for each contact surface. It arrange | positioned so that the 1st base | substrate of a laminated body might be opposed, and the laminated body and the base film were pinched | interposed.

  In this state, the mirror finish finishing plates are brought close to each other (the mirror finishing touch plate and the base film are brought close to each other), and heated and pressure-molded (thermocompression bonding) for 40 minutes under the conditions of 140 ° C. and 8 MPa. A melamine decorative board having a thickness of 0.3 mm was obtained.

(Example 2)
In the formation of the second layer, the acrylic resin emulsion was applied to the second surface side of the first layer so that the solid content was 10 g / m ² .

Moreover, the prepreg formed as follows was used as a 2nd base material (core material layer). First, a glass cloth having a basis weight of 104 g / m ² (Taiwan Nanya Co., Ltd., trade name “Nanya-2116”) and urethane acrylic composite resin emulsion (Chuo Rika Kogyo Co., Ltd., trade name “SU-100”, average Particle size: 84 nm, dispersion medium: water) was applied so that the solid content was 2 g / m ² . Then, it dried for 150 seconds with a 120 degreeC hot-air dryer, and produced the prepreg (2nd base material) whose resin ratio is 2% and volatile content rate 3%.

  Except for the above, a melamine decorative board having a thickness of 0.3 mm was obtained in the same manner as in Example 1.

Example 3
In the formation of the second layer, the acrylic resin emulsion was applied to the second surface side of the first layer so that the solid content was 5 g / m ² .

  Except for the above, a melamine decorative board having a thickness of 0.3 mm was obtained in the same manner as in Example 1.

Example 4
A first substrate having a first layer and a second layer was formed as follows.

On one surface side (second surface side) of a titanium oxide-containing decorative paper (Dai Nippon Printing Co., Ltd.) having a basis weight of 80 g / m ² , an urethane acrylic composite resin emulsion (Chuo Rika Kogyo Co., Ltd., Product name “SU-100”, average particle size: 84 nm, dispersion medium: water, and acrylic resin emulsion (manufactured by Nippon Zeon Co., Ltd., product name “Nipol LX-851E”, average particle size: 200 nm, dispersion medium : Water) was mixed so that the solid content weight ratio was 100: 30, and the solid content was 50 g / m ² .

Subsequently, melamine resin (reaction molar ratio: 1.4, resin solid content: 50% by mass) is 50 g / m ² on the other surface side (first surface side (design surface side)) of the titanium oxide-containing decorative paper. It was coated so that

  After that, they were dried for 90 seconds with a 120 ° C. hot air dryer. In this way, the urethane acrylic composite particles are supported on the second surface side of the titanium oxide-containing decorative paper, and the melamine resin is supported on the first surface side (design surface side) of the titanium oxide-containing decorative paper. The first layer thus formed and an intermediate layer made of acrylic resin particles on the second surface side of the first layer were simultaneously formed to obtain a first substrate. The first substrate had a resin ratio of 58% and a volatile content ratio of 4%.

  Except for the above, a melamine decorative board having a thickness of 0.3 mm was obtained in the same manner as in Example 1.

(Example 5)
First, an acrylic film (manufactured by Kaneka Co., Ltd., “SANDUREN SD001NAT”) was prepared.

  Next, in the formation of the first substrate, a first substrate was obtained in the same manner as in Example 1 except that the intermediate layer was not formed. A second substrate was obtained in the same manner as in Example 1.

  The acrylic film and the obtained second substrate are stacked in this order on the second surface side of the obtained first substrate, and the acrylic film is placed between the first substrate and the second substrate. It was set as the laminated body inserted. A melamine decorative board having a thickness of 0.35 mm was obtained in the same manner as in Example 1 except that such a laminate was used.

(Comparative example)
Titanium oxide-containing decorative paper (Dai Nippon Printing Co., Ltd.) having a basis weight of 80 g / m ² was prepared as a surface layer base material.

