JP6720597B2 - Melamine resin decorative board - Google Patents

Description

The present invention relates to a melamine resin decorative board.

Melamine resin veneer has excellent heat resistance, abrasion resistance, chemical resistance, stain resistance, etc. and has a beautiful appearance in terms of design, so it can be used for a variety of furniture, walls, doors, partitioning materials, vehicle interiors, etc. Widely used in various fields.

As a technique related to such a melamine resin decorative board, for example, the one described in Patent Document 1 (JP 2011-102014 A) can be cited.
Patent Literature 1 discloses a wiping decorative board having a surface layer formed of a resin composition containing a melamine resin, a carbinol-modified silicone oil, and a silane coupling agent as essential components.

JP, 2011-102014, A

The technical level required for various characteristics of the melamine resin decorative board is becoming higher and higher. The present inventor relates to a conventional melamine resin decorative board, in which a dimensional change is likely to occur when a use environment changes, and when the decorative board is attached to a wall surface, stress of the decorative board occurs, and the decorative board is removed from the wall surface. We found the problem of peeling.

The present invention has been made in view of the above circumstances, and provides a melamine resin decorative board having excellent dimensional stability when the decorative board is attached to a construction surface.

The present inventor has conducted extensive studies in order to achieve the above object. As a result, the inventors have obtained the knowledge that the water vapor transmission coefficient of the melamine resin decorative board is effective as a design guide for suppressing the dimensional change when the use environment changes, and completed the present invention.

According to the invention,
A melamine resin decorative board comprising a melamine resin layer, and a decorative layer constituted by a gas barrier layer provided on one surface of the melamine resin layer,
The gas barrier layer is composed of at least one selected from silicon nitride, silicon oxynitride, and silicon oxide,
According to JISK7129:2008B method, there is provided a melamine resin decorative board having a water vapor transmission coefficient of 10 g·mm/(m2·24 h) or less in the decorative layer, which is measured in an environment of 40° C. and 90% RH.

ADVANTAGE OF THE INVENTION According to this invention, the melamine resin decorative board which was excellent in dimensional stability when affixing on a construction surface can be provided.

It is sectional drawing which shows an example of a structure of the melamine resin decorative board of this embodiment. It is sectional drawing which shows an example of a structure of the melamine resin decorative board of this embodiment.

Embodiments of the present invention will be described below with reference to the drawings. In all the drawings, the same reference numerals are given to the same components, and the description thereof will be omitted as appropriate. Moreover, the figure is a schematic view and does not match the actual dimensional ratio. In addition, "-" between the numbers in the sentence represents the following from the above unless otherwise specified.

FIG. 1 is a cross-sectional view showing an example of the configuration of the melamine resin decorative board 100 of this embodiment.
The melamine resin decorative board 100 includes at least a decorative layer 110 including a melamine resin layer 101 and a gas barrier layer 103 provided on one surface of the melamine resin layer 101.
The water vapor permeability coefficient of the decorative layer 110 is 10 g·mm/(m ² ·24 h) or less.
Here, the water vapor transmission coefficient is measured in an environment of 40° C. and 90% RH in accordance with JIS K7129:2008B method.

Hereinafter, the melamine resin decorative board 100 according to the present embodiment will be described in detail.

In the melamine resin decorative board 100, the water vapor permeability coefficient of the decorative layer 110 is 10 g·mm/(m ² ·24 h) or less. Thereby, as described above, it is possible to improve the dimensional stability when the melamine resin decorative board 100 is attached to the construction surface.

According to the study by the present inventor, it has been clarified that in the conventional melamine resin decorative board, dimensional change is likely to occur when the use environment changes. Until now, there has not been a sufficient index as an index showing a melamine resin decorative board that is excellent in dimensional stability when the decorative board is attached to a construction surface.
The present inventor has newly found that by controlling the water vapor transmission coefficient of the decorative layer 110, it is possible to suppress the dimensional change when the melamine resin decorative plate is attached to the construction surface even if the use environment changes. did. The melamine resin decorative board 100 according to the present embodiment controls the water vapor permeability coefficient of the decorative layer 110 to be 10 g·mm/(m ² ·24 h) or less based on such knowledge. This can improve the dimensional stability when the melamine resin decorative board 100 is attached to the construction surface. Therefore, even if the use environment changes, the stress generated due to the dimensional change can be reduced, and when the decorative plate is attached to the construction surface, it is possible to prevent the decorative plate from peeling off from the construction surface. Further, peeling between the layers constituting the melamine resin decorative board 100 can be suppressed.
It is not clear why such a melamine resin decorative board 100 is excellent in dimensional stability when attached to a construction surface, but the water vapor permeability coefficient of the decorative layer 110 is 10 g·mm/(m ² ·24 h) or less. It is considered that this is because the melamine resin decorative board 100 has a structure in which the amount of water entering and exiting is small and the dimensional change due to absorption and release of water due to changes in the operating environment does not easily occur.

