JP2000024584A - Production of decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance surface properties by adapting a liquid resin compsn. while taking a means for temporarily suppressing the impregnation properties of a decorative base material when a surface protective layer is provided to the decorative base material having impregnation properties by using the resin compsn. and subsequently releasing the suppressing means. SOLUTION: When water is infiltrated into a decorative base material 2 as a means for temporarily suppressing the impregnation properties of the decorative base material 2 prior to providing a coating layer on the surface of a decorative material by using a liquid resin compsn., water is sprayed on the base material 2 unwound from a paper feed stand 1 by a spray device 31. After spraying, the liquid resin compsn. is applied to the base material by a roll coater 4 and the coated base material is heated and dried in a drying zone 5 to be taken up by a paper discharge stand 6. At this time, since the decorative base material 2 runs in a state impregnated with water in a process on and, after water spraying, an apparatus is constituted of a material not corroded by water such as stainless steel. Since water is removed by thermal drying, drying temp. is pref. set to 100 deg.C or higher.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative material having a coating layer on its surface, and more particularly, to a method for forming a coating layer on a surface of a decorative material using a liquid resin composition. The present invention relates to a method for producing a cosmetic material having excellent surface properties by performing coating while preventing impregnation of a composition with a base material, allowing the resin composition to sufficiently remain on the surface, and applying an effective coating to the surface.

[0002]

2. Description of the Related Art When a resin composition is used to form a coating layer on a fibrous material such as paper, nonwoven fabric, wood, or other porous material, a resin composition is used. As a result, the amount of the resin composition remaining on the surface is reduced due to the penetration into the decorative material base material. As a result, the physical and chemical properties of the surface are often not sufficiently exhibited.

Some attempts have been made to solve this problem, but they are still insufficient for the following reasons. First, (1) a resin composition in which a coating layer is formed using a resin composition is used, for example, if a decorative material base material is impregnated with a resin in advance, for example, an impregnated paper or a paper-to-paper reinforced paper containing a resin component is used Although the permeation of the material is suppressed, a separate resin is required in the decorative material base in addition to the resin composition for forming the coating layer, and the number of steps is increased. (2) Prior to providing a coating layer using a resin composition on the surface of a decorative material base material, there is also a method of providing a layer called a sealer layer for preventing the penetration of a top coating resin composition.
This increases both the process and the material, and a high-price curable resin is often used for the resin composition for forming the sealer layer, resulting in an increase in cost. (3) Although it is conceivable to increase the coating amount of the resin composition to be applied in anticipation of penetration into the decorative material base material, it is unavoidable to use a lot of materials, and due to uneven density of the decorative material base material, Coating irregularities are likely to occur, and appearance irregularities are likely to occur. (4) It is conceivable to reduce the penetration by dividing the application to the base material of the cosmetic material several times instead of once.
As in the case of the above (3), a large amount of material is used and unevenness easily occurs.

[0004]

The problem to be solved by the present invention is that when applying a liquid resin composition to a decorative material substrate, the amount of the resin composition to be applied is not increased, and the conventional process is difficult. Can be easily implemented by improving the process of
It is an object of the present invention to provide a method capable of providing a cosmetic material having excellent surface properties by suppressing penetration into a base material.

[0005]

In the present invention, when a surface protective layer is provided on a cosmetic material substrate having an impregnating property by using a liquid resin composition, the impregnating property of the cosmetic material substrate is temporarily reduced. Applying the resin composition while taking suppression means,
Then, the above-mentioned subject was solved by releasing the above-mentioned control means.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, a decorative material substrate to which a liquid resin composition can be applied has the following impregnating property. Broadly speaking, it can be applied to various papers, non-woven fabrics and woven fabrics, but even plastic films or plastic sheets that are porous or contain a large amount of filler are impregnable. Therefore, it is applicable. A fiber-reinforced plastic plate or the like is also applicable because it has impregnation properties of the liquid resin composition. Since the wood-based substrate has impregnation properties, it is also applicable, and examples thereof include a wood board, a plywood, a particle board, and a medium-density fiberboard called MDF. In addition, the present invention can be applied to a composite of the same group such as papers. Further, the present invention can also be applied to a material such as steel wool obtained by processing a metal into a fibrous shape.