Next, on one surface side (second surface side) of the titanium oxide-containing decorative paper, an emulsion of urethane acrylic composite particles (manufactured by Chuo Rika Kogyo Co., Ltd., trade name “SU-100”, average particle diameter: 84 nm, dispersion medium: water) was applied so that the solid content was 40 g / m ² .

Subsequently, melamine resin (reaction molar ratio: 1.4, resin solid content: 50% by mass) is 50 g / m ² on the other surface side (first surface side (design surface side)) of the titanium oxide-containing decorative paper. It was coated so that

  Thereafter, they were dried for 90 seconds with a hot air dryer at 120 ° C. to obtain a surface layer material (first layer) having a resin ratio of 53% and a volatile content of 3%.

  In addition, the said melamine resin mix | blended raw material melamine and formalin with the predetermined | prescribed mixing | blending ratio in the reaction kettle (preparation), after adding a catalyst, it heated up to the boiling point and made it reflux-react. Then, after confirming that melamine dissolution was completed, when the reaction end point was reached, the resin solid content was adjusted by dehydration and synthesized by a method of cooling.

On the second surface side of the obtained first layer, a glass cloth having a grammage of 104 g / m ² (made by Taiwan Nanya Co., Ltd., trade name “Nanya-2116”) is superimposed as a core material layer to obtain a laminate. It was. This laminate was heat-press molded for 40 minutes under the conditions of 140 ° C. and 8 MPa to obtain a melamine decorative board having a thickness of 0.3 mm.

  Table 1 shows the constituent materials of each layer of the melamine decorative board of each example and comparative example.

2. Test method The following evaluation was performed about the melamine decorative board obtained by each said Example and comparative example.

(1) Nonflammability test "Standard (2) ii) 4.10.2 exothermic test" in the work standard "Fireproof and Fireproof Performance Test / Evaluation Business Method" 4.10 Nonflammable Performance Test / Evaluation Method -Evaluation method and 4.13 Gas hazard test / evaluation method ".

  The item of the above-mentioned business standard “Fireproofing Performance Test / Evaluation Business Method” describes the performance evaluation method related to the certification based on the provisions of Article 2, Item 9 (non-combustible material) of the Building Standard Law.

(2) Boiling resistance test It processed by the method based on the boiling resistance test of JISK6902, and the presence or absence of the swelling of the test piece after 2-hour immersion in boiling water and the delamination was confirmed.

(3) Contamination resistance test It processed by the method based on the contamination resistance test of JISK6902, and the presence or absence of the contamination material residue on the sample surface was confirmed.

(4) Bend formability test Based on the bend formability test (Method A) of JIS K6902, external bending and internal bending were performed at room temperature and 10 mmR to confirm the presence or absence of cracks on the decorative sheet surface.

(5) Surface hardness (pencil hardness) test An evaluation was performed by a pencil hardness test in accordance with JIS K5600.

(6) Arithmetic average roughness Arithmetic average roughness of the design surface of the melamine decorative board of each Example and Comparative Example using a light interference type surface shape roughness measuring device (trade name “Wyko NT1100” manufactured by Veeco). Ra2 was measured.

  These results are shown in Table 1. In Table 1, the “arithmetic mean roughness Ra1 of the surface on the intermediate layer side” of the core material layer in each example and comparative example is the surface on the first surface side of the core material layer (second substrate) ( This means the arithmetic average roughness Ra1 of the surface on the intermediate layer side, and was measured using the apparatus used in (6) above.

  As can be seen from Table 1, the decorative melamine board of the present invention exhibited good bending workability and nonflammability, and had a good mirror surface. On the other hand, in the comparative example, a good mirror surface could not be formed.

  ADVANTAGE OF THE INVENTION According to this invention, while being excellent in a nonflammability and bending workability, the melamine decorative board provided with the design surface in which the mirror surface process was given can be provided. Moreover, the manufacturing method of the melamine decorative board which can manufacture such a melamine decorative board easily can be provided. Therefore, the present invention has industrial applicability.