From the viewpoint of further improving the dimensional stability when the use environment changes, it is more preferable that the moisture vapor permeability coefficient of the decorative layer 110 is 6 g·mm/(m ² ·24 h) or less. The lower limit of the water vapor transmission coefficient of the decorative layer 110 may be, for example, 0.001 g·mm/(m ² ·24 h) or more from the viewpoint of the flexibility of the melamine resin decorative board 100.

The water vapor permeability coefficient of the decorative layer 110 can be controlled by appropriately adjusting the types of constituent components of each layer constituting the decorative layer 110 and the forming method of each layer. In the present embodiment, the water vapor permeability coefficient of the decorative layer 110 can be adjusted by appropriately selecting the type of constituent components of the gas barrier layer 103 and the forming method thereof.

In the melamine resin decorative board 100, the surface hardness on the decorative layer 110 side, which is measured by a pencil hardness test according to JIS K5600, is preferably 5H or more. This makes it possible to improve the scratch resistance of the melamine resin decorative board 100.
The surface hardness on the decorative layer 110 side can be controlled by appropriately adjusting the types of constituent components of each layer constituting the decorative layer 110 and the forming method of each layer.

In the melamine resin decorative board 100, the weight change rate defined by 100×(X ₂ −X ₁ )/X ₁ is preferably 7.0% or less, and more preferably 4.0% or less.
Here, when the melamine resin decorative board 100 attached to the construction surface is stored for 168 hours in an environment of 40° C. and 95% RH, the weight of the melamine resin decorative board 100 before storage (the weight of the adhesive layer and the adherend is Exclude) is X _1, and the weight of the melamine resin decorative board 100 after storage is X ₂ (excluding the weight of the adhesive layer and the adherend).
When the weight change rate is equal to or less than the upper limit value, the melamine resin decorative board 100 can more effectively suppress the dimensional change due to water absorption and release even if a large change occurs in the use environment. The stress generated due to the dimensional change of the resin decorative plate 100 can be further reduced. As a result, it is possible to suppress the peeling from the construction surface when it is attached to the construction surface, and it is possible to suppress the separation between the layers constituting the melamine resin decorative board 100.

The weight change rate of the decorative layer 110 can be controlled by appropriately adjusting the types of constituent components of each layer constituting the decorative layer 110 and the method of forming each layer. In the present embodiment, the weight change rate of the decorative layer 110 can be adjusted by appropriately selecting the type of constituent components of the gas barrier layer 103 and the forming method thereof.

The melamine resin decorative board 100 may be wound and laminated in a roll shape. At this time, a support base material may be provided on one side or both sides, and the support base material may be interposed and wound and laminated. As a method of winding and laminating the melamine resin decorative board 100 in a roll shape, for example, by winding the long sheet-shaped melamine resin decorative board 100 in a roll shape, the melamine resin decorative board 100 is wound and laminated in a roll shape. be able to.

<Melamine resin layer>
Hereinafter, the melamine resin layer 101 will be described.
The melamine resin layer 101 is a layer containing a melamine resin, and preferably a layer containing a melamine resin and a decorative layer base material. This makes it possible to provide the surface with a suitable surface hardness and to obtain the melamine resin decorative board 100 that is not easily scratched.

As such a melamine resin layer 101, for example, a structure in which a resin layer containing a melamine resin is carried on the first surface side which is the design surface of the decorative layer base material; Which has a structure in which a resin layer containing a melamine resin is carried on both the first surface side and the second surface side opposite to the design surface; the first surface serving as the design surface of the decorative layer base material Examples thereof include a structure in which a resin layer containing a melamine resin is carried on the side, and a resin layer containing a thermoplastic resin is carried on the second surface side opposite to the design surface.
Among these, as the melamine resin layer 101, a resin layer containing a melamine resin is carried on the first surface side that is the design surface of the decorative layer base material, and on the second surface side opposite to the design surface side. Those having a structure in which a resin layer containing a thermoplastic resin is supported are particularly preferable. The thermoplastic resin is preferably one or more selected from acrylic resins and urethane resins.
As a result, flexibility can be imparted to the melamine resin decorative board 100, and the outward bending workability of the melamine resin decorative board 100 can be improved.

The decorative layer base material used for the melamine resin layer 101 is a sheet-like base material, and the material thereof is not particularly limited, but, for example, pulp, linter, synthetic fiber, glass fiber or the like can be used. If necessary, a titanium oxide-containing decorative paper containing a pigment such as titanium oxide can be used.