The following are typical examples of various papers. That is, tissue paper, kraft paper,
It is titanium paper or the like. A resin-impregnated paper which has been impregnated with a resin in advance for the purpose of strengthening between papers can also be used since it has impregnating properties.
In addition to these, the present invention can also be applied to linter paper, paperboard, and gypsum board base paper. A group of raw materials often used in the field of building materials, such as a raw material of vinyl wallpaper having a vinyl chloride resin layer containing a large amount of filler on the surface of paper, is also applicable. Further, the present invention can be applied to the following papers used in the office field and ordinary printing and packaging. That is, it is coated paper, art paper, sulfuric acid paper, glassine paper, parchment paper, paraffin paper, Japanese paper, or the like. Although different from these papers, the following woven or nonwoven fabrics of various fibers having the appearance and properties similar to paper can also be used as the base material for the decorative material. The various fibers are inorganic fibers such as glass fibers, asbestos fibers, potassium titanate fibers, alumina fibers, silica fibers, or carbon fibers, or synthetic fibers such as polyester fibers or vinylon fibers.

[0008] Examples of the plastics constituting the plastic film or the plastic sheet which is porous or contains a large amount of filler include the following various examples. That is, polyethylene resin, polypropylene resin, polymethylene resin, polymethylpentene resin,
Polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl alcohol copolymer resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene na Phthalate-isophthalate copolymer resin, polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, polyamide resin represented by nylon 6 or nylon 66, cellulose triacetate resin,
Cellophane, polystyrene resin, polycarbonate resin, polyarylate resin, polyimide resin, or the like.

In addition to these, ceramic building materials such as gypsum board, calcium silicate board, and wood chip cement board, ceramics, fired tiles, etc. are also applicable materials unless surface coating or glaze is applied.

The decorative material base material may be subjected to an arbitrary process such as giving an appropriate pattern by printing such as gravure printing or embossing.

In order to impregnate water into a decorative material substrate, a method of coating a paint or the like, such as a spray coating method, a roll coating method, a dip coating method, a curtain flow coating method, etc., can be used. By ringing, excess water can be removed and an appropriate amount of water can be given. The amount to be impregnated with water depends on the porosity of the decorative material base material, so that there is no problem when providing the surface protective layer using the liquid resin composition.
0.5-20g per 1m x 1m of the surface of the cosmetic material base
It is preferable to set the degree. When impregnating with water, whether to perform from the same side as the side to which the liquid resin composition is applied later, depending on the amount of water to be impregnated and the nature of the decorative material base, When it is desired that the vicinity of the surface to which the liquid resin composition is applied is not impregnated with water or has a low degree of impregnation, impregnation may be performed from the side opposite to the side to which the liquid resin composition is applied.

When water is impregnated into the decorative material base, the viscosity of the water itself is low and the water cannot be stably retained in the decorative material base, so that the next step is performed immediately, preferably immediately after the impregnation. A liquid resin composition is applied. 1 and 2 are diagrams schematically showing the method and apparatus of the present invention.

In the method shown in FIG. 1, water is sprayed on a substrate 2 unwound from a paper feed stand 1 by a spray device 31 first. Immediately after the spraying, the liquid resin composition is applied by the roll coater 4 and then the drying zone 5 is applied.
And then wound up by the paper discharge stand 6. In this example, water is applied from the back surface of the decorative material base material, and the liquid resin composition is coated from the front surface. In the process after the spraying of water, since the decorative material base material travels while being impregnated with water, it is necessary to configure the apparatus with a material such as stainless steel that does not corrode with water. The temperature is preferably 100 ° C. or higher in order to remove water by thermal drying.

In the method shown in FIG. 2, instead of the spray device 31, water is applied by a roll coater 32, and immediately after coating, a smoothing roll 33 is used to regulate excess water. Drying is performed with warm air heated in the drying zone 5, and thereafter, irradiation is performed by the electron beam irradiation device 7.

As the liquid resin composition, a thermoplastic resin composition, a thermosetting resin composition, an ionizing radiation-curable resin composition, or the like may be used, and any of them may be used. In order to improve the properties
A thermosetting resin composition or an ionizing radiation-curable resin composition is suitable. When using a thermoplastic resin composition or a thermosetting resin composition, it is dried after application, and when using a thermosetting resin composition, it is desirably heated and cured. When an ionizing radiation-curable resin composition is used, it is crosslinked or polymerized by irradiating ultraviolet rays or an electron beam and cured.