DESCRIPTION OF SYMBOLS 100 Melamine decorative board 11 Surface layer 111 1st surface 112 2nd surface 12 Core material layer 13 Intermediate | middle layer 10 1st base | substrate 11 '1st layer 12' 2nd base | substrate 13 '2nd layer 14 Core material Layer 15 Protective layer 16 Support layer 20 Substrate film 30 Mirror surface finish plate (mirror finish plate)

Claims (12)

It is composed of a laminate in which a surface layer, an intermediate layer, and a core material layer are laminated in order,
The surface layer is a first surface serving as a design surface, a first surface serving as a mirror surface, and a second surface opposite to the first surface, and is in contact with the intermediate layer. A surface layer base material, a resin containing a melamine resin supported on the first surface side of the surface layer base material, and the surface layer base material. It is composed of a surface layer material composed of a thermoplastic resin carried on the second surface side,
The core material layer is composed of a core material made of a prepreg containing glass cloth or glass cloth as a base material,
The intermediate layer is made of an intermediate layer forming resin, and the average thickness of the intermediate layer is larger than the arithmetic average roughness Ra1 of the surface of the core layer on the intermediate layer side. Board.   The melamine decorative board according to claim 1, wherein the arithmetic mean roughness Ra2 of the first surface of the surface layer is 300 nm or less.   The melamine decorative board according to claim 1 or 2, wherein an average thickness of the intermediate layer is 5 µm or more.   The melamine decorative board according to any one of claims 1 to 3, wherein the arithmetic average roughness Ra1 is 0.1 to 10 µm.   The melamine decorative board according to any one of claims 1 to 4, wherein the average thickness of the melamine decorative board is 0.4 mm or less. It is a manufacturing method of the melamine decorative board of any one of Claim 1 thru | or 5, Comprising:
A first substrate having the first layer made of the surface layer material and the second layer made of the intermediate layer forming resin; and a second substrate made of the core material layer material. And a process of preparing
Disposing the second base so as to face the surface of the first base on the second layer side;
A contact plate having a mirror-finished contact surface is disposed so that the contact surface faces the surface of the first base on the first layer side, and an elastic modulus at 140 ° C. is 1 Arranging a base film of ˜50 GPa so as to face the second base;
The melamine decorative board is obtained by thermocompression bonding the first substrate and the second substrate by bringing the abutment plate and the base film close together while heating at least the first substrate. Process,
The manufacturing method of the melamine decorative board characterized by including the process of removing the said board and the said base film from the said melamine decorative board.   The first layer supplies a resin varnish containing a resin containing the melamine resin to the first surface side of the surface layer base material, and on the second surface side of the surface layer base material. The manufacturing method of the melamine decorative board of Claim 6 formed by supplying the resin varnish which has an average particle diameter smaller than the said arithmetic mean roughness Ra1, and contains the particle | grains comprised with the said thermoplastic resin. .   The second layer has an average particle size that is larger than the average particle size of the particles made of the thermoplastic resin and smaller than the arithmetic average roughness Ra1, and is made of the intermediate layer forming resin. The method for producing a melamine decorative board according to claim 7, wherein the decorative varnish is formed using a resin varnish containing particles.   The said 2nd layer has an average particle diameter of 150 nm or more, and is formed using the resin varnish containing the particle | grains comprised with the said resin for intermediate | middle layer formation. The manufacturing method of the melamine decorative board as described.   The average thickness of the said base film is 0.1-1.0 mm, The manufacturing method of the melamine decorative board of any one of Claim 6 thru | or 9.   The said base film is a manufacturing method of the melamine decorative board of any one of Claim 6 thru | or 10 comprised with the thermoplastic resin whose softening temperature is 120-160 degreeC.   The method for producing a melamine decorative board according to any one of claims 6 to 11, wherein a heating temperature in the thermocompression bonding is 130 to 150 ° C, and a pressure is 2 to 8 MPa.