The melamine resin used for the melamine resin layer 101 is not particularly limited. For example, those obtained by reacting melamine and formaldehyde under neutral or weak alkaline can be used.
The reaction molar ratio of formaldehyde to melamine ((molar amount of formaldehyde)/(molar amount of melamine), and hereinafter may be simply referred to as "reaction molar ratio") is not particularly limited. It is preferably 1.0 or more and 4.0 or less, more preferably 1.0 or more and 2.0 or less, still more preferably 1.1 or more and 1.8 or less. When the reaction molar ratio is at least the above lower limit value, unreacted components can be reduced, storage stability can be improved, and cost can be reduced. Moreover, when it is at most the above upper limit, the flexibility of the resin after curing can be improved. As the melamine resin, one kind may be used alone, or two or more kinds of melamine resins having different reaction molar ratios and weight average molecular weights may be used in combination. As the melamine resin, a commercially available melamine resin such as a melamine resin manufactured by Sumitomo Chemical Co., Ltd. can be used.

The weight average molecular weight of the melamine resin is not particularly limited, but is preferably 200 or more and 500 or less, and particularly preferably 250 or more and 350 or less. When the weight average molecular weight is not less than the above lower limit, unreacted components can be reduced, storage stability can be improved, and cost can be reduced. Moreover, when it is at most the above upper limit value, the impregnation property into the decorative layer base material can be improved. The weight average molecular weight can be measured, for example, by GPC (gel permeation chromatography, standard substance: polystyrene conversion).

The carrying amount of the melamine resin in the resin layer carried on the first surface side that is the design surface of the decorative layer base material is not particularly limited, but is preferably 80% by mass or more and 100% by mass or less. And particularly preferably 95% by mass or more and 100% by mass or less. When the content of the melamine resin is at least the above lower limit value, the surface hardness and stain resistance of the melamine resin decorative board 100 can be more effectively improved.

The method of supporting the resin layer containing the melamine resin on the first surface side or the second surface side of the decorative layer base material is not particularly limited. A resin varnish obtained by dissolving a melamine resin in a solvent is applied to a decorative layer base material using a known device such as a spray device, a shower device, a kiss coater, or a comma coater, and then at 80°C or higher and 130°C or lower. Examples include a method of heating and drying.

The solvent that dissolves the melamine resin is not particularly limited, and examples thereof include water and methanol. Of these, water is preferred. In addition, a poor solvent may be used as long as it does not adversely affect. The solid content (all components excluding the solvent) of the resin varnish is not particularly limited, but is preferably 30% by mass or more and 70% by mass or less, and particularly preferably 45% by mass or more and 60% by mass or less. This can improve the impregnation property of the resin varnish into the decorative layer base material.

The melamine resin layer 101 is preferably provided with a resin layer containing a thermoplastic resin on the second surface side which is the side opposite to the design surface of the decorative layer base material.
The thermoplastic resin has adhesive properties with metals and various materials, and can impart flexibility to the melamine resin decorative board 100. Therefore, by supporting the thermoplastic resin on the second surface side, the adhesive strength between the melamine resin layer 101 and the base material layer 120 described later can be improved, and the bending workability of the melamine resin decorative board 100 can be improved. The effect of improving can be obtained.

The thermoplastic resin is not particularly limited, and examples thereof include acrylic resin, urethane resin, vinyl acetate copolymer, urethane acrylic composite particles, styrene butadiene rubber (SBR), nitrile rubber (NBR), and the like. To be Of these, urethane-acrylic composite particles are preferable. As the thermoplastic resin, it is possible to use one containing one of these alone, or one containing two or more different types of thermoplastic resins mixed together.
Of these, the thermoplastic resin preferably contains an acrylic resin and a urethane resin.

In the present embodiment, by using the thermoplastic resin, good adhesive strength with the base material layer 120 described later can be exhibited. Further, urethane resin is particularly excellent in toughness, elasticity and flexibility, and acrylic resin is particularly excellent in transparency, durability, weather resistance, chemical resistance and film forming property.

In the present embodiment, the urethane-acryl composite particles mean particles having a different phase structure of acrylic resin and urethane resin in a single particle. Since each of the urethane resin and the acrylic resin has a high adhesive strength with the base material layer 120, by using the urethane acryl composite particles, a better adhesive strength with the base material layer 120 can be exhibited.
Further, urethane resin is particularly excellent in toughness, elasticity and flexibility, and acrylic resin is particularly excellent in transparency, durability, weather resistance, chemical resistance and film forming property. Further, in the present embodiment, the “heterogeneous structure” means a structure in which a plurality of phases made of different kinds of resins exist in one particle, and examples thereof include a core-shell structure, a localized structure, and a sea-island structure. ..
Further, the arrangement state between the particles when the urethane-acrylic composite particles are carried on the second surface side of the decorative layer base material is not particularly limited, and examples thereof include a linear structure. The structure of particles and the arrangement state between particles can be confirmed by, for example, a scanning electron microscope (SEM).
Among these, the urethane-acrylic composite particles are particularly preferably of a type having a core-shell structure having an acrylic component as a core and a urethane component as a shell. When the urethane-acrylic composite particles have the above core-shell structure, the surface contour becomes a urethane composition when loaded on the second surface side of the decorative layer base material, so the second surface side of the decorative layer base material is: While having the characteristics of both the urethane resin and the acrylic resin, the characteristics of the urethane resin are imparted to the outer shell.