[0016]

(Example 1) General paper having a basis weight of 50 g per square meter (Tenma OPA, manufactured by Tenma Special Paper Co., Ltd.) was used.
Gravure ink (HA, manufactured by The Inktech Co., Ltd.)
T, a nitrocellulose resin and an acrylic resin as binders) were used to perform solid printing and pattern printing. Subsequently, water was sprayed around a square meter with a spray device as shown in FIG. 1, and 15 g of water per square meter was impregnated with a spray device impregnated with 15 g. Next, using a gravure roll, OP
Ink (KR90, a polyurethane resin type, manufactured by The Inktech Co., Ltd.) was coated at a rate of 5 g per 1 m2, dried in a drying zone set at 100 to 110 ° C, and wound up. (Comparative Example 1) The same operation as in Example 1 was performed except that the spraying step was omitted. (Comparative Example 2) Except that the step of spraying was omitted and “impregnated paper” (GF601, manufactured by Kojin Co., Ltd., the total amount of resin and paper resin per square meter) which was previously impregnated with resin was used. Performed in the same manner as in Example 1.

(Embodiment 2) In the system as shown in FIG.
Roll coating with water, and immediately after coating, a paint containing an electron beam curable resin (The Inktec Co., Ltd.
EB40, epoxy acrylate) was used, except that roll coating was performed. (Comparative Example 3) The step of roll coating water was omitted,
Others were performed similarly to Example 2. (Comparative Example 4) Example 1 except that "impregnated paper" (Kotojin, GF601, total amount of resin and paper per 60 m2, 60 g) was previously impregnated with resin and sold. Was performed in the same manner as described above.

(Evaluation) Evaluation methods of the decorative sheets obtained in the examples and comparative examples will be described. Abrasion resistance test JAS special plywood Same as abrasion resistance C test. Judgment based on wear end point Stain resistance JAS special plywood Same as the Soil A test. Judgment of blue ink only Tensile test The decorative sheets obtained in Examples and Comparative Examples were evaluated by attaching them to a substrate particle board with a polyvinyl acetate resin emulsion type adhesive. JAS special plywood Same as the plane tensile test.

[0019]

[Table 1] (Evaluation Results) In Examples 1 and 2, the surface appearance was
The abrasion resistance, stain resistance and the results of the plane tensile test were also good. In Comparative Example 1 and Comparative Example 3, the surface appearance was poor and the stain resistance was insufficient due to the large penetration into the substrate. In Comparative Examples 2 and 4, the permeation into the base material was small and the appearance of the surface was good, but the adhesive strength was insufficient because the adhesive did not easily penetrate when attached to the particle board.

[0021]

According to the present invention, when a liquid resin composition is applied to a decorative material substrate, unnecessary penetration can be prevented, and the amount of the liquid resin composition used can be minimized. And the surface properties can be sufficiently ensured. Further, the method of the present invention has an advantage that it can be easily performed only by adding a device for applying water to a normal line.

[0022]

[Brief description of the drawings]

FIG. 1 schematically illustrates the method of the present invention.

FIG. 2 schematically illustrates the method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Paper feed stand 2 Substrate 31 Spray device 32 Roll coater 33 Smoothing roll 4 Roll coater 5 Drying zone 6 Paper discharge stand 7 Electron beam irradiation device

Continued on front page F term (reference) 4D075 AC25 BB62Y BB79Y CA02 CA34 CA47 DA04 DB18 DC31 EA05 EB38 4F100 AA40A AJ04 AK01B AK25 AK51 AP00 AR00A BA02 DG10A DG15A EJ83A GB08 GB33 GB81 HB00 HB00A JD

Claims (2)

[Claims] When providing a surface protective layer using a liquid resin composition on a cosmetic material base material having impregnation properties, while taking measures to suppress the impregnation property of the cosmetic material base material temporarily, A method for producing a cosmetic material, comprising applying a resin composition and thereafter releasing the suppressing means. 2. The method for producing a decorative material according to claim 1, wherein said suppressing means is water impregnation.