In addition to the thermoplastic resin, the resin layer containing the thermoplastic resin may contain a small amount of a thickener, a penetration accelerator, an antifoaming agent, etc., if necessary.

The thermoplastic resin preferably contains thermoplastic resin emulsion resin particles having an average particle size of 30 nm or more and 100 nm or less, and particularly preferably the average particle size of the thermoplastic resin emulsion resin particles is 60 nm or more and 90 nm or less. As a result, the supportability (impregnation) between the fibers of the decorative layer base material is improved, and the decorative layer base material can be more supported (impregnated) inside the decorative layer base material, so that the melamine resin decorative board 100 has good flexibility. It is possible to impart sex.

The method for supporting the resin layer containing the thermoplastic resin on the second surface side of the decorative layer base material is not particularly limited, and the resin layer containing the melamine resin is the first of the decorative layer base materials. It can be carried out in the same manner as the above-mentioned method of supporting on the surface side or the second surface side. That is, a method in which a thermoplastic resin dissolved or dispersed in a solvent is applied and heated and dried can be used.

The solvent used for the thermoplastic resin is not particularly limited, and examples thereof include water. In addition, a poor solvent may be used as long as it does not adversely affect. The solid content (all components except the solvent) of the thermoplastic resin solution is not particularly limited, but is preferably 25% by mass or more and 60% by mass or less, particularly preferably 30% by mass or more and 45% by mass or less of the thermoplastic resin solution. This can improve the supportability (impregnation) of the thermoplastic resin solution to the decorative layer base material.

The content of the resin layer (that is, components other than the decorative layer base material) in the melamine resin layer 101 is not particularly limited, but may be, for example, 40% by mass or more and 60% by mass or less in terms of solid content. it can.

The thickness of the melamine resin layer 101 can be, for example, 0.05 mm or more and 0.5 mm or less.

<Gas barrier layer>
The gas barrier layer 103 is superior to the melamine resin layer 101 in gas barrier properties. Thereby, the water vapor permeability coefficient of the decorative layer 110 can be reduced.

Examples of the material forming the gas barrier layer 103 include metals and metal oxides capable of forming a thin film having a barrier property, and one kind selected from silicon nitride, silicon oxynitride, silicon oxide, aluminum oxide, aluminum and the like. Alternatively, two or more kinds are preferable. This makes it possible to effectively reduce the water vapor transmission coefficient of the decorative layer 110 while maintaining the wear resistance and scratch resistance of the melamine resin decorative board 100.
The silicon oxide may contain silicon monoxide or silicon suboxide in addition to silicon dioxide.

Further, as the material forming the gas barrier layer 103, for example, a gas barrier resin layer formed of silicone resin, polyvinylidene chloride, polyvinyl alcohol, ethylene/vinyl alcohol copolymer, acrylic resin, acrylic resin, or the like is used. You can also
Furthermore, an inorganic component such as silicon oxide and an organic component such as a silicone resin can be used in combination.

As the gas barrier layer 103, one containing silicon oxide is particularly preferable. This makes it possible to further improve the abrasion resistance and scratch resistance of the melamine resin decorative board 100, and more effectively reduce the water vapor permeability coefficient of the decorative layer 110.

The gas barrier layer 103 containing silicon oxide can be formed by, for example, a sol-gel process, a vacuum process such as a vacuum deposition method, a sputtering method, a CVD method, or the like.

It is particularly preferable that the gas barrier layer 103 includes a glassy film having a siloxane skeleton. This makes it possible to further improve the abrasion resistance and scratch resistance of the melamine resin decorative board 100, and more effectively reduce the water vapor permeability coefficient of the decorative layer 110.

The glassy film having a siloxane skeleton can be formed of, for example, a glass coating material.
In the present embodiment, for example, a vitreous film is formed from a glass coating material, and the vitreous film is further cured to age the layer containing the vitreous film. And a factor for controlling the weight change rate of the decorative layer 110.

The gas barrier layer 103 including a glassy film having a siloxane skeleton can be produced, for example, as follows.
First, a glass coating material is applied to the design surface side of the melamine resin layer and dried.
Next, the applied glassy film is cured and aged. Thereby, in the obtained melamine resin decorative board 100, the water vapor permeability coefficient of the decorative layer 110 and the weight change rate of the decorative layer 110 can be reduced. It is presumed that this is because the denseness of the vitreous film is improved by aging. Aging can be performed, for example, under the conditions of 20 to 60° C. and 5 days to 50 days.

As the glass coating material, for example, Silagcital (trademark) manufactured by Sumitomo Chemical Co., Ltd., TS-56 manufactured by Tokuyama Corporation, or the like can be used.

The gas barrier layer 103 may be composed of a single gas barrier layer, or may be composed of a plurality of gas barrier layers. When the gas barrier layer 103 is composed of a plurality of gas barrier layers, it may be composed of the same kind of gas barrier layer, or may be composed of different kinds of gas barrier layers.

The thickness of the gas barrier layer 103 is preferably 0.001 μm or more and 100 μm or less, and more preferably 0.01 μm or more and 50 μm or less, from the viewpoint of the balance of barrier properties, adhesiveness, abrasion resistance, scratch resistance, handleability, and the like. ..

<Base material layer>
In the melamine resin decorative board 100 of the present embodiment, as shown in FIG. 2, it is preferable to further provide a base material layer 120 on the surface of the melamine resin layer 101 opposite to the gas barrier layer 103.
The base material layer 120 is not particularly limited, and examples thereof include one or two or more kinds selected from a fiber base material, a prepreg, and a metal layer.
Thereby, various functions such as heat resistance, nonflammability, rigidity, and handleability can be imparted.
Further, the base material layer 120 can be used as a structure of one layer or two or more layers, but one layer is preferable. This facilitates control of interlayer adhesion strength between the melamine resin layer 101 and the base material layer 120 and warpage of the decorative board.

(Fiber substrate)
The material of the fiber base material used for the base material layer 120 is not particularly limited, and examples thereof include natural fiber, synthetic fiber, semi-synthetic fiber, regenerated fiber, and inorganic fiber. More specifically, for example, polyamide resin fibers such as polybenzoxazole resin fibers, polyamide resin fibers, aromatic polyamide resin fibers, wholly aromatic polyamide (aramid) resin fibers, polyester resin fibers, aromatic polyester resin fibers, Examples thereof include polyester resin fibers such as wholly aromatic polyester resin fibers, polyimide resin fibers, fluororesin fibers, glass fibers, carbon fibers, ceramic fibers, and metal fibers (stainless fibers). Thereby, the hygroscopicity of the melamine resin decorative board 100 can be reduced. Among these, it is particularly preferable to use the glass fiber base material from the viewpoints of nonflammability, strength, low hygroscopicity and the like.

The glass fiber base material is not particularly limited, and examples thereof include a glass fiber woven fabric and a glass fiber nonwoven fabric. Among them, glass fiber woven cloth (glass cloth) is preferable in terms of noncombustibility and strength. The material of the glass constituting the glass fiber woven fabric is not particularly limited, and examples thereof include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, and H glass. Can be mentioned. Among these, T glass is preferable. As a result, the coefficient of thermal expansion of the glass woven fabric can be reduced, and the effect of suppressing the warpage of the melamine resin decorative board 100 after being affected by the environment can be obtained.

The weight of the fibrous base material is not particularly limited, but it is necessary to satisfy the requirement that there should be no cracks or penetration after burning, which is the requirement for nonflammability in Article 2-9 of the Building Standards Act. In this case, the basis weight is preferably 100 g/m ² or more. The upper limit of the weight is not particularly limited, but the basis weight is preferably 250 g/m ² or less in terms of material cost and workability.

(Prepreg)
The prepreg in the present embodiment is a sheet-shaped material in which a fiber base material carries a resin composition containing a thermoplastic resin, a thermosetting resin, a filler and the like. The resin composition is not particularly limited as long as the interlayer adhesive strength between the melamine resin layer 101 and the base material layer 120 is sufficient to form the melamine resin decorative board 100. Examples of the fiber base material include the same as the fiber base material used for the base material layer 120.

When a thermoplastic resin is used as the resin supported on the fiber base material, the thermoplastic resin is preferably contained in the prepreg in an amount of 0.1% by mass or more and 20% by mass or less, and 0.5% by mass or more and 10% by mass or more. It is particularly preferable that the content is not more than mass %. Thereby, the interlayer adhesive strength between the melamine resin layer 101 and the base material layer 120 can be improved.

The thermoplastic resin is not particularly limited, but examples thereof include acrylic resin, urethane resin, ethylene vinyl acetate resin, and styrene butadiene rubber (SBR). Among them, acrylic resin and urethane resin are preferable, and it is particularly preferable to contain acrylic resin and urethane resin.

When a thermosetting resin is used as the resin supported on the fiber base material, it is preferable that the thermosetting resin is contained in an amount of 0.1% by mass or more and 20% by mass or less with respect to the entire prepreg, and 0.5% by mass. It is particularly preferable that the content is 10 mass% or less. This makes it possible to improve the interlayer adhesive strength between the melamine resin layer 101 and the base material layer 120 without lowering the high incombustibility and bending workability of the melamine resin decorative board 100.

The thermosetting resin is not particularly limited, and examples thereof include phenol resin, melamine resin, epoxy resin, oxetane resin, (meth)acrylate resin, unsaturated polyester resin, diallyl phthalate resin, urea resin, maleimide resin. Among them, phenol resin is preferable from the viewpoints of nonflammability, heat resistance, and adhesiveness.

The method for supporting the resin composition on the fiber base material is not particularly limited, and examples thereof include a method in which a resin dissolved in a solvent is applied to the fiber base material and heated and dried.
The solvent used for dissolving the resin is not particularly limited, and examples thereof include methanol. Examples include a method of diluting the resin 5 to 14 times and applying a coating liquid having a varnish solid content adjusted to 3% by mass or more and 10% by mass or less. As a result, the supportability (impregnation) of the resin on the fiber base material can be improved.

The thickness of the base material layer 120 is preferably 0.01 mm or more. Thereby, the effect of improving the heat resistance and the incombustibility of the melamine resin decorative board 100 can be obtained.
Further, the upper limit of the thickness is not particularly limited, but as the thickness increases, the thickness and weight of the melamine resin decorative board 100 increase, and the cost also increases. It is preferable to set it within a range, and it is preferable to set it to 0.35 mm or less.

(Metal layer)
The metal material forming the metal layer is not particularly limited, but examples thereof include aluminum, copper, stainless steel, nickel and the like. These may be used alone or in the form of an alloy of two or more kinds of metals. Among these, aluminum is preferable in terms of versatility, stability over time, price, and the like. Further, as the form of the metal layer, a metal plate, a metal foil or the like can be used.

The thickness of the metal layer is not particularly limited, but is preferably 0.01 mm to 3 mm from the viewpoint of heat resistance, noncombustibility, rigidity, flexibility, handleability of the melamine resin decorative board 100, and 0.02. More preferably, it is ˜2 mm.

<Cosmetic layer>
The decorative layer 110 has the melamine resin layer 101 and the gas barrier layer 103 described above. For example, it can be obtained by forming the gas barrier layer 103 on the melamine resin layer 101.

<Method for producing melamine resin metal decorative plate>
The method for producing the melamine resin decorative board 100 is not particularly limited, but, for example, after laminating the decorative layer 110 and the base material layer 120, heating at a temperature of 130 to 150° C., a pressure of 1 to 10 MPa, and a time of about 3 to 120 minutes. A method of applying pressure may be mentioned. Further, during molding by heating and pressurization, a mirror finish can be obtained by stacking a mirror finish plate on the design surface side of the melamine resin decorative plate 100, and an embossed plate or an embossed film can be used for emboss finish. can do.

When a metal layer is used as the base material layer 120, it is preferable to bond the melamine resin layer 101 or another base material layer 120 to the metal layer via an adhesive. For example, a method in which a liquid or semi-solid adhesive is applied on the metal layer and then pressure-bonded at 0.1 to 0.5 MPa with a cold press or a roll press, or a film-like adhesive is applied onto the metal layer. After pasting, a method of pressure bonding with a hot press at 0.1 to 0.5 MPa can be mentioned.
The method of applying the liquid or semi-solid adhesive on the metal layer is not particularly limited, but it is preferably performed by a roll coater capable of heating.
In order to improve the adhesive strength, the surface to be adhered of the metal layer may be previously subjected to a primer treatment, a metal layer corrosion treatment, a sanding treatment, or the like.

The adhesive is not particularly limited, for example, epoxy resin adhesive, acrylic resin adhesive, urethane resin adhesive, synthetic rubber adhesive, ethylene vinyl acetate copolymer adhesive, polyolefin Examples thereof include a system adhesive and a polyamide adhesive. Thereby, the adhesive strength between the melamine resin layer 101 or the other base material layer 120 and the metal layer can be improved.
Among these adhesives, urethane resin adhesives are preferable. As a result, flexibility can be imparted to the melamine resin decorative board 100, and the outward bending workability of the melamine resin decorative board 100 can be improved.
Moreover, the property of the adhesive is not particularly limited, and for example, a liquid type, a semi-solid type, a film type or the like can be used.

The embodiments of the present invention have been described above, but these are examples of the present invention, and various configurations other than the above can be adopted.
Hereinafter, examples of the embodiment will be additionally described.
1. A melamine resin decorative board comprising a melamine resin layer and a decorative layer constituted by a gas barrier layer provided on one surface of the melamine resin layer,
According to JIS K7129:2008B method, a melamine resin decorative board having a water vapor permeability coefficient of 10 g·mm/(m2·24 h) or less in the decorative layer, measured under an environment of 40° C. and 90% RH.
2. 1. In the melamine resin decorative board according to,
A melamine resin decorative board having a surface hardness of 5H or more on the decorative layer side, as measured by a pencil hardness test according to JIS K5600.
3. 1. Or 2. In the melamine resin decorative board according to,
The melamine resin layer is a melamine resin decorative board including a melamine resin and a decorative layer base material.
4. 1. Through 3. In the melamine resin decorative board according to any one of,
When the melamine resin decorative board is stored in an environment of 40° C. and 95% RH for 168 hours,
The weight of the melamine resin decorative board before storage is X _1, and
When the weight of the melamine resin decorative board after the storage is X ₂ ,
_{100 × (X 2 -X 1)} / X 1 defined in the weight change rate is less than 7.0%, a melamine resin decorative plate.
5. 1. Through 4. In the melamine resin decorative board according to any one of,
A melamine resin decorative board, wherein a base material layer is further provided on the other surface of the melamine resin layer.
6. 5. In the melamine resin decorative board according to,
A melamine resin decorative board in which the base material layer is one or more selected from a fiber base material, a prepreg, and a metal layer.
7. 1. Through 6. In the melamine resin decorative board according to any one of,
A melamine resin decorative board in which the gas barrier layer includes a glassy film having a siloxane skeleton.
8. 1. Through 7. In the melamine resin decorative board according to any one of,
Roll-shaped melamine resin decorative board.

Hereinafter, the present invention will be described with reference to Examples and Comparative Examples, but the present invention is not limited thereto.

1. Production of melamine resin decorative board (Example 1)
A titanium oxide-containing decorative paper (manufactured by Dainippon Printing Co., Ltd.) having a basis weight of 80 g/m ² was used as a decorative layer base material, and an emulsion of urethane acrylic composite particles (on the second surface side of the titanium oxide-containing decorative paper ( "SU-100" manufactured by Japan Coating Resin Co., Ltd., average particle size: 84 nm, dispersion medium: water) was applied so as to have a solid content of 40 g/m ^2, and then the first surface side of the above decorative paper ( A varnish containing melamine resin (reaction molar ratio of formaldehyde to melamine: 1.4, resin solid content: 50% by mass) is applied to the design surface side so as to be 50 g/m ^2, and then a hot air dryer at 120° C. For 90 seconds to obtain a melamine resin layer having a resin layer (that is, a component other than the decorative layer base material) content of 53 mass% and a volatile content of 3%.
The melamine resin was synthesized by the following method. First, raw material melamine and formalin were charged in a reaction vessel at a predetermined mixing ratio, and a catalyst was added. Then, the temperature was raised to the boiling point and a reflux reaction was performed, and it was confirmed that the melamine dissolution was completed. Next, when the reaction end point was reached, the resin solid content was adjusted by dehydration and cooled.
A glass coating material (TS-56, manufactured by Tokuyama Corp., hard coating solution for plastic lenses) was applied and dried on the design surface side of the melamine resin layer so that the gas barrier layer had a thickness of 4 μm. The coating/drying was carried out by a bar coating method so that the surface would have a uniform thickness and dried at 60° C. for 5 minutes. Then, it was aged (aged) at 40° C. for 10 days to prepare a decorative layer 1.
On the second surface side of the obtained decorative layer 1, a glass cloth having a thickness of 0.2 mm (“WEA7628” manufactured by Nanya Plastic Co., Ltd.) was laminated as a base material layer, and heated and pressed under the conditions of 140° C. and 2 MPa for 40 minutes. Molding was performed to obtain a melamine resin decorative board having a thickness of 0.3 mm.

(Example 2)
A decorative layer 2 was prepared in the same manner as in Example 1 except that the gas barrier layer was applied and dried to a thickness of 0.1 μm to obtain a melamine resin decorative plate.

(Example 3)
A decorative layer 3 was produced in the same manner as in Example 1 except that the gas barrier layer was applied and dried so that the thickness was 20 μm, and a melamine resin decorative plate was obtained.

(Example 4)
A glass coating material (manufactured by Sumitomo Chemical Co., Ltd., Silagcital (trademark)) was applied and dried so that the thickness of the gas barrier layer was 4 μm, and then cured (aged) at 20° C. for 30 days. A decorative layer 4 was produced in the same manner as in Example 1 to obtain a melamine resin decorative board.

(Comparative Example 1)
A decorative layer 5 was produced in the same manner as in Example 1 except that the gas barrier layer was not provided to obtain a melamine resin decorative plate.

(Comparative example 2)
A decorative layer 6 was produced in the same manner as in Example 2 except that no curing was performed when the gas barrier layer was provided, and a melamine resin decorative plate was obtained.

2. Test Method (1) Water Vapor Permeability Coefficient A decorative board for measuring the water vapor permeability coefficient is a melamine resin decorative board, in which the base material layer is not laminated and only the decorative layer is heated and pressed at 140° C. and 2 MPa for 40 minutes. Got
The water vapor permeability coefficient of the obtained decorative board was measured. The water vapor permeability coefficient was measured in accordance with JIS K7129:2008B method at 40° C. and 90% RH environment.
◯: 10 g·mm/(m ² ·24 h) or less ×: Exceeded 10 g·mm/(m ² ·24 h)

(2) Weight change rate The melamine resin decorative boards of Examples and Comparative Examples were cut into 20 mm square pieces, allowed to stand in a 23° C. 50% RH environment for 168 hours, and then the initial weight X ₁ of the melamine resin decorative boards was measured. ..
After measuring the initial weight X ₁ , a double-sided pressure-sensitive adhesive sheet (manufactured by Konishi Co., Ltd.) was attached to the base material layer, and then an aluminum plate (thickness 1 mm) was laminated to prepare a test piece. The weight Y _{1 of the} test piece was measured, and the weight Z of the double-sided pressure-sensitive adhesive sheet and the aluminum plate was calculated from Y ₁ -X ₁ .
Next, after the test piece was allowed to stand in a 40° C. 95% RH environment for 168 hours, the weight Y _{2 of the} test piece was measured, and from Y ₂ -Z, the weight X ₂ of the melamine resin decorative board after storage in a high humidity environment was calculated. It was measured. It was calculated _{100 × (X 2 -X 1)} / X weight change ratio defined by _one.
◯: 7.0% or less ×: 7.0% excess

(3) Appearance (whitening/turbidity)
The design surfaces of the melamine resin decorative boards of Examples and Comparative Examples were visually observed from various angles and evaluated according to the following criteria.
○: No bleaching/turbidity observed ×: Whitening/turbidity observed

(4) Adhesiveness Cellophane tape (trade name “Cellotape (industrial, “Cellotape” is a registered trademark) No. 405 18 mm×35 m manufactured by Nichiban Co., Ltd.) No. 405 18 mm×35 m )) was applied, and the applied part was rubbed firmly with a finger (it was confirmed that the color seen through the tape changed uniformly). Within 5 minutes after sticking, it was peeled off vigorously in the direction of 60 degrees, and evaluation was carried out according to the following criteria.
◯: No peeling ×: Peeling

(5) Pencil Hardness The melamine resin decorative boards of Examples and Comparative Examples were evaluated by the pencil hardness test according to JIS K5600.
◯: Hardness is 5H or higher ×: Hardness is 4H or lower

(6) Heat resistance The melamine resin decorative boards of Examples and Comparative Examples were treated by a method according to the heat resistance test of JIS K6902, and after the test, presence or absence of abnormalities such as swelling, peeling, and cracks was confirmed.
○: None ×: Yes

(7) Hot water resistance The melamine resin decorative boards of each Example and each Comparative Example were treated by a method based on the hot water resistance test of JIS K6902, and after the test, the presence or absence of swelling and whitening was confirmed.
○: None ×: Yes

(8) Contamination resistance The melamine resin decorative boards of Examples and Comparative Examples were treated by a method based on the stain resistance test of JIS K6902, and after the test, the presence or absence of residual contamination material on the surface was confirmed.
○: None ×: Yes

(9) Reliability test A double-sided pressure-sensitive adhesive sheet (manufactured by Konishi Co., Ltd.) was adhered to the base material layer of the melamine resin decorative plate (1220 mm width x 2420 mm length) of each example and each comparative example, and then treated with a primer. A test piece was prepared by sticking it on a plaster board.
The prepared test piece is put into an environmental tester, and after 24 hours in a 40° C. 95% RH environment → 24 hours in a 40° C. 20% RH environment, a total of 10 cycles are performed, and then 23° C. 50% RH. It was left standing in the environment for 24 hours, and then, the presence or absence of floating or peeling was confirmed.
○: No floating or peeling ×: There is floating or peeling

The results of the above tests are shown in Table 1.

100 melamine resin decorative board 101 melamine resin layer 103 gas barrier layer 110 decorative layer 120 base material layer

Claims (7)

A melamine resin decorative plate comprising a melamine resin layer and a decorative layer constituted by a gas barrier layer provided on one surface of the melamine resin layer,
The gas barrier layer is composed of at least one selected from silicon nitride, silicon oxynitride, and silicon oxide,
According to JISK7129:2008B method, a melamine resin decorative board having a water vapor permeability coefficient of 10 g·mm/(m ² ·24 h) or less in the decorative layer, which is measured in an environment of 40° C. and 90% RH. The melamine resin decorative board according to claim 1,
A melamine resin decorative board having a surface hardness of 5H or more when measured from the gas barrier layer surface side of the decorative layer , which is measured by a pencil hardness test according to JIS K5600. The melamine resin decorative board according to claim 1 or 2,
The melamine resin layer is a melamine resin decorative board including a melamine resin and a decorative layer base material. The melamine resin decorative board according to claim 3 ,
When the decorative layer base material is a glass cloth having a thickness of 0.2 mm, and the melamine resin decorative board is stored in an environment of 40° C. and 95% RH for 168 hours,
The weight of the melamine resin decorative board before storage is X _1, and
When the weight of the melamine resin decorative board after the storage is X ₂ ,
_{100 × (X 2 -X 1)} / X 1 defined in the weight change rate is less than 7.0%, a melamine resin decorative plate. The melamine resin decorative board according to any one of claims 1 to 4,
A melamine resin decorative board, wherein a base material layer is further provided on the other surface of the melamine resin layer. The melamine resin decorative board according to claim 5,
A melamine resin decorative board in which the base material layer is one or more selected from a fiber base material, a prepreg, and a metal layer. The melamine resin decorative board according to any one of claims 1 to 6,
A melamine resin decorative board in which the gas barrier layer includes a glassy film having a siloxane skeleton.

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